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By Richard Crawshay, Duncan Hutchison

Continuous Mining Systems Limited have developed an efficient, high-capacity, in-line loading unit capable of handling shot rock in tunnel driveages at extraction rates up to 970 tonnes (1,000 tons) per hour. A smaller 408 tonnes (450 tons) per hour loader is also available These in-line loading units called "Osciloaders"® provide a continuous flow of material from the muck pile to an anciliary conveyance eliminating the cyclic or interrupted movement noramlly associated with gathering arm or bucket type loaders. The osillating lip fluidizes the material, reduces the penetration force required and facilitates and regulates the material flow onto the adjacent conveyor. The conveyor is wide and accommodates very large material with ease, transporting and elevating it to a height suitable for a waiting conveyance at the rear of the machine. The "Osciloader"® is currently being utilized for production mining by a major company in Sudbury, Ontario. Both truck and conveyor anciliary haulage are being utilized. The paper describes the development of the loader and how it may be applied in tunnelling applications.

Jan 1, 1987

By H. Soto, J. Jara, F. Nava, J. B. Hiskey, B. J. Scheiner

Laboratory tests showed that ozone can destroy free cyanide and weakly complexed cyanide (copper and zinc cyanides). The iron cyanide complexes were resilient to ozonation but they were effectively eliminated by precipitation with Fe (II) ions under controlled pH conditions. Tests carried out with effluents from a number of gold mills confirmed the results obtained previously in the laboratory. The industrial samples contained cyanide in the form of free cyanide and also complex copper, zinc and iron cyanides. Solutions that contained up to 184 mg/L total cyanide, after the ozone treatment analyzed only 2-3 mg/L dissociable cyanide and 50-90 mg/L CN(t) (accounted for by iron complexes). After precipitation with ferrous ions total cyanide was reduced below 1.5 mg/L. For most solutions ozone consumption ranges from 3 to 6 g per g of cyanide destroyed. However, certain impurities (such as SCN and S203 ), present in some effluents, increase ozone consumption and make it more difficult to reduce copper concentration to satisfactory levels.

Jan 1, 1993

By Louise H. Michaud

An interactive mine planning system that employs recent advances in 3D computer graphics capabilities and 3D geologic modelling to aid with the tasks involved in producing dragline mine plans was developed. As well as offering large potential saving in the time required to carry out the planning tasks, the system offers immediate visual feedback to the planning engineer. This can greatly aid in the conceptual understanding of complex geology and mine plans. The package incorporates the generation of a three dimensional Gridded Seam Model (GSM) as the basis for the development of the geologic database. This modelling method is capable of accurately representing rugged topography and multiple coal seams, including folding and faulting. The GSM is then integrated with an interactive graphics mine planning system in order to develop one model and one database for the generation of the mine design, the depletion of the coal resources and the movement of spoil material. The gridded structure of the model also provides the foundation on which all mine and spoil pile volumes are calculated.

Jan 1, 1992

By Ryan Lindmark, Guoxing Gu, Zhenghe Xu, Jacob H. Masllyah

Induction time is often referred to the time required to form a stable three-phase contact between a gas bubble and a flat or droplet surface in a liquid medium. It can be used to quantify the attachment process in aflotation system. Various techniques have been developed to measure this important parameter. Due to its importance in flotation systems and other processes, significant advances in refining the induction time measurement techniques have recently been made. This paper summarizes these recent advances and describes a novel method developed to monitor bubble attachment to a pendant bitumen drop or bitumen-coated flat surface. This visualization-based method offers a higher sensitivity and accuracy than the previously developed apparatuses in the induction time measurement. As an example, the induction time for oxygen bubble-bitumen attachment was measured at a fixed bubble size as a function of temperature in two different aqueous solutions. The results showed that higher process temperature is favorable for oxygen bubble-bitumen attachment and hence bitumen flotation. Addition of calcium to the aqueous solution slightly decreased induction time.

Jan 1, 2005

By P. Massacci, F. La Marca, G. Bonifazi

Some deposits of inhomogeneous materials, which occur near the surface and are exploitable by open-pit mining, may he characterized in real time prior to mining through groundsurface imagery. If the slice to be stripped is not overly thick, surface texture and color properties may be extrapolated to its entire thickness. Image-analysis techniques for processing ground-surface images acquired in situ or in the laboratory shortly after their acquisition have been developed. These images yield pattern vectors representative of red, green and blue (RGB) color component distributions and hue, saturation and brightness (HSB) texture parameters. The techniques were applied to a sandy ore deposit containing three lithotypes. Geostatistical analysis indicated that the data used to characterize the lithotypes were reliable. The correct recognition of the lithotypes was carried out using a multibarycenter classification algorithm. Such in situ image-analysis procedures provide a means for selecting the ore to be mined, selecting the proper ore-processing method and determining the appropriate blend to he processed. This can be done either before or during mining.

Jan 1, 2000

By David Sainsbury, Bevan Thompson, Yuejun Cai

The practice of placing loose rockfill as passive support in open stoping voids, of narrow vein mineral deposits, lends itself to the sterilisation of substantial mining reserves in the requirement for regional crown/sill pillars. Significant benefits are to be gained by the Australian mining industry via the development of improved guidelines for the extraction of such sterilised mine pillars. The application of selectively injecting specifically developed ettringite (calcium sulphoaluminate hydrate) type cement grout into loose rockfill, enables an artificial pillar to stabilise the surrounding rockmass and prevent the caving of loose rockfill from the previously backfilled void during extraction of remnant crowdsill pillars. This paper presents the results of laboratory testing used to reduce the technical risks associated with the design of cemented rockfill pillars. A laboratory testing program was devised to investigate the critical parameters influencing the performance of a stabilised rockfill matrix, along with the critical parameters influencing the interpretation of laboratory test samples. The factors investigated include; sample size and shape, particle size distribution, curing time, water quality, cement : water ratio and the confinement effect.

