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By Donald Babbitt

In 1971, during the planning and design stages of a $300 million expansion, the Iron Ore Company of Canada Ltd. through its Engineers, Canadian Bechtel Ltd., came out with a preliminary request for two (2) 10,000 LTPH belt conveyor scale systems. These Systems were to provide weighing accuracies within 2.5% of the iron ore pellets and concentrates in transit on two (2) 72" wide conveyors from the stockpiles to the ships. Each conveyor system would be fed by a rail mounted bucket wheel reclaimer, with the conveyed material moving directly to the ship loaders with no inter- mediate surge and/or storage bins between the stockpiles and the ships. The bucket wheel reclaimer discharge rates would vary from 0-9600 LTPH in cyclic periods, with the periods varying from 1-5 minutes - dependent on the level of the reclaim buckets in relation to the stockpile as well as the slewing rate of the reclaimer. There would be frequent interruptions for bucket wheel repositioning (laterally and vertically), changing ship holds, and trimming ship holds. These frequent zero flow conditions, approximately 500 per 150,000 ton ship, could last 1-5 minutes. In addition, the conveyors on which the scales were to be mounted would be over the water and subject to the wind and cold of Northern Quebec. These Systems would be in use 350 working days of the year and would load 30,000,000 LT/yr. (An average of 90,000/working day).

Jan 1, 1975

By K. Park, J. Sohn

Recovery of industrially useful metals from various secondary sources is an important issue in Korea whose natural resources are limited and needs in the strategic metals are on the rise. In order to meet such needs, researchers at the Korea Institute of Geoscience and Mineral Resources have launched a number of projects to help the nation to recover various metals from secondary sources. In this study, silver is successfully recovered from spent silver-oxide batteries first by distillation to remove mercury. The distilled residue was next subjected to leaching of silver using nitric acid. The study involves finding optimum conditions to leach silver from the distilled residue and subsequently to recover silver from the leach liquor by chemical precipitation. The chemically precipitated products are then subjected to reduction roasting to recover silver metal.

Jan 1, 2002

By Panshi Xie, Yingyi Zhang, JIANJIE DUAN, Shenghu Luo

The most important safety aspect associated with great mining height in steeply dipping coal seam mining is the stability and control of the roof. When soft coal and hard gangue make up the immediate roof of a working face, the soft-coal interlayer plays a significant role in gangue damage and can cause problems such as roof collapse in front of the support, collapse of partial area supports and other problems that can affect the stability of the supports and the surrounding rock system. This study found that the first weighting step of a multigangue roof is larger than that of a nongangue roof, but periodic weighting steps are similar. The overburden collapse height is lower in a multigangue roof than in a nongangue roof due to the buffering and supporting function of the collapsed gangue. Failure of the coal interlayer is the key factor in the collapse of multilayer gangue. The limited load of the interlayer and maximum resistance of the support is concluded by the hard gangue and soft coal interlayer mechanical model. The maximum resistance of the support increased with the dip angle of the seam and burial depth. Certain measures are proposed to control the stability of the gangue roof, including zoning control of the mining height and resistance and advancing the support while maintaining roof contact, thus ensuring the integrity of the support and surrounding rock system.

By H. Colijn

The trend in the coal industry for many years has been to make everything "bigger and faster" This also held true for loading and storage facilities. Where once a million ton per year mine was rare, three to five million ton per year mines are not uncommon today in the bituminous industry. This greatly increased production, made possible through mechanization, required greatly improved loading facilities just to get the coal away from the mine. Also, there is a trend toward combining production from more than one mine and cleaning it in a single preparation plant. In addition to increased loading capacity, this frequently necessitates raw coal storage and blending facilities. The development of the unit train, more than any other factor, has contributed to the widespread construction of storage and high-speed loading facilities for clean coal. In the export market, the construction of ever larger coal bulk carriers has contributed to a need for faster and larger loading facilities at ports. The present engineering and construction cost of these larger facilities make it essential that the flow and handling properties of the particular coals are fully known. These properties can be measured well in advance and the proper design criteria established. This eliminates costly surprises later on during start-up and operations. This paper will review coal and coal refuse properties, such as shear strength, cohesion, friability, and the flowability of coal and how they affect the design criteria of storage silos.

