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By Ronald E. Feltman

Most engineering firms engaged in the design and manufacture of milling components and systems have established, through the years, a relatively well defined system design procedure. The process design engineer has at his disposal several alternative approaches to the successful completion of this task. Unfortunately, while these alternatives, at first glance, appear to be rather straight Forward, any attempt to implement them into a fully integrated commuter design program becomes increasingly more complex when one addresses himself to the problem in total. This paper summarizes Kennedy Van Saun's approach to the solution of this problem through a planned system design. Following the problem definition and discussion, a detailed analysis and system design synthesis is presented; the major aim here being to provide a system design which may be programmed and run on a relatively inexpensive computer installation such as the IBM 1130 system currently in use at Kennedy Van Saun. A summary section is also included, which Provides a general outline guide to the program systems design of equipment which, while quite different from milling system functionally, nevertheless lends itself to the approach used in this paper.

Jan 1, 1969

By J. O. Marsden

The Candelaria copper-gold mine is located approximately 25 km south and east of Copiapo in Region III, Chile. The original concentrator was designed to treat 28,000 t/d (30,800 stpd) of chalcopyrite-bearing ore through a circuit consisting of a single 11.0 m (36 ft) diameter SAG mill, two ball mills, conventional rougher and scavenger flotation, column cell cleaner flotation, and ceramic disc filtration. The plant was commissioned in August 1994 and quickly reached capacity and expected levels of metallurgical performance. In May 1996, a decision was made to double the capacity of the concentrator by the addition of a second line of equipment. The expanded facilities were commissioned in October 1997, less than 18 months after the decision to proceed, and well within the budget. The original concentrator facilities were replicated or duplicated as much as possible, however, a number of important equipment changes were made to take advantage of industry developments since the original concentrator was designed. These included the use of Eimco 120 m3 (4,200 ft3) cells for rougher and scavenger flotation and the installation of a Svedala VTM -800 Vertimill for regrinding. This paper describes the rationale behind these changes and explores the reasons for the success of the project.

Jan 1, 1999

By L. Adler

To mine safely and efficiently the working conditions must be systematically de¬fined. Their uniqueness distinguishes mining from other engineering professions. The worst case in underground mining is delineated and termed "encumbered space'", since it "seriously impedes motion or action." Working space is inherently hazardous, transitory, and expensive, inducing it to be of low quality, tight and congested, vulnerable and deteriorating, and isolated and inaccessible. These adverse conditions, are damaging to cumbersome, mobile equipment, and affect all activities, including surface work. The conditions are reorganized using the fundamental engineering dimensions: space, matter time, people, and money. Comprehensive tables are presented with attention paid to "disaster potentials". Examples are cited.

Jan 1, 1982

By R. V. Ramani, S. Shankar

The phenomenon of re-entrainment is seen in environments such as sand dune formation, soil erosion, fugitive dust emission and the spread of radionuclides from accidents involving nuclear weapons. A thorough review of existing literature reveals that work on re-entrainment of dust in mine atmospheres is scant. The present study was undertaken as a part of ongoing research at the Generic Mineral Technology Center on Respirable Dust at the Pennsylvania State University on the development of methods to predict ambient dust concentrations in mine atmospheres (Ramani, 1983). The contribution of re-entrainment to the spatial and temporal concentration of dust in mine airways is being studied. The research has included wind tunnel and in-mine studies. A set of seven experiments was performed under controlled conditions in the US Bureau of Mines' Lake Lynn Laboratory mine. Two types of source coal dust, anthracite and bituminous, were subjected to various airflow rates and were subjected to walking by two different individuals. Six sets of instruments were used along the test section for sampling airborne particles. The average air velocity just above the coal dust bed varied between 2.1 to 3.2 m/sec. Due to re-entrainment as a result of the airflow conditions, the average respirable dust concentration in the center of the mine airway increased to 0.09 mg/m3 (standard deviation = 0.03 mg/m3) from an initial value of 0.02 mg/m3. The concentration of all (total) airborne dust increased to 0.17 mg/m3 (standard deviation = 0. 10 mg/M3) from an initial value of 0. 02 mg/m3. The action of people walking, however, caused higher amounts of re-entrainment. The average concentration of respirable and total dust at the center of the mine airway increased to values of 0. 28 mg/m3 (standard deviation of 0.12 mg/m3) and 1.53 mg/m3 (standard deviation of 1.0 mg/m3), from initial values of 0.03 and 0.05 mg/m3, respectively. It was observed that the dust concentrations were much higher near the floor, immediately at the end of the coal-dust bed. Depending on the level of activity and the amount of dust deposited in the mine airways, re-entrainment may become an important source of airborne dust in areas away from the point of actual mining.

