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By L. Thompsen

High-pressure grinding rolls (HPGR) offer capacity increases, savings in operating costs and metallurgical advantages. The first installation of the Polycom HPGR in a copper ore treatment plant occurred in July 1995 at Cyprus Sierrita’s mining complex near Green Valley, AZ (Fig. 1). Until that time, the benefits this technology offers for copper and gold ore were only demonstrated on testwork. In other industries, such as diamonds, HPGR have proven to be reliable in industrial-scale plants and have set a new standard for this kind of ore treatment plant. HPGR are also successfully used for the comminution of coal, blast furnace slag and in cement and pelletizing plants. The installation at the Cyprus Sierrita Mine should prove the economical benefits in commerical-scale copper mining, confirming the results of comprehensive testwork(Fig. 2).

Jan 1, 1996

By Michael von Seebach

High-pressure grinding rolls subject the feed material to pressures of 200 N/mm? During this process considerable size reduction and the Formation of flakes occur. This paper describes the basic consideration For design and operating of this type of mill. It is also shown that the particle size distribution resulting from this process is typical for grinding processes but untypical for crushing processes. High pressure grinding rolls are designed in size of up to 2.8 m roll diameter allowing feed material top sizes of 250 mm. The rigid frame, bearing and drive - train design allows a broad application of the high-pressure grinding rolls operating the machine in open or semi-closed and closed circuit for dry and moist feed materials. Operating results show that capacity increases of up to 100 % can be accomplished with this technology. The high-pressure grinding roll also, allows for lower operating and maintenance costs due to energy savings of up to 20 L and reduction of wear to less than 1 76 for dry and less than 0.1 5 for wet grinding. Other advantages of the high-pressure grinding rolls are smaller equipment sizes than a ball or SAG-mill for a given capacity resulting in lower building sizes with reduced capital in- vestment costs.

Jan 1, 1987

By Oliver Gutsche

High-pressure roll mill comminution of heterogeneous multicomponent feeds was simulated with artificial limestone-quartzite mixtures using a piston-die press. The influence of heterogeneous interactions between components of the mixture on grinding path, energy utilization and energy split have been examined. Primary fractures are governed by differential fracture strength and attrition resistance of the components at heterogeneous contacts; subsequent secondary and tertiary fracture events are governed by coarse-fine interactions in the particle-bed. The weaker component is preferentially ground out of the feed size fraction and concentrates in the fines. Energy split among the components in the mixture is a function of their relative fracture strengths. It doubles for limestone and decreases by a factor of 5 for quartzite over the entire range of the mixing ratio.

Jan 1, 1995

By Tim Lundquist

Disa Technologies Inc. provides innovative, sustainable solutions for mineral processing and remediation through its patented High-Pressure Slurry Ablation (HPSA) technology. HPSA processes solid feed material in slurry form, propelled by high pressure pumps through opposing nozzles that generate impinging jets within a collision housing. This process induces particle-to-particle collisions in a high energy zone, creating intergranular fractures along grain boundaries. In our batch scale and continuous operating testing, we have found that controlling key processing variables such as nozzle velocity, slurry solids percentage, and the number of passes can allow for controlled size reduction and maximum mineral liberation. Since 2018, Disa Technologies has demonstrated the versatility of HPSA by testing it on diverse materials, including phosphate, copper, uranium, vanadium, zinc, rare earth elements, lithium, nickel, mineral sands, gold tailings, and more. The intent of this paper is to present an overview of our test results describing in detail impacts on size reduction, recovery, and grade with a focus on HPSA's adaptability across ore types. Looking forward, it explores the potential to process materials such as DR-grade iron, clay, PGMs, bauxite, and various tailings. Additionally, it examines planned advancements in HPSA technology, including optimized nozzle spacing, higher capacity models, improved tonnage-to-footprint ratios, enhanced maintenance features, and expanded nozzle configurations.