Jan 1, 1979

By Y. Yu

Florida phosphates ore typically processed by reverse flotation with an intermediate acid-scrubbing step. A single-reagent flotation process, using fatty acids or amines as the collector, would eliminate the intermediate scrubbing step plus an additional flotation step. This would not only simplify the process flowsheet but would also result in reduced reagent costs. The potential of single-reagent flotation of Florida phosphates using fatty acids as the collector is examined in this study. Introduction The beneficiation scheme now used for Florida phosphates involves the following three steps (Smith, 1976: Lawyer et al.. 1978, 1984: Moudgil et al, 1976, 1979, 1986, 1987): •rougher flotation of fluorapatitc particles using a fatty acid-fuel oil mixture as the collector. •scrubbing of fatty acid, and •cleaner flotation of silica particles using amine collector. Several attempts have been made to simplify the process flowsheet by floating either apatite or silica (not both, as is the current practice). However, single-reagent flotation schemes have had limitations in meting the concentrate-grade requirements of the phosphoric acid plants. In this study, an attempt was made to use a minimal amount of the fatty acid-fuel oil collector to obtain an acceptable grade (rougher) concentrate. Invariably, the recovery in such cases is expected to be lower than in the conventional rougher-flotation step. Therefore, scavenger flotation of tailings with additional fatty-acid collector was conducted to improve the phosphate recoveries.

Jan 1, 1997

By J. L. Boyd

The mining and processing of basic metals relies on water as a medium for transport. Metallurgical ores are ground, concentrated, leached and refined in an aqueous medium. Water is used for temperature control during processing and in air pollution abatement during smelting. All of these process steps result in liquid wastes. Many of the aqueous wastes from ore processing areas become the raw product for a second stage and water recycling may begin. The point at which water recycling or reuse has been initiated in the past, rather than water discharge, was where water conservation was manditory due to a shortage, where process conditions would allow or benefit from reuse, and where economic considerations demanded reuse. The Fontana, California plant of Kaiser Steel Corporation is an example of an integrated steel plant that was forced to practice water conservation and reuse due to its location in an arid environment.1 Only a small amount of water required to maintain the water reuse system in balance with respect to dissolved solids and product quality is discharged. The Butte, Montana copper ore processing plant of The Anaconda Company obtains 66% of the water required for production by recycling, after clarification and chemical treatment, 30 MGD of wastewater from its tailings ponds. This operation is estimated to save the company about $1200/day over a once through water system.2 Here plant location and economics favored water reuse.

Jan 1, 1975

By Nathaniel Arbiter

The development of flotation machines since the first industrial use of the process can be divided into three stages. The first, up to about 1930, was marked by diversity in the means for contacting floatable mineral with the air/ water interface and for generating the interface, as well as in cell design. By 1927 Taggart (1) could list 170 patents covering flotation cells, and he mentioned dozens which were or had been in operation. He divided cells into eight categories according to design, type of separating interface, and where in the cell and how separation took place. These were: (1) Film or skin flotation with wet or dry oiling of surfaces; (2) pulp body process with bubbles generated chemically by pressure reduction, by vacuum or by boiling; (3) agitation-froth processes involving local supersaturation with air; (4) bubble column; (5) pneumatic; (6) cascade; (7) subaeration; and (8) combination and miscellaneous types and processes. Most widely used then were the agitation-froth, sub- aeration, pneumatic types. By 1943 a significant reduction in categories had occurred to the two main divisions of mechanical and pneumatic cells according to whether agitation and aeration were (a) by an impeller with or without compressed air, or (b) by compressed air alone. Cells at that time were still relatively small; the Morenci Concentrator completed in 1942 used 432 1.7m3 (60 cu ft) Fagergrens for roughing 45,000 and later up to 55,000 t/d.

Jan 1, 1979

By Bruce D. Hanson

A computer model capable of simulating the basic production system in a variety of underground mining methods has been developed at the Twin Cities Mining Research Center. This Bureau of Mines paper describes the simulation of the basic production system at the working face, which includes drilling, blasting, mucking, and roof bolting. The model is event-oriented; that is, the status of the system is updated at the occurrence of an event. All event or activity times, including failure and repair of equipment, are treated as stochastic variables. A location dimension, in addition to the time dimension, is used, allowing the simulation of multiple location systems. To aid the user in determining the efficiency of his system, the model provides several reports. An event or activity report gives the frequency of occurrence total active time, and cumulative delay statistics for each event. An equipment report delineates the availability and utilization of all equipment. A production report provides information on various performance measures such as tons produced and holes drilled. The cost report gives the cost of various elements in the system. Operating data from an actual mining situation were used in validating the model. In addition to the description of the model, examples of simulation experiments which were performed on a room-and-pillar mine system are given. Use of the model to determine methods for improving the efficiency of the system is discussed.