Jan 1, 2001

By E. D. Attanasi

The US mining industry finished the traumatic 1980s with a strong economic performance. Worldwide economic growth and capital spending led to tight metal markets. So, 1989 metals prices were generally higher than average 1988 prices. Financial markets' volatility resulted from US junk bond defaults, heavy US savings and loan losses and effects on the US budget deficit, higher energy prices, and the seemingly intractable problems of some debtor countries. Moreover, the events in Eastern Europe promise fundamental changes in the world economic system for the 1990s. US mining companies that survived the decade had weathered economic changes that, at one point, reduced industry employment by 40%, drove oil companies to divest or liquidate recently acquired mineral subsidiaries, and led to substantial write-offs of reserves. Canadian and other international minerals firms experienced similar industry upheavels. The forced modernization and capacity rationalization produced an internationally competitive US industry. For example, even though 1989 US copper production was 27% greater than in 1980, industry employment was less than half the 1980 level. The steel industry and other minerals industries showed similar productivity improvements.

Jan 1, 1990

By A. J. Benham, H. Kessler

In the UK a high proportion of land-won sand and gravel is extracted from sub-alluvial gravels and river terrace gravels located within river valleys. However, extraction from deposits of this type is increasingly proving to be less acceptable. Quarries within river valleys often have a high visual impact and the cumulative impact of these operations in close proximity to each other can be high (figure 1). River valley operations are almost always restored to open water. Whilst these may be attractive for nature conservation and provide leisure activities, they can also have a serious impact on the natural hydrology of the flood plain. Wet restoration of quarries located close to airports or airfields can also lead to concerns regarding increased risk of bird strike on aircraft. The Civil Aviation Authority recently suggested that an exclusion zone of 13 km be applied around all airports and airfields to reduce the potential for bird strikes on aircraft. This action is likely to have a serious impact on the availability of potential sand and gravel extraction sites in river valleys.

Jan 1, 2005

By R. F. McFarlin, H. E. El-Shall

Since its inception, the Institute of Phosphate Research has examined every promising proposal in order to find an economical, practical and environmentally sound method of dewatering phosphatic clays. The in-house development of the FIPR/DIPR process (DIPR = Dewatering Instantaneously with Pulp Recycle) would appear to answer that quest. When small amounts of fibrous materials are mixed with clay slurries and flocculent, rapid dewatering occurs. Clay solids contents of 20 to 25% can be attained by simply rolling the clay mass down an inclined screen. Higher solids (>40%) are reached by physically pressing the cake; e.g., with a belt press. Because mechanical pressing devices are too expensive for phosphatic clay treatment, FIPR has developed the "sandwich" method of simultaneously dewatering the phosphatic clays and reclaiming the mine cut, as well as a second alternate, the "median strip" proposal. Economic projections of these bench-scale alternates suggest that the FIPR/DIPR process should be no more costly than present practice, when credit is given for the simultaneous reclamation accomplished.

Jan 1, 1993

By William C. Grady

The environmental and economic problem created by pyrite in coal are well documented. The removal of pyritic sulfur prior to, or during, utilization has been the object of considerable research, however, much of this research has proceeded without a proper knowledge of the microscopic occurrences of pyrite in coal. This paper investigates the forms, occurrences, and variations in the distribution of pyrite in major West Virginia coal scan. Twenty-nine samples from twenty-two major west Virginia coal scans were selected for this study (see Table I). The samples were selected so as to be representative of the major coal producing areas of the state. All samples, except five, were collected at active surface mines, as indicated in Table I, and all except one were channel samples. The time interval between sampling and preparation of polished microblocks varied from two months to two years, though most were prepared within three months of collection. Grinding, screen¬ing, and riffling of samples to obtain 250 grams of -20 mesh coal for microscopic analysis strictly followed ASTM procedure D2013-72.

