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By L. Tondo, W. Lim

The high pressure grinding rolls (HPGR) is a relatively new technology which offers the potential benefits in energy savings, circuit simplicity and improved product characteristics in minerals processing applications. Over 300 machines are now operating world-wide, but most of these are used for grinding cement clinker, and relatively few are used in conventional mineral processing. One of the rea- sons for its current limited use in the minerals processing industry is that design, scale-up and flowsheet assessment procedures are seen to be relatively immature and untested. This has reduced confidence in the potential application of the technology. To help rectify this situation an industry funded research project was undertaken, one of whose aims was to develop and prove a mathematical model of the HPGR and a scale-up procedure. Data were collected from tests using laboratory, pilot and in one case a full scale unit (2.2m diameter). A range of feed types were tested including quartz, limestone, kimberlite, bauxite, iron ore and gold ore. These data were then used to develop models of the size reduction performance, power draw, throughput and operating gap for a wide range of pressures, feed sizes, and roll speeds. This paper describes the models that have been initially developed and illustrates their accuracy using some of these data.

Jan 1, 1998

By Richard Meriwether Smith

Mining-related earthy bodies in contact with the atmosphere are now counted, generally, as minesoils. Because soils within this broad category are extremely young the influence of parent material is stronger than in older soils, where climate, organisms, and topography have had time to interact with near-surface rocks to form more distinctly differentiated profiles. Understanding of minesoil properties and processes is aided by definitions of rock types in terms of chemical, physical, and mineralogical characteristics that are, with some degree of consistency, translatable into soils. Geological correlations based on age or sedimentary sequences are helpful if they assure details of mineralogy and lithology, but our pedologic objectives demand that any conflicts involving rock types must be resolved in favor of distinctions having strongest implications for soil properties after mining. Chemically this approach emphasizes accounting of potential acid-base status, plant nutrient availability by adapted and calibrated extraction procedures, and absence of biotoxins. Physically it anticipates particle sizes, shapes, and arrangements in readily pervious soil profiles that will favor plant growth with desired levels of moisture and oxygen. Concurrently we are considering soil property suitability for uses other than growth of plants. Above all we need to be able to predict pedogenic processes in the particular environment, including rate as well as direction of chemical and physical change.

Jan 1, 1974

By S. K. Kawatra, T. C. Eisele

Coal-cleaning operations commonly produce a fine-waste stream containing a considerable amount of coal. The recovery of this coal is normally not economical because the coal is mixed with large amounts of difficult-to remove clay slimes and is often heavily oxidized or contaminated. Conventional froth-flotation machines cannot, in a single flotation stage, produce an acceptable product from such material, and even flotation columns often have difficulty cleaning this type of feed. A new type of flotation column was designed specifically to deal with these problems, and a column of this design was installed and tested in a coal-cleaning plant in Ohio. The feed coal tested was the plant&apos;s tailings-thickener product. The coal was 80% -176 µm and had a heating value of 8401 Btu/ lb. The coal contained 39.8% ash, as fine clay, and 2.83% total sulfur. Because previous attempts at conventional flotation of this type of material had been abandoned, plant personnel believed that the coal was too heavily oxidized and contaminated for flotation to be effective. However, by using the new column it was possible to recover up to 85% of the calorific value in a product containing < 11 % ash, and it was possible to recover 60% of the calorific value in a product containing <8% ash. In addition, the bulk of the pyritic sulfur was also rejected from the coat.

Jan 1, 1996

By J. H. Bassarear, J. D. Vincent

General. Copper, the first metal used by man, today is the third in consumption after iron and aluminum. Compared to these it is relatively rare, with less than 0.01% of the earth&apos;s crust copper, 8% aluminum, and 5% iron. Nevertheless. our modern civilization is heavily dependent upon copper because of its high conductivity and resistance to corrosion, ease of working, durability, wide range of properties by virtue of its readiness to form alloys with other metals, and its attractive colors and texture that make it so desirable for many crafts and arts. These attributes explain why copper is chosen for a long list of uses, including electrical wiring, switchgear, and bus bars; piping, roofing, and siding; and manufactures of brass, bronze, and other alloys. The fact that copper ore is mined in nearly all parts of the world is significant. Its importance is shown in Table I, which gives figures on world production from 1968 to 1977. In the Free World, North and South America and Africa are preeminent. The table also shows the generally upward trend of production in this period; accurate figures for 1978 and 1979 from the same source are not yet available (1980), but it is certain that major environmental, economical, and political factors continued to disturb the industry in those years and into 1980.

