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By Suresh P. Babu, Joseph W. Leonard, Richard Muter, D. P. Sen

OUTLOOK FOR COAL UTILIZATION In 1975, about 650 million tons of bituminous coal and lignite mined in the United States was used to meet 55% of the primary energy input for electric power generation and 26% of the total industrial consumption.1 Even though this amounts to only 21% of the total energy requirements, it is believed that with the declining natural gas resources and uncertainty of liquid fuel imports, coal will assume a more dominant role in suppplying our future energy needs. A regional breakdown of the coal reserves of the United States along with their characteristics is shown in Table I. At present the United Stares Energy Research and Development Administration (ERDA) and the US Bureau of Mines (USBM) are financing extensive research programs in advanced mining methods and energy conversion processes. The increased demand for wal which may result from these research programs may also create large-scale environmental protection problems. As more and more coal is mined the production of undesirable coal fines and dust also increases proportionally. The USBM and the Environmental Protection Agency (EPA) research in this field includes development in the areas of instrumentation for qualitative and quantitative analysis of wal dust, protective devices, and dust collectors. Dust control by water sprays, steam, and foam are also being investigated. Other aspects of safety in mining include developing methane drainage techniques prior to coal mining, fire and explosion prevention, and neutralization and disposal of acid mine waters. It is the belief of coal technologists that when the emphasis shifts to coal as the primary source of energy. the existing methods of mining and preparation of coal must be improved considerably to supply large quantities of quality coal for energy conversion. It is the objective of the present large-scale research financed by ERDA to produce substitute fuels from coal. Large-scale gasification pilot plants are being constructed by Bituminous Coal Research, Consolidation Coal Co., Institute of Gas Technology, and the Pittsburgh Energy Research Center to produce coal gas of natural gas standards at 1,000 psig. The processes being adopted by these pilot plants are oriented towards recovering most of the sulfur from coal by absorbing H2S and its subsequent conversion to elemental sulfur. The environmental protection standards will be strictly followed in using the results of these pilot plants to construct large-scale coal gasification plants in the latter part of the 1970's. With the increasing awareness of the need for air pollution control, considerable research is being done to minimize sulfur dioxide emission from thermal power plants. Utilization of limestone and dolomite scrubbing systems and caustic treatment of stack gases have proved to reduce sulfur and nitric oxide emissions by about 90 to 96%.3 Currently, about 22 scrubbers are in use in the United States to reduce sulfur in stack gas emission. In the long-term, it appears that optimal combinations will be developed involving both advanced coal preparation technology and wet scrubbing. The sulfur compounds are converted either to elemental sulfur of sulfuric acid. Besides the sulfur compounds, the major byproduct of the coal utilization industry is the large amount of coal ash. The Coal Research Bureau at West Virginia University has developed a practical use for coal ash as a structural material. The coal industry will undergo revolutionary changes when coal becomes the primary source of energy. New coal mining and preparation processes will be introduced to meet the ever-increasing per capita energy requirements. 2. BENEFICATION Introduction Coal preparation, like the beneficiation of ores, is also aimed at the separation of values from associated waste. Even though the unit operations involved when enriching ores and coal are similar, there are certain characteristics unique to coal preparation. Unlike the scattered and concentrated veins of underground minera1 ores, coal is distributed uniformly and very much in abundance in the coal mines. Coal occurs as the metamorphosed sedimentary deposits of vegetable matter, while metal and mineral deposits occur in great varieties of forms, structures, and origin-from igneous to sedimentary and metamorphic. The mined coal, being much more friable than mineral ores, is subjected to less intensive size reduction operations. Ores are usually ground to a very fine size for subsequent concentration, while coal is crushed to a coarser size, since considerably less liberation is needed to achieve the desired degree of separation. Since mineral matter is to a great extent discretely distributed in coal, concentration is mainly achieved by taking advantage of differences in specific gravity between clean coal and associated waste. In general, about 90% of coal is concentrated using specific gravity separation and about 10% by froth flotation. In contrast, these operations are frequently reversed in the beneficiation of ores. In coal preparation almost all fractions separated during various stages are made use of. while large amounts of gangue material are rejected in the concentration of ores. Hence, coal generally has a much lower ratio of concentration than ores. Since ore deposits are frequently more variable and mineralogically complex than coal, beneficiation of ore may require more plant flexibility and point-to-point quality control. This characteristic difference between the mineral ores and coal is attributed to the generally used one-step processing in coal as compared to the multiple-step processing of ores. Dewatering to enhance the energy content of coal is usually considered a major unit operation. Even though thickening and filtration are common for dewatering ore concentrates and cleaned coal, vibrating centrifuges and disk filters find unique application in the coal industry for achieving these types of solid-fluid separation. In coal preparation, thermal drying is carried out in separate units at the mine. While ore concentrates are usually dried at the smelter. Although the drying of ores is seldom considered dangerous, volatile matter and combustible dust are reasons why the thermal drying of coal can be hazardous. Open air storage of ores and mined coal results in partial oxidation. Unlike the oxidation of ores, the oxidation of the pyritic and carbonaceous constituents of coal together with the heat of condensation of moisture contribute to spontaneous heating and the subsequent combustion of coal in storage. Among the other significant difference between concentration of ores and coal are the weight and capacity of processing equipment. Coal processing employs less cumbersome, higher capacity units while the beneficiation of ores usually requires much more massive and frequently lower capacity equipment. Properties of Coal Which Influence Design The widely varying and heterogeneous composition of coal, due to metamorphism, determines the preparation design and uses of the resulting products. Petrography serves as a useful system of classification to identify the coal types present and their distribution. Early