Jan 1, 2025

By Isobel Yeo, Luca Cocchi, Sven Petersen, Nico Augustin, Sean Plunkett, Ingo Klaucke

Exploration for seafloor massive sulfides is currently mainly focused on investigation for active hydrothermal vent fields. However, most of the resource potential is thought to be related to inactive, large deposits that had enough time to accumulate sufficient tonnage. At the same time, ageing of these deposits will ultimately result also in burial acted by either sediments and/or volcanic deposits. We currently lack the technologies to explore for these deposits in a time- and cost-efficient manner. In the fall of 2012 we used a number of AUV-based technologies to explore and image a sulfide occurrence at the Palinuro Volcanic Complex in the Tyrrhenian Sea (Mediterranean Sea; Fig. 1) where sampling and drilling have documented a buried polymetallic barite-pyrite dominated site (Petersen et al., 2014). Sulfide mineralization is here covered by volcaniclastic and pelagic sediments and only red sediment staining and the presence of few tubeworm bushes indicated recent hydrothermal activity - black smoker venting is absent. We used AUVbased high-resolution bathymetry, sidescan sonar imaging, subbottom profiling, as well as magnetics to describe, in a quantitative way, the previously known sulfide-bearing areas as well as to successfully explore for new hydrothermal sites including large chimney structures (Figs. 2). Additionally chemical sensors (CTD, Eh, turbidity) investigated the water column for signs of hydrothermal activity in areas not previously investigated, but at the end, only weak anomalies were found in the southern part of the summit.

Sep 1, 2014

By Dewey W. Marino

Conventional remote sensing applications for the exploration of natural resources has largely been the domain of low resolu­tion Earth orbiting systems such as Landsat™ which can sample a broad range of the spectrum. As the classic application of remote sensing, it has proven its worth through the discovery of numerous mineral deposits worldwide. Often this technique relies more on the spectral content of the imagery for narrowing potential sites on the ground, but often cannot reveal the detailed context of the observed response. As the dawn of the new era in remote sensing grows closer, high-resolution imagery is proving its worth for the definition of mineral potential and its cost sav­ing advantages for mine management.

Jan 1, 1998

By A. R. Wagner, E. Berkman

The use of high-resolution seismic surveys in coal exploration and mine development is becoming established as a standard technique in the industry. Their most significant contribution is in the effectiveness of reducing the number of core holes needed to understand the complex geological nature of coal by identifying geologic faults and mapping coal seam continuity and relative coal thickness. With these goals in mind, a high-resolution seismic survey was conducted in 1980 in the Wasatch Plateau coalfield of Utah. As a result of the success of this initial survey, numerous additional surveys have been performed over the past six years.. The interpretations of these subsequent surveys have led to the location of faults, fluvial channel sandstones, and coal thickness trends. This paper presents a review of high-resolution seismic technology as applied to coal exploration followed by three case histories, two of which illustrate the utility of the technique related to coal thickness determination and faulting and one that serves as an example of pitfalls in interpretation.

Jan 1, 1987

By Thomas Pea, Heiner Kontrus, Jérôme Steinkühler

In tunnel condition assessment, the trend is towards comprehensive 3D measurement combined with high quality image texture to document and quantify damages to the tunnel surface and to create a cohesive data base of the structural conditions throughout its lifespan. The faster such measurements can be made on site, the less it impacts traffic conditions of the highly sophisticated subway systems. The Dibit high-speed 3D scanning system which is based on Photogrammetry and LiDAR technology enables data acquisition in tunnels at a speed of up to 60 mph. Given the high rate of speed the system can operate, tunnel shutdowns can be drastically reduced, and tunnel safety increased. The photorealistic texturing of the 3D-model allows the identification and analysis of smallest material damage (e.g., cracks ≥0.3 mm wide). The publication illustrates technical details and 3D results of the innovative system from measurements that were performed in the subway tunnels of the Bay Area Rapid Transit System in San Francisco, CA (total length 66.23 km).

Jun 13, 2021

By Robert G. Ditchburn

The Mariana arc is an ~1,400-km-long intraoceanic arc that marks the southern extension of the Izu-Bonin arc, and is host to 62 ?volcanic centers? of which at least 27 (21 submarine) are hydrothermally, or volcanically active. A surface ship cruise in early 2003 mapped the distribution of hydrothermal plumes emanating from these centers, followed by remotely operated vehicle (ROV) cruises with ROPOS in 2004 and Jason II in 2006. With the exception of one volcano (East Diamante), none of the vent sites visited by the ROVs were host to sulfide mineralization. Rather, they were characterized by high sulfidation mineral assemblages dominated by native sulfur. The sulfur was seen marking the vicinity of vent sites, or as sulfur ?chimneys? (e.g., NW Eifuku and Nikko), or more spectacularly as ?lakes? of molten sulfur, either occupying the summit crater of the volcano (e.g., Nikko), or perched on the flanks of the volcano, near the summit (e.g., Daikoku). Gas (H2S and CO2) was discharging through the molten sulfur. Evidence for these lakes to have either been substantially ?deeper? in their recent past (e.g., Nikko), or existing at other volcanoes (e.g., Seamount ?X?) is given by remnant ?pillars? of native sulfur that are reminiscent of rock pillars in lava lakes found along mid-ocean ridges.