Jan 1, 1985

By V. B. Achanti, A. W. Khair

This paper deals with the effects of various bit geometric parameters on the failure characteristics of rock material. Improving the rock-cutting efficiency of continuous mining machines has proven to be an interesting research topic during the last few decades. In the current study, an automated rotary rock-cutting simulator, duplicating a continuous miner, was used to study these parameters in the laboratory. The improvement of bit performance in terms of its life, cutting efficiency, dust production and energy consumption has drawn widespread attention. Research has demonstrated that optimizing bit parameters can result in efficient fragmentation of rock. Indiana limestone rock material was used in this study. The bit tip angle, bit tip size, bit spacing, depth of cut and cutting velocity of the rotary drum were varied to investigate the failure characteristics. The cutting pressure, penetrating pressure and the depth of cut were monitored on the simulator during the cutting process. Airborne dust and settled dust were measured for each experiment. Then, the specific airborne dust and specific energy were determined for each type of bit. Triaxial tests were carried out to correlate the failure angle of the rock in the static case to the dynamic cutting process failure. The physical and mechanical properties of the rock were also determined to assess their influence on the wear characteristics of each bit.

Jan 1, 2000

By A. English, Edward Martinez, L. A. Haas, N. W. Johnson, Harrison Copper, M. E. Tawil, C. C. Harris, G. V. Jergensen, D. Halbe, M. P. Amsden

Declining US ore grades along with skyrocketing energy, materials, labor, and regulatory costs underscored the urgency for technological innovation in the mineral processing area. Re¬liance on the scale-up and automation of unit operations was the sector&apos;s primary battle plan. Debate continues on the upper size limit of concentrating plants and whether process controls should be centralized or distributed in the mill. In the materials handling area, the economics of large-scale and mobile systems, particularly conveyors, were well documented in the literature. Comminution, the most costly and energy consuming area of the processing flowsheet, saw improvements in process controls and liner designs. The trend toward larger grinding units stalled somewhat during the year owing to some operational problems at commercial plants. Research and development of apparently less expensive physical separation processes-that also boast recovery of cleaner and more environmentally acceptable products -gained momentum during the year. Because of escalating capital cost requirements for new plant capacity, the year saw a greater interest by mill designers to re-examine existing capacity. The focus here is clearly to modify or retrofit unit operations with more efficient components as an alternative to installing more costly new equipment. The problems facing the processing sector during the 1970s can be expected to continue in the decade ahead. Technological gains from scale-up and process controls appear

Jan 5, 1980

By Harry M. Edenborn, Richard W. Hammack

Experiments were done to determine if a mushroom compost-based sulfate reduction system could be used to treat nickel-contaminated mine waters. Sulfate reduction systems were established in columns containing acid-washed mushroom compost. Simulated mine waters containing 2000 mg/L sulfate and 50 to 1000 mg/L nickel were adjusted to pH 4.5 and pumped through the columns at flow rates between 15 and 25 mL/hr. During the first nine days of operation, virtually all influent nickel was removed in the columns by sorption and ion exchange mechanisms. The nickel removal rate then dropped to 18 to 30 mg Ni/day (7.8 to 12.8 nmol/ g-substrate/day), probably due to low sulfate reduction rates. When sodium lactate was added to the inflow, a sustained and seven-fold increase in the nickel removal rate was observed. Bacterial sulfate reduction rates measured in mushroom compost-based wetlands exposed to coal mine drainage are 2 to 20 times faster than the rates observed in this study. Low sulfate reduction rates in the columns may have been due to the inhibition of microbial activity by high nickel concentrations and the removal of labile organic compounds from the mushroom compost substrate during acid-washing. Results of this study indicate that bacterial sulfate reduction can effectively treat nickel concentrations up to 500 mg/L if labile carbon is nonlimiting.

