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By A. B. Seal, C. J. Bise

Excessive noise has long been a hazard in the coal-mining industry. Studies conducted during the mid-1970s and mid-1990s consistently show that hearing loss within the mining industry persists, in spite of regulatory requirements and sampling technology advances. When the U.S. Mine Safety and Health Administration's new health standards to protect miners from hearing loss took effect in September 2000, the potential developed to reevaluate sampling approaches with regard to noise-source hazards, such as task-based methods. This paper describes results from a Pennsylvania State University research project now being conducted at an underground coal mine. Each occupation was reviewed, and a list of tasks or processes performed by each was generated. Traditional personal noise dosimetry, static sound pressure levels and equipment sound mappings have been performed. Job tasks indicating the greatest levels of daily noise exposure and contributions to noise dose have been identified and will be discussed.

Jan 1, 2003

By Michael J. Fiannaca

Disseminated epithermal gold metallization occurs within a breccia unit interpreted to be a submarine debris flow. Cold is associated with oxidized pyrite, fluorite, and jasperoidal silica. A minimum of 9 million tons of open-pittable mining reserves will be cyanide heap leached as run-of-mine ore at a rate of 1.0 million tons per year. Careful evaluation of the combined results of successive sampling projects has established the pit plan, mineable reserves, and process metallurgy of the operation. The sampling procedure utilized for a given test depended upon geological interpretation as well as the procedures, successes, and failures of previous tests. This paper summarizes the sampling and testing procedures of the development effort in light of the project goals and attendant problems in achieving them.

Jan 1, 1984

By J. D. Grenia

The Buick Mine is a joint venture of American Metals Climax, Inc., and Homestake Mining Company located 120 miles by road southwest of St. Louis, near the village of Boss, in the 'New Missouri Lead Belt' (See Figure 1). Since start-up in 1969, over four million tons of lead-zinc ore have been mined and milled at Buick. Situated about 1,100 feet below the surface at an elevation 270 feet above sea level, the flat lying sinuous ore bodies are up to 250 feet wide, 85 feet high and several thousand feet long. Mineralization is galena, sphalerite and chalcopyrite in dolomite, Access to the mine is through two 18'Ø concrete lined vertical shafts - one for servicing and the other for hoisting ore (See Figure 2). The mine is being worked by a modified room and pillar method using both rubber tired equipment and a sub-level rail haulage. Ore is broken from first pass headings, back and bench faces and transported by load-haul-dump units to ore passes located on 900 foot centers. The ore is pulled from chutes on the sublevel 90 feet below into 15 ton bottom dump cars and delivered in 10 car lots by a 15 ton diesel locomotive to a 42" gyratory crusher (See Figure 3). A recent innovation has been the introduction of two 50 ton trucks with plans to haul up to 60% of the ore on the mining level to an ore pass feeding directly to the primary crusher (See Figure 4). Ventilation raises up to 16'Ø, which were originally planned for 900 foot centers, are now driven on 450 foot centers.

Jan 1, 1973

By N. T. Mirafuente

The device called "Dynastat" which is described in this paper provides in situ borehole measurements of dynamic and static parameters for use in a wide range of design applications. In the dynamic mode, the Oynastat allows measurement of shear and compressional wave velocities. From these velocities in situ dynamic Young's modulus and other dynamic elastic parameters can be calculated. In the static mode, the device allows measurement of load versus deformation from which in situ static Young's modulus can be determined. Information on in situ horizontal stress fields can also be estimated from the load deformation curves. In both mining and civil engineering applications, in situ measurements of material properties are indispensable for accurate evaluation of design problems. Laboratory dynamic and static test measurements in comparison to in situ measurements are often misleading due to difficulties in obtaining undisturbed samples and in accounting for effects of discontinuities, etc., for mass properties. The authors contend that among in situ borehole measurements, the method employed with the Dynastat is the most accurate and detailed technique of measurement. The Dynastat employs the crosshole method of shear and compressional wave velocity measurements and also performs as a borehole jack to obtain load-deformation relationships of materials at exactly the same location at depth in boreholes.

