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By John H. Bassarear, Harold W. Sorstokke

The fourth expansion within 10 years was completed at Pima Mining Co. during late 1971. The first three expansions increased capacity from 3000 to over 40,000 tpd. Conventional crushing and grinding practices were used in the original 10-section mill. Total capacity is now approximately 54,000 tpd. Expansion IV includes a new primary crusher and a radial stacker conveyor that feeds stockpiles for both concentrators. The -8-in. primary product is fed from the reclaim stockpile to the new mill by two pairs of pan feeders, each pair feeding a separate conveyor. The reclaim conveyors each feed 28 X 12-ft semiautogenous mills operating with an 8% charge of 4-in. balls. Autogenous discharge is screened, oversize recycling by conveyors, with -%-in. undersize feeding two conventional 161/2 X 19-ft ball mills in closed circuit with cyclones. Cyclone overflow is pumped to three parallel rows of 300-400 cu ft flotation cells. Rougher and scavenger concentrates produced are sent to the original mill for regrind, cleaning, and filtering.

Jan 1, 1974

By G. J. Benard

In the 1970’s, several plants have been built and others are in the design stage which use solvent extraction for recovery of copper from acid leach solutions. Other plants are presently being built for the recovery of nickel and cobalt from laterite ores by prereduction and ammonia leaching. A review will be given on the materials of construction for these leaching and solvent extraction processes. Many plants have factors in common which permit selection with a greater degree of accuracy. Based on pilot plant corrosion data, effective use of materials of construction includes proper selection of materials, substitution of lower cost plastics for alloys, and selection of materials resistant against chloride stress corrosion cracking.

Jan 1, 1974

By Robert A. Campbell, Robert J. Brison

The problem of optimizing from an economic standpoint the capacity of grinding equipment in the design of a new concentrator is discussed. Although directed specifically to copper flotation mills employing conventional wet, grinding, the material presented is considered applicable with modifications to other types of ores and other grinding methods. A general approach to optimizing the grinding capacity is outlined and illustrated by an example. The' interrelation between grinding capacity and other aspects of the project is considered. The problem of regrind capacity and its relation to preceeding and subsequent processing steps is also discussed. Finally, factors are considered that may, in certain cases, dictate modifications of the suggested approach.

Jan 1, 1974

By G. E. Erdman

Gouverneur Talc produces a dry mineral filler from the tremolite talc rocks located near Gouverneur, New York. The raw material for this rock powder is a silicate rock and dust is controlled by water sprays whenever it becomes a problem underground. In the milling operation, there are some nine baghouse-type dust collectors which are utilized for the control of dust created in the crushing and grinding process. These collectors have been installed over a period of years since 1947 and are assigned to specific areas where the particle sizing of the dust can be returned to the plant circuit or product involved at the point of collection. It has been found very advantageous to mount most of these collectors on the top of the mill building and packhouses where the return of the dust can be accomplished by a gravity feed. In the years of effort involved in efficient control of dust generated in the plant, many things have been learned in the construction of ducts for control valves. The company has found useful such things as grasshopper legs for interconnecting silos with similar products, the elimination of fiat dust ducts, cleaning cyclones for coarse dust or heavy loadings, refractory linings for cyclones and certain duct areas, and the avoidance of square intersections when diverting or combining ducts. Operating cost records indicate that collectors handling the finest dust have the least expense. Operating costs on high-temperature dusts generally run higher than other types of material collected. Experience further indicates that the multiple cyclone-type collectors can provide a low cost and efficient way of removing hot dusts from process air streams before the introduction of the material into a baghouse. High moisture conditions and cold northern climates have been found to combine and create conditions under which baghouses can not efficiently function as dust collectors. Gouverneur Talc feels that its several dust collection systems have been a considerable maintenance expense but well worth the cost when it came to safeguarding the employees' health and preventing air pollution.