Jan 1, 1992

By W. Belobraidich

Kennecott&apos;s Ray mine is located about 145 km (90 miles) north of Tucson in the Mineral Creek mining district of central Arizona. Mining in the district started in the late 1800&apos;s. The Ray mine itself was first mined by under- ground methods in 1911 and was changed to an open-pit operation in 1952. Mineralization is complex and includes sulfide, silicate, and native copper mineralization, as well as minor amounts of molybdenite. Sulfide ore, mined at Ray, is shipped by rail to Kennecott&apos;s concentrator and smelter at Hayden, 32 km (20 miies) away. Silicate ore, mostly chrysocolla, is processed near the mine in a vat leaching-electro- winning plant. The mine consists of two sulfide areas: (1) the West pit and the Central pit (the original Pearl Handle pit) and (2) a silicate area on the northeast perimeter of the Central pit. The pit now is over 304 m (1000 ft) deep and approximately 3048 m (10,000 ft) long. Roads within the ultimate pit are limited to a grade of 10%, while those outside the pit are limited to 8%. The mining equipment consists of 40 Wabco 1094 (120-st) haulage trucks [ranging from 109 to 227 t (120 to 250 st)], 12 electric shovels [ranging from 6 to 23 m (7 to 25 yd)], and 3 11-m (12-yd) Dart production loaders.

Jan 1, 1979

By Jeffrey M. Listak, Gregory J. Chekan

The U.S. Bureau of Mines, in an effort to improve coal conservation and utilization is currently investigating longwall panel layouts to maximize coal recovery and minimize interactive problems in multiple-seam operations. When longwalling coalbeds in descending order, the transfer of stress from overlying gate roads is a major design constraint affecting pillar stability in the lower mine. The lower mine gate road pillars must be properly designed to withstand the additional load transfer if gate roads are superpositioned in successive seams. The Bureau&apos;s MULSIM/NL model was used to analyze load transfer mechanics for superpositioned gate road pillars. Analysis of Longwall Pillar Stability (ALPS), which is an empirically based design method for longwall gate road pillars, was used to calibrate model input parameters. The attributes of both the MULSIM/NL model and ALPS were combined to develop a modified method for estimating pillar stress for multiple-seam cases. The modified method uses a multiple-seam (MS) factor to estimate the stress on the lower mine gate road pillars when superpositioning is practiced. Numerical analysis shows that the MS factor is dependent upon the interburden thickness and pillar width and is presented in a series of graphs relating these two parameters. Several examples are included to illustrate the use of the MS factor for estimating lower mine pillar stress and resulting stability factors.

Jan 1, 1992

By J. Brent Hiskey

INTRODUCTION Metal electrodeposition processes are of fundamental technological importance to a number of fields. Electrorefining, electrowinning, electroplating, and electrogalvanizing have all been the subject of intense study for over a century. More recently, electrochem- ical deposition has played a critical role in advances in microelectronics and lately has been an enabling technology for the production of certain nanostructured materials. Electrometallurgists have most frequently been concerned with the structure and morphology of massive deposits. For example, in metal recovery steps such as electrorefining and electrowinning, deposits demonstrating adherent coarse-grained characteristics are most desirable. In the case of electroplating, a bright fine-grained, tenacious and strongly adherent deposit is required. The fabrication of microelectronic devices and the production of nanoscale structures such as nanoparticles, nanowires, and nanorods requires a keen understanding of early stage deposition effects. The initial stages of metal deposition, usually referred to as electroclystallization, are fundamentally linked to nucleation and growth phenomena. Early stage deposits are typically very ordered. Whereas, bulk metal deposition structures are much more ran- dom. In both cases, the discharge of a metal ion at an electrified interface is represented by simple cathodic reduction as follows: [ ] Me(H2O)xn[ ] is a hydrated metal ion residing in the bulk solution and Me is the metal atom occupying a crystallographic lattice position. A similar reduction reaction can be

Jan 1, 2005

By B. K. Parekh

The International Symposium on Comminution was organized at Camborne School of Mines, Cornwall England. Papers covered the fundamental and practical aspects of comminution in the mineral industry. Although comminution equipment design has not changed fundamentally during the last 50 years, methods of control and optimization have improved considerably. A simulation model for batch ball milling in the rotating mill was developed as a step toward continuous simulation of ball and autogenous milling. New concepts in jaw crusher technology design and the concept of a 1.6- x 2.1-m (66- x 84- in) jaw crusher with open feed throat has resulted in power savings. The use of cone crusher technology in comminution circuits with particular reference to machine design, plant flowsheet and control figuration has been reported by Boliden Allis, of Sweden. The Whiten steady state crusher model form has been used to develop a quantitative model of 2.1-m (7-ft) cone crushers. This was done by incorporating liner age (wear) and liner length as variables on the selection of particles for breakage and thus on the product size distribution. Another paper by Lira and Karetsky discussed the development of a model based on a multisegment ball mill developed by Whiten and Kavetsky. It is capable of simulating the performance of a coarse grinding ball mill of a given diameter, ball size and mill speed.

