{"id":8160,"date":"2023-09-08T16:14:25","date_gmt":"2023-09-08T16:14:25","guid":{"rendered":"https:\/\/controlconceptsusa.com\/?p=8160"},"modified":"2023-09-20T16:17:04","modified_gmt":"2023-09-20T16:17:04","slug":"processing-mined-materials-challenges-and-solutions","status":"publish","type":"post","link":"https:\/\/controlconceptsusa.com\/processing-mined-materials-challenges-and-solutions\/","title":{"rendered":"Processing Mined Materials: Challenges and Solutions"},"content":{"rendered":"<p><img decoding=\"async\" class=\"wp-image-8161 aligncenter\" src=\"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2023\/09\/shutterstock_2261229835-1024x683.jpg\" alt=\"small piles of extracted rare earth minerals \" width=\"416\" height=\"277\" srcset=\"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2023\/09\/shutterstock_2261229835-1024x683.jpg 1024w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2023\/09\/shutterstock_2261229835-300x200.jpg 300w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2023\/09\/shutterstock_2261229835-768x512.jpg 768w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2023\/09\/shutterstock_2261229835-1536x1024.jpg 1536w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2023\/09\/shutterstock_2261229835-2048x1365.jpg 2048w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2023\/09\/shutterstock_2261229835-600x400.jpg 600w\" sizes=\"(max-width: 709px) 85vw, (max-width: 909px) 67vw, (max-width: 1362px) 62vw, 840px\" \/><\/p>\n<p>Mined materials are used in almost all industries, from construction to consumer goods. However, these materials can be challenging to move and process because of their physical and chemical properties.<\/p>\n<p>Let\u2019s take a closer look at the common problems that can occur while processing mined materials, and how we can help.<\/p>\n<h2>Types of Mined Materials<\/h2>\n<p><span style=\"font-weight: 400;\">Mined materials range from metallic ores like iron and copper to non-metallic minerals such as potash and gypsum. The <\/span><span style=\"text-decoration: underline;\"><a href=\"https:\/\/www.world-mining-data.info\/?World_Mining_Data___Mineral_Raw_Materials\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">World Mining Data<\/span><\/a><\/span><span style=\"font-weight: 400;\"> names five different categories:<\/span><b><\/b><\/p>\n<ul>\n<li aria-level=\"1\"><b>Iron and Ferro-Alloy Metals: <\/b><span style=\"font-weight: 400;\">Iron, Chromium, Cobalt, Manganese, Molybdenum, Nickel, Niobium, Tantalum, Titanium, Tungsten, Vanadium<\/span><\/li>\n<\/ul>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Non-Ferrous Metals:<\/b><span style=\"font-weight: 400;\"> Aluminium, Antimony, Arsenic, Bauxite, Beryllium, Bismuth, Cadmium, Copper, Gallium, Germanium, Indium, Lead, Lithium, Mercury, Rare Earth Minerals, Rhenium, Selenium, Tellurium, Tin, Zinc<\/span><\/li>\n<\/ul>\n<ul>\n<li aria-level=\"1\"><b>Precious Metals: <\/b><span style=\"font-weight: 400;\">Gold, Platinum-Group Metals (Palladium, Platinum, Rhodium), Silver<\/span><\/li>\n<\/ul>\n<ul>\n<li aria-level=\"1\"><b>Industrial Minerals: <\/b><span style=\"font-weight: 400;\">Asbestos, Baryte, Bentonite, Boron Minerals, Diamond (Gem\/Industrial), Diatomite, Feldspar, Fluorspar, Graphite, Gypsum and Anhydrite, Kaolin (China-Clay), Magnesite, Perlite, Phosphate Rock (incl. Guano), Potash, Salt, Sulfur, Talc (incl. Steatite and Pyrophyllite), Vermiculite, Zircon<\/span><\/li>\n<\/ul>\n<ul>\n<li aria-level=\"1\"><b>Mineral Fuels: <\/b><span style=\"font-weight: 400;\">Steam Coal (including Anthracite and Sub-Bituminous Coal), Coking Coal, Lignite, Natural Gas, Petroleum (incl. Natural Gas Liquids), Oil Sands, Oil Shales, Uranium<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">Each of these has unique flow characteristics that present distinct challenges. For instance, metallic ores often possess high density, while non-metallic minerals may be prone to moisture retention.