Jan 1, 1976

By G. F. Raymond

Discussion by G.F. Raymond Knudsen's study presents two curious conclusions: • The kriging of blasthole assays can systematically overstate mill head grades by as much as 21% as a result of unbiased sample variance. • No estimation method is able to reduce this bias to a small margin. The study is based on a simulation using real data and what are presumed to be actual variogram parameters from a real deposit. Although I have no doubt that the first conclusion (21% overestimation) is correct for the author's simulation, I do not believe this represents a realistic mining situation. Over the past 15 years I have done extensive comparisons between exploration drill-hole assays, blasthole assays and mill head grades on seven major open-pit mines, including some very erratic gold deposits. Commonly, nugget effects on blasthole variograms were 10% - 20% higher than on exploration variograms. And in one extreme case, the difference was 50%. Even in the extreme case, ordinary kriging on blastholes agreed well with the mill head grade over the long term. In Knudsen's simulation, the blasthole nugget effect is assumed to be 200% higher than exploration data's. He supports this by variogram plots from each. My guess is that the apparent, large difference between these variograms results from a failure to account for the proportional effect (blasthole assays are likely from a higher-grade area). A simple check would be a comparison of the variance of exploration samples nearest blastholes. As for a nearly conditionally-unbiased estimator of a large random error, the arithmetic mean of all of the data certainly qualifies, provided there is an even data spacing. As a corollary, so does simple kriging, which would include, in this case, a large weighting to the arithmetic mean. Similarly, using a large number of samples with ordinary kriging or indicator kriging would significantly reduce the bias in the case of a large nugget effect for the variogram.[ ] Reply by H. Peter Knudsen Raymond questions two conclusions in the paper. First, he wonders whether a 21 % overestimation represents a realistic mining situation. I agree that 21 % is high, but overestimation in the range of 10% to 15% is certainly common in my experience. Furthermore, several years ago I consulted on a gold mine that was experiencing a 45% overestimation due, predominantly, to poor blasthole samples: In further questioning of the 21 % value, Raymond wonders whether the nugget effect of the blastholes is really so much larger than the nugget values of the exploration data. It is consistently larger throughout the deposit. In my experience with six Nevada gold mines, the high nugget value is not unusual. In fact, for some reason, nugget values for blasthole samples are typically about 0.0005 (opt squared). I am of the opinion that this high nugget effect observed at many gold mines is predominantly due to the inherent inadequacies of the blasthole sample and subsequent sample preparation. The second conclusion Raymond questions is the inability of the estimators tested to reduce the conditional bias. In fact, the conditional bias is extreme with the polygon estimator and greatly reduced by ordinary kriging. However, it was not eliminated. Raymond suggests using simple kriging, or perhaps a larger number of samples, to reduce the conditional bias. The technique of simple kriging may be less affected by the random errors in the data, but I did not test the technique. Using a larger amount of data presupposes that too few samples were used initially. In ordinary kriging and indicator kriging, the screen effect comes into play and ensures that samples beyond the second screen are given zero weight. Hence, increasing the sample size does not change the estimates nor the conditional bias. The main point of my paper is that the random unbiased errors (a fact of life in blasthole samples) cause a conditional bias in our estimates. The mechanics by which the conditional bias is introduced are nicely explained by Springett. My paper simply shows that the bias is also present when working with linear estimators, such as ordinary kriging, and even with nonlinear estimators, such as indicator kriging.[ ]

Jan 1, 1993

By Waclaw Trutwin

The idea of automatic or remote control of the mine ventilation process generally, and methane concentration particularly, attracts the attention of mining engineers more and more. The advantages of introducing mine ventilation control systems are breaking traditional reluctance. The change of attitude is not only because of the requirements of modern exploitation technology, but it is also due to the recent progress in development and successful introduction of reliable monitoring systems and actuators in the form of controlled ventilators and doors [1]; [2], [3], [4], [5], [6]. Many 'years of theoretical and experimental studies of the dynamics of mine ventilation processes created the needed base for a proper design of an automatic control system [7],[8],[9], [10]. From these studies must, however, be drawn a fundamental conclusion, which may be regarded as the motto of this paper: An automatic control system for mine ventilation ill-conditioned or improperly designed is capable of creating hazard situations in response to random disturbances, much more, severe in consequence than a traditional ventilation system without any automatic or remote control! This statement is easy to prove if the dynamic properties of the ventilation process are taken into consideration. The ventilation process, as a matter of fact, is described by non-linear equations, and it must be expected that the process has more than one state of equilibrium. In other words, in the ventilation process may exist not only one but also more than one steady-states of flow, of which some are stable and others unstable. In certain circumstances, there may be no steady-state at all, and the process will oscillate [8], [11] , [12] . The state of flow in a network tends towards a steady-state and the actual steady-state established will depend on the initial conditions or disturbances in flow (fire,. etc.), which steady-state from the total number that will be . We frequently observe jumps from one steady-state to another. Disturbances in flow conditions which may cause such transitions are events of random character, occurring very rarely. Concluding, it must be stressed that there has to be a control system adjusted to the ventilation process in order to avoid situations mentioned above. There is only one alternative available and suitable for examination or study of the dynamics of a given mine ventilation problem: either by continuous monitoring of the real process, or numerical simulation of the process using a mathematical model. The advantages of the second method are obvious. This method allows consideration of every possible case very quickly and cheaply in relation to the first method. The aim of the paper is to show again that the simulation of the mine ventilation process and particularly a methane concentration process, separately or combined together with a control system, are real possibilities. A simulation method requires precise specification of the problem under consideration. For example, if we intend to examine a methane-concentration control system, the following items have to be specified: - expected target function of the control system. - structure of the control system. - mathematical model of control system, including sensor system, data preparation system, controllers, decision routine, regulators, etc. - structure of mine ventilation network. - mathematical model of ventilation process, including air flow and methane concentration processes. - pattern of disturbances which may occur in the controlled process as well as initial conditions on a 'start-up' of the system. Using typical computer programs for numerical solution of equations in the mathematical model of the problem involved, we are able, within the adequacy of the model, to simulate every case specified by the disturbances and initial conditions. As a result of simulation, it is expected that the following parameters could be defined: - transient flow in the network. - transient state of methane concentration in working areas. - stability of flow and methane concent¬ration. - stability of the control system. - range of control. - efficiency of control, etc. It is obvious that simulation methods readily allow for modifications to existing systems such that desired results will be obtained. Also optimisation problems could be solved by use of the simulation methods. In order to illustrate these general thoughts, a brief presentation of a mathematical model of methane concentration and