Jan 1, 1974

By R. T. McLamore

Lack of sufficient native permeability or skin damage caused while drilling wells for in situ leach mining projects may necessitate stimulating injection and production we1ls to increase the leaching rate to economic levels. Such stimulation processes could include acidization, hydraulic fracturing, or explosive fracturing. This paper describes an explosive fracturing process that is being developed primarily to stimulate the production of oil and gas wells, but may be useful in in situ leach mining projects as well. The process utilizes a liquid explosive that has unique safety features. The chemicals that form the explosive are subdivided into two pumpable, non- detonable components. Technology has been developed to pump these two components independently but simultaneously into the well and blend them together downhole to form the explosive. As such, surface facilities and personnel are not exposed to explosive hazards. The explosive formulations utilized in the process have been subjected to numerous safety and characterization tests and been qualified for use in deep wells with temperatures and pressures up to 250°F and 10,000 psi. The explosive composition can be varied to produce an explosive ranging, energetically, from a blasting agent to a high explosive that can be detonated after injection into a borehole, a porous media or into thin naturally occurring fractures within the roc

Jan 1, 1974

By Leland L. Mink, Roy E. Williams, C. Daniel Kealy

The passage by Congress of Public Law 92-500 (the 1972 Water Pollution Control Act amendment) has placed a new emphasis on the need for methods to minimize the escape of water from tailings ponds. Presumably tailings pond seepage will fall under the jurisdiction of the act. This paper is designed to explain some of the problems caused by leakage from tailings ponds and to present a method by which leakage can be minimized if not eliminated. Ground-water pollution in one case studied by the authors results from leaching of old jig tailings that are intermixed with the upper part of a sand and gravel aquifer. Anomalous concentrations of zinc, lead, and cadmium occur in ground water and soil samples taken from the portion of the sand and gravel aquifer containing the old jig tailings. Analysis of water samples from a tailings pond located in the area indicates that the pond water is not the source of the heavy metal concentrations found in the down-gradient ground water. However, leakage from the pond and water from the pond's decant system combine with natural ground water to compound the problem by raising the water table into old jig tailings which cover the upper portion of the aquifer. The ground water which discharges from this aquifer causes a statistically significant decrease in the quality of the receiving stream water. The shallow ground water contains oxygen; therefore, corrective measures include lowering the water table to depths below the old jig tailings which cover the aquifer at ground level. This, in turn, implies elimination of ground-water recharge by subsurface leakage from the pond. A laboratory study and a mathematical model study have revealed that seepage from such ponds can be minimized by a carefully designed and managed peripheral tailings discharge system. The process involves maintaining the slime zone and the free-water surface near the center of the pond so that the slimes retard downward and semilateral movement of pond water. The free-water surface must not be allowed to extend out over the nonslime portion of the tailings during or after pond operation. Mathematical model output reveals that this method can hold the subsurface discharge rate to as little as 110 gpd per acre of pond water area. The technique should be applicable to any tailings pond system in which the loss via seepage of poor quality water must be minimized or where recharge of ground water by losses from a tailings pond must be minimized, regardless of the reason.

Jan 1, 1974

By L. S. Darken, H. A. Wriedt

The equilibria at 1 atm total pressure and 600° to 1300°C (1112° to 2372°F) between gas mixtures with various partial pressures of the reactive constituents (principally sulfur dioxide, carbon dioxide, water vapor, oxygen or carbon monoxide, and hydrogen) and coexisting solid phases (groups variously including calcium oxide, calcium carbonate, calcium sulfide, calcium sulfate, iron, ferrous sulfide, and the iron oxides) are examined. Tables and charts show the combinations of temperature, oxygen activity, and carbon dioxide partial pressure under which the various groups of the solid phases coexist and the corresponding sulfur dioxide pressures. In the presence of calcium sulfide, calcium sulfate, and calcium oxide, the partial pressure of sulfur dioxide has a peak value at each temperature which increases from 101 atm at about 800°C (1472°F) to 1 atm at about 1200°C (2192°F). With water vapor present, hydrogen sulfide may predominate among gaseous sulfur compounds, particularly at low temperatures and oxygen activities; under all other circumstances considered, sulfur dioxide is the dominant gaseous sulfur-bearing species.

