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By Chris Howell

PotashCorp?s Aurora phosphate mine, in Beaufort County, NC, operates four low pressure boilers and four high pressure boilers to meet its process steam requirements. Maintaining these boilers is critical to meeting production demands. Processing phosphate ore into phosphoric acid requires large amounts of sulfuric acid and steam. Ore is mined from the phosphate deposit with large bucket excavators after 9 to 30 m (30 to 100 ft) of overburden is removed. The phosphate ore is mixed with water to make a slurry that is pumped to the mill. Elemental sulfur is burned in the presence of air to make sulfuric acid. This process is highly exothermic and boilers produce steam while cooling the process. The phosphate ore is reacted with sulfuric acid and the resulting products are refined into different grades of phosphoric acid for fertilizers, feed stock and food additives. Plant operators at the mine were challenged with boiler feed water that was high in silica and other contaminants. As a result, boiler operations were experiencing difficult, labor-intensive operations and equipment deterioration. This resulted in higher operating costs and diminished processing performance. The facility was operating an aged boiler feedwater pretreatment system that included warm lime softening followed by pressure filtration and a cation/anion/mixed bed demineralizer system. The demineralizer required frequent regeneration and chemical usage was high and costs were difficult to predict. Depressurized well water (DPW water), used for plant utility water and boiler makeup, is very high in silica, in the range of 60-70 ppm. Silica can form scale at pressures below 600 psig. Above 600 psig, silica starts to volatize, carrying over with steam to potentially form deposits on downstream equipment and processes. Mine officials decided to upgrade the boiler feedwater pretreatment system to a state-of-the-art reverse osmosis (RO) membrane system. This new system, which started up in March 2009, has improved operating performance and reduced water consumption and overall operating expenditures.

Jan 1, 2011

By J. A. M. Cano

Introduction Since the beginning of operations at the pellet plant at Ponta Ubu ES, Samarco Mineração SA has produced pellets for direct reduction and blast furnace processes. Of the total amount of pellets produced from 1977 through 1993, 55 % are used in the blast furnace, about 45 Mt (49.6 million st). The principal components of pellet gangue are calcium oxide, magnesium oxide, silica and alumina. They should be added in adequate quantities to guarantee the mechanical resistance of the fired pellets under blast furnace conditions. Over the years, the pellets produced by Samarco had a silica content between 2.5% and 2.8% and varying binary basicity preferably between 0.8 and 0.85. On the other hand, the increasing amount of industrial waste in siderurgical plants caused by the increase of steel production has caused some countries to put into practice methods to reduce the volume of slag produced in the blast furnace. This paper's goal is to find an alternative for decreasing the amount of slag produced in the blast furnace. It is possible to decrease pellet gangue by decreasing the silica content to about 2%, leaving the metallurgical properties and quality of pellets unaltered. For this work, Samarco pellets were used with Si02 between 2.5% and 2.8%, pellets with high silica and pellets with Si02 between 2.0% and 2.3% low silica. Both were partially fluxed by the range of varying basicity CaO/SiO2 from 0.8 to 0.95 during production. Experimental tests on pilot scale Thhis work began in January 1986 in the pilot plant (pot grate, Fig. 1) at Samarco. Its goal was to obtain preliminary data that would indicate the bybility of the project. It also formed a solid base to extend the studies in tests on an industrial scale of production for blast-furnace pellets. The pot grate is a test furnace composed of a gas burner, a combustion chamber and a grate, connected by hot air ducts. The burner is fed by a mixture of LPG and air. It reaches high temperatures through oxygen injection. The combustion chamber heats the air that comes from the turbocompressor. This hot air flows through the ducts to the grate on which the pellet samples are fired. During updraft drying, downdraft drying, preheating, firing and afterfiring, the upward and downward direction of the air flow can be controlled by valves driven by pneumatic cylinders. The pot grate indurator was fully automated in August 1989. Positive and negative pressures measurements resulting from gas passing through the pellet layer, as well as temperature readings, are recorded in graphs in relation to time for all tests. The tests depend on the various steps carried out in sequence that can influence the results of the tests. Therefore, some criteria were adopted to restrict the number of variables in the process. This was done to facilitate the results of the analysis. The pellets were composed of concentrate, bentonite, hydrated calcitic lime and metallurgical coal, all regularly used in the pellet plant. The material balance of the pellets mix was determined from the chemical analysis of the components. Table 1 shows the chemical characteristics of the concentrate and the additives used in the pilot plant and industrial tests. The basicity has a marked influence on the metallurgical properties of the pellets produced by Samarco with a silica content between 2.5% and 2.8%. However, for pellets with low silica (about 2%), it was necessary to study the variation in the parameters of quality in a wide range of basicities to deliniate with precision a scope of work. A large variety of low-silica blast-furnace pellets were produced at the pilot plant with binary basicity varying between 0.8 and 0.95. After chemical analysis, those pellets were separated into five groups of different binary basicity (0.8, 0.84, 0.87, 0.90 and 0.95). Each was then split, one part for metallurgical tests in the laboratory at Samarco and another to be evaluated in a laboratory for metallurgical tests in Germany. It was agreed that the tests to evaluate the quality of the pellets in the two [ ]