Jan 1, 1996

By J. E. Feddock

To succeed in today's competitive coal market, coal companies must continuously improve production and lower cost. However, the coal industry's historical management practices must change to remain viable? The practices of the current day efficient coal mine manager are reviewed and examined using W. Edwards Deming's definition of management. The statistical tools, including Pareto Charts, Control Charts and Scatter Diagrams, which identify the problems management must approach differently to increase productivity at a coal mine, are discussed.

Jan 1, 1993

The need for an integrated approach to optimization of unit operations in both the pit and the mill has long been recognized, but the complexity and nature of the overall problem has up to now resisted solution. This paper reports on a modeling methodology which couples symbolic and numeric computing to unify operations in both the pit and mill. The ultimate goal of this work is to optimize all operations that are influenced by blasting. Blasting plays a key role in all facets of operations. Obviously, drilling and blasting costs are determined by blast design, but the down-stream costs that are closely related to blasting results are often treated as separate functions: loading, hauling, cleanup, and crushing and grinding are all heavily influenced. Diggablilty and bucket fill factor are a function of fragmentation, the condition of the floor and uniformity in the shape of the muck pile. Likewise, cycle times and loading delays partially determine haul cycles, while fragmentation distribution and size determines the efficiency of truck loading. Removal and breakage of oversize causes loading delays and increases cleanup costs. The influence of blasting doesn't stop at the crusher. Mill productivity, power consumption, and maintenance are a function of the feed. Even at the SAG mill a reduction of a critical particle size during blasting can increase throughput. Thus, a bottle-neck for production far removed from unit operations in the pit can be alleviated by a modification in blast design. The question is: how do we optimize blasting with respect not only to itself but to al\ related mining and milling operations? For that matter, how do we even model blasting so that we can control the results of a blast?

Jan 1, 1991

By J. H. Wilhelm

Continuous thickeners can be sized either from previous experience, continuous pilot-scale test results, or from batch settling tests. Although it is a relatively simple process to size full-scale thickeners when previous experience or pilot-scale operating data are available, batch testing is often the only realistic method for sizing thickeners due to time restrictions, budget limitations and availability of sample material. Many authors have, therefore, suggested means of running batch tests and analyzing the resulting data. Fundamental thickening theory had its beginning with the work o£ Coe and Clevenger(1). In order to determine the size of the thickener settling area, they proposed that a series of batch settling tests be run at various initial concentrations. The solids handling capacity at each concentration can then be determined and the lowest capacity (maximum area requirements) used to size the thickener. Kynch(2) developed a mathematical analysis in which the relationship between solids concentration and settling rate can be obtained from a single batch settling curve. Talmage and Fitch(3), Yoshioka(4)(5) and Dick(6), have enlarged upon these works to give a basis for methods of sizing thickeners.

Jan 1, 1979

By M. Beale

Fuzzy logic and neural networks are new technologies being applied in many areas of engineering and business. While it is not always clear which kinds of problems are best suited to these technologies, and which problems are best approached with more standard methodologies, both fuzzy logic and neural networks appear to show great promise in the field of control systems. This paper demonstrates two advantages that these technologies offer: Easy controller design in the absence of a mathematical model of the plant to be controlled, and adaptive control capable of quickly responding to changes in the plant.

