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By Amy McBrayer, Andrea Brickey

Area mining is a surface mining method that allows for efficient mining and contemporaneous reclamation of tabular or bedded deposits, e.g., coal. Mine planning methods for area mines differ from those of open pit metal mines. Area mines in the Powder River Basin (PRB) use various processes for mine planning at both the strategic and tactical stages. With the ever changing commodity markets, it is becoming increasingly important for mine operators to be able to react quickly to the changing business environment. Tools that allow for the development and rapid comparison of production schedule scenarios are key to ensuring agile mine operations. A survey of mine engineers responsible for mine design and production scheduling at coal operations provides clarity on the current mine design and production scheduling processes in the PRB, as well as a discussion on potential solutions to upcoming challenges. In this article, we describe various mine planning processes used by the coal producers in the Powder River Basin. The survey identifies a clear gap in the ability to create comprehensive schedules associated with limited tools and lack of engineering labor needed to frequently conduct the mine design and scheduling process.

Jul 8, 2023

By M. Sadegh Safarzadeh, Stanley M. Howard

The two-dimensional predominance area (Kellogg) diagram (PAD) surfaces bounding the three-dimensional Cu-As-S-O system were constructed at 900 K. The computations employed gases As4O6(g), O2(g), and SO2(g) as the independent coordinate species to generate diagrams of As4O6(g) − O2(g),O2(g) − SO2(g), and As4O6(g) − SO2(g), while the third gas (As4O6, O2, or SO2) was fixed. The results indicate that there is no shared boundary between enargite (Cu3AsS4) and copper sulfate (CuSO4); however, at PO2 < 10−6 atm, PAs4O6 < 10−10 atm, and PSO2 > 10−4 atm, CuSO4 is the stable phase at 900 K. The chemical driving force for oxidation of intermediate phases between enargite and copper sulfate is substantial except for basic sulfate (CuO · CuSO4).

By M. Sadegh Safarzadeh, Stanley M. Howard

The two-dimensional predominance area (Kellogg) diagram (PAD) surfaces bounding the three-dimensional Cu-As-S-O system were constructed at 900 K. The computations employed gases As4O6(g), O2(g), and SO2(g) as the independent coordinate species to generate diagrams of As4O6(g) − O2(g),O2(g) − SO2(g), and As4O6(g) − SO2(g), while the third gas (As4O6, O2, or SO2) was fixed. The results indicate that there is no shared boundary between enargite (Cu3AsS4) and copper sulfate (CuSO4); however, at PO2 < 10−6 atm, PAs4O6 < 10−10 atm, and PSO2 > 10−4 atm, CuSO4 is the stable phase at 900 K. The chemical driving force for oxidation of intermediate phases between enargite and copper sulfate is substantial except for basic sulfate (CuO · CuSO4).

By C. D. Litton

Laboratory experiments were conducted to determine the responses of a prototype smoke detector and a commercially available photoelectric smoke detector to smoke particles generated from various combustion sources. The prototype smoke detector combines optical scattering measurements with ionization chamber measurements in order to reduce/eliminate nuisance alarms due to the presence of airborne dusts or diesel exhaust particles. The commercially available smoke detector is designed for use in harsh environments where airborne dust represents a major problem due both to nuisance alarms and detector contamination. In the experiments, the responses of the two detectors were measured when exposed to smoke particles from the exhaust of a diesel engine and from a variety of fire sources, including wood, coal, styrene butadiene rubber, and No. 2 diesel fuel. For the solid fuels, data were obtained for both smoldering and flaming combustion. This report describes the experiments, their results, and the use of these results as they apply to early-warning fire sensors capable of the rapid and reliable detection of fires in atmospheres that may or may not be contaminated by either airborne dust or the products produced from diesel engines. Subsequent to these laboratory experiments, six smoke detectors were installed in an underground limestone mine for further testing and evaluation. DISCLAIMER: The findings and conclusions in this report have not been formally disseminated by the National Institute for Occupational Safety and Health and should not be construed to represent any agency determination or policy.