Jan 1, 1980

By Yu. A. Polozov, V. A. Lagunov, O. Yu. Lushinkova, Yu. I. Svirskiy, Eh. Ya. Kipko, Roy A. Williams

The reliable quality assessment of grouting operations is one of the key issues in establishing impermeable grout curtains around shafts, drifts and tunnels. Reliable opera¬tional information on the decrease in the permeability of rock during the grouting process facilitates the assessment of the effectiveness of the completed curtain and assures production quality. Quality control and assurance also fa¬cilitates the early detection and elimination of possible de¬fects in the grout curtain. Thorough control of the grouting process provides the capability to evaluate decreases in the permeability of water-producing fracture zones prior to the beginning or the continuation of excavation of the shaft, tunnel or drift. In order to achieve this objective, post¬grouting hydrodynamic investigations are conducted prior to the initiation or re-initiation of work on the underground workings to measure the decrease in the permeability coef¬ficient of aquifers during grouting operations. 8.1 QUALITY ASSURANCE AND CONTROL OF THE ISOLATION OF ROCK BY GROUTING THROUGH HOLES DRILLED FROM THE SURFACE Quality assurance and control are based on measuring the decrease in the permeability coefficient of water-pro¬ducing horizons as a result of injecting grout into the drill¬holes. For this purpose, the value of the acceptable residual permeability coefficient is calculated beforehand based on the acceptable value of ground water inflow into the shaft, drift or tunnel as specified by the "construction norm and integrated practice (SNIP)" (Anon., 1976). Having ob¬tained the values of aquifer thickness, permeability, and head distribution for each aquifer from flowmetric data (dis¬cussed in Chapter 3), the average value of the permeability coefficient of all aquifers intersected by the shaft is calcu¬lated as [ ] where Ki is the permeability coefficient of the "ith" aqui¬fer; Pi is the pressure of the "ith" aquifer; and M; is the thickness of the "ith" aquifer. The total expected inflow of ground water into the shaft is [ ] where RK is the radius of the contour of influence; RCFB is the radius of the shaft; and p is the coefficient of dynamic viscosity of the ground water. The necessary reduction of the coefficient of permeabil¬ity of the aquifer [ ] where Q is the expected inflow of ground water into the shaft from eq. 8.2; Q.-fin is the acceptable inflow of ground water; and a is the safety factor. By knowing the average permeability value of the rock and the permeability reduction coefficient, it is possible to determine the value of the acceptable residual permeability coefficient for all the aquifers [ ] The values of the permeability coefficient, pressure, and thickness for each aquifer are determined from the data gathered during the hydrodynamic investigations conducted in grout holes prior to beginning the grouting operations as discussed in Chapter 3. After injecting the grout into the first of the holes, the injection into each of the following grout holes is preceded by repeated hydrodynamic investi¬gations. Using the data obtained for each water-producing zone, a graph is constructed where the numbers representing the grout holes in their order of grouting are placed on the abscissa, and the values of the aquifer permeability coeffi¬cient are placed on the ordinate (Fig. 103). This curve char¬acterizes the change in permeability of the given hydro¬stratigraphic unit as grouting operations are completed, one hole at a time. The results of grouting operations are considered to be positive when each sequential observation records a steady decrease in the permeability of the aquifer. The permeabil¬ity measured prior to the injection of the grout into the last hole must be lower than or equal to the acceptable perme¬ability as determined by the application of eqs. 8.1 through 8.4. Table 8.1 presents illustrative data on the hydrogeo¬logic properties of aquifers at a mine shaft prior to the initiation of grouting operations. Data also are presented on the reduction in the permeability coefficient during the in¬jection of the grout. The shaft in question intersects eleven aquifers. Based on data concerning aquifer pressure, thick¬ness, permeability, and the expected inflow rate of water for each of the strata, the average permeability coefficient is calculated according to eq. 8.1 as K = 0.2 x 10-12 m2. The