Jan 1, 1991

By L. Alan Weakly

The purpose of this paper is to present a viable method of reinforcing rock pillars by utilizing fully grouted reinforcing steel and a cement - fly ash mortar. Although the fully bonded bolt concept is not new, as exemplified by the present widespread use of resin bolts within United States mines and by the use of cement grouted reinforcing used as back pins in the Kiruna Iron Ore Mine in northern Sweden, (1) (2) the method of stabilizing mine pillars with fully bonded reinforcing is new. This method, called the "grout-rebar system", was first incorporated at St. Joe Minerals Corporation’s Fletcher Mine in December of 1972. The system was used on an emergency basis before extensive research on the mechanics of the system could be completed. Since December of 1972, however, approximately 206 pillars have been reinforced at Fletcher and the system is currently being used on a regular basis at two other St. Joe mines and at two competitor mines in the area. Basically, this paper is a case study of the efforts, research and results of utilizing the grout-rebar system, on a selective basis, at the Fletcher Mine. In addition to information about the system, this paper will explain in detail the three rock mechanics instruments developed by St. Joe and used to measure and monitor rock movement to validate the grout- rebar system.

Jan 1, 1977

By J. A. Ryder

Compressed air is a relatively inefficient yet very convenient vehicle for transmitting mechanical energy. It is inefficient when compared to, say, hydraulic or electric energy systems since compressor and pneumatic machine efficiencies are quite low (in the range 20-65%) and reticulation losses can be quite high unless adequate pipe diameters are used to minimize friction drops. It is convenient in that capital and maintenance costs of pipes and machines are exceptionally low, the equipment is flexible and lightweight, the technological level is simple, the form of the energy supply is intrinsic- ally safe, and as an additional minor but psychologically important benefit, it provides a ready source of cooling and air supply for emergency use in deep hot mines. It is for these reasons that compressed air is a premier source of energy for many forms of underground equipment, in particular hand or rig-mounted rockdrills, some forms of rock- handling equipment, and a host of minor applications including agitators, small-lift pumps and temporary f am installations. In a typical S. African deep-level gold or platinum mine, compressed air generation accounts for 15% of the total mine electrical energy bill - more than is used for hoisting. In these mines it is not uncommon for over 100 km of underground compressed air piping to be installed, primarily to supply handheld rockdrills.

Jan 1, 1979

The concept of optical basicity is now being widely applied to rationalize and predict the chemical properties of slags. It employs signals from a probe ion to indicate the "state" or relative "freeness" of the oxygen ions in the slag, and hence provides a fundamental measure of slag basicity. Values of the bulk optical basicity of a slag can either be measured spectroscopically in samples of transparent solid glassy slag, or calculated very simply and accurately from the chemical composition of the slag. The way in which these values vary in different systems are illustrated as isoptical basicity lines on ternary diagrams, and the patterns obtained are discussed. The difficulties associated with assigning optical basicities to the oxides of transition elements are also reviewed briefly. It has been demonstrated that these bulk values can be used as the basis of a flux control model for steelmaking to achieve end-point chemistries much more reliably. Furthermore, several correlations have been established which allow the prediction of the slag-metal distribution of various solute elements. This approach has been used to predict the phosphorus distribution at the end of steelmaking, and also to custom design fluxes for the ladle and tundish to aid in the control of residual elements in the steel such as suphur, hydrogen and nitrogen.

Jan 1, 1990

By G. Lodewijks

Today most belt conveyors used for the transportation of bulk solid materials are driven in a centralized way with all drives in one location. The dynamics of these systems has been studied since the early seventies of the previous century and are well understood. Compared to the more conventional belt conveyor system with a centralized drive station positioned at the head and/or tail of the system, a decentralized driven layout with drive stations distributed along the whole length of the belt offers a number of advantages. However, to make a decentralized driven configuration a good alternative to a centralized driven, the system designer will have to balance these benefits with the increased complexity. The full potential of a decentralized driven system can only be realized if the right balance is found between the locally applied drive force and the motion resistances occurring along the system. From previous research it was found that in a multiple driven belt conveyor system the most dominant belt behavior occurs in the belt section between the tensioning device and the first drive station. In this paper different possibilities are analyzed to improve this dominant belt response and optimize the starting behavior. This can be accomplished by changing the predescribed start up profile, starting the drive stations in sequence rather then all at the same time and altering the locations of the drive stations.

