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By Osvaldo A. Bascur, J. Pat Kennedy

Large metallurgical complexes have more data than a small city and much of it is "real time," changing rapidly as internal and external conditions evolve. As corporations buy and sell assets and reengineer their staff, the structures and tools that were used to understand these data are lost. The lack of an integrated approach makes the profitability of metallurgical plants lag behind that of other industries despite technical advances that have occurred in recent years. This results in significant deterioration in the ability to maintain a "smart” operation. The solution is to use the sophisticated new tools built for the Internet so as to leverage information in a familiar browser format that people can use and understand. Combining real-time infrastructure with portal technology is becoming an accepted methodology. This paper introduces real-time portals and team sites to support decision making by work- groups which require both real-time and documentary information from manufacturing assets, vendors, head office and the Internet. Workers get insight from the overall process effectiveness index based on key variables such as losses due to plant availability, performance efficiency and rate of quality. Real-time portals and smart clients are part of any real-time performance management (RtPM) solution. Three case studies in large metallurgical complexes are presented. PLANTS ARE YOUR STRATEGIC HANDICAP Information technology is arguably one of the fastest moving technologies used by the mining/metallurgical industry. However, the business model for managing that

Jan 1, 2004

By F. F. Aplan

Prologue Antoine Marc Gaudin (Fig. 1) was truly a giant in the field of mineral processing, and his shadow is still cast long on our profession. "Tony," as his students affectionately called him (but never to his face), came to the United States in 1917 and enrolled at Columbia University where he studied under Professor Arthur F. Taggart. Later, as a lecturer, he wrote his classic comminution paper (Gaudin, 1926). This important work led to his appointment as an associate professor at The University of Utah, where he conducted highly original work on flotation fundamentals that is still widely quoted today (Gaudin et al., 1928-30). In 1929, he was appointed Research Professor of Ore Dressing at the Montana School of Mines in Butte. Shortly thereafter, he published his first book, Flotation (Gaudin, 1932). Because Gaudin could so quickly cut through the fog to get to the essence of a problem, this is still a valuable reference book. It is a valued part of my personal library, and I consult it frequently. Over the next decade, he conducted an outstanding graduate research program at Butte, but, more importantly, he honed his undergraduate lectures and produced the century's outstanding text in the field, Elements of Mineral Dressing (Gaudin, 1939). More than 50 years later, this terse book is still found to contain most of the elements of the discipline. Its sections on the

Jan 1, 1994

By Larry Powell

Rend Lake is an Army Corps of Engineers reservoir located in Franklin and Jefferson Counties in south-central Illinois. The lake consists of 20,000 acres of water and 19,000 acres of public access land. The site attracts over two million visitors a year and is surrounded by campgrounds and other recreational facilities. The lake overlies the largest tonnage of low sulfur coal in the state. Coal is being removed beneath the lake from five mines operated by three coal companies. Currently high extraction mining operations are approaching low-lying, environmentally sensitive, and high-use recreational areas. Advanced planning to maximize coal extraction and minimize potential effects of subsidence requires the development of procedures to assess the impact of high-extraction mining on the land use of the area. The Bureau of Mines, the Corps of Engineers, and the coal companies have initiated research to assess the following proposed planning steps to ensure the maximum recovery of the coal resources while minimizing impacts to surface land use: 1) Establish a dialogue between the surface and mineral owners; 2) develop a geographic information system to aid in assessing existing land use and potential changes; 3) assess the potential effects of subsidence on drainage, wildlife habitats, and changes in land use prior to mining; 4) coordinate the mining displacements with surface activities to minimize disruption; and 5) develop appropriate mitigation plans before mining occurs.