Jan 1, 1994

By David A. Holmes

Zeolites are crystalline, hydrated aluminosilicates of the alkali and alkaline-earth metals. Their crystalline framework is based on a three dimensional network of SiO4 tetrahedra with all four oxygens shared by adjacent tetrahedra. The alkali and alkaline-earth cations are loosely bound within this framework structure and may be exchanged, to varying degrees, with other cations or molecular water. Most zeolites can be reversibly dehydrated. At present, close to 40 natural zeolite minerals have been identified and over 100 zeolites have been synthesized. Zeolites are a family of hydrous aluminosilicate minerals whose physical properties provide unique features for a wide variety of practical applications. Zeolites have been known for more than 200 years, but it was not until the middle of this century that their economic potential and widespread occurrence in sedimentary rocks were known. Since 1950, literally thousands of articles and patents have appeared in technical literature, and commercial pro¬duction of natural zeolites may now exceed 1 Mt worldwide an¬nually. In the past 40 years, the zeolite mineral group has changed from that of a museum curiosity to one of an established industrial mineral commodity. According to Breck (1974), zeolites are characterized by the following properties: 1) High degree of hydration, 2) Low density and large void volume when dehydrated, 3) Stability of the crystal structure of many zeolites when dehydrated, 4) Cation exchange properties, 5) Uniform molecular-sized channels in the dehydrated crys¬tals, 6) Ability to adsorb gases and vapors, 7) Catalytic properties. All zeolites are molecular sieves, but not all molecular sieves are zeolites. Activated carbon, activated clays, alumina powder, and silica gels are also molecular sieves. Molecular sieves are materials that can selectively adsorb molecules on the basis of their size, shape, or electrical charge (Clifton, 1987). Commercial application of zeolites is based on the following physical properties: molecular sieving, ion exchange, adsorption, and catalysis. Potential commercial utilization includes hundreds of possible applications. The principal uses at this time, however, are as fol¬lows: -Ammonium-ion removal in waste stream treatment, sewage treat¬ment, pet litter, and aquaculture, -Odor control, -Heavy metal ion removal from nuclear, mine and industrial wastes, -Agricultural use, such as soil conditioner and animal feed supplement. An estimated 800 kt to 1 Mt of natural zeolites were produced and consumed worldwide in 1991. Eight small operators reported collective production and consumption of an estimated 18 kt of natural zeolites in the United States during 1991, mostly for feed additives and for odor control, aquacultural, agricultural, catalytic, and ion exchange applications (Eyde, 1992).

Jan 1, 1994

"In this review, the sintering process is first described and analyzed to identify the key factors affecting the structure and quality of iron ore sinter. Under fixed sintering conditions, the granulation efficiency, nucleus stability and primary sinter melt volume and properties of the iron ore are considered to have significant influence on the sinter structure and quality. Discussion is then focused on the effects of the chemical, physical and mineralogical characteristics of the iron ore on these key factors, and the consequences for sinter quality.IntroductionSintering is the most economic and widely used agglomeration process to prepare iron ore fines for blastfurnace use. In modern blast furnaces, particularly in East Asia, iron ore sinter typically constitutes more than 70% of blast-furnace ferrous feed. High sinter quality and efficient sinter production are thus required both to withstand extreme operating conditions and maintain the productivity of modern blast furnaces. At the same time, due to the increasing depletion of high-grade iron ore resources from large deposits, iron ore producers are moving toward developing an increasing number of deposits of much smaller sizes to maintain current production levels. It is therefore imperative for iron ore producers to develop long-term strategies to maintain the quality and consistency of the iron ore fines they are producing while exploiting these smaller, complex deposits. The iron grade, gangue minerals present, overall mineralogy as well as physical characteristics of iron ore fines being mined from these different deposits vary considerably. Overall, ores now have highly complex mineralogy, are becoming more porous and friable, and contain increasing amounts of gangue minerals, which will have important implications for the sintering process and sinter quality.Blending is one of the most effective options being explored by iron ore producers to deal with multiple small complex deposits. This allows the iron ore producers to reduce the number of products and take full advantage of the unique characteristics of each individual deposit to achieve long-term product consistency while increasing production. Blending is also a common practice in sinter plants as it is almost impossible to produce from one single ore a high-performance sinter mixture with the required processing characteristics. A typical sinter mixture used in Japanese steel mills (Nakano and Okazaki, 2007; Matsumura et al., 2013) often contains five or more ores to achieve balanced sinter quality and productivity with relatively low cost of raw materials."

