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By W. H. Langer

Around the beginning of the 20th Century, annual aggregate production in the United States amounted to about 50 million short tons. Today annual aggregate production is nearly 2.5 billion tons. Over a third of the States in the country produce more aggregate than the Nation did at the turn of the century. I would like to describe some of the historical events that allowed this nearly 50 fold increase in aggregate production. You might wonder why I want to talk about history. Some of our best ideas lie buried in the past, waiting to be rediscovered in the present. Almost every issue that the aggregate industry experiences today has been recognized for at least a decade; many of those issues have been recognized for a half a century; and a few of them have been recognized for nearly a century. The main reason for this article is to save the past from the forgetful indifference of the present-to faithfully preserve the past, to illustrate the insights of our predecessors, and to demonstrate how little of what we know today is really new.

Jan 1, 1998

Jurist, educator and historian Neil Reynolds will be the keynote speaker at the National Mining Hall of Fame's 11th annual induction banquet on Sunday, Oct. 11,1998 at the Pointe Hilton Resort in Phoenix, AZ. Reynolds is Municipal Court Judge for the City of Leadville, CO, home of the National Mining Hall of Fame & Museum, and a fifth-generation resident of the community. His family staked mining claims on nearby Mount Massive in 1862. Judge Reynolds is a fulltime faculty member at Colorado Mountain College, Chairman of the Lake County Historic Preservation Advisory Board and practices law in Leadville. In announcing the speaker, Board Chairman Richard Moolick said seven inductees into the National Mining Hall of Fame will join 138 mining greats previously honored in the annual ceremonies. This year's inductees will be enshrined by Thomas Falkie, president and chief executive officer of Berwind Natural Resources of Philadelphia, PA. Moolick also announced that Jeffrey Clevenger will be the master of ceremonies for the induction banquet. Clevenger is executive vice president of Cyprus Amax Minerals, Englewood, CO and president of Cyprus Climax Metals, Tempe, AZ. A cocktail reception at 6:30 p.m. will precede the black-tie (optional) dinner, to begin at 7:30 p.m. For additional information, contact Esther Mellott at 719 486 1229. Here are the biographies, then, of this year's seven inductees to the National Mining Hall of Fame & Museum.

Jan 1, 1998

By L. G. Austin

Introduction My first contact with industrial milling was during the time I worked in the electricity generating industry in the United Kingdom. In visits to power stations to investigate either deposits in the boiler furnaces or polluting deposits settling around the stacks. I had to check the performance of the vertical coal pulverizers, since poor pulverization aggravated both problems. Naturally, then, when I came to the USA in 1957 to take a PhD in fuel technology at Penn State, I was put to work to review the science of coal pulverization. After this reviewing, I was completely confused. On one hand, there was a well-developed understanding of stress-strain equations, and a rap- idly developing knowledge of how stressed, brittle solids fractured, based on the Griffith crack theory. On the other hand, reading in the grinding literature gave me: • Kick's Law, which was clearly not correct in the light of modern fracture theory; • Rittinger's Law, which was also clearly not correct; • Bond's Third Law of Comminution, which was claimed to have something to do with the Griffith crack theory, but where the connection between the two was made by intuitive pseudo- scientific reasoning I could not accept; • the choice of mill motor power for the most common type of coal mill, the Raymond pulverizer, was calculated from the fan power required to move air through the mill. Although I could accept the empirical connection between the two, it made no sense from the point of view of fracture energy. Even today, most books or review chapters on size reduction start from these laws. incorrect statements abound in the literature, such as “the Hardgrove Index is based on Rittinger's Law," which it is not, "The Bond theory states that work input is proportional to new crack tip length produced in particle breakage," which is not true, etc. My own test work showed that these "laws" did not fit the data for grinding of coal. At about this time, Epstein (1 948) and Broadbent and Callcott (1 956), following the original work by R.L. Brown (1941) at the British Coal Utilization Research Association, proposed describing breakage as a series of fracture stages. I took their concepts and developed the basic differential equation for a batch grinding process continuous in time, analogous to a batch chemical reactor. Robin Gardner then joined the project and did his PhD on treating batch grinding in the same way as a batch chemical reactor. He found that the basic equation had already been partially derived by Sedlatschek and Bass (1 953) in Germany. We confirmed experimentally the validity of the equations for describing batch grinding (1 962) and formulated the equation describing steady-state continuous grinding in a fully-mixed mill. At about the time this work was published, Gaudin and Meloy (1962) and Filippov (1961) independently published essentially the same equations, but without experimental proof of the validity of the concepts. I will give a brief overview of what these beginnings had led to in the design of mills for size and power, and show some of the results of this more detailed understanding of grinding processes. Concepts of Fracture Mills such as tumbling ball, rod, pebble and autogenous mills and vertical mills such as the Raymond, and E-type apply compressive stress to lumps or particles relatively slowly. Compressive stress applied to a particle of an elastic brittle solid imparts overall strain energy to the solid and produces local regions of tensile stress, (Fig. 1) (Berenbaum and Brodie, 1959). Irwin (1949) showed from solution of the stress-strain solutions that a small hole in a region of tensile stress reduces stress concentration at the hole, that is, the tensile stress at the tip of a crack or flaw in a solid is much higher than the general tensile stress in the region. The longer the crack, the higher the stress concentration. Griffith (1920) hypothesized that when the regional tensile stress is large enough, then the chemical bonds at a preexisting crack tip are stretched to breaking point, as illustrated in Fig. 2. When the bonds break, the crack becomes longer, the tensile stress concentration increases, the situation is unstable and a crack opens up (propagates) a surface of tensile stress, creating its own tensile stress at the leading edge. Stored strain energy is converted to the kinetic energy of the moving stress field, which is analogous to sound propagation through the solid, so the crack tip accelerates to velocities approaching those of sound. The moving crack will pass through regions that were previously under regional compressive stress. The equations for "ideal" and "Griffith" strengths are where a is the intermolecular distance, y is Young's modulus, g is the energy