<\/span><\/p>\n<h2>Challenges in Material Flow<\/h2>\n<p><span style=\"font-weight: 400;\">Material flow problems can lead to machine downtime and increased maintenance costs, which decreases profitability. The most common flow issues encountered while handling mined materials are: <\/span><\/p>\n<ul>\n<li aria-level=\"1\"><b>Bridging. <\/b><span style=\"font-weight: 400;\">The material forms an arch above the outlet of a hopper or silo. This slows or even completely stops the flow, causing production delays. <\/span><\/li>\n<li aria-level=\"1\"><b>Ratholing. <\/b><span style=\"font-weight: 400;\">The material accumulates along the vessel walls, forming a channel that restricts the flow. \u201cOld\u201d trapped material also remains in the vessel, instead of first in\/first out flow. <\/span><\/li>\n<li aria-level=\"1\"><b>Segregation. <\/b><span style=\"font-weight: 400;\">The materials segregate based on size or density during flow, resulting in inconsistent quality and potential waste of valuable resources.<\/span><\/li>\n<\/ul>\n<h2>Dangers of overflow<\/h2>\n<p>While material blocks slow or stop the flow, there\u2019s also a danger of overflow\u2013when equipment breaks down, causing tons of material to suddenly spill to the ground.<\/p>\n<p>The material spill can injure workers, release potentially flammable powders into the air, and take days to clean up.<\/p>\n<p>A processing facility may have to completely shut down operations until a material spill is cleared. Workers will also have to manually clear the material, which can pose health and safety risks.<\/p>\n<p>That\u2019s why mining industry regulations require mines and mined materials facilities to have safety devices and protocols in case any equipment malfunctions.<\/p>\n<h2>Ensure safe and efficient flow of mined materials<\/h2>\n<p>Control Concepts, Inc. provides a complete solution for material flow problems. Our two superstar products, AirSweep and DAZIC, can work together for smooth and safe operations.<\/p>\n<p><a href=\"https:\/\/controlconceptsusa.com\/airsweep\/\" target=\"_blank\" rel=\"noopener\">AirSweep<\/a> is a material flow aid that guarantees on-demand, first-in\/first out flow. It is used in the mining industry to resolve bridging, ratholing, and segregation\u2013and save a lot of time and money in the process!<\/p>\n<p>AirSweep&#8217;s patented nozzle delivers quick bursts of compressed air or gas along the container walls, breaking down bridges and ratholes without damaging the container or the material. It can activate even heavy, wet, or sticky mined materials. (Read more about AirSweep in the <a href=\"https:\/\/controlconceptsusa.com\/mined-materials\/\" target=\"_blank\" rel=\"noopener\">mined material industry<\/a>.)<\/p>\n<p><strong><img decoding=\"async\" width=\"845\" height=\"411\" class=\"alignnone size-full wp-image-8162\" src=\"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2023\/09\/Screenshot-2023-09-08-at-8.58.45-AM.png\" alt=\"Airsweep flowstream list of stubborn material \" srcset=\"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2023\/09\/Screenshot-2023-09-08-at-8.58.45-AM.png 845w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2023\/09\/Screenshot-2023-09-08-at-8.58.45-AM-300x146.png 300w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2023\/09\/Screenshot-2023-09-08-at-8.58.45-AM-768x374.png 768w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2023\/09\/Screenshot-2023-09-08-at-8.58.45-AM-600x292.png 600w\" sizes=\"(max-width: 709px) 85vw, (max-width: 909px) 67vw, (max-width: 1362px) 62vw, 840px\" \/><\/strong><\/p>\n<p><span style=\"font-weight: 400;\">DAZIC zero speed switches prevent material spills. It monitors the operational speed of rotating, reciprocating, or conveying equipment. It then triggers an alarm or shuts down a system if the equipment is operating at an unsafe or inefficient speed.