Jan 1, 1985

By E. D. Attanasi, M. W. Bultman, J. H. DeYoung

The 1987 recovery in the US mining industry permitted modest increases in exploration expenditures that year (Fig. 1). Favorable market conditions apparently allowed the gains to be sus¬tained in 1988. There was great uncer¬tainty early in the year as to whether world and US economic growth would be a casualty of the October 1987 worldwide stock market crash. By nearly all measures, the performance of the US minerals industry was strong¬. A weak US dollar and the strong growth of worldwide capital spending resulted in in¬creased US exports of con¬sumer and producer durable items as well as strong domes¬tic demand for metals. In fact, 1988 US steel industry exports reached levels not attained since the mid-1970s. It was re¬ported that steel industry labor productivity is now roughly twice the 1981 level. Among metals with signifi¬cant average nominal price increases in 1988 over 1987 levels were copper (43%), alu¬minum (52%0), and zinc (44%). Even though domestic copper production has grown since 1984 by 30% in mining and 24% in refining, em¬ployment in mining and milling is 4% below the 1984 level. Domestic unit costs are reported in the range of $1.10 to $1.33/kg (50 to 60 cents per lb). The US base metals industry is proba¬bly in its best cash position in many years. However, there has not been a large increase in exploration expendi¬tures. This is due mostly to the percep¬tion that worldwide capacity can easily be increased. Industry reports do show that "low cost" copper producers have been buying reserves from weaker com¬panies. The 1987 Society of Economic Ge¬ologists (SEG) survey of exploration activity indicated that 95 cents out of every exploration dollar spent by US and Canadian firms was for base and precious metals (Economic Geology, January 1989). Press reports, though, make it clear that most of that spending was targeted for precious metals. US claim staking data (Fig. 2) rein¬forces this suspicion. The apparent lag in new claim filings in Alaska and phe¬nomenal growth in filings in the lower 48 states suggests that exploration is directed at relatively low risk targets. In the conterminous 48, more than 40% of the new claims were made in Nevada, indicating an emphasis on gold (although even Nevada had some base metals exploration). Even with a price decline during 1988, the difference between the gold price and average global "cash" production cost of $7.30/g ($227 per oz) still leaves room for an attractive return (Northern Miner, 1988). Exploration plans and results Metals Economics Group (Halifax) indicated in its 1988 exploration survey that exploration expenditures by US and South African firms would be at about 1987 levels. It also reported that Canadian and Australian firms were ex¬pected to reduce their exploration spend¬ing significantly. Firms in both coun¬tries were caught in changes in tax laws. In Canada, the Mining Ex¬ploration Depletion Allow¬ance (MEDA) once permitted generous tax write-offs to in¬dividuals investing in miner¬als exploration. It was to be replaced in January 1989 with the Canadian Exploration In¬centives Program (CEIP). Although structured and ad¬ministered differently than MEDA, CEIP can provide an equivalent or possibly greater financial incentive for min¬eral exploration, for junior mining companies. In 1987, it is estimated that junior com¬panies accounted for two¬-thirds of the off-property (or grass roots) exploration ex¬penditures in Canada. Australia will revoke the tax exemption for gold in 1990. Australian operators, therfore, were expected to concentrate efforts on speeding up pro¬duction during 1988 and 1989. In 1988, Chile and Mali announced special efforts to attract gold explora¬tion by foreign companies. The Cana¬dian government continues to express concern about the write-off (and drawdown) of base metal reserves. Falconbridge did announce a new initiative to identify additional base metal reserves in the Sudbury district. Discoveries Gold deposits dominated discoveries