Jan 1, 1998

By H. Para, A. Aguirre, G. Artadi

Mining is a very important economical activity in Peru which has been recently developed without considering environmental aspects. Here, we show an experience at the Milpo mine, situated 4,200 meters above sea level; a mining company that has the value of being one of few from the last decade that is engaged in consolidating a model of environmental protection. The model includes aspects of contamination prevention and control, with bioindicators such as pasture cultivation, vegetables, forests, and hydrobiological species breeding. Socially, through means of development programs in natural areas, forestation and support to rural agriculture, together with environmental education, it is being demonstrated that it is possible to ensure tangible results in environmental conservation and the well-being of the populations around the mine.

Jan 1, 1998

By E. De Souza

Rockbursts and rockfalls cause very large safety and productivity losses in underground mines. One of the major unsolved problems of safe, economical rock support in underground mining has been that of maintaining anchorage during dynamic rock loading conditions or seismic related occurrences. It is recognized that the large displacements and high strain rates in excavation walls and underground structures cannot be countered by increasing the strength of stiff rock-reinforcing systems but must be accommodated by introducing yieldability into the support elements. This paper introduces a low cost yieldable support system which provides viable solutions to dynamic support loading. Such system should not only provide a feasible and more effective rock mass stabilization strategy but improve mine safety and reduce losses.

Jan 1, 1998

Spirals have become one of the most popular methods for treating fine coal. Unfortunately, spirals tend to produce an undesirably high specific gravity cut-point and often misplace significant amounts of coal and/or rock. In the present study, a process-engineering tool known as linear circuit analysis was used to identify problems with traditional spiral circuits and to suggest alternative configurations. These analyses indicate that a modified rougher-cleaner circuit incorporating a middlings recycle stream offers the best option for improving performance while maintaining a reasonable circulating load. In light of this finding, a full-scale test circuit was installed and evaluated at an existing preparation plant. Data obtained from the plant tests indicate that the new spiral circuit can simultaneously reduce cut-point and improve separation efficiency. Preliminary economic analyses show that the new circuit provides an attractive payback on the capital investment.