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">DAZIC can be installed on any equipment that has a rotating part, including conveyor belts, bucket elevators, motors, and more. It is inexpensive, durable, and reliable\u2013and used by both global manufacturing firms and small, local businesses.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">For many of those companies, DAZIC is an important part of plant efficiency and safety compliance. (Read more about how a <\/span><a href=\"https:\/\/controlconceptsusa.com\/meet-safety-regulations-with-dazic\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">zero speed switch helps you meet safety regulations<\/span><\/a><span style=\"font-weight: 400;\">.) <\/span><\/p>\n<h2>Success stories<\/h2>\n<p><span style=\"font-weight: 400;\">AirSweep and DAZIC have helped mined materials facilities prevent the toughest material flow problems.<\/span><\/p>\n<ul>\n<li>A <a href=\"https:\/\/controlconceptsusa.com\/case-history\/airsweeps-crush-flow-issues-at-minerals-processing-plant\/\" target=\"_blank\" rel=\"noopener\">mineral processing plant<\/a> took an hour to fill one supersack with mined materials. AirSweep reduced filling time to just two minutes, for a 1200% increase in productivity.<\/li>\n<li>One of the <a href=\"https:\/\/controlconceptsusa.com\/case-history\/airsweep-exceeds-expectations-you-should-be-on-billboards-everywhere\/\" target=\"_blank\" rel=\"noopener\">fastest growing mining companies in Africa<\/a> were concerned about the safety issues and high energy consumption of air cannons \u2013 especially since workers still spent up to two hours a day clearing leftover material blocks. AirSweep completely solved the problem, prompting them to say, \u201cYou should be on billboards everywhere!\u201d<\/li>\n<li>A <a href=\"https:\/\/controlconceptsusa.com\/case-history\/dazic-prevents-a-dangerous-dust\/\" target=\"_blank\" rel=\"noopener\">global tire manufacturer<\/a> that uses carbon black installed DAZIC zero speed switches to meet safety standards. A carbon black spill could cause flash fires and breathing problems, and complicated cleaning processes since the material doesn\u2019t dissolve in water and solvents.<\/li>\n<li><span style=\"font-weight: 400;\">A <\/span><a href=\"https:\/\/controlconceptsusa.com\/case-history\/dazic-speed-switches-can-literally-prevent-250-tons-of-problems\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">ready-mix concrete plant<\/span><\/a><span style=\"font-weight: 400;\"> loads up to 250 tons of gravel an hour into its feeders. \u201cIt would be a nightmare if the DAZIC didn\u2019t shut the conveyor belt down. I don\u2019t even want to think about it,\u201d said the plant supervisor. They installed DAZIC zero speed switches nearly 20 years ago\u2013and they are still working! \u201cThey have never quit.\u201d<\/span><\/li>\n<\/ul>\n<h2>Take charge of the material flow of mined materials<\/h2>\n<p><span style=\"font-weight: 400;\">With AirSweep and DAZIC, you&#8217;re not just investing in a product \u2013 you&#8217;re investing in smoother operations, consistent product quality, and ultimately, a more robust bottom line. <\/span><a href=\"https:\/\/controlconceptsusa.com\/contact\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">Contact us<\/span><\/a><span style=\"font-weight: 400;\"> to find out more about how to improve material flow in your facility. <\/span><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Mined materials are used in almost all industries, from construction to consumer goods. However, these materials can be challenging to move and process because of their physical and chemical properties. Let\u2019s