Jan 1, 1976

By D. Malhotra

The number of variables which can effect flotation of molybdenite is very large. This paper discusses the effect of two operating variables, namely, the degree of aeration and agitation, on the grade and recovery of molybdenite. A series of factorially designed flotation tests were carried out in a "Leeds Automatic Laboratory Flotation Cell." The analysis of flotation results indicate that molybdenite can be characterized into fast-floating and slow-floating components. The rates of fast-floating components, which do not create a problem in flotation, could be varied by changing agitation of airflow rates. However, the rate of slow-floating components was stable and was only a function of residence time in the float machine. The degree of aeration has a significant effect on the grade of MoS2 with only a slight effect on the recovery of MoS2. The degree of agitation has a slight effect on the grade, but does not effect the recovery of molybdenite. The implications of the results on the design of flotation cells and control and optimization of the existing circuits is subsequently discussed.

Jan 1, 1977

By J. B. Hedrick

Rare earths were not mined in the United States in 2008. However, processing of intermediate rare-earth concentrates continued throughout the year at the Mountain Pass Mine in California. Consumption of refined rare-earth products increased. U.S. rare earth imports were primarily from China, with lesser amounts, in decreasing order, from France, Hong Kong, Japan, Austria and Russia. The United States imported 100 percent of its supply of yttrium metal and compounds primarily from China. United States In 2008, lanthanide concentrates were processed by Chevron Mining Inc. (previously Molycorp Inc.) at its mine site at Mountain Pass, CA. Chevron Mining sold its entire holdings in the rare earths mine to Molycorp Minerals LLC in September and operations continued at the site through-out 2008. Major uses for these mineral commodities were in automotive catalytic converters, petroleum fl uid-cracking catalysts, permanent magnets, glass-polishing compounds, ceramics, metal-alloying additives, phosphors and recharge-able batteries. Three domestic companies produced and sold lanthanide intermediate concentrates and refined products. Chevron Mining sold its interests in the Mountain Pass Mine to Molycorp Minerals LLC on Sept. 30, 2008. Molycorp Minerals LLC is an investment company owned by Resource Capital Fund IV L.P., Pegasus Partners IV, LP, The Goldman Sachs Group Inc., Traxys North America LLC, Carint Group LLC and Mark Smith. The Molycorp operation previously mined the rare earth fluocarbonate mineral bastnäsite by hard-rock surface methods, and the mine remained on care and maintenance in 2008. Molycorp maintained significant stocks of bastnäsite concentrates, intermediate concentrates and high-purity rare earth compounds at its operations at Mountain Pass. In October 2007, Chevron Minerals completed phase one of its three-stage plan and restarted the rare earth separation plant at Mountain Pass. The company also processed intermediate rare earth concentrates from existing stocks during the first three quarters of 2008. Molycorp Minerals LLC maintained production in the last quarter of the year. The mine at Mountain Pass has been closed since 1998. Future plans are to restart processing of stockpiled bastnäsite concentrates followed by reopening of the mine.