Jan 1, 1993

By R. Edward Williams

The Spa1lation Process Because of the low thermal conductivity of many hard rocks, rapid heating of these rocks produces a thin surface layer in which the temperatures attain high values. Thermal expansion of this surface layer is constrained by the reminder of the still cool rock, and when stresses within the surface rock become high enough, the surface rock breaks away from the cooler rock behind it and flies or falls off as a thin flake called a spall. Then the next, newly exposed surface is heated, and the process continues. This process is the basis of spallation drilling. The hot gases from a jet burner provide the heat for spallation to occur, and their high velocity provides a scouring action that transfers heat to the rock and removes the spalls as rapidly as they form. Spallation is a process which works in very hard rock. It is dependent upon the thermal expansion coefficient and the thermal diffusivity of the rock but is also affected by any discontinuities in the rock. To date the efforts which have been made to evaluate the various rock according to their spallability has been minimal. As the success of this process is dependent upon the characteristics of rock it is expected that the study of rock mechanics will prove to be of greater value to this program than to the other mechanism for drilling and excavating rock. Commercial Uses of SPALLATION In the 19408s, the Linde Air Products Division of Union Carbide (UC 1 began developing spallation for use in mining taconite ore, which is presently the chief source of iron in the United States. In this work UC developed a jet-piercing tool that burned fuel oil with oxygen to produce spallation and contained mechanical cutters to remove rock that was not amenable to spallation. The UC jet-piercing machines have since produced about 40 million feet of shallow blast holes used for emplacing explosives in the taconite mines. During this work it was found that hole diameters could be increased by merely reducing the advance rate of the burners and that existing holes could be enlarged by making another pass through the hole with the same burner. The Browning Engineering Go. of Hanover, N.H., has developed a hand-held spallation burner to cut slots in granite. It has been used for a quarter of a century and is now standard equipment for quarrying granite throughout the world. This burner, which resembles a small jet engine oriented with its exhaust pointed downward, is the forerunner of a flame jet burner used to spall experimental holes in granite at maximum rates in excess of 100 ft/hr when operating in hard, competent granite. It uses No. 2 fuel oil, which is burned with compressed air. The system uses water to cool the burner and the exhaust gases. These gases, along with the steam produced from the cooling water, blow the spalls from the hole. Experimental Work Theoretical and experimental work has been accomplished by the Massachusetts Institute of Technology and the Los Alamos National Laboratory. This work is reported in Refs. (3) and (4). To verify the experimental results of this work laboratory scaled down field tests were conducted using two we1 1 characterized granites from quarries in Barre, VT and Westerby, RI, under defined heating conditions. In the laboratory tests a propane - oxygen heating torch was used to direct a flame at the granite surface and the spal 1 ing process was examined at various heating rates with a high-speed video taping system operated at 200 frame per second. This produced a time-lapse sequence where the onset of the spallation process was easily distinguished. Also the heat flux from the torch to a flat surface at various stand off distances and flows was measured. A similar set of tests was conducted using the more easily quantified and uniform heat source of a 1.5 kw GO2 laser. This allowed accurate

Jan 1, 1986

By J. A. Herbst

Introduction The ability to evaluate the improvement resulting from the implementation of an automatic control system is essential to the Justification of its cost. This evaluation may occur after anew control system has been commissioned. In other cases an existing plant which is operated manually may be automated only In part in order to determine In ether the met of it should be. Finally. in some instances dynamic isolation my be used prior to installation of the control system to determine the strategy to be used or to evaluate the improvements In process performance expected from automatic control. This paper describes the development of a methodology for making these evaluations. In order to obtain an accurate assessment of Improvements In a short time, statistical methods can be employed. Mineral processing plant, are subjected to many types of both random and deterministic disturbances of various duration. The statistical method, available for process control at analysis are designed to counter the obscuring effects that random disturbances have on such as evaluation. The basis for evaluation and comparison is some freely chosen measures of process performance termed the performance index or objective function. The experimental data used to calculate the performance index should, if possible, be collected by alternately running a circuit Or plant with the two or more type, or control being tested ("serial testing”) or more preferably, by running two circuits with the two type, of control side by side ("parallel testing") . The performance index is a random variable so that when comparing two types of control, statistical hypothesis testing must be used. By testing s hypothesis statistically one accept, or reject, a (null) hypothesis [ ] concerning the mean or variance of one or more performance indices. For example, a hypothesis Ho might be that the mean of a performance index with stabilizing control is larger than with manual control. Defining a Performance Index The performance index, denoted by [ ] , is a measure by which alternative strategies or situations my be cam peered on either s technical or an economic basis (see Table 1). Technical measures are concerned with the effects of control on process variables or outputs or on the deviations of controlled variable, from their setpoints. For commotion circuit, important technical measures of performance are throughput, product fineness and the consumption of liners, media and electrical energy. For flotation circuits important technical .satires are recovery, grade and reagent consumption. Economic measure such a, cost and profit n usually determined from a combination of technical measures and are usually the final factor upon which a decision may be made, although a control system my achieve higher values of technical measure , the control effort expended my be of such magnitude that the economic measures, such as cost, are poor. Running Comparisons Comparison, between automatic and manual control are normally done with data obtained before and after control system Installation, unless ore characteristics remain the same during the period of data collection the results will be biased. By running the test circuit with the control system alternately turned on and curled off until all possible ore type, have been run through the circuit, unbiased result, can be obtained. This mode of testing is termed “serial testing.” An alternative and potentially more powerful and quicker made of testing is "parallel testing" in which two circuits, one with the type of control being tested and one without, arm run aide by side. In this type of testing both circuits process the same ore so that valid results occur sooner than with aerial testing. The data may be averaged before testing or the differences in the performance indices may first be calculated before averaging. However, the two circuits must be nearly identical in their mechanical characteristics otherwise differences other than the degree of control will bias the results. It mechanical differences exist than it my be necessary to adjust one or the circuits prior to testing. Sometimes it is possible to correct far mechanical differences based on Inherent efficiency calculations made with a model. Hypothesis Testing Once the data is collected, hypothesis fencing can be carried out to determine if the automatic control system has resulted in a statistically significant improvement. One can construct a histogram of the distribution or performance indices with am without control such as Figure 1, or the