Jan 1, 1989

By Vernon R. Shorter, Wayne N. Clark

Introduction Coal is the US's largest indigenous fossil fuel resource and is used to power 57% of this country's electrical generation (NCA, 1986). Congress, however, is focusing its attention on the acid rain issue and public sentiment is leaning toward further curtailments of SO2, NO, and particulates from utility and industrial coal-burning facilities. The Cool Water plant has proven that integrated-gasification-combined-cycle (IGCC) technology can reliably produce economical electrical power while limiting SO2, NOx, and particulates to a rate of only one-tenth of the federal New Source Performance Standards for coal-fired plants. Process water requirements at Cool Water are 40% less than those of a conventional coal-fired utility plant equipped with flue-gas desulfurization units for stack gas scrubbing, thus reducing waste water treatment requirements (Clark and Shorter, 1985). The IGCC technology employed at Cool Water has now been demonstrated to efficiently convert coal to electricity in an environmentally superior fashion. The Cool Water Coal Gasification Program is an unincorporated California association of six partners whose commitment is proving that the integration of gasification with combined cycle power production (IGCC) is commercially viable and environmentally safe. The 120 MW Cool Water plant began commercial production on June 24, 1984. The Program is operating it for a five-year commercial demonstration period. The Program is about halfway through this period. Much of that which was intended to be proven is now fact. In this mid-term assessment, the authors report that the com-

Jan 2, 1987

By R. A. Pyper

Laboratory leaching experiments were conducted to ascertain the effectiveness of acidic solutions of thiourea, CS(NH2)2, for dissolving gold from finely disseminated gold ores. The ore tested was from the Chipmunk orebody of the Northumberland mining district in Nye County, Nevada, USA. Extractions of up to 90 percent were attained from the ore. Extraction was shown to be dependent on thiourea concentration, ferric sulfate oxidant concentration, acid concentration, and leaching time. Optimum conditions were an ambient temperature leach near pH 1.0 utilizing 100-200 kg/t thiourea and 50 kg/t ferric sulfate for 8 to 24 hours.

Jan 1, 1981

By W. C. Yates

Lack of visibility from large, open-pit haulage truck cabs has become a serious safety problem. Anaconda conducted a research program to develop a low cost system to alert haulage truck operators to small vehicles present in blind areas. Several systems were developed and tested. As open-pit haulage truck size has increased, so has the size of the blind areas. Mine utility vehicles, pickup trucks, and cars are concealed within these blind areas and become safety hazards. Figure 1 shows the typical blind areas of a 136 t (150-ton) haulage truck. The areas of greatest concern are at the rear center and front right corner of the truck. In these "no visibility" areas many small vehicles have been crushed by large haulage trucks at various mine sites. In most instances, the occupants escaped the vehicle before it was destroyed. But injuries and death have occurred. In most cases, the accidents were attributed to negligence or carelessness by the small vehicle driver. The limited visibility problem still exists, though, and a solution is needed. Initial Solution The usual plane mirror on the driver's side and the convex mirror on the right front of the haulage truck allow only limited rear visibility. The typical, right side convex mirror is generally small and difficult to locate at a glance. This convex mirror also presents an image that distorts distance perception. These mirrors are of¬ten broken and immediate replacement not demanded or made. The US Bureau of Mines, in a contract with M.B. Associates, San Ramon, CA, developed an improved visibility system. It consisted of a larger, left view mirror and unique, blind area viewer. The large 230 x 690 mm (9 x 27 in.) left mirror has a small convex spot mirror near the bottom. The entire unit can be quickly replaced if broken. The large size provides a full view of driver orientation features such as the rear tire and the top of the load bed. The right 300 x 410 mm (12 x 16 in.) mirror has a convex surface and is quite rugged. The 510 mm (20 in.) spherical radius presents the operator with some distance distortion, but objects in its view are easily seen. The "blind area viewer" consists of a modified fresnel lens that allows the driver to "look around the corner." Installation of three of these lenses on the front of each haulage truck is rec¬ommended for adequate blind area coverage. This system significantly increases an operator's field of view and allows viewing of objects within about 3 m (9.8 ft of the truck. Many open-pit mines are nor mounting on smaller vehicles a long whip with a flag and lamp or both. This increases vehicle visibility to haulage truck operators. The whip is permanently attached to the mine vehicle. It can also be magnetically attached to transient vehicles. The whip system. though, is inadequate for visibility in the critical rear and right front blind areas. Alternate Solutions All of these visibility aids as¬sume an attentive driver. In addi¬tion, areas such as the rear blinc, area are not covered. Based on the inadequacy of existing visibility systems, Anaconda made a com mitment to further the truck de¬tection technology. The best ap¬proach was considered to be ar active system. It would notify the haulage truck operator that an en¬croaching vehicle is present. Sev¬eral systems were considered, in¬cluding ultrasonics and elec¬tromagnetics. For the ultrasonic system, com mercial and in-house design were looked at. Designing an( building transducers with the spe cific beam shape to match the haulage truck blind spots re¬quired a major technological breakthrough. False alarms ap¬peared difficult to prevent en¬tirely. They were caused by pass¬ing, trailing, or leading vehicles a., well as nonthreatening objects. As a result of these problems, the ul¬trasonic technique was not pur sued. An alternative, an electro