Jan 1, 1998

ITEC Environmental Colorado has begun reprocessing the tailings from old mining sites near Boulder, CO. And if the technology behind ITEC's pilot project at Gold Hill proves successful and profitable, the company plans to launch similar reprocessing operations in other parts of the state. The pilot project is under the watchful eye of state and federal authorities. They hope the technology becomes the answer to cleaning up old mining sites throughout the West. Remining and environmental cleanup on an economic basis, then, are ITEC's hopes in one the most environmentally conscious counties in the state. Clean up the mine dump sites and recycle the land, for a profit. In June 1998, ITEC Mineral Inc., ITEC Environmental Colorado's Canadian parent, acquired the Gold [ ] Hill Mill facility in Boulder County. Included in the acquisition was 4.4 hm2 (11 acres) containing the Gold Hill Mill and 283 hm2 (700 acres) of additional properties adjacent to the facility. ITEC estimates that there are about 910 kt (1 million st) of dump rock in the area. That is enough to make the operation viable. ITEC will sell the metals recovered through its reprocessing operations. However, due to low metals prices, ITEC is not expecting to make much money on the recovery of precious and base metals. Instead, the company plans to resell the reclaimed land for residential and commercial development or open space. The Gold Hill Mill site is the first of 17 sites in Colorado that ITEC Mineral hopes to clean up and recycle the land. Most notable among the sites is the historic Central City/Black Hawk mining district, which ITEC believes holds considerable potential. The Gold Hill Mill is located 14 km (9 miles) west of the city of Boulder and less than a half mile from the small town of Gold Hill. The mill was. last operated in 1992. The operation was forced to close that year due to environmental and cash flow problems. Gold Hill is in the middle of a region with more than 32 Mt (35 million st) of mine tailings. Independent geologists have' established the average grade of the Gold Hill mine tailings to be 4.5 to 5.3 g/t (0.13 to 0.155 oz/st) of gold and 28 to 44 g/t (0.83 to 1.29 oz/st) of silver. According to these studies, the Gold Hill mine tailings are five times richer in precious metals than the tailings of the Norebec Manitou property in Canada that ITEC is also remining, reclaiming and restoring. Upon acquiring the mill, ITEC undertook a refurbishing program that included adding a second ball mill. This increased the Gold Hill Mill's capacity to 180 t/d (200 stpd). The operation employs 15 people. "The Gold Hill Mill site will demonstrate the efficiency of our integrated remining, reclaiming and restoration process," said Maxine Stewart, president of Denver, CO -based ITEC Environmental. "The abundance of similar mine sites in Colorado presents a number of opportunities to bring the benefits of the ITEC system to other communities around the state." Holly Huyck is technical advisor to the Clear Creek Watershed Advisory Group. She said: "ITEC is cleaning up an orphan mine site that otherwise would continue to contaminate the Boulder Creek watershed with acid and excess metals. This is a win-win situation: ITEC gains marketable minerals while it reclaims mined land and helps to improve the watershed."

Jan 1, 1998

Direct force measurements were conducted using an atomic force microscope (AFM) to study the mechanism of copper-activation of sphalerite. The force measurements were conducted between a sphalerite plate and a hydrophobic glass sphere in xanthate solutions of various pHs. The glass sphere may represent the hydrophobic air bubbles interacting with minerals during flotation. The force measurements conducted with unactivated sphalerite in 10') M KEX solutions did not show the presence of hydrophobic force. On the other hand, the results obtained with copper-activated sphalerite at pH 9.2 and 4.6 showed strong hydrophobic forces. However, the results obtained at pH 6.8 showed no evidence of hydrophobic force, which provides an explanation for the difficulty in floating sphalerite at neutral pH.

Jan 1, 1998

By R. G. Reddy

Solid state reduction of roast movat chromite ore with carbon was carried out as a function of C/FeO ratio and temperature in the range 800°C to 900°C by thermogravimetry analysis (TGA). A two stage mechanism, (1) the reduction of FeO present in Roast Movat with carbon monoxide; and (2) the regeneration of CO by the oxidation of carbon with CO2 was proposed. The rate controlling step is the carbon oxidation reaction. A kinetic equation, that of random nucleation, was proposed. The activation energy for the reduction was determined to be 55800 J/mole and is compared to those activation energies determined for other chromite ores.