Jan 1, 2008

By R. J. Zagrocki

Rekindled public concern about lead toxicity has intensified the awareness of lead-bearing materials in contact with the environment and the human population. Lead's common association with other metals makes the increasingly restrictive lead standards a primary concern for a large number of metal and metal-related industries. In commercial scale demonstration tests with lead-bearing wastes, the HRD Flame Reactor process has a demonstrated ability to separate and recover over 95% of the lead as a recyclable oxide, while rendering the remainder of the material as vitrified, non-leaching, and nonhazardous co-product. Recent Flame Reactor process tests and preliminary cost data for secondary lead soda slag are highlighted.

Jan 1, 1992

By M. Manrique, S. A. Pirzada, P. R. Taylor

A thermal plasma-assisted laminar flow reactor was used to evaluate the kinetics of converting alumina to sodium aluminate in flight. Free energy minimization calculations were used to determine experimental conditions. The experimental variables included alumina particle size, alumina/sodium nitrate molar ratio, temperature and residence time. A mathematical model for the conversion was developed and validated. Experimental and mathematical results are presented.

Jan 1, 1998

By Robert Charles Alfred

Evolution is continuing in the field of rock drilling, Campbell Limestone Company is experimenting in the higher air pressure phase of drilling, It has been determined that there is a definite relationship between Air Pressure, Penetration Rate, Bit & Tool Wear and Life, In our drilling we have determined that &e higher air pressure gives a better penetration rate with less bit wear per foot. Drilling with 180 to 200 PSI air pressure, instead of 100 PSI for air and/or churn drills, has decreased our primary costs by approximately one half.

Jan 1, 1963

By J. R. Evans

In order to patent an industrial mineral placer mining claim, it must incorporate an economic deposit. Each ten acre parcel is evaluated for its mineral -in -character nature. Nonmineral -in -character parcels cannot be patented. Economic concerns include: claim locations, dummy locators, common variety nature, "excess reserves," and environmental constraints. Also, geologic and mineralogic studies, sampling and testing procedures are vital. Mining, milling, processing cost, and taxes must be evaluated. Product marketability analysis is necessary before starting any cash flow or discounted cash flow study. Valid data is essential to evaluate an economic industrial mineral deposit.

Jan 1, 1997

By Steve Kral

It is agreed in mining and regulatory circles that a safe and healthy working environment for underground miners is the major challenge for mine operators. Underground mine ventilation is complex. And it is becoming even more difficult as mines become larger, deeper and more complicated. At the Seventh US Mine Ventilaton Symposium, a group of mine ventilation experts from industry, government and academia attempted to solve some of the problems in ventilating underground mines. The meeting, sponsored by the Underground Ventilation Committee of SME and the University of Kentucky, was held in Lexington, KY June 5-7, 1995. Andrzej M. Wala, symposium chairman, commented that previous mine ventilation symposiums have focused mainly on work in North America. The 1995 symposium, however, broadened its borders to include several international papers. Of the 77 papers presented and bound into the Proceedings volume, 25 are from operations and research centers outside of the United States and Canada.

Jan 1, 1995

By Pieter-Jan Kleiterp

Highwall mining is a mining method to extract coal from a final boundary in opencut mining, trench mining or contour mining. This boundary may have been reached because of economic constraints (economic strip limit) or geographic constraints, such as spoil heaps and rivers. Coal is mined from visible, horizontal, or near-horizontal coal seams by making rectangular, parallel, unsupported drives with an unmanned cutterhead and coal transport system. This is controlled from a mining unit, or launch frame, positioned outside the drive, in front of the highwall. Removal of overburden is not required or is limited to small quantities only.