Jan 7, 1982

By Steve Kral

In December 2013, the Colorado Department of Transportation (CDOT) completed the widening of the eastbound tunnel on Interstate 70 (I-70) from two lanes to three. Work on the westbound tunnel began earlier this year and is scheduled for completion in December. The Twin Tunnels project is located in the mountains about 55 km (35 miles) west of Denver. They were bored during the 1960s when I-70 was being built and became the main access to Colorado?s growing number of ski areas and the state?s Western Slope. Throughout the decades following their construction, traffic on I-70 continued to increase and now the tunnels have a major bottleneck. Com-mutes to and from the mountain resorts, particularly on weekends, have become long and slow. Adding a third lane through the tunnels will help alleviate the congestion. (A complete report on the project can be found in T&UC, December 2013, page 61.) Once the eastbound tunnel was completed late last year, CDOT authorized the funding to begin work on the westbound side. That made economic sense, as the equipment used on the eastbound tunnel needed to only be shifted across I-70 to begin work on the westbound side, rather than removing it in December and bringing it back in March when construction began on the westbound tunnel. Work on the westbound tunnel uses essentially the methods that were used on the eastbound tunnel ? removal of the existing concrete lining and using drill-and-blast methods for tunneling widening. The main difference between the two tunnels is that the westbound side requires more blasting on both ends to widen I-70 to three lanes.

By Norbert Patzelt, Johann Knecht

Future ore reserves of major gold producers in North America and elsewhere will consist of refractory gold ores. About 60 % of the current U.S. gold production is mined in Nevada. Several of the large gold operations in this state indicate that 40 to 90 % of their future ore feeds will contain refractory gold. To com­pound problems, average head grades for refractory U.S. gold ores had fallen from 8 - 9 g/mt to about 4 g/mt by 1991. In Latin America, 52 % of the gold operations will require milling for optimal recovery. Deeper reserves are, like in North America, refractory. Therefore a special treatment process is needed in order to allow for the gold ore to be leached downstream in a conven­tional cyanidation process for a high gold recovery. There are several options available for this oxidation process like treat­ment of the gold bearing ore in pressure oxidation, in a biooxi­dation or in a roasting plant depending on the reason for the refractoriness. If organic carbonaceous matters and sulfides are the prima­ry reasons for the refractoriness, whole ore roasting is a pre­ferred method for the treatment of this type of ore. Since dry ore is to feed to the roaster, a dry grinding mill is advantageous. For the dry grinding system, the moisture content and the ore char­acteristic is of importance. Those parameters decide the mode of the grinding system. For autoclave systems common wet grind­ing systems can be applied. This paper deals with technical aspects for dry grinding plants and gives an outlook on and pos­sibilities for new grinding systems.

Jan 1, 1996

By Gordon M. Pugh, David G. Rasmussen

INTRODUCTION Variations of cut-and-fill stoping are the most com¬monly used methods for mining narrow, nearly vertical veins in the United States. These methods offer the best results for maximum recovery with minimum dilution of ore from veins that are irregular along either the strike or dip. The vein is developed along the strike length in 61 to 122-m (200 to 400-ft) blocks or stopes and vertical lifts of 48 to 61 m (160 to 200 ft). The level development is either on the vein or parallel to the vein with crosscuts intersecting the vein at right angles. Chutes, manways, and haulageways are established in the center of the stopes at the lower level of the ore block. Mining then proceeds by blasting down horizon¬tal cuts of the vein in both directions from the chutes. As the blasting continues to the outer limits of the stope, the broken ore is slushed into chutes. When a complete horizontal cut has been made, the service raise, including chutes, is raised to a height of a few feet from the back and the stope is filled with either sand fill or waste rock. Then the mining cycle is re¬peated until the stope reaches the level above. LEVEL DEVELOPMENT PRACTICES FOROVERHAND CUT-AND-FILL STOPING The two basic methods used are: the development of the haulage drift within the vein, or development of the haulage drift paralleling the vein in the foot or hang¬ing wall with crosscuts intersecting the vein perpendicu¬larly at 61 to 122-m (200 to 400-ft) intervals. The il¬lustrated methods of development show some of the variations which can be used to develop a stope block. Development for cut-and-fill stoping does not require the more elaborate schemes outlined for shrinkage or sublevel long-hole stoping. Many factors must be considered before deciding on a particular development plan and usually the nature of the vein or host rock will dictate which specific method to use. If the vein is relatively straight, then develop¬ment on the vein is feasible. Excessive ground pressures will necessitate the leaving of a sill pillar (Fig. la) and highly fractured or "heavy" ground will require timber¬ing (Fig. 1b). Development on the vein has the advan¬tage of reducing capital outlay and waste handling prob¬lems since the mined rock has value. But removal of the sill pillar is costly and time-consuming. Also, where no sill pillar is left, excessive timbering and subsequent level repair is a drawback. Development in either the footwall or hanging wall is the more common procedure and offers greater flexi¬bility in overall development of consecutive stoping blocks by partially disassociating the level development from stoping (Fig. 2). Chutes, manways, and service compartments com¬prise the next stage of development and are established in a variety of ways. They provide access to the stope, ventilation ducts, and muck removal. Several different development systems are in common use and average costs for each have been developed. Raise borers are used to establish ventilation and ac¬cess from level to level. They are normally reamed with 1.5 or 1.8-m (5 or 6-ft) cutterhead and may either be left bald or lined with a 1.2-m (4-ft) diam corrugated liner plate, depending upon ground conditions. The use of an Alimak raise climber is another effec¬tive method of driving a raise from level to level. The size usually is 2 m (7 ft) square. This will accommodate square-set timber which is later installed. This method of raising is not common, although it is a valuable tech¬nique especially when level spacing is several hundred feet.