Jan 1, 2009

By MATT RENAUD, Mustafa Kumral

Mining corporations have spread their operations worldwide in the last few decades. The reason behind widening operations geographically can be seen as it being part of a risk diversification strategy. Given that the technical, financial and social risks are high, favorable deposits, taxation regimes and legislative frameworks create incentives for international mining operations. On the other hand, international mining activities add the risks of permitting, investing, operating and decommissioning to the corporations. These risks could emerge from defaulting, corruption, resource nationalism, social license to operate, and political and legislative uncertainties and instabilities.

By Y. Paul Chugh

NIOSH and the Illinois Clean Coal Institute are funding studies on characterization of coal and quartz dust in Interior Basin mines since 2009. Coal dust characteristics vary significantly and, are vital for the development of the engineering controls. This paper presents wettability characteristics of coal dust with respect to its chemical and physical properties, since wettability is considered to be a primary dust control technique. Particle size distribution, inter-particle interactions during wetting and quartz associations with organic and inorganic matter in coal seams is critical for understanding wetting phenomena. Silica content in the un-wetted fractions was found to be very high during wetting tests. Wetting of quartz may be limited by its association to hydrophobic materials as well as buoyancy forces resulting from particle size characteristics and particle-particle interaction in the wetting agent. Temperature of the wetting solution and effective contact time between dust particles and water droplets are found to be two important variables affecting the wettability. The characterization data obtained from this study can be utilized to develop engineering controls.

Jan 1, 2011

By Dapeng Zhang, Brij Moudgil, Shibo Zheng, Chunhui Feng, Wenyi Song, Wending Xiao, Patrick Zhang

Separation of dolomite from phosphate is the most challenging problem in phosphate mineral processing. Over 50% of the future phosphate reserve in Florida contains too much dolomite to process using the current industry practice. The current phosphoric acid production practice requires less than 1% MgO in the phosphate concentrate as the feed material. The Florida Industrial and Phosphate (FIPR) Institute has collaborated with worldwide experts in the field to address this issue. As a result, the industry is now offered three feasible options. Option 1 offers three methods for reducing MgO content in the concentrate from the Crago process, including adding a dolomite depressant in the rougher flotation step, dolomite flotation of the cleaner concentrate, and scrubbing the cleaner concentrate in quartz sand. These methods could reduce MgO content in the final concentrate by 20–40%. Option 2 involves crushing and grinding of high-dolomite phosphate pebbles followed by dolomite flotation at slightly acidic pH using a new collector that does not require phosphoric acid as a phosphate depressant, achieving a final concentrate analyzing less than 0.9% MgO at about 87% P2O5 recovery. Option 3 is a gravity separation technique using an innovative separation jig, and its full potential remains to be demonstrated.

Colloidal interactions play a critical role in mineral processing, including grinding, physical separation (particularly flotation), dewatering, and tailings management. Despite great energy input in comminution to liberate valuables from gangues, heterocoagulation between valuables and gangues would prevent the separation of valuables from gangues. On the other hand, selective coagulation/flocculation to increase the size of desired fine particles could enhance physical separation and dewatering, while dispersion is needed for fine grinding. To control the state of colloidal dispersions by creating favorable conditions, it is of paramount importance to study colloidal interactions in a relevant system and understand underlying mechanisms. This review summarizes recent advances in developing the-state-of-the-art techniques and novel methods of measuring colloidal forces, including atomic force microscope, surface force apparatus, zeta potential distribution measurement, quartz crystal microbalance with dissipation, and our recently developed integrated dynamic force apparatus. The basic principle of each technique was introduced first, followed by a summary of critical information derived for the relevant mineral processing systems. Finally, the pros and cons of each technique were discussed to emphasize the use of complementary techniques that assist in solving fundamental problems in mineral processing.