Jan 1, 1991

By A. Hayatdavoudi, E. Apande

Introduction Troublesome shales have plagued the petroleum industry for more than 50 years. Unstable boreholes have been experienced when drilled into shale formations; sane have been studied almost at the beginning of rotary drilling. A little progress has been made since then, but much is still to be learned. No simple solution exists so far, but good drilling practices combined with good mud practices have been helpful. It is well known that shales in general have a strong affinity for water, and when water is adsorbed, the stability of the shale section of a well is reduced; cohesive strength will be re- bed, properties will be altered and shale will generally expand and/or crumble. The amount of water a shale will adsorb depends on the characteristics of its clay mineral and the ionic concentration of surrounding fluid. Fluid loss and the resulting hydration of an unstable formation can lead to serious downhole problems. The rate of fluid loss depends greatly on the permeability of the deposited cake. In impermeable formations, however, there is no loss of fluid into the formation. As such, shale, because of its very low porosity and almost no permeability, could be termed impermeable. Yet there is strong evidence that shale surfaces are wetted by an invasion of fluid into the formation through microfractures and jointed planes. It is this wetting that causes the shales to swell and slough into the hole, resulting in problems such as increased mud volume and treating costs, bridges and fill-up, stuck pipe, overgauge hole, poor cement jobs and increased cement requirements, and logging and completion difficulties. Drilling operations have been defeated by severe shale problems, resulting in & hole being plugged and abandoned after several weeks of drilling. Shales are we1l known as being difficult and costly to drill. Numerous fishing jobs have plagued drilling operations, and the cost of reaming tight holes ad weighting up the drilling mud to control shale sloughing has been high. The concept of controlling water loss to stop sloughing was introduced in the 1920's. It was known-then that calcium in fresh water re- strains clay £ran excessive swelling (theory of osmosis) . This reinforced the belief that calcium-based muds such as lime, gypsum and calcium chloride should minimize hydration of clays. Lime muds were then introduced for this purpose and others in the 1930-1940 decade1. They were used for shale inhibition but were not effective. In an attempt to improve them, a special calcium-type mud beam popular during the 1950's. Hole enlargement continued and they too were considered ineffective. During & early 1960qs, papers were published claiming that shale swelling could be prevented by using high concentrations of chemical thinner called Chrane Lignosulfonate1. This began the era of highly treated lignosulfote muds. Unfortunately, the hole enlargement problem continued. During & mid-1960’s, oil based muds were used for the purpose of inhibition of shales. Not until 1966 did Mondshine2 suggest that the water phase be saturated with calcium chloride. The cost of using oil based mud was considered by most operators not worth the additional hole stability. The potassium chloride-polymer muds were also used in many fields in the United States and western Canada. The use of these muds has been claimed to prevent clay swelling by inhibition and encapsulation in sane areas of western Canada. They are also expensive and their ueneral application is still experimental. To reduce filtrate loss when sloughing shale becomes a problem during drilling is a reasonable practice. This study will investigate the use of cationic organic additives to mud to form a protective barrier between the shale - which are primarily composed of clays - and water that will keep water from entering the microfractures and will also prevent them from hydrating. In so doing, an understanding of modern clay chemistry and & dispersive properties of cationic additives in water based systems will be our most valuable tools. This study will also present and solve a mathematical model for simulating cation transport phenomena in fractured shales using the Framdlich equilibrium adsorption isotherm. The studies will analyze wellbore failure and stability as affected by cationic organic material.

Jan 1, 1986

By Jozef S. Stachulak

Inco Limited operates 11 underground mines in the Sudbury District. The mines are located on the rim of the Sudbury Basin, an oval with the axis in the range of 27 and 60 km. The ore dips to at least 3000 m below surface. The ores are mined primarily for nickel and copper. Total ore production from underground is in excess of 55,000 tons per day. Over 40 surface fans have been installed since the late 1960's. All of the fans are adjustable pitch, axial flow units. A major factor influencing ventilation design in the last 30 years has been the introduction of diesel equipment underground. Volumes per fan have ranged from 60 to 330 (cubic metres per second), with motors from 100 to 2500 hp. Fans of the axial flow type have been in common use for main fan installations at Canadian mines for many years. The standard arrangement has been to mount these fans horizontally, i.e. with the fan shaft and the long axis of the housing horizontal. This is a natural arrangement for an underground fan, but for a surface installation, a vertically mounted fan has definite advantages. The surface area taken up by a typical vertical fan installation is generally about one quarter of that with a horizontal fan of the same capacity. (1) This is not a problem with isolated fans and flat surface outcrop sites, but where the installation is to be near existing buildings, or where there are poor surface soil conditions, space and cost considerations greatly favour vertical fans. MAIN FANS INSTALLED There are 43 main surface fans in operation at 11 mines. Twenty-seven of these fans are supply units, and 75% of them are vertical installation. The remaining 16 units are main surface exhaust fans, with predominantly horizontal installation. Within the last five years, some 20 main booster fans have been installed underground at several mines. Axial flow fans, with adjustable pitch blades, are used for both surface and underground installations. Exhaust fans are equipped with stainless steel or cast aluminum blades. Main underground fans are arranged horizontally and the majority of them have a floating shaft between the fan shaft and the motor. (2) The size of the fans in service varies from 1.8 m to 5 m in diameter, with the majority ranging from 1.8 to 2.5 m. The pressure produced by these fans varies from 0.25 kPa to 2.0 kPa. At Inco Limited, two main fans in parallel are preferred, rather than a single fan, so that if one fan fails, the remaining fan can still supply up to 70% of normal air quantities, while the damaged fan is repaired. This requires closure doors on each of the fans so the fan can be isolated in case of failure. It is more expensive than a single fan, but results in less production interruptions. The fan installations are well away from sharp inlet and outlet bends. FAN DESIGN INTEGRITY Both the mine operator and the fan manufacturer must understand that the main fan is critical to the mine operation, and that everything technically possible must be done in design and manufacture to ensure the highest degree of reliability. Some of the design parameters and criteria, based on Inco experience, are outlined and discussed below. RESONANT FREQUENCIES AND HOUSING MODEL ANALYSIS Any fan assembly will have many different resonant frequencies. It is a challenge to the designer to arrive at a design in which forcing frequencies do not coincide with any of these resonant frequencies to produce unacceptable vibration levels in operation. Finite element analysis is a useful tool that can be used to identify the most critical of these, so that housing and blade stiffness can be adjusted to change any resonances that might be close to forcing frequencies. Shaft critical speeds should be at least 25% above the fan operating speed, and there should be sufficient separation between other resonant and forcing frequencies to avoid excitation that might result in high vibration levels. QUALITY ASSURANCE Radiographic Blade Examination Mine fan blades are normally cast in small lots. To ensure that the castings are sound, a full radiographic examination is recommended in the highly stressed lower 1/3 of the blade.