Jan 1, 1974

By K. A. Natarajan, I. Iwasaki

The meaning and the utility of redox potential (Eh) measurements in sulfide flotation systems are examined. Since some preliminary plant Eh and laboratory flotation data were available, experiments were made to establish the pH range at which a platinum electrode might be used for such measurements without much difficulty in aerated systems. Triangular wave voltammetry was used to study the surface conditions of the electrode immersed in pyrrhotite suspensions at different pH. The measured Eh both at the plant and the laboratory is interpreted in terms of the experimental water-oxygen line.

Jan 1, 1974

By Takahide Wakamatsu, Douglas W. Fuerstenau

Contact angles on alumina are related directly to the adsorption of alkyl sulfonates at the solid-water interface and thus are strongly controlled by the pH of the solution, the concentration of surfactant, and the number of carbon atoms in the alkyl chain. As the pH of the solution is increased above the point of zero charge, sulfonate adsorption ceases and alumina remains hydrophilic. However, in neutral and acidic solutions, contact angles increase markedly in magnitude when the adsorbed sulfonate ions form hemimicelles at the solid-water interface. Under a wide variety of solution conditions, a limiting value of the contact angle is attained at the point of reversal of the zeta potential. Finally, contact angle phenomena are empirically correlated with the sulfonate adsorption density through the work of adhesion.

Jan 1, 1974

By Rex T. Ellington

The fluidized bed is an effective method for investigating retorting phenomena and possibly a commercial means of retorting oil shale. Both were examined by Sinclair Oil (now part of Atlantic Richfield Co.) in the period 1965-1698. The results of the work show that the presence of an oxidizing environment during retorting results in loss of oil yield which indicates that vapor phase oil burns in preference to combustion of coke on spent shale. Consideration of hardware indicates that there are several possibilities for commercial embodiment. As a companion to shaft-type retorts the fluidized bed could have good potential. Realistic assessment of costs suggests that further development may have to wait commercialization of another process.

Jan 1, 1974

By T. J. Hudson, P. B. Queneau, J. D. Prater

The process parameters for effective utilization of nitric acid as an oxidant for copper-iron sulfides have been developed. Leaching variables found to be important were acid concentration, temperature, time, atmosphere, pressure, mineral type, particle size, and percent solids. Particular attention was devoted to analysis and control of fumes evolving during the oxidation. Data were recorded on metal extraction, elemental sulfur formation and oxidation, product gas composition and evolution rate, reagent consumption, and residue flotation response. The study was concluded by laboratory testing a flowsheet based on the foregoing observations. Ninety-eight percent of the copper contained in a chalcopyrite-bornite concentrate was recovered, requiring 1.6 lb of nitric acid to be regenerated externally per pound of copper extracted. Iron remained in the leach residue as hydrogen jarosite and was ultimately rejected from the system by froth flotation. Sixty percent of the sulfur contained in the copper concentrate reported in the elemental form; the remainder was oxidized to sulfate and eliminated with the hydrogen jarosite in the flotation tails or by neutralization of the solvent extraction raffinate with lime. Nitrogen was evolved primarily as NO and NOD; up to 3% N2O also was present. Gases containing sulfur were absent except when pyrrhotite was solubilized in the absence of soluble copper. In this case, HAS was evolved.