Jan 1, 1982

By Eberhard Stolarski, Michael Tacke

When the oxidized surface gold deposits are mined out, the underlying refractory gold ores become the challenge of treat­ment systems. The size and value ofrefractory gold ore reserves are a function of recovery efficiency and operating cost. The start-up of LURGI's gold roasters at NEWMONT's Carlin site has established whole ore gold roasters as a key to high gold recoveries. The ores from several deposits of the Carlin trend are roast­ed utilizing LURGI / NEWMONT technology, which has achieved gold recoveries approaching 95%. This is in dramatic contrast to the traditional perception that roasting is limited to gold recoveries in the mid 80's. Extensive investigation in pilot scale is required to achieve stable high gold recoveries for most variables in the ore body. The key question for all pilot tests is the classic question of (ROM) run of mine ore roasting or concentrate roasting. All variables are dominated by the leaching/ recovery char­acteristics of the natural ores. The degree ofrecovery improve­ment by roasting / calcining establishes the frame of the eco­nomical conditions. The full range of flexibility is required for the design of the plant to allow for ore variations in heat values, combustible con­tents, agglomeration behavior and off-gas composition. The variables in the ore body influence, therefore, the price of the plant proportionally to its flexibility. Concentrates are usually fairly stable in composition, com­bustion behavior, heat values and particle size since they are a product of the very selective flotation process. Flotation is not the successful process step when the tailings remain high in refractory gold contents.

Jan 1, 1996

By G. W. Luxbacher

Coal mine infrastructure is rarely designed solely on the basis of ventilating the underground workings. Instead the optimization of a mining sequence, the minimization of coal quality variation, reduction of coal losses by adapting to property boundaries and geologic structure (seam inclination, roof conditions, coal thickness, etc.) or other similar considerations have formed the objective for mine plant design and layout. Infrastructure development may also reflect a desire to maximize production early in the life of the mine or to permit flexibility in mining according to market conditions. Requirements for coal mine ventilation, established by the 1969 Coal Mine Health and Safety Act, have mandated changes in the traditional concepts of mine plant design in the United States. Mines, in operation prior to the passage of the Act have experienced severe limitations when attempting to adapt the existing mine infrastructure to meet the requirements of the law. In addition the increased quantities of air required, velocity limitations on trolley haulage and belt lines, the establishment of separate intake escapeways and gob area ventilation have com- pounded the inherent complexity in planning mine ventilation systems. Past practices in mine ventilation planning and design are no longer adequate. Given the complexity of today's ventilation systems, effective planning and design approaches are required. As such, the interrelationship between the overall coal mine plant design and ventilation system design is examined. An approach to ventilation system design constrained by global considerations of mine plant design, is presented. The proposed approach is, however, applicable to the design of new mine ventilation systems as well as to the modification of existing systems.