Jan 1, 1986

By S. P. Lewis, R. L. Sundeen

Most of us are aware of the ever increasing use of underground space. At the Advisory Conference on tunneling in Washington, D. C. in June of 1970, the demand for construction oriented tunneling during the 1970s was estimated at some 21,000 Km of length with an excavation volume of 675 million cubic meters. Of this total, 11 million cubic meters were forecast for underground parking. Though this is a small portion of the total, it is significant to note it represents a 280% increase over the previous decade. Other areas of unusual increase were railroad tunnels, 150%, and rapid transit tunnels, 160% (1). Faced with this increasing demand, the need for improved excavating efficiency is obvious. Great strides have been made. In Japan, for example, several new long tunnels have been driven parallel to old existing ones at costs as much as 50; under those of the original tunnels (1). This is an impressive achievement. I am certain, however, that we would all agree that even greater improvement is required. Great emphasis is being placed upon sophisticated systems which include among others, mechanical borers, thermal fracturing, and various methods of rock weakening and softening. However, in hard rock excavation the fact remains that the drill-blast method continues to be the most widely used system. Undoubtedly it will continue to be one of the most important techniques in the forseeable future.

Jan 1, 1974

By D. J. Lachel, Douglas E. Hansen, Bruce Kennedy

The very high cost of exploration and development for new mines requires that a carefully planned, complete, and technically competent geotechnical evaluation be applied to the ore body and the surrounding rock. The ground conditions must be predetermined sufficiently so that, during the development and exploitation stages, unexpected conditions will be of minor consequence. Ground conditions are a major factor affecting the cost of excavated items such as shafts and inclines. For example, shafts cost less to sink in tight dry ground than in highly pervious ground below the water table, with all other factors being equal. The proper mining methods also is dependent upon the ground conditions. Bad ground for room-and-pillar mining may be ideal for caving methods; whereas, ideal ground for room-and-pillar mining would be extremely difficult for a caving operation. To do a proper engineering design, the parameters of strength, deformability, and permeability must be determined, in addition to the loads that will be applied as a result of the mining activity. The required degree of accuracy for each parameter depends upon the individual case. For example, the strength of massive rock in which openings of small cross-sectional area are to be driven at shallow depths needs to be resolved only within several thousand kilopascals (pounds per square inch). Under such conditions, the rock strength is not likely to be of great economic importance unless the rock is very weak. Large openings at great depths require a much more accurate appraisal of rock strength and deformation characteristics. Ground water conditions are important at any depth. Today, a number of techniques exist for evaluating conditions before opening up the ground for development. These techniques and their applications are described in more detail later in this text. The evaluation of ore body ground conditions should start at an early stage, as soon as the deposit has been proven viable for a mine. Economic geology investigations mainly serve to define the value and limits of the ore deposit. To do this properly, the geology of the site is determined in at least as much detail as is necessary to define the "controls" for the ore body. The ground-condition evaluation must determine the engineering properties of the ore body and the surrounding material. This includes the structural geology as it relates to rock strength; i.e., the frequency, extent, and orientation of discontinuities such as faults, joints, bedding, etc. Ground water conditions also must be determined. It is important that the detailed geology of the site be determined at an early date. Reasonable geotechnical parameters must be established during this time period, so they can be used in mining model studies that include both physical and mathematical models. The ultimate goal bf-the geotechnical evaluation is to predict the ground behavior as the excavations are made and how the ground behavior will affect the safety and economic well-being of the mine. The formulation of a ground-condition evaluation program should be planned carefully to determine the particular geotechnical parameters only in as great a detail as will have a bearing on the mine design. For instance, it is not necessary to make numerous triaxial tests in strong rock when the mining will be conducted within a few meters (feet) of the surface in a regime of gravity loading and an absence of tectonic stresses. Similarly, it is not necessary to invest large amounts of time and effort in the determination of joint strengths if the orientations of the joints are such that the failure could not occur along them. Generally, the determination of ore body ground conditions can be divided into four main steps: 1) The general and structural geology of the site must be determined; this is determined primarily during the economic evaluation. 2) The material behavior characteristics of the deposit and the vicinity must be determined. 3) The ground water hydrology of the deposit and the vicinity must be determined. 4) Miscellaneous ground support considerations must be established. Gross features are defined first, followed by a series of increasingly detailed investigations. Specifically, the geology study should start by utilizing techniques such as remote sensing, topographic map interpretation, geologic mapping, etc. After the gross features, such as major faults, have been delineated, the studies are directed toward defining the more detailed elements of jointing, rock strength, ground water hydrology, and other characteristics. This information is used to formulate an assessment of the strength of the ore body and the surrounding rock. Finally, all of the gathered information is integrated to make an assessment of the rock behavior in relation to the types of openings, the excavation methods, the support requirements, etc., that should be used for the rock conditions that are present. The mine design and the geotechnical assessment should be an iterative process. General conclusions about the rock conditions will dictate a type of mine plan. The specific mine plan then should be modified by specific geotechnical considerations. For example, an initial assessment may conclude that the ore body is strong and that a strong rock unit is present over the ore body. Thus, one definite possibility is to mine the deposit by room-and-pillar methods. However, subsequent investigations may reveal faults through the deposit, requiring relocation of the mine openings so that pillars and other structures are in sound rock. In other words, the final mine plan should be compatible with the geotechnical aspects of the ore body.