Jan 1, 1998

By E. Peuraniemi, S. Strömberg, S. Jyrkönen, A. Jokilaakso

Several sulfidic raw materials have been flash oxidized in a laboratory furnace in oxidizing atmospheres at temperatures of 500-1100°C. Chemical analysis was used to determine the oxidation degree, and optical and scanning electron microscopy combined with energy dispersive analysis were used for characterization of the reacted particles. The studied materials included both Cu and Ni concentrates and mattes. In fixed conditions, the temperature dependence of sulphur removal rate was found to be equal for all the copper concentrates studied. Nickel concentrates and Cu- and Ni-mattes were, however, found to be less reactive. Most of the particles were found to spheroidize and to fragment to small droplets under intensively oxidizing conditions. The product particles were frequently found to be iron oxide cenospheres or dense spheres with a composition of mixed Cu-(Ni-)Fe oxides.

Jan 1, 1998

By Serge Payant, Michael G. Li, Lionel J. J. Catalan

Alkaline solution rinsing for decommissioning of an acid-leached residue was evaluated by column experiments, neutralization tests and solid characterization by XRD and SEM. It was found that consumption of a strong alkali during residue neutralization was much greater than that required to neutralize the soluble acidity. The excess alkalinity was consumed by solid-phase conversions unnecessary for the success of decommissioning. Alkaline rinsing did not reduce the time requirement for decommissioning when compared with plain water rinsing. Since no benefit is gained to compensate for the additional costs associated with excess alkali consumption, we conclude that strong alkaline solution rinsing is in fact inferior to simple water rinsing.

Jan 1, 1998

By Noris Del Be1 Belluz

Drilling underground in the Grasberg dewatering drifts has routinely hit water aquifers with high flow rates and pressures. Two types of holes are used. Pilot holes probe ahead of the tunnel development to intersect aquifers ahead of the face. And dewatering holes dewater rock formations that will drain water from the Grasberg pit and allow tunnel development to proceed safely. Recently, static pressures of >8.3 MPa (> 1,200 psi) have been recorded with flows from a 100 mm (4 in.) HQ core hole measured at 5,700 L/min (1,500 gpm). The waterflows can be slightly acidic, necessitating the use of stainless-steel collar gear to resist corrosion. These rates were anticipated and contingencies were planned early on to deal with these conditions. PT Freeport Indonesia (PTFI) established procedures to maintain the safety of the drill crews, to enable coring of the rock, and to maintain the safety of the miners driving the drifts. The collar gear controls the waterflows because these drill holes are a vital source of water for the concentrator.

Jan 1, 1998

By C. Bemelmans, L. Chia, T. O’Keefe

Lead alloys function effectively as oxygen-evolving anodes in copper SX-EW operations, and they are highly resistant to corrosion. However, the presence of an organic (from solvent extraction circuits) in the electrolyte seems to enhance solution line attack. Laboratory tests showed that lead is soluble in D2EHPA, Acorga and LIX 984 to a limited, yet measurable, degree. Lead alloys and various lead phases formed on the anode were tested to evaluate their effect on the corrosion process in organic media. Possible causes for anode corrosion and mechanisms responsible for their initiation are discussed.

Jan 1, 1998

By Donald J. McKee

The product sizing and tonnage from a grinding circuit are the end result of a series of linked size reduction stages which always involve: fragmentation in mining; degradation in transport of ore; crushing and finally grinding. A case study is presented which illustrates the substantial effect on autogenous mill throughput of different mining practice. It is shown that it is possible to model each of the size reduction steps of fragmentation, degradation, crushing and grinding. The way in which this predictive capability is used is dependent on the operating constraints of each mine-mill combination.