take a closer look at the common problems that can occur while processing mined materials, and how we can help. Types of Mined Materials [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":8161,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"inline_featured_image":false,"footnotes":""},"categories":[90,1019],"tags":[213],"class_list":["post-8160","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-airsweep","category-news-and-information","tag-news"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v26.8 (Yoast SEO v27.0) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Processing Mined Materials: Challenges and Solutions Control Concepts, Inc.<\/title>\n<meta name=\"description\" content=\"Mined materials are used in many industries. However, it can be challenging to move &amp; process due to their physical and chemical properties.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/controlconceptsusa.com\/processing-mined-materials-challenges-and-solutions\/\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"Control Concepts USA\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"5 minutes\" \/>\n<!-- \/ Yoast SEO Premium plugin. -->","yoast_head_json":{"title":"Processing Mined Materials: Challenges and Solutions Control Concepts, Inc.","description":"Mined materials are used in many industries. However, it can be challenging to move & process due to their physical and chemical properties.","robots":{"index":"index","follow":"follow","max-snippet":"max-snippet:-1","max-image-preview":"max-image-preview:large","max-video-preview":"max-video-preview:-1"},"canonical":"https:\/\/controlconceptsusa.com\/processing-mined-materials-challenges-and-solutions\/","twitter_misc":{"Written by":"Control Concepts USA","Est. reading time":"5 minutes"},"schema":{"@context":"https:\/\/schema.org","@graph":[{"@type":"Article","@id":"https:\/\/controlconceptsusa.com\/processing-mined-materials-challenges-and-solutions\/#article","isPartOf":{"@id":"https:\/\/controlconceptsusa.com\/processing-mined-materials-challenges-and-solutions\/"},"author":{"name":"Control Concepts USA","@id":"https:\/\/controlconceptsusa.com\/#\/schema\/person\/4adf025d9423fe94f784b73a083afb0e"},"headline":"Processing Mined Materials: Challenges and Solutions","datePublished":"2023-09-08T16:14:25+00:00","dateModified":"2023-09-20T16:17:04+00:00","mainEntityOfPage":{"@id":"https:\/\/controlconceptsusa.com\/processing-mined-materials-challenges-and-solutions\/"},"wordCount":905,"publisher":{"@id":"https:\/\/controlconceptsusa.com\/#organization"},"image":{"@id":"https:\/\/controlconceptsusa.com\/processing-mined-materials-challenges-and-solutions\/#primaryimage"},"thumbnailUrl":"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2023\/09\/shutterstock_2261229835-scaled.jpg","keywords":["news"],"articleSection":["Airsweep","News and Information"],"inLanguage":"en-US"},{"@type":"WebPage","@id":"https:\/\/controlconceptsusa.com\/processing-mined-materials-challenges-and-solutions\/","url":"https:\/\/controlconceptsusa.com\/processing-mined-materials-challenges-and-solutions\/","name":"Processing Mined Materials: Challenges and Solutions Control Concepts, Inc.","isPartOf":{"@id":"https:\/\/controlconceptsusa.com\/#website"},"primaryImageOfPage":{"@id":"https:\/\/controlconceptsusa.com\/processing-mined-materials-challenges-and-solutions\/#primaryimage"},"image":{"@id":"https:\/\/controlconceptsusa.com\/processing-mined-materials-challenges-and-solutions\/#primaryimage"},"thumbnailUrl":"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2023\/09\/shutterstock_2261229835-scaled.jpg","datePublished":"2023-09-08T16:14:25+00:00","dateModified":"2023-09-20T16:17:04+00:00","description":"Mined materials are used in many industries. However, it can be challenging to move & process due to their physical and chemical