Jan 1, 1982

By Kathleen Kreiss, A. James Ruttenber

INTRODUCTION Early in the morning of July 16, 1979, there was a breach in the earthen retaining dam of a tailings pond at the United Nuclear Corporation's (UNC's) Church Rock uranium mill. The acidified liquid and tailings slurry spilled through the damaged portion of the retaining wall into an arroyo that is a tributary to the Rio Puerco river system. The Rio Puerco runs through Gallup, New Mexico, and eventually crosses the New Mexico-Arizona border (Fig. 1). On its way to Gallup, the Rio Puerco and its tributaries pass through land with a checkerboard pattern of ownership, with portions owned or leased by the Navajos, individuals, the Bureau of Land Management, and the State. In terms of tailings liquid volume (3.6 x 108L; 94 million gal), the UNC spill ranks as one of the largest. The mass of solids released in the slurry (10.0 x 105 kg; 1 100 tons) appears to be close to the median for accidents of this kind, however [U.S. Nuclear Regulatory Commission (NRC), 1979]. The UNC first opened its Church Rock uranium mill in 1977 on land adjacent to acreage belonging to the Navajo tribe. The mill, which is next to the UNC Church Rock mine, is located approximately 16 km (10 miles) northeast of Gallup, New Mexico (Fig. 1). Gallup, a town of 18 000 people, is the closest population center. The region surrounding the plant site is sparsely populated by Navajos, at a density of approximately 5.8 persons/km2 (15 persons/sq mile). The UNC mill and mines employ approximately 650 persons, and the adjacent Kerr-McGee uranium mine employs about 300. The UNC mill normally processes 3.2 x 106kg/day (3 500 tons/day) of uranium ore, depositing the acidified tailings slurry in a series of three earthen holding ponds. The tailings ponds are located east of the pipeline arroyo that feeds into the Rio Puerco approximately 2.4 km (1.5 miles) from the southernmost tailings dam. The liquid portion of the tailings slurry evaporates in the ponds; hence, under normal conditions, there is no surface flow from the holding ponds to the arroyo. Both runoff from the plant site after heavy rains and possible seepage from the tailings ponds may deliver radionuclides to the arroyo-river system, however. The dam across the southernmost tailings pond was considered to be in keeping with the state of the art. However, the New Mexico Environmental Improvement Division (NMEID) had warned UNC about dangers of locating the pond over a heterogeneous geological formation. The state Engineer's Office approved of the site only after UNC agreed to strict design criteria. Others have pointed to dangers of constructing earthen dams for impoundment of uranium mill tailings (Carter, 1978). Causes of the dam break were multiple: the UNC mill filled the tailings pond to a level that exceeded permit criteria; the tailings pond was lined improperly; the dam was constructed using clay that was compacted excessively, resulting in cracking and subsequent seepage; and the unstable substrate beneath the dam permitted differential settling. The UNC Church Rock mine has continuously released dewatering effluent into the pipeline arroyo at a rate of 88.3 L/sec (1 400 gal/min) since 1968. Before 1975 this effluent was not treated; after 1975 it received precipitation treatment for removal of Ra-226. Radionuclides are also released into the river system through the dewatering of the Kerr-McGee uranium mine 1.6 km (1.0 mile) north of the UNC mill. During usual mining operations, approximately 227 L/sec (3 600 gal/min) are released into the pipeline arroyo and subsequently into the Rio Puerco. The Kerr-McGee mine began continuous release of dewatering effluent in January 1972. In 1974 Kerr-McGee began Ra-226 precipitation treatment of its dewatering releases, but NMEID data indicate that treatment has often been incomplete. The effluent from both mines has been responsible for transforming the downstream portion of the Rio Puerco from a sporadically dry riverbed into a continuously flowing stream and has contributed to the current levels of background radiation along the river system (Table 1). This paper will summarize the postspill monitoring efforts and relate the assessment of this spill to the general question of evaluating the health effects of nuclear fuel-cycle wastes. The data pertaining to the measurement of radionuclides in the Church Rock environment and the radionuclide concentrations in animals will appear in forthcoming reports. CHURCH ROCK HEALTH EFFECTS ASSESSMENT APPROACH The initial health effects evaluation involved identifying the radionuclides that were released into the river system from the tailings pond. Table 1 lists the State of New Mexico maximum permissible radionuclide concentrations for liquids released to unrestricted areas, the typical tailings liquid concentrations, and postspill river water concentrations. The tailings liquid contained comparatively high levels of Th-230, Ra-226, Pb-210, and Po-210--all of which, according to postspill river water samples, had exceeded the state maximum permissible concentrations (MPC) at one time or another. After the radionuclides in the tailings were identified, pathways through which humans could be exposed were clarified. Environmental monitoring data were then used to quantify the important pathways of human exposure. Water samples were collected from the river, from test wells dug near