Jan 1, 1980

By Robert W. Lawson

INTRODUCTION The two basic types of mine-air compressors are the positive-displacement compressors and the dynamic compressors. Positive-displacement compressors con¬fine successive volumes of air within a closed space and increase the pressure by reducing the volume of that space. Reciprocating and rotary compressors operate on this principle. Dynamic compressors utilize an impeller to acceler¬ate the air, with the increased air velocity converted to pressure through a stationary diffuser. Centrifugal compressors and turbocompressors operate on this principle. Reciprocating Compressors Reciprocating compressors include both single-stage and multistage units. For mine service the most com¬mon is the two-stage intercooled compressor having an atmospheric pressure intake and a discharge pressure of 689 to 861 kPa (100 to 125 psi). The cylinders of a reciprocating compressor may be either single acting or double acting. In the single-acting cylinder, compression occurs on only one side of the piston, while, in double¬acting cylinders, compression occurs on both sides of the piston. Fig. 1 shows a cross-sectional view of a typical two-stage double-acting water-cooled reciprocat¬ing compressor. Fig. 2 illustrates the sequence of opera¬tions occurring in the cylinder of a reciprocating com¬pressor. Most modern mine compressors are double acting and are driven by electric motors. Induction motors are used on low-powered compressors, and synchronous motors are used on larger compressors. Steam-driven compressors once were common and still are applied where a reliable source of low-cost steam is available. For this type of compressor, steam is a desirable power source since a governor that senses the discharge pres¬sure can be used to control the steam inlet. This can be used to regulate the compressor speed to compress only air sufficient to meet the mine's requirements (up to the capacity of the unit). Unlike a constant-speed electric¬driven compressor, no other regulation is required for the cylinders of a steam-driven unit. Rotary Compressors Rotary compressors include sliding-vane, liquid¬piston, two-impeller straight-lobe or cycloidal, and helical-lobe units. Each of these has specific advantages and applications. Of these, the helical-lobe or "screw" compressor has the greatest application for supplying "100-lb air" [689 kPa (100 psi) ] to small- and medium¬size underground mines. Fig. 3 illustrates the operation of a sliding-vane compressor. Fig. 4 illustrates the operation of a helical lobe or screw compressor. Fig. 5 illustrates the operation of a two-impeller straight-lobe compressor. Fig. 6 illustrates the operation of a liquid¬piston compressor. Centrifugal Compressors Centrifugal compressors deliver 0.94 m3/s (2000 cfm) or more of air, and they are best suited to supply¬ing large volumes of compressed air for base loads. The efficiency of a centrifugal compressor declines rapidly when its operation deviates from its design point. If the power cost is not a critical consideration, a centrif¬ugal compressor is attractive as a result of the low initial and installation costs and the high degree of reliability. Fig. 7 illustrates a typical four-stage centrif¬ugal compressor, and Fig. 8 is a cross section of this type of unit. COMPRESSOR SELECTION The process of selecting a compressor requires sev¬eral considerations, including the capacity, the control system, the location, the power supply, and the cooling provisions. Compressor Capacity To determine the required capacity, the total air quantity and pressure requirements must be calculated. The air consumption of various tools, as listed in Table 1, must be included in this calculation. Some of the other considerations include: 1) The correction factor for altitude, as listed in Table 2, must be included in the calculation. While pneumatic tools require additional compressed air as the altitude increases, the compressor produces less. 2) A correction factor must be incorporated for the use of multiple tools. Table 3 lists appropriate correc¬tion factors for rock drills.

Jan 1, 1982

WELCOME to the world-class Cripple Creek district where gold exploration and production continue 95 years after the initial discovery. More than 21 million troy ounces of gold have been recovered, valued at greater than $7.8 billion using today's gold price ($371/oz). The Cripple Creek district is localized within and around the margins of a silica-undersaturated alkalic diatreme-intrusive complex. The diatreme appears to be comprised of three sub-basins: 1) a sub-basin east of the Cresson (Fig. 1); 2) a southwestern sub-basin between Victor and Cripple Creek; and 3) a northwestern sub¬basin within which the Globe Hill and Ironclad pits (Fig. 1) are located. The recognition of three separate basins was made by G. F. Loughlin and A. H. Koschmann (1935, Fig. 8) who prepared a contour map on the floor and walls of the composite Cripple Creek basin. The northwestern and southwestern sub-basins are apparent due to the discontinuous exposures of a partially exhumed ridge of Precambrian rocks (Fig. 1). The separation of the eastern and southwestern sub-basins was recognized in mine exposures where a fault-bounded ridge line extends from the vicinity of the Ajax mine toward the Precambrian "island" (Fig. 1).