Jan 1, 2015

Introduction Agrico Mining Co.'s Florida mining division has three surface mines and employs nearly 700 workers. The division produces some 6.3 Mt (7 million st) of phosphate rock annually. It is a good business. And Agrico has made it better by making it safer through a new approach to mine safety. In one year, Agrico - the second largest phosphate mining company in the US - recorded a stretch of one million manhours without an accident. That same year, the direct cost of accidents dropped to $9137 from a previous five-year average of about $50,000. Together with Don Roe, division manager of safety and security, Division General Manager Don Morrow made 1981 a watershed year for safety at Agrico. Morrow called on consultants from Safety Management Services of Du Pont's Specialty Services division to strengthen a safety program that was already better than average. From the late 1970s and into 1981, lost-workday cases (LWCs) were costing Agrico an estimated average of $22,000 each. And they were occurring with alarming frequency. In 1977, the company recorded six LWCs at an incidence rate of 0.64. This was followed by a jump to nine cases in 1978. In 1979, both occurrences and the rate increased - 10 LWCs at a 1.19 rate. The number of LWCs decreased to seven in 1980, with a rate of 0.71. Agrico instituted a far-reaching safety program in 1981, which began to take full effect in 1982. LWCs dropped from five in 1981, to three in 1982. And the direct cost plummeted from $110,346 to $28,828. In 1983, the mines recorded only one LWC. Its $9137 cost represented a reduction of $101,209 since the Safety Management Services of Du Pont had been called in. Through early 1984, the LWC incidence rate at the facility's three mines, phosphate drying plant, and transportation department was down to 0.26. This is 84% lower than the 1982 mining industry average, making it the safety leader among all Agrico companies, including its chemical plants. New Approach Agrico had the basics of a safety program in place when the Du Pont consultants arrived. But Du Pont suggested changes in responsibilities and company philosophy that formed the foundation of

Jan 1, 1985

By Kenneth K. Humphreys

Over the past four years, the Coal Research Bureau of West Virginia University has presented a number of papers on operations research in the coal industry before various AIME meetings and meetings of other societies. These papers have been followed up by further presentations in the technical press. The emphasis of all of these papers has been to demonstrate applications of operations research to the solution of numerous types of coal industry problems. In each case, effort has been made to demonstrate that operations research does not require extensive knowledge of computer science or use of sophisticated higher mathematics. In fact, for most applications, satisfactory results can be obtained by a single individual in a minimum of time with no aids other than a pencil and paper and a knowledge of basic arithmetic. The most recent efforts by the Coal Research Bureau have been directed toward the continuing industry problem of optimizing the location of mining facilities. Preliminary work in this area was presented before the Central Appalachian Section of AIME and subsequently published in the May, 1972, issue of Coal Age. This initial presentation illustrated techniques for determining optimum locations of facilities based upon material transport effort under the assumption of constant cost per ton mile of haulage effort. The present paper will expand upon this earlier work and introduce economic factors. In the design of a mine or mining system, careful consideration must be given to the sites selected for each element of the system. Optimum placement of facilities is vital to minimize capital and operating cost. Thus, barring unfavorable geological conditions or other exceptional factors, facilities should be located at those points which represent the minimum cumulative cost over the life of the property. Most cost factors are independent, or essentially independent of the location of fixed facilities. Thus, for example, regardless of the location of the shaft, the direct cost to mine any given ton of coal is essentially constant. The major 1

Jan 1, 1972

By S. C. Sun

A process was developed to recover coal, clays and pyrite from coal wastes. The process consists of fine grinding followed by coal flotation and pyrite flotation leaving the clays in the flotation pulp. A bituminous coal refuse, containing l0% S-30% C*, was treated by this method to yield a coal product containing 4% sulfur, 10% ash; a pyrite product containing 45% sulfur (84% FeS2), 1% carbonaceous material and a clay product containing 2% sulfur (3.5% FeS2). The coal yield was about 89%. The pyrite yield was about 77%. The process steps may be entirely flotation, or gravity separation (hydrocyclone) may be used to increase the pyrite: coal ratio in the flotation feed. Cost estimation shows a profit of $2.28 per ton of low pyrite grade refuse (Labor, maintenance, overhead and plant depreciation were not included). The development of this process consisted of three parts: 1) exploratory tests, 2) optimization tests and 3) confirmatory tests.

Jan 1, 1968

By C. W. Matthews

Introduction Screening is defined as a mechanical process which separates particles on the basis of their size and their acceptance or rejection by a screening surface. The key element in this method of particle sizing is obviously the screening surface, the medium that contains the apertures for the passage of the undersize material. This surface must be strong enough to support the weight of the material being screened, flexible enough to yield to the vibrating force applied to it, yet light enough to provide a reasonable ratio of open area to attain a practical through- put. To balance all of these factors is difficult enough. The problem is compounded, however, because screening media are made in a great variety of types, shapes, sizes, and materials of