Jan 1, 1981

By James F. ` King

This paper reviews the changes which have taken place in the supply of smelter-grade alumina and refinery-grade bauxite over the past twenty years. It highlights the current situation and identifies some trends which are to be expected in the medium- and longer-term future.

Jan 1, 1986

By Luigi P. Gonano, John C. Sharp

The Drakensberg Pumped Storage Scheme in South Africa with an operating head of 500m is located in sedimentary rocks containing relatively weak argillaceous strata. The paper describes design and construction aspects of the high pressure concrete-lined tunnels, and the associated investigation techniques and construction controls.

Jan 1, 1983

By A. Afrouz, F. P. Hassani

The types of bulkhead that contain backfill in stopes under various pressures and mining conditions are outlined. Conventionally adopted theoretical and empirical techniques were integrated in the design and construction of each type of bulkhead utilized underground. Methods to monitor the performance of bulkheads are discussed.

Jan 1, 1993

By S. K. Kawatra, Harrison R. Cooper

In the last 30 years, on-¬stream slurry analyzers have proven to be of great use in the control of mineral processing circuits. This review discusses the two most popular methods, x-ray fluorescence and neutron activation analysis, and also considers techniques which are still under development.

Jan 1, 1986

By R. C. Freas

The physical and chemical properties of mica are unique relative to most other industrial minerals. As such, mica is suitable for a variety of functional applications in new and emerging markets. This paper examines some of these applications and particularly the contribution mica makes in end product performance.

Jan 1, 1997

By Tracy T. Morris

The current state of the mining community has made it imperative for operations to reduce costs and increase productivity in order to remain competitive. This has been done in Colorado with the installation of an Outokumpu flash flotation machine for the production of a gold/silver/lead concentrate.

Jan 1, 1987

By S. Hodgson

The Red Dog zinc/lead deposit in northwest Alaska is the second largest zinc deposit ever discovered. Being developed by Cominco Alaska with startup scheduled for early 1990, it will ultimately be the largest zinc mine in the Western World. Table 1 illustrates the reserves of the deposit.

Jan 1, 1988

By Fathi Habashi

SOLVENT EXTRACI ION involves two operations: 1) Extraction The metal values in the aqueous phase are extracted by agitation with an organic solvent immiscible in that phase. The two phases are then allowed to separate; the aqueous phase is discarded or recycled and the loaded organic phase saved.