Jan 1, 1986

By N. P. Titkov

This paper presents the results of laboratory and pilot plant investigations for the development of efficient methods of beneficiating hematite ores from the Krivoi Rog, Kursk Magnetic Anomoly, Olenogorsk, and other localities. The tests included gravity, magnetic (in a high intensity field), flota¬tion, and magnetizing roasting methods. It was possible to develop efficient beneficiation methods depending on the mineral composition of the ore and degree of dissemination of ore and gangue minerals. The paper shows the relationship between the iron silicate and quartz content of the ore and the technologic indices of the various beneficiation methods. Some of the conclusions based on these investigations and the technical and economic computations related to the cost of one ton of pig iron produced from concentrates obtained by the various beneficiation methods are: 1. If the hematite ore is not disseminated uniformly, it is expedient to use a combined gravity and flotation process. Ore particles up to 50 am. in size are beneficiated by gravity (heavy suspension, jigging, and others) and yield a lump concentrate. The middlings from this process are recrushed and floated; 2. Finely disseminated hematite ores, containing small quantities (less than 5 percent) of iron silicates, are most effectively beneficiated by flotation. Anionic (sulphate soap, tall oil emulsion with various foam depressors) as well as cationic collectors may be used. Depending on the mineral and chemical composition of the ore, it is possible to obtain concentrates containing up to 65 percent iron with an extraction up to 94 percent; 3. Finely disseminated, mixed hematite-magnetite ores may be beneficiated by flotation or a magnetic separation-flotation process; 4. Finely disseminated hematite ores, containing large quantities of iron silicates and earthy hematite ores are most efficiently beneficiated by the magnetizing roasting method. This method will yield concentrates containing up to 68 percent iron with extractions up to 90 percent. Although beneficiation by the magnetizing roasting process is costly, it will nonetheless, when employed on this type of ore, yield the least expensive pig iron.

Jan 1, 1960

By Chris Lynagh, Collin Schroeder

Determining the best excavation method is a critical step in successful tunnel construction. In rock tunneling, several factors can dictate the excavation method, such as: (1) rock characteristics, (2) tunnel size and length, (3) nearby utilities/infrastructure, and (4) contractor’s preferred means and methods. This paper discusses the various rock tunnel excavation methods utilized on the Doan Valley Storage Tunnel Project (DVT), a project constructed as part of the broader Project Clean Lake in Cleveland, Ohio. The differences between each method’s initial and final lining, geology, and cycle sequence will be analyzed and compared.

Jun 13, 2023

By Ellen Amoako Afful, Michael Moats, Guang Xu, Ashish Kakoria

Electrowinning and solvent extraction are crucial steps in the production of high-purity copper. However, safety concerns have been raised regarding the acid mist generated from the electrowinning process. The mist generated results in health risks to workers and damage to machinery and infrastructure. Currently, chemicals and pellets are used to control acid mist. However, the effectiveness of these controls may vary depending on the type of organic solvent used in the solvent extraction process, which can influence the generation of acid mist. This study aims to evaluate the impacts of organic solvents and surfactants on acid mist suppression. In this study, an electrolyte is contacted with organic solvents to simulate the solvent extraction. The electrolyte is dosed with 20 mg/L of surfactant at each contact. Acid mist testing is performed on the electrolyte separated from the organic phase at the end of the solvent extraction step. The mist collected is analyzed to determine the level of acid mist generated. The results of this study indicate that organic solvents and surfactants showed significant acid mist suppression, but with somewhat different suppression efficiencies. After first contact, Licorice and the organic, for instance, showed a suppression efficiency of up to 69.7% but its efficiency gradually decreased as the number of contacts increased.

Feb 1, 2025

By David R. Kalasky

One of the primary areas of computer application in mine ventilation has been the analysis of mine ventilation networks. A variety of network analyzers that are aimed toward the solution of flows in a given network has been developed. These programs typically use the Hardy Cross or other iterative algorithm for solution of any network, even those that are complex. The computer software has become more efficient and sophisticated over time and has thus been widely adopted for ventilation network analysis. One of the shortcomings of these programs is that they have been developed with the idea of analyzing the ventilation requirements at a single point in the lifetime of a mine. This provides the ventilation engineer with an important tool for analysis but falls somewhat short of providing a convenient means to economically com- pare alternative methods for ventilating a mine. The program described in this paper provides such a tool. The principal concepts that were necessary for the completion of a computer program that analyzes ventilation alternatives is the capability of efficiently determining the ventilation requirements at a variety of times during the lifetime of the ventilation system and some method of analyzing the costs of the alternatives on a realistic comparative basis. To accomplish this task, the authors began using Penn State's mine ventilation simulator designated as PSU/MVS, Didyk et al. (1977a, 1977b) and added the necessary additional software to accommodate the need for multi-period, time-dependent analysis of the net- work. The software was then tested on a coal mine ventilation problem with a 23-year life. The problem points out the value of such a program for ventilation analysis.