Jan 1, 1996

By B. Hearn, O&apos

Falconbridge, Ltd. operates six mines (the strathcona, Fraser, Lockerby, Onaping, East and Kidd Creek) in the Sudbury and Timmins districts of northern Ontario (Fig. 1). These mines vary in depth to approximately 1500m and experience a wide variety of ground conditions. Problems of greatest concern include rockbursting, backfill pillar stability, wall and pillar stability, and the use of cable anchors. A study was initiated approximately two years ago to identify how numerical models could aid in the examination and possible understanding or solution of these problems. This paper discusses the use of numerical models at Falconbridge and describes a case history of their use in examination of rockbursting at the Strathcona Mine.

Jan 1, 1988

By AJIT SWAIN, SUNATI MOHANTY

The abstract discusses the importance of predicting the dewatering performance of industrial hydrocyclones from laboratory models. It highlights the challenge of scaling up design and operating parameters for efficiency estimation. The paper describes experiments with a 2-inch and 4-inch hydrocyclone using silica sand. It details the development of a model using the Nageswararao hydrocyclone model and a simulator to estimate model parameters. The model is validated with experimental data, and a new model is developed using 4-inch hydrocyclone data. The technique is then extended to predict dimensions for a full-scale dewatering cyclone operating at higher throughput and solid concentration.

Mar 30, 2022

By DEBASHISH MISHRA, SOMU MANDAL, ASFAR MOBIN KHAN, JAI KRISHNA PANDEY, NIROJ KUMAR MOHALIK, SANTOSH KUMAR RAY

Coal is a low-cost fuel with high calorific value. Statistically, the global coal mining industry suffered 12,489 fatalities in 104 reported mining accidents from coal dust explosions during 1900 to 2020. This review article discusses the occurrence, mechanism and explosibility parameters of coal dust explosions and presents a literature survey of the laboratory and computational fluid dynamics (CFD) simulation methods of studying them, as well as a comparison of the two methods.

Feb 1, 2023

By Jr. Zink

An economic and operational evaluation of the unrecovered metal, physical conditions, and chemical environment in a leach pad should be made prior to decommissioning. This evaluation will help determine the possibility and method of secondary and/or enhanced metal recovery and the method(s) to be used for detoxification and heap closure. The evaluation requires quantitative sample collection in a locally variable, yet grossly homogenous material. An assessment of a valley fill heap leach pad was made using a technique borrowed from placer technology called sonic drilling. The sonic drilling technique produced very satisfactory core recovery and sample quality. At this site, drilling results demonstrated that the method of heap construction produced expected features after extensive long term leaching. Rather than a uniformly homogenous pile of metallurgically depleted crushed ore, an assemblage of solution channels, un-oxidized sections, unleached areas, and compaction due to various factors, were found. These conditions are thought to represent a normal, rather than unique, situation for a valley fill heap leach. The lack of this information can have a significant impact on the economics and methods of heap re-handling and ultimate closure.