Jan 1, 1998

By M. Canty

Results are presented that were gathered during pilot-and field-scale testing of an innovative technology, sulfate-reducing bacteria (SRB), designed to treat and control acid mine drainage (AMD). The project was performed under the Mine Waste Technology Program (MWTP), which is funded by the U.S. Environmental Protection Agency (EPA) and jointly administered by the EPA and the U.S. Department of Energy through an Interagency Agreement. The MWTP is implemented by MSE, Technology Applications, Inc., located in Butte, Montana. Sulfate-reducing bacteria, a common group of anaerobic bacteria, produce hydrogen sulfide and bicarbonate when supplied with sources of carbon and sulfate. Hydrogen sulfide reacts with metal ions in AMD, precipitating them as metal sulfides; the bicarbonate serves to help neutralized the drainage. Pilot-scale testing was performed within eight packed-bed reactors at a temperature representative of a field application of this technology in a northern climate, nominally 8°C. The reactors, packed with an organic substrate, were operated continuously in upflow configurations receiving AMD at a flow rate corresponding to a 5-day retention time over a test duration of 60 days. During this time, numerous physical and chemical parameters were monitored. Pilot-scale metal removal efficiencies reached 99% for zinc, 99% for aluminum, 96% for manganese, 98% for cadmium, and 96% for copper. Iron and arsenic removal was not as effective as the aforementioned metals, which was largely attributed to the high levels of iron and arsenic contaminating the organic substrate. Evidence existed that both adsorption and sulfate reduction were occurring within the reactors.

Jan 1, 1998

The Peruvian mining industry has seen an explosion of foreign investment since President Albert? Fujimori's government was first elected in 1990. Since then, Peru has taken some large steps toward recovery, making it the envy of most other developing countries. A measure of political stability was gained in 1992 when Shining Path leader Abimael Guzman was captured. In addition, the country has taken on a huge privatization program, rewritten its foreign investment laws and has reined in its annual inflation rate from 1,700% in 1990 to about 8% by late 1997. Small wonder then that attendance at the XXIII Peruvian Institute of Mining Engineers conference reached a record level, many of whom are employed by some of the world's largest mining companies. About 2,700 mining industry professionals from all over the world attended the week-long event, held in late September in Arequipa. That was an increase from 1995s 1,600 attendees, that meeting also held in Arequipa.

Jan 1, 1998

By D. Potter

Freeport Exploration initiated regional reconnaissance exploration programs in Irian Jaya, the easternmost province of the Republic of Indonesia in 1990 (see figure 1). Irian Jaya occupies the western half of the island of New Guinea. Freeport was awarded an initial contract of work which totaled 2.6 million hectares (6.4 million acres) and was subsequently awarded additional?concessions which added 1 million hectares (2.5 million acres). The concessions require work commitments and periodic relinquishments. Due to these relinquishments Freeport?s current land position totals l. 9 million hectares (4.7 million acres).

Jan 1, 1998

By A. B. Holland-Batt

In the 1960s and 1970s, incremental development rather than innovation was the norm for gravity separation. However, the last 15 years have seen a number of new developments in this area. The article reviews the traditional gravity-separation techniques and then examines the newer developments such as centrifugal separators. Emphasis is placed on novel devices or improvements that offer better control or improved performance.

Jan 1, 1998

By H. Sevim

Placement of coal combustion byproducts into abandoned sections of underground coal mines for the purpose of subsidence mitigation has been investigated in Illinois. Several handling and transportation systems have been examined. Prototype pneumatic and hydraulic placement systems have been developed and demonstrated. The demonstration site, Peabody No. 10 mine in Pawnee Illinois, is selected as a case study. It is found that, for a project of 5 years, transporting 150,000 tons of byproduct annually from a power plant located 32 km (20 miles) to the mine would cost $1.80 per ton and placement into underground would cost $3.07 per ton.

Jan 1, 1998

By W. M. Schafer

The risk that water quality will be degraded by mining activity can be evaluated using risk analysis techniques. Water quality impacts can occur where water-rock interactions with tailings, waste rock, or leached ore lead to increased loading of constituents into surface or groundwater. Constituent loads contributed by mining facilities are determined by the migration route and chemical evolution of mine water. Mass load contributions from mines can be determined by estimating the prototype pore water in contact with mining waste, predicting the rate and timing of flow, assessing the degree of geochemical attenuation, and modeling chemical mixing with natural surface or groundwater. Mining facility siting and design measures can alter the chemical evolution of mine water by varying the quantity or quality of flow. Stochastic risk management techniques provide a powerful tool for quantitatively identifying the environmental consequences of various siting and design alternatives.

Jan 1, 1998