Jan 1, 2010

By Fitzhugh T. Lee

Results from the first part of a two-part investigation of the stability of highwalls in open-pit coal mines in the Paleocene Fort Union Formation of the western Powder River Basin of Wyoming and Montana indicate that these highwalls are subject to time-dependent deformation. Field investigations and laboratory physical properties tests of coal and overburden rocks suggest that several factors influence highwall stability. Some of these factors are rebound of overconsolidated rocks, desiccation, water, orientation and spacing of fractures, and strength and deformation properties. Factors of safety for a typical highwall in the study area (calculated by the finite element method) may be less than 1.0 when open fractures are present and the highwall has degraded. Although it is concluded that most open-pit highwalls in the Fort Union Formation within the study area have adequate short-term stability, these highwalls do deteriorate and become progressively less stable. Because of this, postmining failures are common and stability conditions could become critical if mining were delayed and then resumed after a period of several months. The second part of the investigation will utilize field measurements of rock-mass properties and instrumentation of actively mined highwalls to obtain data for comparison with the results of the initial investigation. Because the height of highwalls will increase as the more shallow coal is exhausted, these data will also be used to predict the behavior of slopes higher than those presently found in the western Powder River Basin.

Jan 1, 1977

By Thomas Sisley, Jozef Zurawski, Richard Switalski

Hilltop Interceptor Contract G is one of the segments of the wastewater control system in the greater Cleveland area. The tunnel is a relief interceptor constructed by the Northeast Ohio Regional Sewer District to minimize combined sewer overflows in the Easterly Service Area. The design study identified the need for a 3.35 m (132 in) diameter, 3.35 km (11,000 ft)in-line storage conveyance tunnel to be constructed at depths of 30 to 70 m (100 to 230 ft).Six structures for access, future flow drop, work shafts and overflow control were required to complete the system. The interceptor reduced the design peak flow from 12.5 m3/s(285 mgd) to 6.1 m3/s (140 mgd) by detaining in line 22,800 m3 (six million gallons) of wastewater.

Jan 1, 1997

By J. Pinkley

In June of 2002 Hilti North America received the first MSHA permissible approval for usage of a powder actuated tool device in a gassy mine atmosphere. The purpose of this paper is to discuss the implementation of this commonly utilized tool technology in the construction industry, to the underground gassy mining industry over the course of the last 5 years. Prior to June of 2002, underground gassy mining industry had attached materials such as ventilation curtains, power cables, communication cables, signage, and other materials by either manually driving individual spads or nails into the mine roof or rib or by attachment to existing roof bolt bearing plates. The Hilti DX 460 powder actuated tool is portable, durable, and lightweight (4.5 pounds). The Hilti DX 460 powder actuated tool system is powered by Hilti .27 caliber permissible explosive boosters. The energy force of the Hilti .27 booster?s acts on a captive piston principle in the Hilti DX 460 powder actuated tool, that applies the setting force for the direct fastening to the individual fastener chosen for the application by the end user. Each year Hilti can be called upon by MSHA to provide booster materials for re-testing per our Hilti DX PAD 1/00 approval.

Jan 1, 2008

By C. H. Lee, F. Concha, L. G. Austin, P. T. Luckie

The Concha-Almendra batch-settling treatment for concentrated suspensions of single-diameter spheres has been modified. This modified version is used in the differential equations of simple batch settling of a particle size range of different density materials. The equations have been programmed for a finite difference solution, and a number of test cases have been analyzed. By cutting the settling column at a fixed fractional height, the material below this height can be treated as underflow and the material above as overflow. The predicted partition curves obtained from treating the settling in this way have Sharpness Indices in the range of 0.5 to 0.6, in the absence of dispersion effects. The Sharpness Indices decrease as dispersion increases. When the feed size distributions are of the Rosin-Rammler form, the partition curves (corrected for the bypass fraction) fit the Rosin-Rammler equation with reasonable accuracy. The predicted Sharpness Index of a component of a mixture of two materials of different densities was unchanged from that of the same materials settled alone. However, for the same, feed size distribution and volume fraction of solids in the feed, the heavier material settled faster, and the lighter settled slower, than when settled alone.