By Arthur M. Langer

Since the promulgation of the first Federal Asbestos Standard by the Occupational Safety and Health Administration in 1972, other federal agencies have modified the standard to better carry on their own unique missions. The instruments used to identify and measure asbestos, the sampling protocol, and the criteria used to define asbestos, have been modified to some degree. The Mine Safety and Health Administration regulates and controls asbestos dust in the mining and mineral commodity industries. However, crushed stone and processed ores contain mineral fragments that are frequently difficult to distinguish from asbestos. Mineral nomenclature, instruments for particle analysis, and sampling strategy must be accommodated to some degree to make asbestos control workable and meaningful. Precedent in other agencies has made consideration of these changes possible. Newly identified amphibole asbestos minerals have further complicated the agency?s regulatory charge. Changes in its Asbestos Standard are now being considered. Crushed taconite ore in the Eastern Mesabi highlights many of these issues. ©2008 Published by Elsevier Inc. Keywords: Amosite; Grunerite asbestos; Crocidolite; Riebeckite asbestos; Tremolite asbestos; Actinolite asbestos; Winchite asbestos; Richterite asbestos; Arfvedsonite asbestos; Fluor-edenite asbestos; Asbestos defects; Cleavage fragment; Mineral habit; Mesabi amphiboles

Jan 1, 2008

By John F. Gamble

Amphiboles are hydrated mineral silicates five of which occur in asbestiform habits as asbestos grunerite (amosite) asbestos, riebeckite (crocidolite) asbestos, anthophyllite asbestos, tremolite asbestos and actinolite asbestos] and non-asbestiform habits (grunerite, riebeckite, anthophyllite, tremolite and actinolite). The asbestiform varieties are characterized by long, thin fibers while non-asbestiform varieties such as cleavage fragments form short fibers with larger widths. The U.S. regulatory method for counting asbestos fibers (aspect ratio [>]3:1, length [>]5 µm) does not distinguish between asbestos and cleavage fragments. The method biases toward increased counts of non-asbestiform cleavage fragments compared to long, thin asbestos fibers. One consequence of this regulatory approach is that workers can be erroneously classified as exposed to concentrations of asbestos (asbestiform amphiboles) above the U.S. 0.1 f/mL exposure standard when in fact they are not exposed to asbestos at all but non-asbestiform amphibole cleavage fragments. Another consequence is that the known carcinogenic effects of asbestos may be falsely attributed to non-asbestiform amphibole cleavage fragments of the same mineral. The purpose of this review is to assess whether amphibole cleavage fragments pose the same risk of lung cancer and mesothelioma characteristic of amphibole asbestos fibers. We identified three groups of workers exposed to non-asbestiform amphiboles: two groups exposed to grunerite (Homestake gold miners and taconite miners) and one group exposed to industrial talc containing non-asbestiform tremolite and anthophyllite in St. Lawrence County, NY. In addition to assessing strength of association and exposure?response trends in the non-asbestiform amphibole cohorts, comparisons were also made with cohorts exposed to the asbestiform counterpart (positive control) and cohorts exposed to the mineral (e.g. talc) that does not contain amphiboles (negative controls). The cohorts exposed to non-asbestiform amphiboles had no excesses of lung cancer or mesothelioma. Similar results were observed in the negative control groups, in stark contrast to the excess risks of asbestos-related disease found in the asbestos cohorts. The only possible exception is the twofold increased risk of lung cancer where exposure was to industrial talc containing cleavage fragments of tremolite and anthophyllite. However, this risk is not considered attributable to the talc or amphibole cleavage fragments for several reasons. A similar increased risk of lung cancer was found in Vermont talc workers, studied in the same time period. Their exposure was to relatively pure talc. There was no relationship between lung cancer mortality and exposure measured as mg/m3 years and years worked. A case?control study reported that all the lung cancer cases were smokers (or former smokers) and attributed the excess to smoking. There were two mesothelioma cases among the NY State talc workers exposed to cleavage fragments of tremolite and anthophyllite, but talc is not a plausible cause because of too short latency and potential for previous asbestos exposure. The positive controls of tremolite asbestos and anthophyllite asbestos exposed workers showed excess risks of both lung cancer and mesothelioma and positive exposure? response trends. St. Lawrence, NY talc does not produce mesotheliomas in animals while amphibole asbestos does. In sum, the weight of evidence fully supports a conclusion that non-asbestiform amphiboles do not increase the risk of lung cancer or mesothelioma. ©2008 Published by Elsevier Inc. Keywords: Amphiboles; Cleavage fragments; Lung cancer; Mesothelioma; Asbestos; Non-asbestiform amphiboles; Grunerite; Talc