Jan 1, 1974

By John D. Batty

With the emergence ofbiooxidation as a viable process for the pre treatment of refractory gold ores, so have the number of publica­tions on this topic increased dramatically. To a novice in the field of biooxidation, the infonnation presented is often confusing and sometimes even incorrect. Infonnation has also been published that is misleading in that it highlights a particular feature of a process that is either totally irrelevant or of no consequence to the ultimate goal viz. achieving the maximum economical gold recovery. To assist a potential user of biooxidation in evaluating the available published infonnation some guidelines or considera­tions for some of the more important aspects are given, as well as some extracts from publications that demonstrate the manner in which information has been presented.

Jan 1, 1996

By Earl Sackett

In its 110-year history as a mining camp, the Boleo copper district of Baja California has weathered significant changes in its operation, ownership, and profitability, despite an inhospitable environment and unique ore body. For some 65 years, under the operation of Compagnie Boleo, the area ranked as the second largest copper producing district in Mexico, with over 560 km of underground workings. As its ore grade-and profitability-declined, operations continued sporadically and with varying degrees of success. Today, operations at Boleo are maintained -despite the economics -while work is underway to devise a viable metallurgical process. Lab tests on a hydrometallurgical method look encouraging and, though this may end the district's days as a mining camp, the feasibility of the process may result in an 18-kt/d full-scale operation.

Jan 7, 1980

Acid Mine Drainage (AMD) is the most serious environmental problem facing the Canadian Mineral Industry today. Acid Mine Drainage results from oxidation of sulphide minerals (e.g. pyrite or pyrrhotite) contained in mine waste or mine tailings. It is characterised by acid effluents rich in heavy metals that are released into the environment. A new acid remediation technology is presented in this paper by which metallurgical residues from the aluminium extraction industry are used to construct permeable reactive barriers (PRB) to treat acid mine effluents. It describes column tests performed to simulate a PRB using Bauxsol?, a chemically and physically treated bauxite refinery residue, as a reactive material. This experimentation shows promising results for the Bauxsol? PRB method in neutralizing pH and removing metals from acidic mine effluents.

Jan 1, 2006

By F. M. Doyle, Jiang Tao, Xu Shi, Chen Jin, E. Peters

Tafel curve technique and leaching tests have been applied to study the kinetics of gold leaching with thiosulfate. Results show that cupric ions and ammonia play the part of catalysts in the leaching of gold with thiosulfate. The activation energy of gold dissolution is calculated as 27.99 KJ/mol in the absence of both cupric ions and ammonia. However, the energy is reduced to 15.54 KJ/mol in a solution of 0.01 mol/L Cu (NH3)2 4* and 0. 5moVL total ammonia. The reaction order of Cu (NH,) g is one in the range of 0.001~0.1mol/L. These results support the electrochemical-catalytic mechanism pro- posed by the authors and explains the behavior of cupric ion and ammonia (Jiang Tao, et al., 1993)

Jan 1, 1993

By D. Doepker

The dissolution of metals from various metal/ non-metal mine tailings has been studied through column leach tests at US Bureau of Mines laboratories. Metal mobilization in unsaturated columns was consistently greater than metal dissolution in water-saturated columns. Leachate pH was also frequently lower when a leachant was passed through columns but showed a mixed residence-time dependence. On the other hand, metal and sulfate ion concentrations in the leachate increased with dry-cycle residence time. Results suggest that acid formation through atmospheric oxidation of pyrite may compete with non-acid-forming oxidation of other metal sulfides. The two processes lead to decreased pH and increased metal mobilization, respectively. Leach tests using sodium lauryl sulfate indicated that microbial activity was not a factor in these studies.

Jan 1, 1991

By B. Yarar, R. Buchan

Mineral-processing techniques were adopted for use in the separation of various plastics used in beverage bottles. A complete flowsheet, which utilized size reduction, heavy-media separation and flotation, was developed to separate PE, PVC and PET. In addition, the mixtures contained cellulose fibers (from labels) and aluminum (from bottle caps). It was demonstrated that, while heavy-media separation allows for the separation of a PVC/ PET mixture, froth flotation can be used to separate PVC and PET. For this purpose, the differential action of a pH 11 alkaline aqueous solution containing methanol and MIBC as surface-tension control agents, has been found to be a suitable flotation medium. This paper reports on some aspects of a flotation flowsheet that was developed for the separation of plastics contained in municipal solid wastes.