properties.","breadcrumb":{"@id":"https:\/\/controlconceptsusa.com\/processing-mined-materials-challenges-and-solutions\/#breadcrumb"},"inLanguage":"en-US","potentialAction":[{"@type":"ReadAction","target":["https:\/\/controlconceptsusa.com\/processing-mined-materials-challenges-and-solutions\/"]}]},{"@type":"ImageObject","inLanguage":"en-US","@id":"https:\/\/controlconceptsusa.com\/processing-mined-materials-challenges-and-solutions\/#primaryimage","url":"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2023\/09\/shutterstock_2261229835-scaled.jpg","contentUrl":"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2023\/09\/shutterstock_2261229835-scaled.jpg","width":2560,"height":1707,"caption":"small piles of extracted rare earth minerals"},{"@type":"BreadcrumbList","@id":"https:\/\/controlconceptsusa.com\/processing-mined-materials-challenges-and-solutions\/#breadcrumb","itemListElement":[{"@type":"ListItem","position":1,"name":"Home","item":"https:\/\/controlconceptsusa.com\/"},{"@type":"ListItem","position":2,"name":"Processing Mined Materials: Challenges and Solutions"}]},{"@type":"WebSite","@id":"https:\/\/controlconceptsusa.com\/#website","url":"https:\/\/controlconceptsusa.com\/","name":"Control Concepts, Inc.","description":"","publisher":{"@id":"https:\/\/controlconceptsusa.com\/#organization"},"potentialAction":[{"@type":"SearchAction","target":{"@type":"EntryPoint","urlTemplate":"https:\/\/controlconceptsusa.com\/?s={search_term_string}"},"query-input":{"@type":"PropertyValueSpecification","valueRequired":true,"valueName":"search_term_string"}}],"inLanguage":"en-US"},{"@type":"Organization","@id":"https:\/\/controlconceptsusa.com\/#organization","name":"Control Concepts Inc.","url":"https:\/\/controlconceptsusa.com\/","logo":{"@type":"ImageObject","inLanguage":"en-US","@id":"https:\/\/controlconceptsusa.com\/#\/schema\/logo\/image\/","url":"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2020\/04\/CCI-Logo-Color.svg","contentUrl":"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2020\/04\/CCI-Logo-Color.svg","width":"1024","height":"1024","caption":"Control Concepts Inc."},"image":{"@id":"https:\/\/controlconceptsusa.com\/#\/schema\/logo\/image\/"}},{"@type":"Person","@id":"https:\/\/controlconceptsusa.com\/#\/schema\/person\/4adf025d9423fe94f784b73a083afb0e","name":"Control Concepts USA","image":{"@type":"ImageObject","inLanguage":"en-US","@id":"https:\/\/controlconceptsusa.com\/#\/schema\/person\/image\/","url":"https:\/\/secure.gravatar.com\/avatar\/79df5baa963b32870b9f3aa029f8fb2a34974afa19c4f08b5bfde9af1945c9a7?s=96&d=mm&r=g","contentUrl":"https:\/\/secure.gravatar.com\/avatar\/79df5baa963b32870b9f3aa029f8fb2a34974afa19c4f08b5bfde9af1945c9a7?s=96&d=mm&r=g","caption":"Control Concepts USA"},"url":"https:\/\/controlconceptsusa.com\/author\/admin\/"}]}},"_links":{"self":[{"href":"https:\/\/controlconceptsusa.com\/wp-json\/wp\/v2\/posts\/8160","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/controlconceptsusa.com\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/controlconceptsusa.com\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/controlconceptsusa.com\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/controlconceptsusa.com\/wp-json\/wp\/v2\/comments?post=8160"}],"version-history":[{"count":0,"href":"https:\/\/controlconceptsusa.com\/wp-json\/wp\/v2\/posts\/8160\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/controlconceptsusa.com\/wp-json\/wp\/v2\/media\/8161"}],"wp:attachment":[{"href":"https:\/\/controlconceptsusa.com\/wp-json\/wp\/v2\/media?parent=8160"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/controlconceptsusa.com\/wp-json\/wp\/v2\/categories?post=8160"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/controlconceptsusa.com\/wp-json\/wp\/v2\/tags?post=8160"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}