Jan 1, 2009

By H. W. Hitzrot

Introduction Mechanical classifiers consist of a settling tank with parallel sides and a sloping bottom equipped with a mechanism which continuously agitates the pulp and removes the settled solids. The functions served by mechanical classifiers include the following: (1) allow the particles larger than the desired size to settle in the tank and provide an overflow product with a minimum of oversize particles, (2) produce an overflow product of sufficiently high solids content to meet the requirements of the subsequent processing steps, (3) agitate the pulp and permit separation of the entrapped undersize particles so they can report in the overflow product, and (4) drain and remove the underflow solids from the settling pool. Various types of mechanisms have been used to agitate the pulp and remove the settled solids, which include: (I) endless belt and chain drags, (2) reciprocating rakes, (3) helical flights mounted on a rotating shaft which extends through the settling pool, (4) helical flights inside of a rotating drum which contains the classifier pool, (5) troughed conveyor belts forming the settling pool in the concave curve of the belt closely following the tail pulley, and (6) low-speed impellers agitating the underflow settled in the apex of cone-type mechanical classifiers.23 The principal use of mechanical classifiers has been in closed¬-circuit wet grinding; however, this application has been widely displaced over the past few decades by the hydrocyclone. The hydrocyclone installation, including its feed pump, offers lower capital costs and requires less floor space. Nominally it produces an overflow prod¬uct of higher solids content, compared with a mechanical classifier, for comparable classification size up to 400µm (35 mesh). However, these advantages of the hydrocyclone are being gained at the sacrifice of some of the advantages of the mechanical classifier. The mechanical classifier requires less power and has lower maintenance costs than the hydrocyclone and its feed pump. The underflow product from the mechanical classifier can have a higher solids content and contain less entrapped undersize particles than the comparable product from the hydrocyclone. Consequently, it is capable of operating at a higher classification efficiency. A reduced circulating load24, 25 results under these conditions in a closed-circuit grinding application. Other applications for mechanical classifiers include desliming, dewatering, and washing operations. Sand-slime separation may be achieved using one or more stages of mechanical classifiers. Typical applications would include washing and deslimining of concrete aggre¬gate or sand; glass sand; abrasives; oyster shells; phosphate rock; iron, nickel, and chromium ores; alumina; zeolites; solar salt; and precipitates from chemical processing. As an example for the latter, Bitzer26 recommended the use of mechanical classifiers for countercur¬rent cementation-in-pulp of copper from the leach liquor. Similarly, mechanical classifiers are used in uranium processing27 for separation of the barren sands from the pregnant leach solution. Depending on the particle size and the effectiveness of the sand¬slime separation, the sand product from mechanical classifiers may be drained to solids content approaching 84%. Thus, mechanical classifiers are frequently used as dewatering equipment for various applications, such as: 1) Make a product having suitable solids content for subsequent transport by belt conveyor. 2) Provide a drained product to reduce cost of drying. 3) Provide a drained, washed, heavy sand product for return to the circuit. 4) Recover fine values from dilute plant effluents from coal, sand, phosphate-rock, and iron-ore washing plants and from steel-mill flue¬dust scrubbers. 5) Drain residual reagents of a preceding process stage prior to conditioning with reagents of different characteristics, e.g., cationic¬anionic flotation of phosphate rock, iron ore, etc. Design and Operating Features The proper selection of mechanical classification equipment re¬quires that the properties of the solids and liquid are adequately de¬fined. The following descriptive information regarding the solids is desired: feed rate, chemical and physical composition, density, tem¬perature, size analysis, and desired separation size. For the liquid used, the following data would be needed: feed rate, density, viscosity, pH, and temperature. Settling Area. The pool area required to permit a particle larger than the separation size to settle depends on the density and shape of the particle and on the density and viscosity of the pulp within the classifier pool. These criteria of the solids and pulp determine the settling rate which, in turn, determines the settling area required. Determination of the settling rate by long-tube batch tests can be used to calculate the settling area. A theoretical approach for estimat¬ing the settling area requirements is discussed in Chapter 1, Classifica¬tion Theory. This procedure can be used when neither test data nor empirical data from similar operations are available. Data on settling-area requirements and settling rates have been compiled by the manufacturers of mechanical classifiers. The approxi¬mate settling area required for a particular separation size can be estimated by using the curve shown in Fig. 65. This curve applies for closed-circuit grinding applications. For dilute velocity classification in open circuit, desliming, the length of the overflow weir, W, multiplied by the weir's mean distance from the feed opening, E, is used as the design criterion, instead of the settling area, in sizing the classifier. The area requirements, W X E, for dilute velocity classification can be expressed in terms of volumetric flow, Q, and settling rate, Rs, as follows: W x E = Q/(18.06 Rs) where W and E are feet, Q is gallons per minute, and Rs is inches per second. Overflow Weir. The hydraulic head, and thus the velocity at which the overflow crests the overflow weir, is one of the factors controlling the particle size of classification. Consequently, the length of the overflow weir must be designed to provide the overflow velocity which allows the particles larger than the desired size of classification to settle in the working area of the pool. Obtaining the necessary

Jan 1, 1985

By Kendall Y. Keuhey

The Mercur Mine, developed and operated by Getty Mining Company, is designed to process 3,000 tons/day of gold ore from the historical Mercur Hill mining district. The mill process involves crushing, grinding, and cyanide carbon in leach for recovery of gold ores ranging from 0.08 to 0.10 oz/ton. During the mining of normal grade ore, a substantial tonnage of material containing 0.02 to 0.05 oz/ton is mined and would be available for heap leaching. Also, Getty Mining is developing methods to test and prepare lower grade material for heap leaching by rejecting a course rock fraction from the grinding circuit SAG mill. This lower grade fraction is suitable for heap leaching, and its removal will upgrade the regular mill feed. Other test methods are directed toward leaching techniques on some 4.0 million tons of tailings that resulted from roasting and/or cyanide leaching Mercur ores in the early 1900s. The natural carbons associated with the Mercur deposits require special treatment to reduce their gold adsorption effects when leached with cyanide.