Jan 1, 1992

By J. A. Marts, R. C. Gilmore, Jr. Bogin, S. A. Saki, J. F. Brune, J. W. Grubb

"Most, if not all longwall gobs contain explosive gas zones (EGZs), i.e., zones of explosive methane-air mixtures that can cause – and have caused – mine fires and explosions. If the coal is prone to spontaneous combustion, oxygen penetration into the gob must be avoided. This paper summarizes the significant research findings from five years of computational fluid dynamics (CFD) modeling research conducted at the Colorado School of Mines (CSM) under funding from the National Institute for Occupational Safety and Health (NIOSH). CSM Researchers have developed CFD modeling techniques to identify where and under what circumstances EGZs can form in longwall gobs and how EGZ formation and oxygen penetration depend on the ventilation method, face and bleeder ventilation parameters, injection of inert gases and the operation of gob ventilation boreholes. Recognizing these explosion and fire hazards is an important first step in improving the safety of longwall coal mines. CSM modeling research has shown that EGZ formation can be effectively controlled by adjusting ventilation parameters, choosing the proper ventilation pattern and injecting inert gases where necessary. INTRODUCTION In a project sponsored by the NIOSH Office of Mine Safety and Health Research, researchers at the Colorado School of Mines have examined gas compositions and flows in longwall gobs in order to assess explosion and fire hazards. Since gob areas are inaccessible, researchers developed a series of computational fluid dynamics (CFD) numerical modeling tools to characterize these hazards. A variety of CFD models were developed to cover progressively sealed as well as bleeder ventilated gobs for both coal and trona mines. The explosion and fire hazards posed by EGZs in longwall gobs can be summarized as follows.• If the EGZ lies closely behind the longwall face, flames and pressures from an explosion can penetrate the shield supports and reach the active face area, creating blast trauma, burn hazards and toxic, unbreathable atmospheres. • EGZs can be pushed around inside the gob by roof collapses and cave-ins. If they get pushed out into the face area, sudden methane inundations and explosion hazards in face areas can result. • Fresh air flowing into the gob can create an explosion hazard as the gas composition in the gob moves from fuel-rich inert to explosive, creating EGZs. • Ignition sources inside the gob can be frictional ignitions or spontaneous combustion. • Bleeder ventilated gobs are surrounded on all sides by an EGZ that forms along the fringe areas between the fresh-air ventilated bleeder entries and the methane-rich interior of the gob. It is suspected that diffusion flames can propagate rapidly along these EGZ fringes if an ignition occurs"

Jan 1, 2015

By R. Miller

Lowering our globe’s emissions is a major effort as we move toward a future net-zero carbon environment requiring significant investment in a new, low-carbon infrastructure, along with key market incentives to change. Industry will play a key part in this transformation, requiring expertise in both energy and emissions. Key elements of the de-carbonization strategy are: energy data, emissions reporting method, governance, de-carbonization project generation and drivers, the MACC, electrification, and the de-carbonization checklist. For a zero carbon future, it will be key for business leaders to understand decarbonization, anticipate technological changes, and implement new business me

Mar 2, 2022

By K. V. Raj, VASU GANGRADE

Airflow in large-opening stone mines is largely dependent on the natural ventilation due to the large cross- section area of the opening. The openings of such stone mines are typically twice or thrice the size of typical underground coal or metal/nonmetal mines. Due to the influence of natural ventilation, air velocities as well as the static pressure drop in the mines are low. Mines rely on auxiliary fans to ventilate active faces to reduce contaminant exposure to mine workers. The National Institute for Occupational Safety and Health (NIOSH) is conducting research on ventilation of large-opening stone mines to reduce worker exposure to dust and other contaminants such as diesel particulate matter (DPM). In order to reduce worker exposure to dust and DPM, an understanding of the airflow pattern due to auxiliary fans in the mine is needed. Under this research, NIOSH researchers are exploring the computational fluid dynamics (CFD) modeling to understand the airflow behavior in large-opening mines. In this paper, the team is presenting the results from three-dimensional CFD modeling of airflow in a large-opening stone mine and investigating the effect of a fan placement with the movement of trucks.