Jan 1, 1997

By R. W. Hughes, R. Koopmans

This paper investigates the effect of varying stress levels on the determination of deformation moduli and examines the sensitivity of the borehole dilatometer in measuring rock mass scale features and its ability to represent rock mass characteristics. Cubical blocks of sandstone, limestone and granite were tested in the laboratory under triaxial stress conditions. Field programs were conducted in both granite and sandstone rock masses surrounding underground openings. The dilatometer's zone of influence was determined by conducting tests within an instrumented concrete cylinder and by performing a finite element analysis. Laboratory and field results suggest that the deformation modulus of a rock mass can be substantially affected by the stress field and that the borehole dilatometer is sensitive enough to profile deformation moduli as dictated by the in situ rock mass characteristics.

Jan 1, 1986

By Majid Ataeepour, Ernest Y. Baafi

High level programming languages such ass C, FORTRAN and BASIC have been used in the mining industry to simulate truck-shovel systems. In addition, some special languages for simulation such as GASP, GPSS, SLAM, PROOF and SIMAN are commonly used. The most recent simulation system ARENA uses graphical modelling approach as well as animation notion. In this paper, the main elements of ARENA required to perform a truck- shovel simulation and to view the simulation results by means of the model animation are presented. The layout of the haulage system including shovels, trucks and dump sites was generated using draw tool in ARENA. All the components of the haulage system were represented by graphical modules. Animation tool was used to depict the performance of the haulage system as the simulation progressed.

Jan 1, 1996

By S. Mathur

Future Florida phosphate reserves contain higher MgO than presently mined deposits. The high MgO content is contributed by dolomite and Mg-rich clay, palygorskite. Selective flocculation was attempted to reduce the MgO content of apatite in synthetic mixtures of apatite with dolomite and palygorskie. Mixed mineral selectivity was predicted in the apatite-dolomite and apatite- palygorskite systems with Poly(ethy1ene oxide) (PEO) flocculant. Loss of selectivity in the mixed mineral systems was primarily attributed to heteroflocculation, which was minimized by addition of a Site Blocking Agent (SBA), a lower molecular weight fraction of PEO, prior to addition of the flocculant. A 80:20 mixture of apatite-dolomite (or palygorskite) was upgraded as 95% apatite at more than 80% recovery level in the product fraction.

Jan 1, 1995

By John C. Morrisey, Harold M. Ray

With full production from the Casteel Mine in 1987 The Doe Run Company, a wholly owned subsidiary of the Fluor Corporation, encountered a significant increase of copper and iron to the Viburnum Mill. This major change of the lead, zinc, and copper metal ratios in the ore created circuit problems which adversely affected concentrate quality. Recognizing the problem, the company embarked on a metallurgical research program to include laboratory, pilot plant, and plant testing. The program developed an innovative copper prefloat process which both increased copper recovery and significantly improved concentrate quality. The process was tested and first operated at Doe Run's Brushy Creek Mill then installed at the Viburnum Mill in 1992. A brief history of development, plant operating data, and other potential applications for the patented processes will be described in the paper.

Jan 1, 1993

By R. R. Oder, R. E. Jamison, E. D. Brandner

This paper presents the preliminary test results obtained using a 0.38-kg/s (3,000-lb/hr) beta prototype MagMill. In processing Upper Freeport coal, the beta prototype recovered 82 % of the weight of the feed and 91 % of the heat content while reducing the potential emissions of sulfur by 61%. Pyritic sulfur in the MagMill product was reduced by 78% compared with that in the feed. For all runs, the mill product particle size was controlled to between 70% and 80% -741m (200 mesh). Recoveries of mercury, arsenic and selenium ranged from 35% to 45% of the amounts found in the feed. Power draw was reduced by 26%, and mill throughput was increased by 9% compared to the pulverizer operating with no magnetic separator attached.

Jan 1, 2002

By Z. Nivolianitou

This article aims at highlighting the importance of technological innovation, namely the potential use of Virtual Reality (VR) technology, as a Sustainable Development Indicator for the minerals industry. Nowadays, VR is regarded as a mature technology for real world representation, and it has been already applied in various domains such as architecture, topography, aeronautics, medicine, and lately in the process industry. Several industrial sectors already use VR tools, as the car industry for improving car ergonomics and design and the aviation industry for both pilot and maintenance crew training. It is well known that the mining industry, as well as the process industry, requires people to work in hazardous environments and situations, often inadequately trained owing to limitations in time and resources, building thus the potential for minor or major accidents.

Jan 1, 2007