Jan 1, 1983

By Z. Yunquan

The flocculation and dispersion behaviors of microsize wolframite and quartz are systematically studied in this paper. For synthetic mixtures, the floc separatory method on gravity units--electromagnetic vibration table (EVT) and lifting column (LC), have been approached. Satisfactory results can be obtained with a weak shearing. A better metallurgical performance can also be achieved for natural ore slimes through the combined technique. The efficiency is better than that of single gravity separation. Finally, the mechanism has been investigated.

Jan 1, 1990

By B. Akwasi Osei

The lack of metrics to assess clamshell formation dredgeability limits the ability of engineers to predict the dredgeability of compact material and increases the risks associated with clamshell selection. Research is needed to develop metrics for predicting clamshell dredgeability. The objective of this paper is to evaluate possible metrics to predict the dredgeability of compact aggregates by hydraulically actuated clamshell dredges. Data on cylinder pressures and displacements, motor current, bucket tilt and cycle time (CT) were collected from a dredge. Work done and motor energy, potential metrics, were computed and their suitability in predicting dredgeability evaluated. Data analysis shows that; there is no correlation between tilt angle and work done or motor energy; a low correlation between CT and work done, and a strong correlation between CT and motor energy. Work done is a better measure of formation dredgeability, than motor energy, as it shows lower variability. However, in difficult digging conditions, work done alone does not accurately predict dredgeability. This work shows that, it is feasible to use cylinder pressures and motor signals data to predict dredgeability.

Jan 1, 2010

By Myron W. Mellor

Much has been published concerning the subject of coal preparation as related to electric power generation however it is always a most vital topic for both utilities and coal producers, It also constitutes a field of study that is never finished since new concepts and changing demands continually require altered perspectives. One graphic illustration that has been used to emphasize the rapidity with which times are changing is the fact that during World War I, a station that consumed 1000 tons per day was looked upon as a large central station, while today some single generators require 1500 tons during the same period, For further emphasis, at that time a 20,000 horsepower turbo-generator was a mighty large machine; today, a unit of this size is planned for driving the boiler water feed pump required for a single large main unit. During the past ten years alone, electric utilities have more than doubled their percentage of coal consumed as compared to the total market. They now account for approximately 40% of the United States consumption and one-third of all production including export, Conversely, approximately 70% of all U. S. steam electric generation is by coal and this percentage is expected to increase. It is further predicted that utility consumption will increase from the current 160,000,000 tons per year to between 400 and 500 million tons in 1975 which is approximately equal to todays total production

Jan 1, 1959

By Justin Kolster, Donald Benjamin, Kyle White

Expansion of the Plum Island Wastewater Treatment Plant requires interconnection of three operating pump stations using only two existing 10-ft diameter shafts for access. These two existing shafts require additional support to allow access 130 feet below grade. Interconnection requires rehabilitation of an existing tunnel, excavation of two new tunnels, and abandonment of additional existing tunnels. Construction has discovered unexpected conditions at all three connection points. The CMAR contracting method has effectively accommodated project team discussion, value engineering decisions, and allocation of risk during preconstruction and construction phase services.

Dec 1, 2022

By James A. Decker

Hanna has developed three production planning systems to help the mine engineers determine the sequence of mining from available ore supples. The Production Scheduling System was developed to give the staff a tool for long range planning by sequencing the removal of blocks from an open pit property. It was needed to determine the year of removal for each block so that the optimum present-valued pit limits could be established by our pit design program. Since in this type of planning short term grade control is less of a factor than it is in daily or monthly planning, the system gives the program greater control and more latitude in block selection. It permits only full blocks to be taken.

Jan 1, 1984

By C. L. Schneider

The calculation of the liberation spectrum in the product from continuous milling operations is a problem of considerable importance and is difficult to solve because the population balance equation must be integrated in two-dimensional space. Complete solutions require the estimation of a large number of parameters unless a structural model of the ore texture can be used. A very simplified textural model based on the use of the modified Andrews-Mika diagram and the PARGEN simulation of multi-phase particles has been formulated and is used to simulate the behavior of a continuously operating laboratory ball mill. A sensitivity analysis for this mill has been done to show the likely effect of model approximations on the predicted liberation spectrum which will be measured.