Feb 1, 2025

By S. Tafazoli, N. Himmelman, D. Chan, E. Chow

"While Wearable Technology has been garnering attention in the consumer market, enterprise and industry have just begun exploring its potential applications. Since February 2014, Motion Metrics International has been working in collaboration with Vandrico Solutions Inc. to apply Wearable Technology to improve productivity and safety in the mining industry. This paper discusses the value proposition of using Wearable Technology to deliver critical notifications in mining. The advantages and disadvantages of various form factors are explored. The challenges, both specific to mining and in general to Wearable Technology, are defined. Finally, the concept of MetricsGear™, the first Wearable Technology platform developed for mining by Motion Metrics International in collaboration with Vandrico Solutions Inc., is described. MetricsGear™ is designed to notify the user with minimal distraction to keep the user focused on their primary task, and aware of mission-critical events. This focus and awareness allows the user to work more efficiently and safely. INTRODUCTION The mining process consists of a series of intricate stages, where certain events or conditions in one stage can have a huge impact on other stages. The notification of these critical events or conditions is vital for ensuring the overall efficiency of the mining process. Critical notifications can be classified as two types: time-critical events and contextual information. Time-critical events are situations where a timely response from a responder can have a significant impact on seizing an opportunity or mitigating cost. Some Human-Computer Interaction (HCI) experts classify notification types based on the Interruption, Reaction, and Comprehension (IRC) framework. Time-critical events are classified to have high interruption, high reaction, and low comprehension due to their urgency. The responder should have just enough information to identify the crisis and react as soon as possible (Chow, E. 2014). For example, when a tooth is lost during shovel operation, it is necessary to recover the missing tooth before it jams the primary crusher. The consequence of missing this critical time period is a jammed crusher that can cause the mine to be out of production until the jammed tooth is extracted (Baumann, M. 2013). In this case, the responder only needs to see an image to confirm if the tooth is missing, and information to identify which equipment and when the tooth went missing (see Figure 1). Contextual information is relevant information that is valuable for the receiver to be aware of as it can present an opportunity to improve efficiency or save cost. According to the IRC framework, contextual information is classified as low interruption, low reaction, and high comprehension. They are not as urgent as time-critical events, but provides more detailed and informative information to assist the receiver. For example, when a shovel’s worn tooth is predicted to require replacement soon, a notification to a GET technician can help him or her schedule a pre-emptive replacement of the tooth in an already planned maintenance to prevent having to reactively schedule another one when the tooth is critically worn. This helps reduce the amount of equipment downtime to maximize production (Baumann, M. 2013). In this case, the receiver will look at the information when he has a moment to spare to get a quick forecast, and make use of this information as needed (see Figure 2)."

Jan 1, 2015

By Jr. Kirschner

An abandoned waste impoundment located within a portion of the Kellogg, Idaho Superfund site constitutes a field research area for studying the feasibility of recovering heavy metals in-situ from unsaturated mine and mill wastes. A prototype in-situ leaching cell has been evaluated using liquid-phase tracer tests and other hydro-geologic tests prior to introducing a lixiviant. The results of the tests suggest that: (1) the cell can be operated excursion-free with a low-density lixiviant at an injection/withdrawal rate of approximately 0.32 l/s; and (2) each hydro-geologic unit is highly heterogeneous at the different scales studied.

Jan 1, 1993

By SK SAHOO, UK SINGH, SK SHARMA, GSP SINGH

Surface mining accounts for most coal production in Indian geo-mining conditions compared with underground methods, whose implementations are in deeper coal reserves and for lower stripping ratio in a congested operating space. The bord-and-pillar method is the preferred underground method in India for reasons of flexibility and investment cost. While previous researchers conducted field investigations on intact overburden conditions, this study focuses on the strata control issues in a bord-and-pillar depillaring working under the influence of the dead-load condition of voluminous and fragmented softcover of overburden dump material. The modeling results helped in ascertaining the criticality of strata behavior and rib-pillar stability in actual mining conditions when compared with the conventional intact overburden.