Jan 1, 2007

Floor heave events in underground mining often happen suddenly and cause risk to workers and equipment. Reducing the risk of floor heave must be addressed in mining layout design. To improve that design one must understand the significant parameters that are correlated to the occurrence of floor heave. To accomplish that goal, researchers from the National Institute for Occupational Safety and Health (NIOSH) completed a numerical study using FLAC3D, taking advantage of its strain softening and ubiquitous joint capabilities to better simulate the floor heave and caving mechanisms involved at an actual mine site.

Jan 7, 2020

By Bill Tucker, Mike Black

"PROJECT OVERVIEW Crossrail, Europe’s largest construction project, will increase London’s transportation capacity by 10% when it opens in 2018. The Crossrail scheme is a combination of surface and underground railway that stretches 118km east-west through central London from Reading, Berkshire and Heathrow airport in the west to Shenfield, Essex and Abbey Wood in the London Boroughs of Greenwich and Bexley in the east. Crossrail will serve 40 stations, ten of which are new, and bring 1.5 million people within 45 minutes commuting distance of London’s key central business districts. 21km of the Crossrail route comprises twin-tunnels beneath the heart of central London. It is the central section of the route, and the challenges that had to be overcome to construct its tunnels under the historic capital that forms the subject of this paper. The route of the Crossrail tunnels can be seen in Figure 1. These tunnels weave their way through the city’s underground landscape, linking eight new underground stations which connect to the existing London Underground network, providing interchanges with nine existing lines as well as the National Rail and Docklands Light Railway networks.Crossrail began construction of enabling works in May 2009 and launched the first of eight tunnel boring machines (TBMs) in May 2012. 42km of major tunneling work was completed in May 2015, and included 11km of sprayed concrete lined tunnels at the five mined stations (Bond Street, Tottenham Court Road, Farringdon, Liverpool Street and Whitechapel) in addition to the bored tunnel sections. The remaining three sub-surface stations at Paddington, Canary Wharf and Woolwich were constructed as large open boxes prior to the TBMs passing through. Crossrail, Ltd. is a special purpose company formed by the project’s joint sponsors, Transport for London and the Department for Transport, to manage design, construction and commissioning of the project. In 2009, Crossrail engaged Bechtel Ltd. as its delivery partner and a joint venture, Transcend (comprised of CH2M, AECOM and the Nichols Group), as its programme partner. The project is being managed by an integrated programme management team which is staffed by Crossrail and its partners. The railway, when opened, will be operated by Rail for London. With tunneling completed in accordance with the project’s master control schedule, the new railway is scheduled to commence dynamic testing in late 2017, with a phased opening of the tunneled sections and stations through Central London in 2018."