Jan 1, 1974

By Marshall D. Himes

The Pima mine, Pima County, Ariz., a 53,500-tpd copper mine, is located 17 miles south of Tucson, Ariz. The mine is in a sequence of Paleozoic and Mesozoic sediments striking east-north-east and dipping southeasterly. These sediments are intruded by a Tertiary quartz monzonite porphyry. The Paleozoic Permian (?) dolomites, limestones, and sandstones have been altered to calc-silicate skarn, marble, and quartzite. The overlying Mesozoic Triassic (?) clastic sediments have undergone some recrystallization and hydrothermal alteration. The clastic metasediments are divided into three distinct lithologic units: lithic arenite, arkose, and interbedded and overlying black argillite. Three types of hydrothermal alteration in the clastic rocks are propylitic alteration (epidote, chlorite, and quartz, with or without sericite), quartz-sericite alteration, and potassic alteration (K-feldspar, quartz, and sericite, with or without chlorite and calcite). The porphyry has undergone potassic alteration. Dominant structures are an east-west postmineral fault in the western part of the pit, and strong low angle faulting and shearing which truncates the ore body at depth. The two joint sets, one parallel to bedding and the other at right angles to bedding are prominent in the mine. Faulting is in two dominant directions, one striking northwest, dipping northeast, and the other striking northeast, dipping northwest. Economic mineralization is prediminantly disseminated pyrite and chalcopyrite, and molybdenite-quartz veinlets. There are less important amounts of magnetite, hematite, sphalerite, galena, tennantite, and bornite. Mineralization is believed to be both structurally and chemically controlled.

Jan 1, 1974

By J. A. Herbst, D. W. Fuerstenau

An analysis of the kinetics of dolomite grinding in a dry ball mill reveals that the following approximations apply for the parameters of the batch grinding model: (1) the size discretized selection functions are proportional to the specific power input to the mill, and (2) the breakage functions can be taken as invariant. These approximations are shown to provide the basis for accurate predictions of product size distributions obtained for several mill speed, ball load, and particle load combinations within the normal ball mill operating range. The engineering implications of these findings are discussed.

Jan 1, 1974

By D. J. Oswald, J. G. Ziegler

It is of common knowledge that loading within a grinding mill, whether ball, rod, pebble, or autogenous, is directly related to the lubrication back pressure developed between the mill journal and bearing shoe during mill operation. The merits of both forced-feed and gravitational-feed bearing lubrication methods are discussed with particular emphasis directed toward their applicability to continuous grinding mill inventory control. Data obtained from wet grinding mill applications in the cement and mining industries is presented to more clearly define the influence of such variables as feed consistency, slurry viscosity, mill retention, bearing oil temperature, grind fineness, and grinding media wear on the measured journal lubrication back pressure during automatic mill feed control. Finally, various grinding mill control schemes for maintaining constant mill loading and consequently optimizing mill operating efficiency are discussed and evaluated as to their advantages and/or disadvantages.

Jan 1, 1974

By Abbas Ali Daneshy

A study of the mechanics of hydraulic fracturing shows the fracture initiation pressure to be a function of the in-situ principal stresses, the formation and fluid properties, and how the wellbore has been completed. The orientation of the hydraulic fracture is perpendicular to the least in-situ principal stress. The geometry of the induced fracture depends on the treatment fluid properties, the injection rate and volume, fluid leak-off and formation properties.

Jan 1, 1974

By William G. Schultz

Sylvite of Canada, a division of Hudson Bay Mining and Smelting Co., operates a new 8500-tpd potash mine ten miles northeast of Rocanville, Sask. This mine, employing less than 60 men in its underground maintenance, engineering, and production operations probably ranks as one of the most highly mechanized and automated mining operations in the world. Access to the flat lying potash bed is through two 16-ft-diam concrete and steel lined shafts 3300 ft deep. The backbone of the operation is two 258-ton, 1500-hp continuous mining machines capable of mining in excess of 700 tph per machine while employing extensible conveyors for haulage. This production capability is complemented by a completely automated haulage, storage, and hoisting system. Of the other unique features of this operation, the principal ones are that the mine was designed and developed by the people that are currently operating it and from the time the shafts were commissioned, the mine was completely developed, equipped, and brought to full production in less than six months.