By A. Juganda, H. PINHEIRO, J. Brune, N. SANDOVAL, G. Bogin, K. Gallagher, F Wilson

The present work discusses the nuances of scaling and flow similarity to develop a 1/40th scale version of a longwall coal mine. Details on the geometric, kinematic, and dynamic scaling of the physical model are presented and discussed. This works also discusses using a 30% CO2 – 70% He gas mixture as a surrogate for methane. It also presents the implications of various Reynolds numbers (ranging from 7,000 to 140,000) and rotation of the shearer drums in the dynamic representation of the airflow and gas mixtures in the physical scaled model.

Mar 19, 2022

By E. M. R. Santos

Acid mine drainage (AMD) is a serious environmental problem in mining activities. Prediction is the first step for evaluate the potential of acid generation and there are some possible methods to estimate it. They are described as static tests, which examine the balance between acid producing and acid consuming materials, and kinetic tests, which attempt to predict drainage quality over time. Static methods are very simple and give a qualitative classification of the ores based on their potential to generate acid drainage. The characterization of ores to determine their acid producing potential is vital for the prevention of long term environmental liabilities. Laboratory tests were conducted under different methodologies to predict the acid producing potential of sulphide overburden, ore materials and tailings from a deposit of copper ore.

Jan 1, 1999

By M. Ashraf Mahtab

In Louisiana salt mines a sudden erruption or outburst of salt and gas occurs when the heading face approaches a pressure pocket (altered salt with high pressure gas). The resulting cavity is semi-ellipsoidal, reaching lengths of 50m or more. Potential risks from the outbursts include loss of life and equipment. A gas outburst is initiated by "disking" of the salt in biaxial compression and propagates by spalling of the cavity walls and further disking. The outburst is terminated by a combination of dilatancy hardening, increase in stress along the cavity axis, and enlargement to boundaries of the pressure pocket.

Jan 1, 1982

By John L. Halls

INTRODUCTION In this section, it is assumed that the reader is an engineer with sufficient training in underground mining work, preferably with budgetary control, to understand the mining methods outlined in other sections of this handbook. The mining-method descriptions are not repeated herein; only sufficient information is provided to enable the reader to comprehend the development of the costs presented. All costs are in 1977 US dollars, except where explicitly stated otherwise. CAPITAL INVESTMENT The capital investment in the underground mining portion of any mining property includes the following: 1) The development of original access involving adits, shafts, declines, etc. It includes the necessary equipment for transporting men, materials, and rock. 2) The purchase of mine equipment including loaders, underground haulage equipment, fans, pumps, electrical distribution, surface facilities associated with the underground mine, etc. 3) Sufficient preproduction mine development to assure steadily increasing production after startup. De- pending upon the mining method used, the preproduction development should provide a supply of three months to one year of ore that is developed and is ready to be stoped. Underground development also includes excavations other than shaft stations, loading pockets, sumps, etc., which usually are associated with the means of access and are excavated by the contractor. These excavations could include a crusher cavern, an ore- storage pocket, and underground workshops that may or may not be included by the shaft-sinking contractor. Portions of these could be delayed until after production begins, but it is preferable to complete them during the development phase, so there is no interference with the production buildup. 4) The staff and labor costs for all phases from inception through final production. 5) The provision of mine-surface equipment and facilities strictly applicable to the underground portion of the operation. The required facilities include a changehouse with a lamp room, a first-aid station, compressors, an electrical substation, workshops, a ware- house, water pipelines to the concentrator, water storage tanks, explosive storage, etc. A concrete-batch plant, a sand-fill plant, and boilers for heating may be required. 6) Other direct and indirect costs. 7) Engineering, design, and procurement costs. 8) Contingency allocations. 9) Contractor's fees, startup costs, and owner's costs. Original Access As part of a study for the US Bureau of Mines, Dravo Corp. conducted an extensive literature research survey covering underground operations in the United States between 1963 and 1973. Table 1 is compiled from the section of that study pertaining to the types of access to underground mines. Table 1 does not include distances attributable to the deepening of existing shafts, nor does it include shafts bored by raise drills or downhole machines that need existing underground workings for the disposal of the cuttings. During the period under review in the report ( 1963 through 1973). concrete-lined circular vertical shafts were the predominant means of providing the first access to a new underground mine; these shafts accounted for 80% of the original access in terms of the number of accesses completed, and 75% in terms of the total verti- cal linear distances. The inside diameters of the conventional circular shafts ranged from 3.7 to 7.0 m (12 to 23 ft). Most (72% ) of these conventional shafts were for production,