Jan 1, 1992

By Khosrow Badiozamani

Traditionally the mining industry has been lagging in application of computers in their daily or long range plan activities compared to other industries. The question then remains as to how the technology of higher computing capacity for less cost is going to affect the mining industry and how the lukewarm reception of engineers in acceptance of computerized mine planning in the past is going to change because of the new wave of high techology. These questions and the reasons for the lack of usage of computerized mine planning systems by engineers will be evaluated in this paper. In addition, alternatives available to the mining industry will be analyzed and the direction of the future "user friendly" software will be discussed.

Jan 1, 1984

By B. C. Lewis

The mining industry has experienced a general trend toward an increasing number of longwall operations, an increasing percentage of underground coal being mined by longwalls, and increasing productivity from the longwalls. Longwall operators have not yet reached a state of mining euphoria. Competitiveness both within the industry and from alternate fuel sources is forcing continued pursuit of higher productivities and lower costs. The following graphics present trends in the industry. Longwall mines, as defined for this presentation, are those reportedly having longwall installations in each of the respective years. Production from both the continuous miner and longwall units is included in the longwall mines. Non-Longwall mines are all other underground mines. Productivity calculations are based on total employee-hours associated with the operation.

Jan 1, 1990

By K. Lang

A test section of the upper most lift and underlying lifts of a large scale copper heap leach operation was instrumented and monitored with advanced wireline geophysics, fiber optics and resistivity electrode arrays. Elemental Capture Spectroscopy (ESC) copper measurements, resistivity measurements from an Array Induction Tool (AIT), electrical resistivity tomography (ERT) and distributed temperature sensing (DTS) with fiber optics provided integrated near real time data about the performance of the heap. During the leaching cycle, ECS provided continuous vertical measurements of copper in the upper most and underlying lifts in the test section of the heap and was used to generate a copper recovery curve. ERT inversion modeling provided high resolution 3D resistivity measurements, which were used to evaluate moisture distribution. DTS measurements of temperature were used to track the PLS front and calculate velocity. AIT induction provided highly precise bulk resistivity measurements. In-situ samplers provided PLS chemistry at multiple points. Properly integrated monitoring data can provide the heap leach operator with information that can be used to evaluate the hydrodynamics and metallurgy of the leaching process in near real time. Problems in the heap, such as pooling, channeling, longer lag and breakthrough times, excess acid consumption, increased solution in inventory, toe saturation and slope stability can be detected in near real time with the in-situ measurements evaluated.

Feb 23, 2014

By T. V. Ramey

Heap leaching in certain parts of the world, such as Chile's Atacama Desert, brings unique design problems in the form of possible large differential settlements of the foundation soils due to the dissolution of salts in northern Chile the soils often contain very high concentrations of soluble salts (nitrates, potassium, magnesium, and common sodium). When a leak in the liner occurs, the escaping solution dissolves these salts and triggers differential settlement. If the settlement is great enough, the geo-membrane tears, the leakage increases, triggering more differential settlement. The nitrate plants have experienced many occurrences of this phenomenon where a brine pond will undergo a sudden and complete loss of the impounded liquors. The authors present a simplified technique to quantify the differential settlement resulting from dissolution and provide a method which can be used to select a geo-membrane with suitable flexibility under axi-symmetric (multi-axial) load conditions to tolerate the predicted settlement. (This paper was previously published for Randol Gold Forum 1996 [Ref. 6]).

Jan 1, 1997

By Matthew T. Mowry

As the mining industry continues to hire young professionals to supplant the growing number of retirees, a well-developed engineering curriculum, coupled with practical, real-world training, can prepare mining engineering graduates to make meaningful contributions in the industry. Successful companies can be measured not only by their reserve base and annual production but also by their retention of mining engineering graduates with zero to five years of operational experience. My personal experience in the industry during the last five years has been varied and rewarding. The knowledge and experience I have gained have taught me valuable lessons that prepared me for my current role.