Jan 1, 1974

By E. T. Turkdogan, L. S. Darken, R. G. Olsson, H. A. Wriedt

Several aspects of the calcination of Michigan limestone were investigated: the rate of calcination of limestone spheres with diameters from 1.8 to 14 cm at temperatures from 800° to 1200°C by a thermogravimetric method; the temperature profile across limestone during calcination; the excess pressure developed in the interior of the stone during calcination; the pore surface area, pore volume, and effective gas diffusivity in burnt lime; and the microstructure of polished and fracture surfaces. It is found that, over a wide range of experimental conditions, the difference between the surface and center temperatures remains essentially unchanged during the latter half of calcination. From the rate of weight loss after about 50% calcination, the value 0.00126 cal per cm sec degree is found for the effective thermal conductivity of burnt lime. From the excess internal pressure measurements, i.e., 0.4 to 6 cm Hg at 800° to 1200°C, the permeability of burnt lime is estimated to be within the range 8 X 10-' to 5 X 10' sq cm. With increasing temperature and time of calcination, the pore structure of burnt lime coarsens as indicated by a decrease in the pore surface area, pore volume, and an increase in the average pore size. For the temperature range 600° to 835°C the ratio (effective gas diffusivity/molecular diffusivity) is about 0.18.

Jan 1, 1974

By M. E. Grimes

A method of predicting uranium extraction rate in underground bacterial leaching of as-blasted ore has been developed. The method is based on the hypothesis that extraction is directly proportional to the volume of a piece of ore that is penetrated by the leaching agent, and that each piece of ore, regardless of size, has been penetrated radially from the external surface to the same depth at a given leaching time. Consequently, given an initial size and assay distribution, extraction should be predictable for a given penetration. Two laboratory bacterial leaching tests under simulated stope leaching conditions were carried out for a periods of 89 and 96 weeks. On completion, the residual ore was screened and analyzed. The information so obtained was employed to provide an elapsed time base for the penetration model, from which predictions of future extraction were made. The finding of solubilized uranium trapped within apparently sol id ore pieces was unexpected. However, it is not recoverable except after crushing, and hence does not affect calculations of underground leaching .

Jan 1, 1974

By Leon Y. Sadler, E. K. Landis

Froth flotation has been described by several authors" as being analogous to a first-order rate process. Although a few investigators"," have found orders other than one fit their data best, the rate is described most often by the first-order equation, [ ] where r is rate of disappearance of floatable mineral by flotation, C(t) is concentration of floatable mineral in the cell, t is time, and k is first-order flotation rate constant. One of the difficulties in using this rate equation to develop a mathematical description of an actual flotation process is the determination of a suitable value of the constant k. The value of k, which reflects the floatability of the floatable mineral, is dependent on the hydrodynamic conditions in the cell, type and concentration of flotation reagents used, pulp density, and pH, method of froth removal, aeration rate, particle characteristics, and many other factors. Therefore, it is reasonable to expect that each particle of floatable material has a distinct value of k and that a unique distribution of k values exists for given feed and cell conditions. This has been observed and discussed by several investigators, and mathematical descriptions of the batch cell and steady-state continuous cell with distributed flotation rate constant have been developed." The mathematical description in the form of a transfer function of the continuous or flow cell under unsteady-state conditions with a distributed flotation rate constant has not been presented in the literature. The purpose of this note is to make such a presentation. The basic features of the perfectly mixed continuous

Jan 1, 1974

By D. Duffey, P. F. Wiggins, F. E. Senftle

An examination of the neutron capture gamma ray method using a 252CF neutron source indicates that this technique may be feasible for process stream analysis of ores. Simulated laboratory experiments were made on iron in taconite and magnetite, and copper and nickel in their respective ores. Satisfactory analyses were obtained for 500-1000-g samples in a combined irradiation and counting time of 100 min. For large industrial size samples this time could be shortened. Based on these experiments, a set of guidelines are given for the use of the neutron capture gamma method in an industrial mill.

Jan 1, 1974