Jan 1, 2008

By Ronny J. Sadri

Under contract to the Department of Energy, Fluor Mining & Metals, Inc. and Bonner & Moore Associates developed a group of computer models that can be used to simulate single seam dragline operations. These models have been subsequently modified by Fluor for use in multi-seam dragline mining situations. The single seam model analyzes the digging, spoiling, and walking patterns of draglines to identify possible parameter changes to increase productivity. Parameters such as key-cutting, panel width, digout length, and bench height, etc., are analyzed in this process. The models were tested using data from four operating mines. Field demonstrations were performed to correlate computer optimization results with field data. Productivity was greatly enhanced at one mine site by a change in some of the operating parameters. The multi-seam study has as its objective the development of a broad- based mine planning tool which would be used to identify and quantify the different procedures employed in multi-seam dragline mines to increase their productivity. The major problem identified in multi-seam mining is the sequencing of the different stripping and mining operations. The multi-seam model has the same capabilities as the single seam model. In addition, it models up to four seams with three partings per seam. It allows the operation of several draglines at different levels, and analyzes the effect of ramps, rehandling, and ancillary mining equipment.

Jan 1, 1982

By Andrzej Walentek

This paper presents the results of numerical modeling of the fractured zone around longwall gateroads. The numerical computations have been based on the results of underground measurements of the fractured zone around longwall gateroads, which were performed for various geological and mining conditions and measured with the use of the endoscopic method with a digital camera. Having results of the underground investigations, trials of duplicating them by the Finite Element Method using software PHASE and the Hoek-Brown failure criterion were performed. In order that the fractured zone predicted by the model-based computations closely simulate that measured underground, some selected parameters in the Hoek-Brown failure criterion were modified based on the earlier determined relations used for prediction of the roof-to-floor convergence in longwall gateroads. As a result, the model-based computations produce results very close to those obtained from the underground measurements. Determination of the fractured-rock zone around the mine roads is of great importance to mining practice, especially in planning and designing supports for longwall gateroads. The influence of the front abutment pressure causes the fractured rock zone around the roads to increase and results in an increase of support load. Moreover, proper determination of the fractured rock zone is one of basic elements in the process of planning roof bolting for mine workings.