Jan 1, 1986

By John C. Stankus, Xiaoting Li

"Underground structures such as square/arch steel sets, king beam structure, etc. are widely used for the roof support in underground mines. In designing and calculating the required carrying capacities of these underground structures, how to identify the potential rock loads on the structures over long term is a challenging question for ground control engineers. Based on design practices of both surface and underground structures, the authors have designed and applied appropriate load factors in underground structural design projects to accommodate different rock types, entry/intersection dimensions, roof geologic conditions, availability of roof bolts and water, etc. Classification of load (reduction) factors for large-span underground intersections are presented for reference. Success of designed underground structures in effectively controlling roof stability over years indicates the applicability of the load factor concept for underground structural design, and its same significance as of the load factor specifications in ASCE/SEI 7-10, ANSI/AWC NDS (2015), and AASHTO LRFD Bridge Design Specifications (2012). The load factor concept will facilitate ground control engineers to appropriately utilize popular structural design software, such as RISA-3D or -2D to efficiently design and analyze underground structures.LOAD FACTORS IN STRUCTURE DESIGN APPLICATIONSIn structures, loads cause stresses, deformations, and displacements. Assessment of their effects is carried out by the methods of structural analysis with the help of load factors. Loads can be increased or decreased by load factors to meet the requirement that design strength be higher than maximum loads. For example, in designing a staircase, a dead load factor may be 1.2 times the weight of the structure, and a live load factor may be 1.6 times the maximum expected live load based on the Load and Resistance Factor Design (LRFD) method. These two “factored loads” are combined (added) to determine the “required strength” of the staircase. Some typical load (adjustment) factors used for structural design are as follows:"

Jan 1, 2019

By H. M. Park

Risk is a major factor in all mining activities, arising from many internal and external variables. The authors? research has resulted in a systematic method for the quantification of risk in mining projects (Park, 2012). This research will be presented in a series of papers, this one and two more that will be published on Mining Engineering?s web site, www.me.smenet.com. This paper identifies the variables associated with risk in mining projects, and their effects. The second paper discusses methods of assessing the overall risk associated with those variables, and presents a statistical model based on a survey of 31 experts. The third paper presents an evaluation of the statistical model, using data from previous mining investment decisions in which the authors have been involved. There are several major competing entities, including BHP Billiton, Rio Tinto, Anglo American, Xstrata, Freeport-McMoRan, Chinese government- run companies and Japanese trading companies, that have large foreign holdings, controlling deposits in most of the world?s established and productive mining districts. In general, the mining industry considers the United States, Canada, Australia and the European countries to have good mining investment environments, but because the major companies have already achieved market dominance in those countries, large investments are required there. Newcomers seeking to enter the industry, either as producing companies or as investing partners, often have difficulty breaking into these established markets. Thus newcomers are increasingly turning to new areas like South America and Africa, which are relatively less developed. The competition among businesses to secure a share of the new market is intense, but there are still good investment opportunities. However, because most of the countries in these areas are not well developed, several additional risks are associated with participation in mining projects in those areas.

Oct 1, 2013

By C. E. Jordan

The fundamental properties of the Bureau of Mines patented dielectric separator were studied to provide insight regarding its design and operating characteristics. Force equations for mineral particles were derived and evaluated experimentally. High dielectric mineral recovery was proportional to the calculated effective dielectric force volume that surrounded each drum electrode wire. Electrode spacing was the most sensitive design parameter, requiring less than 0.4-cm electrode spacing for a good separation. Operating characteristics and ore characteristics were investigated. With a dielectric constant difference as small as 2, good separations were made on a laboratory scale at energy consumption below 12 kw?h/mt.

Jan 1, 1985

By M. L. Mellish

In 1989, for the third consecutive year, both the production and consumption of coal in the United States reached record levels. Domestic coal consumption totaled 806.5 Mt (889 million st) in 1989, a 5.4 Mt (6 million st) increase from the year before (Table 1). US coal exporters also had a banner year. For the first time since 1982, exports ex¬ceeded 91 Mt (100 million st). US coal production in 1989 rose by a surprising 27.3 Mt (30 million st), reaching 889 Mt (980 million st) for the year. To a certain extent, the sizable difference between production and demand growth was due to smaller consumer stock withdrawals. Coal consumers withdrew only 12.7 Mt (14 million st) of coal from their stocks in 1989, com¬pared to 22.7 Mt (25 million st) in 1988. Despite strengthening coal consumption, exports, and production, coal prices to all domestic sectors declined slightly during the year. That essentially continued the trend of the past several years. On the labor front, the United Mine Workers of America struck the Pittston Coal Group in 1989. It was a bitter work stoppage that was not settled until February of 1990. This was the first major coal strike since 1985. The strike also precipitated a series of wildcat outages by UMWA members in June and July. At their peak, more than 40,000 UMWA members participated in the wildcat strikes. Except at Pittston, however, most miners were back to work by August. It is estimated that perhaps 4.5 to 9.1 Mt (5 to 10 million st) of coal production was lost due to the Pittston and associated wildcat strikes. However, some of this production may have been recouped by other coal companies not affected by the wildcat strikes, and by the affected companies after the strikes ended.

Jan 1, 1990