Jan 1, 1982

By W. C. Foshee

The large volume of water used in coal preparation plants makes water recycling a necessity. Economical cleaning of dirty water usually requires flocculation with an efficient organic polyelectrolyte. This paper discusses identification of optimum flocculant systems. Supporting laboratory data with on-site tests and full scale field trials supplies information necessary for matching the polymer to the plant.

Jan 1, 1979

By Robert H. Oliver

Flowsheet flexibility in new 750 TPH coal cleaning plant provides three unusual capabilities. Two compartment drum coarse H.M. washer can be adapted to provide two stage separation. Coarse section of plant can be operated without fine section when washing surface mined coal. Fine section can operate with flotation cells bypassed if strip coal oxidation kills the froth. Plant can be fed by belt from bulk storage, front end loader from storage piles and truck from the mines. Raw coal and each of four washed products can be fed by belts to three separate loading points on two separate railroads.

Jan 1, 1979

By Tsuneyoshi Funazaki, Takayoshi Nakamura, Keizo Miki, Takashi Imaishi

The underground portion (about 10 km) of Tokyo Wan Aqua-Line consists of eight shield tunnels connected with Kawasaki Man-Made Island in between, at four underground locations. The connection work had to fulfill strict precision and safety requirements in the ground about 60 m below soft seabed, but was completed successfully in May 1997. This report describes the connection work in detail, featuring the method of investigating shield machines’ relative positions, ground freezing method and connection mechanism and procedures. It also mentions the present state of Tokyo Wan Aqua-Line that was put in service on December 18, 1997.

Jan 1, 1999

By S. R. Dindarloo

"Truck-shovel systems are the dominant material loading and haulage machinery in open pit mining operations. Optimal selection, sizing, and allocation of this capital intensive equipment is highly desirable for both achieving production targets and improving the mine’s economics. In this study, discrete event simulation technique was applied for modeling material transportation in Golegohar open pit iron ore mine in Iran. Direct observation of the material loading and haulage for duration of three months resulted in statistical modeling of the operation in the form of probability distribution functions. These probability models were used as the inputs of a stochastic simulation model constructed in GPSS/H simulation language. The model was validated through comparison with the actual operation and was used to test different what-if scenarios and sensitivity analysis of the current system. Some modifications in the number of trucks, shovels, and dispatching strategies were proposed. Simulation resulted in considerable improvements in the mine’s production and economics.INTRODUCTION There are three different mechanisms of discrete, continues, and hybrid material transportation in open mines, including but not limited to: i) in-pit crusher and conveyor belts (hybrid), ii) slurry piping (continues) and iii) truck-shovel system (discrete). Although, each mechanism has its advantages, the truck-shovel system is the dominant method of material loading and handling in open pit mines owing to its high production rate, excellent flexibility, relatively low operating and capital costs, and good maintainability. General objectives of optimal equipment selection include: i) meeting the long and short term requirements of production rates, ii) human & equipment safety, iii) environmental protection, and iv) economic operations (Figure 1).The two most important decision factors on a truck-shovel system selection and sizing are the equipment geometry and size. Geometry (equipment width, weight, turning radius, swing angle, etc.) is mostly controlled by mine’s designs and layouts, as well, as operational constraints. After selection of a favorable geometry based on the constraints; the next step is to select the equipment manufacturer. Once the geometry and manufacturers are selected; the next step is to decide on models (e.g. Bucket size) and required number of each unit"

Jan 1, 2015