Jan 1, 1995

By M. R. Yalamanchili, J. D. Miller

Discussion by M.R. Yalamanchili and J.D. Miller The authors, M. S. Celik et al., should be recognized for their efforts to describe the flotation behavior of boron minerals. In the case of borax and other soluble salt minerals, analysis of the flotation chemistry has been difficult because of the high ionic strengths associated with these soluble salt systems. However, considerable progress has been made in this area, and recently a surface charge/collector colloid adsorption model was proposed by Miller and his coworkers to explain the collector adsorption phenomena observed in soluble salt flotation systems (Milleret al, 1992; Yalamanchili et al., 1993; Miller and Yalamanchili, 1994; Yalamanchili and Miller, 1994a: Yalamanchili and Miller, 1994b). In this work, the sign of the surface charge of alkali halides in their saturated brines was established on the basis of nonequilibrium electrophoretic mobility measurements by laser-Doppler electrophoresis (Miller et al., 1992). Generally, these results are what would be expected from the simplified lattice-ionhydration theory. This electrokinetic information coupled with the stability and prevalence of collector colloids in such soluble salt flotation systems indicates that the selective flotation of alkali halides is due to the adsorption of oppositely charged collector colloids by heterocoagulation. Experimental flotation/bubble attachment results for 21 different alkali halides (Yalamanchili et al., 1993; Yalamanchili and Miller, I994b) confirmed that the flotation response of soluble salt minerals with weak electrolyte collectors can best be explained by the adsorption of oppositely charged collector colloids rather than by the adsorption collector ions and/or neutral molecular dipoles as originally suggested by many researchers (Fuerstenau and Fuerstenau, 1957; Schubert, 1967; Roman et al., 1968). In addition, the flotation of certain alkali oxyanions (Pizarro et al., 1993) and double salts such as schoenite and kainite can be explained by the same collector colloid adsorption mechanism (Miller and Yalamanchili, 1994). The borax flotation results reported by Celik et al. need to be examined in terms of the above mentioned surface charge/ collector colloid adsorption model. Unfortunately, the authors seem to be unaware of this recent work that nicely describes soluble salt flotation with weak electrolyte type collectors such as amines and carboxylates. In view of our past work, the flotation characteristics of borax were of particular interest, and, in this regard, the results of dodecyl amine flotation of borax reported by Celik et al. have been examined in further detail in the light of experimental results from our laboratory. In our research, a vacuum flotation technique was used to study the flotation response of borax (Na2B407.10H20), which has a solubility of 39 g/L at 25 °C) with dodecyl amine hydrochloride as collector. These chemicals were purchased from Eastman Kodak and used as received. Saturated solutions of borax at desired pH values were prepared by continuously stirring the salt solutions over a period of about 10 hrs. It should be mentioned that the conditioning time to achieve equilibrium is an important variable and can significantly change the flotation response of some soluble salts (Yalamanchili et al., 1993). Collector was added to the saturated borax solutions containing about one gram of 100x 150 mesh borax particles, and conditioning was done for about 20 minutes prior to flotation. The borax flotation recoveries from saturated brine are presented in Fig. 1 as a function of collector addition at the natural pH of 9.3, as reported both by Celik et al. and as measured in our laboratory. In addition, the region of precipitation for the dodecyl amine hydroborate is included in Fig. 1. It can be seen in Fig. 1 that the flotation response curves are separated by about one order of magnitude in R12NH3CI collector addition. The flotation results of Celik et al. show that the maximum borax recoveries can be obtained below the solubility limit of the dodecyl amine hydroborate collector. However, in our experiments borax flotation seems to occur only after the precipitation of the dodecyl amine hydroborate collector as might be expected from the collector colloid adsorption model (Yalamanchili et al., 1993) if borax were negatively charged. Further analysis by nonequilibrium and equilibrium electrophoretic mobility measurements for borax indicates that borax is negatively charged at the natural pH of 9.3, as discussed below. The reliability of the nonequilibrium electrophoretic measurements has been demonstrated previously for alkali halides and alkali oxyanions (Miller et al., 1992; Miller and Yalamanchili, 1994). The equilibrium and nonequlibrium electrophoretic measurements for borax were found to be consistent and are presented in Table 1. These results provide clear evidence that borax carries a negative surface charge in its saturated brine (pH 9.3), and the sign of the surface charge of borax reverses and becomes positive if the pH is reduced to 8.6. The equilibrium between borax and its saturated brine can be described by the following reaction: [2Na2B407.1OH2O-4Na++B407=+HB4O7 +OH+19H20] It appears that the oxyanions of the borax lattice provide