Jan 1, 2016

By Rainer Kahrger

This paper is a follow-up to the paper presented at the SME meeting in April of 1996. Since then, the El Abra facility has been started up, 9 months ahead of schedule, and has processed about 45 million tons of ore and produced over 700 million pounds of copper. For those unfamiliar with the El Abra materials handling and leaching facilities, a brief overview of the facility is provided. The paper will then deal in detail with such aspects of Conveyor 103, the long regenerative overland conveyor, including: actual running resistance starting and stopping procedures emergency brake test at 10,000 t/h Additionally, we shall take the opportunity to report on a catastrophic culvert collapse in October 1996, which stopped the conveyor abruptly at full speed and under high load condition, causing a belt breakage. We would like to use this opportunity to thank the management of El Abra and Cyprus Amax for providing assistance and allowing us to present this paper. The El Abra team deserves a great compliment for building this one billion dollar facility in record time in a remote area of a high-altitude desert with no existing infrastructure, and for bringing it so quickly up to full operating capacity. The El Abra management had to assemble a completely new operator team. Considering the above circumstances, it took a great effort by all involved to achieve success. The official performance test which was required by the lending banks was successfully concluded in November 1997.

Jan 1, 1998

By Andrew B. Cecala, Emily J. Haas, Jay F. Colinet

A sociotechnical system (STS) creates a framework that allows an examination of how social and technical factors affect organizational outcomes within a specific environmental context. STS has been rigorously studied with a primary research focus addressing worker-technology interactions. Although these interactions are important, the social processes and interactions that occur whenever any technical or environmental change is introduced into the system have been undervalued. If social processes are better understood, mining organizations could efficiently prepare and stabilize for such changes. With this goal in mind, we sought to extend STS theory through applying principles of meta-design to analyze the results of two case study interventions. Specifically, we studied the impact of an unregulated dust control technology (the Helmet-CAM) and a regulated dust control technology (the Continuous Personal Dust Monitor) on factors within an STS including employees’ knowledge of, communication about, and use of technology to mitigate respirable dust sources. The results are presented in a way that first, addresses the overarching principles of meta-design STS including organizational participation, flexibility, and communication and second, examines how technology implementation processes differ when the organization is complying with a formal, higher-level requirement. Results show that a prominent focus on the social factors within an STS framework could help reduce unpredictability on the technical side and may improve communication within the system to help reduce adoption time, especially if and when accompanying a new, formal work process.

By Andrew B. Cecala, Emily J. Haas, Jay F. Colinet

A sociotechnical system (STS) creates a framework that allows an examination of how social and technical factors affect organizational outcomes within a specific environmental context. STS has been rigorously studied with a primary research focus addressing worker-technology interactions. Although these interactions are important, the social processes and interactions that occur whenever any technical or environmental change is introduced into the system have been undervalued. If social processes are better understood, mining organizations could efficiently prepare and stabilize for such changes. With this goal in mind, we sought to extend STS theory through applying principles of meta-design to analyze the results of two case study interventions. Specifically, we studied the impact of an unregulated dust control technology (the Helmet-CAM) and a regulated dust control technology (the Continuous Personal Dust Monitor) on factors within an STS including employees’ knowledge of, communication about, and use of technology to mitigate respirable dust sources. The results are presented in a way that first, addresses the overarching principles of meta-design STS including organizational participation, flexibility, and communication and second, examines how technology implementation processes differ when the organization is complying with a formal, higher-level requirement. Results show that a prominent focus on the social factors within an STS framework could help reduce unpredictability on the technical side and may improve communication within the system to help reduce adoption time, especially if and when accompanying a new, formal work process.

By Congling Shi, Marek Borowski, Yue Wang, Jianwei Cheng, Xixi Zhang, Xuan Xu

As the first barrier to prevent accidents caused by explosions in underground coal mines, the integrity and stability of mine seals have great effects on mine workers’ lives and underground production safety. In this paper, the mechanical responding performance of typical mine seals under the impact load are studied by using numerical simulation method. By such simulation studies, the safety of different seals subjected to the explosion load is evaluated. Seals’stability are also investigated under effects caused by various influence factors including thickness of mine seal, cutting depth into surrounding rocks, rock type, and the roof-tofloor convergence under given the explosion load. The research results can provide theoretical basis and reasonable improvements for mine seal’s construction practices for improving its anti-explosion performance.