Jan 1, 2009

By Francis S. Kendorski

INTRODUCTION Caving offers the lowest cost per ton of any large-scale mining method, but its successful application demands an ore body that conforms to several rigid requirements. The deposit must be of wide areal extent, massive and not spotty in ore values, and insensitive to ore dilution. It must also be a rock mass that breaks up readily. There are only three active caving operations in the US-Climax, Henderson, and San Manuel-but caving methods have recently taken on new importance as deeper lower grade mineral occurrences and ore bodies are found. These deposits are too deep for surface min¬ing methods, and too low grade to support any type of underground mining except a bulk method such as caving. Announced discoveries or indications that may be amenable to caving include: Climax&apos;s Mt. Emmons molybdenum discovery in Colorado; Molycorp&apos;s Goat Hill molybdenum prospect in New Mexico; the Phelps Dodge molybdenum deposit in Beaver County, UT; Arizona copper occurrences such as Asarco&apos;s Sacaton, Hanna&apos;s Casa Grande, Noranda&apos;s Lakeshore, and Ken¬necott&apos;s Safford; Anaconda&apos;s suspected deep copper de¬posit in Butte, MT; Anaconda&apos;s Carr Fork, UT, deposit; and perhaps others. CAVABILITY&apos;S ROLE IN FEASIBILITY STUDIES Caving is a system of underground mining which removes support from underneath an ore body. As a result, the rock mass fractures, fails, and flows vertically downward by gravity to be collected in previously ex¬cavated funnels. Types of ore that have been mined by caving include molybdenum, copper, iron, nickel, as¬bestos, and diamonds (Julin and Tobie, 1973). It is primarily a large-scale method, with production rates of more than 45 300 t/d (50,000 stpd) having been achieved. However, the initial capital investment before return is very high, often in the hundreds of millions of dollars. The cavability of an ore body or mineral occurrence is a critical item in the feasibility study of a proposed mine, not only from the point of overall minability, but from the point of impact on other costs such as blasting, loading, hauling, crushing, and grade recovered. Aside from the often-asked question of, "Will it or will it not cave?" the real questions are, "Can we afford to make it cave, carry the rock away, and extract the mineral?" The last is not a topic of this chapter, but the first two are. The cavability of an ore deposit or mineral occur¬rence is based on many things, but clearly, if a large enough area is undermined, any rock mass will cave. The result could be a violent collapse as occurred at Urad, CO (Kendrick, 1970), or perhaps the rock mass will cave beyond the ore boundary. Another unfavor¬able result could be ore blocks that are too large for the equipment and orepasses to handle without considerable secondary blasting. Weak rock with numerous fractures may produce a very fine ore when it caves, resulting in dilution and ground control problems. DETERMINING STRUCTURAL DOMAINS It has long been recognized that the geologic nature of an ore body is important to cavability (King, 1946). Such items as weak rock material, intensity of fractur¬ing, and severity of faulting all contribute to the success of a caving operation, and information regarding these is required as a minimum for the cavability determination. In practice, the rock mass-defined as the blocks of intact rock together with the intervening fractures, joints, faults, bedding planes, and other discontinuities-that contains the ore body, as well as the surrounding and overlying rock, must be examined in a systematic and detailed fashion. Surficial geology maps must be pre¬pared, exploration holes drilled, and core logged for en¬gineering information. The fracturing of the rock mass must be studied to ascertain the three-dimensional dis¬tribution of fractures and their characteristics, and faults must be located and described. The strength and other mechanical properties of the rock material, the fracture surfaces, and the fault filling materials must be tested and reported for later use by designers and planners. With this basic information and an understanding of the geologic setting, the rock mass can be divided into one or more structural domains which tend to behave similarly in response to engineering activities (Robertson and Piteau, 1970). One must keep in mind that the determination of the structural domains goes beyond the geologic units present. Several lithologic units may be lumped together, while a single lithologic unit can be divided into multiple domains. Major faults often form their own domain, and the direction of engineering ac¬tivity-for example, cave advance to the north rather than the south-may alter rock mass behavior, resulting in different domains. As an example of the detailed rock fracture map¬ping required for such studies, the structural domain determinations at the Climax mine (Kendorski, 1973) are shown in Fig. 1. The circles are Schmidt equal area projections of the three-dimensional attitudes of frac¬tures (Ramsay, 1967) mapped in detail at various rock exposures. The attitude of fractures is important to the cavability determination since it dictates the directional behavior of the rock mass as it fails, and determines the effectiveness of arching, keying, and rock block inter¬locking. Low-angle fractures must be present to allow movement of the rock in the vertical direction during undermining (Mahtab and Dixon, 1976); if low-angle planes of weakness are absent, the rock mass may arch with a keystone effect, rather than moving vertically downward.