Jan 1, 1995

By Wallace Jarman

Introduction As with many gravity concentration processes, pneumatic concen¬tration traces its origin in antiquity. The use of winnowing to separate chaff from grain has long been known, and such procedures were undoubtedly practiced in ancient civilizations for the concentration of ores and the separation of slag from metal whenever specific gravity, size, and shape differences were favorable. Taggart142 has reported on the use of dry rockers and dry panning techniques for use with gold ores in arid regions such as Western Australia. The present day air table was developed in the last century for this purpose. Devices and Processes Classification. All classifiers make a separation on the basis of size, shape, and specific gravity. In addition to specific gravity and size, particle shape factor is often particularly important to pneumatic processes, and advantage is taken of the fact that both flat and fibrous particles settle at velocities substantially lower than that of their equiv¬alent spheres. Another factor of importance in this process is the bulk density of the material since substances such as exfoliated ver¬miculite or partially opened fibrils of asbestos have bulk densities significantly lower than those of the pure in situ mineral. Winnowing takes advantage of all of these physical factors to affect a separation starting with a closely sized feed, and vermiculite has been separated from rock by this process.142 When air classifiers are used to size minerals, the separation will often not be perfect because heavy particles will respond similarly to somewhat coarser light particles while flat, elongated, and low bulk density particles will act as would particles finer than the cut size. An example of a classification process that also results in concentration is the zig-zag classifier"' used to separate paper from glass, metal bottles, and cans during the recycle of municipal solid waste. Application of this process to minerals showing the proper specific gravity, size, and shape differ¬ences is obvious. An important device of this type is an air-aspirated screen used to remove asbestos from its associated rock during the dry processing of that mineral.144 The raw ore is crushed and screened and the asbes¬tos removed by aspiration from the surface of the screen by virtue of its shape and low bulk density. Hindered Settling. Based on the discussion in the section on "Hindered Settling Concentration and Jigging," the use of air devices could be anticipated in desert areas or where moisture may be deleteri¬ous to the product to be separated. Such processes have three major defects: (1) dust may be difficult to contain, (2) fines are difficult to process, and (3) the process is inherently less efficient than are wet processes as may be seen from Eqs. 3 and 4 in the section on "Hindered Settling Concentration and Jigging p. 4-47." Taggart142 has reported on the use of both dry panning and a dry rocker for gold separation in and regions. The dry panning makes use of winnowing, defection on the basis of specific gravity and shape during fall, and hindered settling. Prescreened placer material is poured from one pan to another as air blows across the falling stream. The process is repeated many times with hand picking to produce a rough concentrate. Magnetic minerals are then removed, and the residue, one grain deep in the pan, is air blown. In dry rocking the gravel is sized on a steeply inclined screen with the undersize fed to a riffle box with a porous bottom which is blown from underneath."' This device was the forerunner of the present-day air table. Air Tables and Jigs.145. 146 At least nine types of these devices have been developed, all but two of them for coal. While the devices used for coal may be characterized as pneumatic jigs, pneumatic tables, and pneumatic landers,145 only pneumatic jigs survive today. The same is true for ores.'" In these devices presized particles are fed to the separator which consists of an inclined vibrating conveyor with a porous surface through which air is carefully introduced to form a fluid bed. The lighter particles are lifted by the air out of uphill conveyance and float downhill, while the heavier particles in contact with the surface are conveyed uphill by the vibrator. Typically both transverse and longitudinal slopes are used. A plan view of a Triple S air table and the type of separation made is shown in Fig. 44.147 Because of its external appearance, the device has been called an air table, although it functions essentially as a jig. However, some of the asymetrical acceleration conveying function of a standard shak¬ing table is also performed by the eccentric vibrator incorporated into this device. Low pressure air is admitted below the vibrating table surface consisting of cloth (e.g., canvas), porous plastic, woven wire, or punched metal supported on a wire mesh or grid. As with a shaking table, the device produces a concentrate, middlings, and tailings. The middlings are recycled or are subsequently treated on another concentrating device. As with many wet separations, presizing by screening is necessary. The oft-repeated admonition of Professor Richards, "Separation without classification is damnation," is cer¬tainly true here. In this way a small heavy particle which might weigh the same as a large light particle and thus report to the same place on the air table has already been removed in the sizing step. Air tables are almost universally encased with a canopy to remove dust by aspiration. Some concentration may also be achieved in this step when favorable specific gravity, size, and shape differences are present. Applications Ore Separations. Air tables were originally developed for ore separations, and they find application in and regions or where water is deleterious or inconvenient to use or remove (e.g., small tonnage materials already dried). They have been used for asbestos, bauxite, calcite, cassiterite, columbite-tentalite, diatomaceous earth, fluorite, gilsonite, graphite, kyanite, manganese minerals, mica, managite, perlite, pyrite, pyrrhotite, vermiculite, and uraninite ores. More recently, air tables have found favor in separating a wide variety of secondary materials such as abrasive grains, bone char, catalysts, fiberglass, scrap glass, scrap wire from its insulation, prills from slag, dross and coke from metal or from each other, metal from crushed crucibles, lead from plastic in old batteries, and cubic particles from flat ones. The devices also finds considerable application in the preparation of food¬stuffs. As stated before close sizing before separation is desirable, and if the specific gravity difference is slight, very tight

Jan 1, 1985

By S. Z. Galiyev

In this paper the basic approach to the present planning and quality management of open-pit ore streams is presented. This is accomplished within the framework of a unified system of information management for the administration of a geotechnological complex on open-pit development of mineral deposits.

Jan 1, 2003