Jan 1, 1970

Mill #4 processes mildly refractory ore from Carlin Trend deposits. Diagnostic analysis of plant operating data was used to generate a mathematical model containing the important parameters influencing gold recovery. The model was used to direct modifications to plant operating practice. The cyanide-dosing strategy was changed to reduce gold losses from preg-robbing and to cut reagent consumption. A finer grind was achieved without capital investment. The density in the carbon-in-leach circuit was lowered, and tighter control was exercised over the plant throughput. These changes resulted in a recovery increase of at least 2%, worth $111,000/month at $300/oz ($9.64/g) gold, and concomitant reagent cost savings of $55,000/ month.

Jan 1, 2000

By Gerald W. Elger

Research at the Albany Metallurgy Research Center has shown that high-purity rutile can be produced from relatively low-grade ilmenite obtained from a massive rock deposit. Ilmenite is first smelted in an electric-arc furnace to separate the iron and produce a slag enriched in titanium dioxide. Titania slag mixed with a phosphate flux is then oxidized to synthesize rutile and form a phosphate-glass matrix which contains the impurities. Attrition scrubbing the treated slag in dilute solutions of phosphoric or sulfuric acid liberates the rutile, which is concentrated by physical methods. Tests show that synthesized rutile containing 95 to 97 pct titania responds to chlorination at the same rate as natural rutile.

Jan 1, 1973

By P. Rusin

A new bacterium, Thiobacillus cuprinus, can extract copper from chalcopyrite as rapidly as T. ferrooxidans. On solution with and without nutrient amendments and bacterial growth media were supplemented with T. ferrooxidans or T. cuprinus in shake flask studies. Both species extracted -42% of the copper using growth media. In one case, T. cuprinus solubilized approximately twice as much copper as T. ferrooxidans utilizing a seeded On solution. Thiobacillus prosperus also oxidizes chalcopyrite and tolerates high chloride concentrations. These sulfide-oxidizing bacteria are representatives of the mixed microbial community found in sulfide dumps. Rates of biological copper extraction from sulfide ores, using the native microbes, have been significantly enhanced by amending On solution with PGM.

Jan 1, 1994

By F. F. Peng

Fine Coal Cleaning Processes including froth flotation, aggregative flotation or oil agglomeration, depend upon the wettability of coal particles in the aqueous solution. The wettability of coals of various ranks, hydrocarbon oil treated coals and oil-agglomerates have been measured using film flotation, induction timer, and froth flotation. Various hydrocarbon collector dispersion techniques are used to alter the surface wettability of coal particles. Change in wettability behaviors, measured by flotation responses, due to various ranks with or without of hydrocarbon collector modification are explained in terms of surface chemistry modifications as analyzed by induction time, film flotation as well as DRIFT Spectroscopy. The relationship between the wettability of coals and collector treated coals, and floatability are discussed.

Jan 1, 1993

By Ulrich Benatzky

Rheinbraun AG, Germany, is the management company of the mining and raw materials division of RWE AG. Rheinbraun's core business and major functional area is opencast lignite mining in the Rhineland. The characteristic feature of opencast mining is continuous operation using bucket-wheel excavators, belt conveyors, and spreaders. The report gives a survey of the conveyor systems used. In addition to the general performance data of these belt conveyors, this report will deal in particular with major components, such as drive stations and individual mechanical components (e.g., conveyor belts, pulleys, gears, couplings, brakes, scrapers), as well as monitoring systems. Finally, an assessment of the conveyor systems, together with future developments, will be given.

Jan 1, 2000

By M. L. Smith

SAG mill throughput is often a bottleneck in increasing metal productivity. Improved size distribution control in the mill feed can be used to increase mill production. This can be accomplished by controlling blast fragmentation as a function of energy input and rock characteristics. Such an approach requires the integration of rock fragmentation and comminution modeling. The optimal mill feed size distribution is determined by adapting a population balance comminution model to a measure of rock hardness or fragility which is also relevant to the rock fragmentation that is achieved by blasting. The relation between the size distribution and fragility of the feed and of the mill's product and the critical size in a SAG mill is examined.

Jan 1, 1993