Jan 1, 1993

By G. W. Riley, D. E. Pickett

HINDERED SETTLING CONCENTRATION In the free settling of mineral particles in a liquid, the falling particles are at a distance from each other so that no particle is affected by its neighbor. In hindered settling, the concentration of particles is sufficiently high so that each particle is affected by its proximity to other particles in the suspension. Richards and Locke86 have described the hindered settling phenomenon as the condition “.. where particles of mixed sizes, shapes and densities in a crowded mass, yet free to move along themselves, are sorted in a rising current of water, the velocity of which is much less than the free-falling velocity of the particles but yet fast enough so the particles are in motion." This is the condition normally encountered in mineral con¬centration processes. The well known Newton equation for free settling of coarse (ap proximately +10-mesh, 1/16-in. or -- 2000-µm) spherical particles is:87 where v," is free settling velocity, cm/sec; p' is density of the fluid; p is density of the particle, g/cm3; d is particle diameter, cm; g is acceleration due to gravity, cm/sec2; and Q is coefficient of resistance, dimensionless, ~0.4. For the settling of fine spheres in water (approximately 150 mesh or 100 µm) the equation of Stokes pertains:87 where µ is viscosity of the fluid in poises and the other symbols have the same meaning as those in Eq. 1. For particles whose size lies between about 10 mesh (--2000 µm) and 150 mesh (100 µm), their settling velocity can be determined from experimental data. These data are available in convenient form in the text by Taggart88 based on the original work of Richards. Alternatively, a Reynolds number-coefficient of resistance plot may be used to determine the settling rate of such particles.87 The settling rate of spherical particles under hindered settling conditions can also be calculated from Eqs. I and 2 by replacing p', the density of the fluid, by p" the apparent density of the suspen¬sion. The concentration of particles in the fluid thus imparts an appar¬ent density to the composite fluid or suspension greater than that of the liquid alone, resulting in a buoyant effect on the larger particles. Particle shape affects the settling rate of both coarse and fine particles. The general effect is to reduce their settling velocities and the effect is greater for coarse particles and for those settling under hindered settling conditions than for fine particles or free settling ones. For two particles of differing densities but settling at the same velocity under Newtonian conditions, the ratio of their diameters from Eq. 1, called the free settling ratio is: where L signifies the lighter particle and H, the heavier particle. Under Stokesian conditions the exponent would be 0.5. For hindered settling conditions the fluid density p' is replaced by the apparent density of the suspension, p", to obtain a generalized equation for the hindered settling ratio: assuming both particles settle in approximately the same regime. The free settling ratio as given by Eq. 3 has been called by Taggart88 the "concentration criterion" and is used to predict the effectiveness of any gravity concentration process (see Introduction to this section). Based on Eqs. 3 and 4, if two particles of densities pH and p,, settle at the same velocity, the diameter of the lighter particle will be larger than that of the heavier particle. For example, in the case of galena (pH = 7.5) and quartz (pL = 2.65) settling in water (p =1.0) under free settling, Newtonian conditions 3.9. Thus, a quartz particle nearly four times as large as a galena particle will settle at the same velocity. Any quartz particle just slightly less than four times the diameter of the largest galena particle may be separated from it. Under hindered settling, Newtonian condi¬tions in a suspension where p" = 1.65, dL/dH = 5.85 or any quartz particle just slightly less than about six times the largest galena particle may be separated from it. Reference to Eq. 4 indicates that a superior separation between two minerals of differing densities is favored by: (1) coarse particles settling under Newtonian conditions, (2) a large difference in (pa - PL), and (3) separation under hindered settling conditions where p" is high. Of course, there are practical limits to increasing p" excessively because at very high percent solids suspen¬sion fluidity would be lost and the hindered settling separation process defeated. Examples of hindered settling separators are the Dorrco-Fahren¬wald sizer,89 the Rheolaveur box 90 the Spitzkasten,89 and the Willoughby washer.91 These devices make a mineral separation on the basis of both specific gravity and size and all of them are essentially obsolete except for the Dorrco-Fahrenwald sizer and similar devices which still find application for the removal of coarse particles from a much finer particle assemblage and for preconcentration ahead of shaking tables. However, nearly all gravity concentration processes (jigs, tables, flowing film concentrators, heavy media separators) and many sizing devices (sizing classifiers, clarifiers, thickeners, hydrosepa¬rators) make use of the hindered settling phenomenon during the separation of particles. JIGGING Introduction In jigging, a mixture of ore particles, supported on a perforated plate or screen in a layer or "bed" with a depth many times the thickness of the largest particle, is subjected to an alternating rising and falling (pulsating) flow of fluid with the objective of causing all

Jan 1, 1985