Nov 1, 2013

By Richard L. Bullock

OPEN STOPING An open stope is an underground cavity from which the initial ore has been mined. Caving of the opening is prevented (at least temporarily) by support from the unmined ore or waste left in the stope, in the form of pillars, and the stope walls (also called ribs or abutments). In addition to this primary support system of open stoping, some secondary support may also be required using rockbolts, reinforcing rods, split pipes, or shotcrete to stabilize the rock surface immediately adjacent to the opening. The secondary reinforcement procedure does not preclude the method classified as open stoping. There are many forms of open-stope mining used to extract the initial material from a mine. Having once established that the mineral and waste rock are competent enough to use an open-stoping method, and assuming that the reserve is not classified as gassy, the Form which the method will take is primarily determined by the dip and thickness of the reserve. How these two factors affect the selection of the open-stope mining is discussed in a later chapter. At this point it will suffice to say that the classification of the open-stopes mining system which follows is based on whether dry' broken materials flows by gravity or whether it must be moved by nongravity methods where energy must be supplied to move the material. Room-and Pillar-Mining Room-and-pillar mining is an open-stoping method where mining progresses in a nearly horizontal or low angle direction by opening multiple stopes or rooms, leaving solid material to act as pillars to support the vertical load. Since the direction of excavation (angle of dip) is below that which would cause the dry material to flow by gravity to a drawpoint or gathering point, the material must be loaded in the room where it was extracted and transported to a point where it will flow, either by gravity or mechanical means, to a central gathering point to be taken out of the mine. This is an important aspect of room-and-pillar mining which differentiates the system from other open-stope mining methods which rely heavily upon gravity to transport ore from where it was broken to a lower elevation, usually through a drawpoint. There are many variations of the method which go by a number of names in local districts: breast stoping, breast-and-bench stoping, board-and-pillar, stall-and-pillar, and panel-and-pillar are all basically open-stope room-and-pillar mining. In some instances detailed stope planning is almost nonexistent; i.e., the operator simply follows the visual pay values, leaves pillars only where necessary, and tries to locate them in the zones of lower value. This method of mining is as old as the beginning of underground mining itself, dating back thousands of years. Early in the history of mining in this country, the term "gophering" was used to describe this method (Peek 1941). The term is appropriate, for it brings to mind the exact results of this type of system-a random and irregular room-and-pillar mine. In other instances where the mineral values are consistent both in physical dimensions and quality, the mine layout can be planned to the last detail, resulting in a uniform room-and-pillar mine. Coal, trona, gilsonite, potash, oil shale, salt, limestone, and sandstone mines can usually follow such a system. Today, most metal mines using a room-and-pillar operation try to mine as regular a pattern as possible but deviation in height, width, thickness, dip, and grade of the ore results in comparable deviation in the mine plan. Variations of the Room-and-pillar System It is necessary to briefly describe some of the many variations of the room-and-pillar system of mining, enabling the reader to fully explore the concepts and become familiar with the terminology used before going on to the details of mine design. Full-Face Slicing: If in the process of opening the rooms the total vertical extent of the mineral values of the particular seam or strata are extracted from the advance of one vertical face, the term used to describe this is full-face slicing. This face is also known as the "breast." There is no mineral of economic value intentionally left either in the floor or the roof (back) to be mined later. To be able to extract the full-face height in one pass, the mining equipment must obviously be designed to reach as high as the back. In an Appalachian coal mine, this may be all of 660.4 mm (26 in.); for a future oil shale property it might be 15.24 m (50 ft). Normally, however, in a majority of mines where the mining face gets over 6.09 to 6.7 m (20 to 22 ft), the tendency is to divide the face into more than one pass. Over this height, it becomes difficult to properly see and remove loose rock from the back with a hand "mining bar." Where the process of taking down loose rock has become mechanized, higher full-face mining can be safely practiced. Most eastern and midwestern coal seams and western uranium, trona, and potash seams in the United States are easily reached in a single face; many limestone, lead, and zinc mines must resort, at least in part, to "multiple-slicing" to remove all the minerals of value. Multiple Slicing (also known as multiple-pass mining): In many cases it is not practical to carry the full vertical height of the mining horizon as a full face. The face is divided into parts known as the breast, bench, and/or brow. Ideally, if the operator knows the vertical extent of the mineralized zone, he will drill and blast the first pass at the top of the zone, thereby

Jan 1, 1982