Jan 1, 1982

By Dominc C. Torre

INTRODUCTION Rapidly increasing capacities of equipment used to load and handle material at the face require improved haulage equipment and better methods of transporting the mined materials or "muck" to the shaft or slope and out of the mine to the processing plant on the surface. Increasingly, those transportation demands are being satisfied with underground belt conveyors. Such con¬veyors provide the most readily available, most efficient, and most reliable method of carrying materials in a continuous and rapid flow from the face loading equip¬ment to the surface plant. Almost universally, belt con¬veyors are used in coal mines and those nonmetallic and metallic mines operating in relatively flat bedded deposits. Belt conveyors are available in a wide range of capacities, mainly limited by belt width, belt speed, and weight of the material to be transported. They can be used on the level, on grades, on the surface, or under¬ground. They provide a rapid and constant flow of material, transporting the material as quickly as it is mined. Length of belt conveyors is almost unlimited. Where the haulage distance exceeds the practical capacity of a single conveyor unit, two or more conveyors can be used in series. Single conveyors more than 1.6 km (1.0 mile) long are common; multiple-unit conveyors in series operation are transporting materials over distances exceeding 16.1 km (10 miles). Depending upon mate¬rials being transported, job conditions, cost of the terrain being spanned, and alternative haulage methods avail¬able, conveyors can be conceivably economical for even greater distances. Table 1 lists maximum belt speeds recommended for most materials, relating belt speeds to belt widths. Table 2 lists capacities of typical conveyors of various widths and speeds, transporting commonly mined mate¬rials of various weights. ADVANTAGES OF CONVEYOR SYSTEMS For several years after their initial introduction, belt conveyors were available only with rigid side frames or a supporting structure of steel and concrete. That con¬struction limited underground applications, due to the cost and relative inconvenience of extending or retract¬ing the belt conveyor in the confined underground environment. However, during the last 20 years, wire-¬rope side-frame belt conveyors, as shown in Fig. 1, have become widely used in underground applications. Even wider use can be anticipated with their application to the fast movement of materials in surface mining operations. Advantages of the wire-rope side-frame belt con¬veyors were realized first in panel or section belt haulage in coal mines. Soon afterward, use of those conveyors was extended to gathering and main-line haulage. The mobility of the wire-rope side-frame conveyor is the principal reason for its success. The conveyor can be extended, retracted, dismantled, moved, and reassembled easily, even in relatively confined under¬ground spaces. The intermediate structure consists of rope support stands, wire-rope side frames, wire-rope tie-off stands, and the necessary carrying idlers and return idlers. An important and very attractive feature is the ability to suspend the conveyor from the roof in an underground mine, as shown in Fig. 2, leaving more room for improved housekeeping and allowing passage of face-service equipment, haulage vehicles, and other mining equipment. The conveyor&apos;s open construction allows quick and easy visual inspection of its com¬ponents for failures or malfunctions; it also facilitates checking and correcting conveyor-belt alignment. Other advantages contributing to the attractiveness and widespread application of wire-rope side-frame conveyors in main-line, slope, and surface installations include: lower capital costs, lower installation costs, lower maintenance costs, reduced impact on idlers and belting, reduced spillage and minimal cleanup, improved conformation to undulating terrain or mine bottoms, and the ability to span most obstacles without heavy structural support. CONVEYOR CLASSIFICATIONS Underground belt conveyors are classified normally according to their function. Generally, conveyors are classified into one of four main categories: 1) Panel or section conveyors normally receive the material to be transported directly from the face-haulage equipment. 2) Gathering conveyors are secondary haulage units that usually receive material from two or more panel conveyors. 3) Main-line conveyors transport all the material mined in the underground operations to the slope or shaft. Normally, they receive the material from two or more gathering conveyors. 4) Slope conveyors generally operate in tandem with the main-line conveyor, providing continuous Table 1. Maximum Belt Speeds Recommended for General Use Run-of-Mine Hard Ores and Belt Width, Coal and Earth, Primary Crushed mm (in.) m/s (fpm) Stone, m/s (fpm) 356(14) 1.52 (300) 1.52 (300) 406(16) 1.52 (300) 1.52 (300) 457(18) 2.03 (400) 1.78 (350) 508(20) 2.03 (400) 1.78 (350) 610(24) 2.54 (500) 2.29 (450) 660(26) 2.54 (500) 2.29 (450) 762(30) 3.05 (600) 2.79 (550) 914(36) 3.30 (650) 3.05 (600) 1067 (42) 3.56 (700) 3.05 (600) 1219 (48) 3.56 (700) 3.30 (650) 1372 (54) 3.56 (700) 3.30 (650) 1524 (60) 3.56 (700) 3.30 (650) 1676 (66) 4.06 (800) 3.81 (750) 1829 (72) 4.06 (800) 3.

Jan 1, 1982

By Dale Matthews

The Getchell Mine, near Winnemucca, NR, was discovered in the 1930s and was initially mined to recover gold from oxide ores. During the 1940s and 1950s, gold was recovered from the highly refractory arsenic sulfide ores using horizontal kilns to roast the ores. During the 1960s, fluid bed roasters were used to oxidize the ore and recover the gold. The mine was shut down from 1968 through 1985. In 1985, heap leaching was started on the low-grade oxide ores that were available. In 1989, a pressure oxidation circuit was started to recover gold from the higher grade sulfide ores. Flowsheet The basic plant flowsheet of the Getchell Mine are shown in Figs. 1 and 2. The plant was designed to process a nominal 2.7 kt/d (3000 stpd) of ore with about an 85% onstream availability and a gold production of 15.5 kg/d (500 oz/ day). Run-of-mine (ROM) ore is fed directly to a wet semiautogenuous grinding (SAG) mill after the +457-µm (+18in.) rock is removed on a stationary grizzly. From the SAG mill, the ore goes to a ball mill where it is ground to 80% -75 µm (-200 mesh) and is then sent to a thickener. The SAG and ball mill operate in closed circuit using cyclones.

Jan 1, 1994