Jan 1, 1985

By A. J. Naldrett

Over the past six or seven years important new ideas have been developed concerning the origin of nickel sulfide deposits. To a large extent these have been stimulated by the major nickel discoveries of the Eastern Goldfields area of Western Australia (Woodall and Travis, 1969; Ewers and Hudson, 1972). Prior to these finds, the most important nickel camps were regarded as being associated exclusively with intrusive rocks such as the Nickel Irruptive at Sudbury or the intrusive peridotites at Thompson, rocks that were thought to have no close association with volcanism. Study of the Australian discoveries, coupled with work in South Africa (Viljoen and Viljoen, 1969) and Canada (Naldrett and Mason, 1968; Pyke, Naldrett and Eckstrand, 1973), has shown that volcanic rocks with true ultramafic compositions and extrusion temperatures of 1400 to 1600°C were a common feature during the Archean. Under certain circumstances economic concentrations of nickel sulfides have formed from these rocks, either settling to the base of their associated flows or accumulating in shallow intrusive feeders to the flows. The aim of this article is to show how these ultramafic rocks can be recognized, how the nickel deposits, if present, are likely to occur within them, and what special features characterize ore-bearing examples of the rocks.

Jan 1, 1975

By J. M. Pachter

Property sales and acquisition are prominent features of today's coal industry. Before selling or buying a site, a company must know the property's economic net worth. Any evaluation of economic net worth would be inadequate if determinations of a property's environmental liabilities and costs were omitted. Short-term and long-term costs can result from liabilities related to reclamation, water treatment, subsidence, and hazardous waste disposal. A structured, interdisciplinary approach can aid in the delineation, summation, and scheduling of these costs and liabilities.

Jan 1, 1986

By Andrea Biagi, Elisa Comis, Gianluca Bella, Enrico De Panicis, Guido Barbieri, Matteo Giani

The Sotra Link Project is a major infrastructure project in Norway involving the design, construction, financing and maintenance of several underground and surface structures between Sotra island and the city of Bergen, among them 23 tunnel portals, 12.5 km of tunnels and a 900 m long suspension bridge. This paper describes the benefits in applying a Building Information Modelling (BIM) approach to tunnelling, from Early Design to the Detail Design Phase. The BIM application to the Sotra Link Project resulted in several improvements, such as efficient handling of clashes and inconsistencies, deeper understanding of effective design choices (reduction of errors), more efficient communication between designers, enhanced control of project quantities and costs. The advantages of the BIM approach during the ongoing Construction Phase are also explained.

Jun 23, 2024

By J. Partyka

Adequate ventilation is a main concern if Lockerby Mine near Sudbury is to be expended. This study investigate a two-fold problem: (1) the new pressure and volume requirements of the main fans due to the theoretical. deepening of the mine, and (2) the effect of the natural ventilation pressure on the main fans. Field data was analyzed with the aid of a newly developed network simulation program, VNETPC Version 3. 0. The density change throughout the mine is accounted for by performing all computations at reference density. Results of the investigation indicate that the existing fan system must be supported by three to five additional underground fans as well, the density effect is significant. If neglected, it will greatly alter the simulation results

Jan 1, 1991

By C. H. Grant

The Dew Chemical Company has been engaged in explosives research since 1953. The incentive for this research was based on the desire to find additional markets and uses for magnesium metal of which Dow is a heavy producer. The thermodynamic calculations for explosives incorporating light metals indicate energies approximately twice that of non-metallized explosives currently being used. Early in 1960, we acquired additional patent rights from independent inventors and decided to set up a development station at Virginia, Minnesota, to conduct a commercial testing and market evaluation program with this new product. The actual manufacturing of the explosive was to take place in the bore holes. Due to the complexities involved in controlling the manufacture of the explosive in the bore hole, performance was sometimes in doubt. Furthermore, our experience indicated that the metallized explosive systems could not be evaluated by the standard laboratory methods then being used, and it was necessary for us to look for more suitable research methods. Tests were conducted on several known methods for explosive evaluation. The most promising were the Navy underwater method for energy evaluation, and a modified Livingston crater method intended to compare explosive performance in rock. After shooting over two thousand charges of eight to 60 pounds under water and in taconites and granites with many types of explosives, we have developed a metallized explosive which is now being manufactured at a pilot plant in Virginia, Minnesota, and is being evaluated commercially.

Jan 1, 1963

By David L. Kuck

Siderophyle platinum-group metals and sane gold are a thousand times more abundant in metal and chondritic meteorites than in terrestrial or lunar rocks. Type I and II carbonaceous chondrites contain granules of the high boiling point metals W, Re, Mo, Ir and Os. Metal meteorites and the metal fractions of other chondrites contain siderophyle Pt, Pd, Ru, Rh, Os, Ir and Au. Spectra of sunlight reflected from asteroids, when compared with those of meteorites and specific minerals, provide a rough classification and guide to sources of precious platin-group metals.

Jan 1, 1982