By Congling Shi, Marek Borowski, Yue Wang, Jianwei Cheng, Xixi Zhang, Xuan Xu

As the first barrier to prevent accidents caused by explosions in underground coal mines, the integrity and stability of mine seals have great effects on mine workers’ lives and underground production safety. In this paper, the mechanical responding performance of typical mine seals under the impact load are studied by using numerical simulation method. By such simulation studies, the safety of different seals subjected to the explosion load is evaluated. Seals’stability are also investigated under effects caused by various influence factors including thickness of mine seal, cutting depth into surrounding rocks, rock type, and the roof-tofloor convergence under given the explosion load. The research results can provide theoretical basis and reasonable improvements for mine seal’s construction practices for improving its anti-explosion performance.

By T. Gupta, T. Ghosh

Rare earth elements (REEs) and their compounds are essential in a multitude of mundane and sophisticated applications such as renewable energy technologies, catalysts, medicine, and defense applications. The global supply deficit could be attributed to the destabilization of REE market that has, as a result, incentivized indigenous production of REEs. Cost-effective and environmentally benign opportunities are being explored for the production of REEs from non-conventional mineral sources including coal and coal by-products to stabilize the supply chain. Coal from Healy coal mine and Wishbone Hill deposits in Alaska have been quantified for REEs and were found to possess elevated total REE concentrations as compared to world average levels (60– 70 ppm). The objective of the study was to concentrate the REEs in the froth phase by froth-flotation of the fine size fraction (< 75 μm). A Box-Behnken design of experiment was employed to ascertain the main and interaction effects of operational parameters on response variable by analyzing 3D response surfaces. Experiments were carried out to maximize REE recovery and concentration by modeling and optimization of three operating variables (frother dosage, pulp density (% solids), and collector dosage). Based on the results, the optimum flotation conditions for maximum recovery at an elevated concentration of REEs in the froth fraction was obtained at 4.2% solids and 32.7 ppm of frother dosage for Healy sample and 10% solids and 37.9 ppm of frother dosage for Wishbone Hill coal sample. The quadratic relationship between the input and response variable was found to be independent of collector dosage suggesting good surface hydrophobicity and floatability of the two coal samples.

By Bijan Taheri, Behrouz Maghsodi, Monireh Heshami, Reza Kohan

A common problem recently encountered with the increase in the rate of input feed at Enrichment Plant 2 of the Sarcheshmeh Copper Complex is the loss of value to the tails, translating to lower recoveries. The feasibility of the direct transfer of part of the high-grade concentrate from rougher stages to an appropriate position along the circuit was studied, and two positions were proposed for direct transfer of the concentrate. One position was the feed flow into cleaner cells, and the other was the feed flow into the recleaner cell. The results indicated that transferring the concentrate from the first unit of the rougher stage to the feed flow into the cleaner cells was feasible, with no limitations, while the second position required the installation of a set of hydrocyclones. It was found that the transfer of concentrate to the proposed positions not only addressed the problem of limited cell capacity, resulting in debottlenecking of the circuit, but also improved metallurgical separation efficiency up to 1.4%.

By Xuchen Fan, Chenyang Zhou, Yuemin Zhao, Liang Dong, Chenlong Duan

A gas–solid fluidized bed using magnetite particles is an effective methodology for coal beneficiation in the field of dry coal cleaning. Broadening the size range of magnetite used in the bed decreases medium preparation cost. In this study, a tapered fluidized bed was used to investigate a magnetite particle size range of −0.5 + 0.074 mm. The results showed that a tapered fluidized bed effectively strengthens mixing of magnetite with a wide size range (−0.5 + 0.074 mm). The results of beneficiation experiments indicated that with increasing tapered angle, separation efficiency increased and then decreased. The highest separation efficiency was obtained at a tapered angle of 10°. The optimal results showed that the ash content of the concentrate decreased from 31.82% to 12.33% with a probable error of 0.11, which indicated that a tapered fluidized bed was efficient to improve fine coal beneficiation performance.