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By P. Zhang

A multiyear, comprehensive study of flotation reagents used in phosphate beneficiation was conducted. The study involved the evaluation of pure fatty acid compounds, comparison of various anionic collectors and testing of iso-acids. Various C12 to C22 fatty acids were tested as Florida phosphate collectors. The saturated fatty acids were found to be very poor collectors when using the standard conditioning procedure, whereas the unsaturated C16 to C22 fatty acids showed fair to good phosphate collecting ability. The C18 fatty acids oleic, impure oleic and linoleic and the C20 eicosenoic acid were shown to be the best phosphate collectors. The best flotation results were obtained using Liqro GA tall oil and oleic acid. Four isostearic/iso oleic acid type fatty acid collectors were compared with a commercial grade oleic acid and with Liqro GA tall oil as phosphate collectors using standard laboratory conditioning and flotation procedures. The most selective collector evaluated was Century 1108, a high isostearic acid-type reagent. However, it was concluded that this excellent-performing reagent was too expensive for commercial use. Overall, the most promising reagent was probably Century MO-5. This collector is essentially an iso-oleic acid/stearic acid mixture (not isostearic acid), and it costs much less. This program laid a sound foundation for developing single collector, all anionic flotation processes.

Jan 1, 2009

By D. J. McKee, D. M. Wiseman

The usefulness of simulation as a technique for metallurgical process design and optimization studies has been greatly extended over the last few years by the development of a number of general purpose simulation packages. The packages, or simulators, all have the common objective of presenting the mathematical models and simulation methods in a form which is readily usable by plant engineers and metallurgists. To date, most simulators have been concerned with steady state simulation, but packages capable of dynamic simulation are now becoming available. The paper outlines the essential features of versatile steady state and dynamic simulators. Typical applications are presented by considering examples of design and optimization studies. Limitation on the use of simulators are also presented.

Jan 1, 1991

By A. E. Ketler

Conventional Atmospheric Monitoring System (AMS) installations for monitoring CO, CH4, O2 and air-velocity throughout underground mines are usually relegated to a modest 3-5 mile extent and with data communication speeds confined to a ponderous 1-5K baud range. New US-MSHA and state regulations require fast reporting of unsafe conditions, and the old 20-30 minute updates are no longer acceptable. To communicate farther and faster has always been a problem, because data reliability degenerates with excessive distances and high speeds. Because of this, very large mines often resort to costly optical-fiber media, using expensive OF cables and repeaters to obtain the necessary coverage. This entails high initial cost, as well as high maintenance and downtime costs to repair or replace broken optical fibers. Rel-Tek has pioneered with its DX-Bus communication data highway, which uses inexpensive twisted-pair telemetry cables, which can now communicate well into the 20-mile extent of the largest mines -- normally a brick wall for low-tech AMS systems. This extended range, enables the use of twisted-pair cables and provides a low cost alternative to OF systems. This paper discusses the DX-Bus, and its latest accomplishment, the ?B-LINK,? a unique high-speed communication repeater that maintains the 19.2K-Baud data rate. On-going innovations to our workhorse Millennia-DX computer software have kept pace with this extra speed/distance phenomenon, resulting in a dually-optimized AMS package: both hardware and software. Cost savings are substantial, and at no sacrifice of reliability ? nearly always at 100%. Sensor updates are measured in seconds, not minutes and hours. Twisted pair copper cable is cheap to purchase and install and a breeze to maintain. Rel-Tek uses the B-LINK's wide branching capabilities to enable the AMS to extend 20-miles both far and wide. Actual experience in large US coal mines -- both longwall and continuous mining operations -- confirms the large mine performance. The ventilation and safety benefits to the mining industry are immeasurable.

Jan 1, 2009

By J. C. Motz

The advantages of producing a fine mill feed have been recognized for many years. The extent to which fine crushing can be carried out will vary and depends on the ore characteristics, plant and crusher design. Unfortunately, the ore characteristics are generally beyond our control, so the concentration of effort lies primarily on the plant arrangement, equipment design and operation Where fine crushing should stop and grinding begin is controversial and is influenced greatly by personal opinions and experiences. Often, this break point will be different if consideration is being given to a new plant in comparison to a modest expansion. Most new plant designs employ the largest and most efficient equipment. The modification of existing plants becomes more complex because of the space requirements and the related equipment already in operation. Fine crushing is, of course, a relative term. Obtaining a final crusher product of minus 3/4" is commonplace today and can occasionally be obtained in an open circuit final crushing stage.

Jan 1, 1980

By Robert E. Baker

Cortez Gold Mines, the United States' third largest primary producer of gold, commenced continuous operations on January 10, 1969. The decision to proceed to production was made in March of 1968 and construction of the mill and stripping operations for the pit began in April and July, respectively. Anomalous conditions on the slope of Mt. Tenabo along the Roberts Mountain thrust fault zone were discovered by the U.S.G.S. while conducting geochemical surveys in the old Cortez silver district. Following the discovery of gold an intensive program of drilling was organized. Drilling outlined an orebody with 3.5 million tons of ore averaging 0.28 ounces of gold per ton. It was on the basis of this reserve that a 1700 t. p.d. cyanide plant was designed. Needless to say, with such a limited ore reserve, economies in design and construction would have to be observed. Cortez Gold Mines is a joint venture with American Exploration & Mining Co., The Bunker Hill Company, Vernon F. Taylor, Jr., and Webb Resources, Inc. , as partners. American Exploration & Mining Co. is the operating partner.

Jan 1, 1969

By John G. Watson, Judith C. Chow, Richard T. Egami, Daniel L. Freeman

A methodology for apportioning ambient PM-10 (particulate matter) concentrations to sources is described and applied to PM-10 concentrations in the vicinity of a large gold mining operation. With this methodology, samples representative of particulate sources such as desert overburden, diesel equipment, milling operations, road surfaces, and others are collected and analyzed to derive chemical source profiles. Ambient 6-hour PM-10 samples collected downwind from the mine are analyzed and used with the Chemical Mass Balance model to apportion ambient PM-10 among the various sources. In an example application, primary contributing source types are found to be desert overburden and diesel equipment. Relative contributions vary according to time of day, with diesel equipment frequently being the dominant contributor during nighttime periods.

Jan 1, 1991

By Edwin F. Shorey, Richard F. Coon, Steven B. Fradkin

Crosstown Interceptor Phase IA is the first deep tunnel element of the Milwaukee Inline Project. The tunnel contract includes 6,492 meters (m) of 9.1-m-diameter tunnel, two access shafts, and partial lining for structural purposes. The work also includes grouting to be performed as directed by the engineer to provide groundwater infiltration control in lined and unlined reaches of the tunnel. This paper summarizes infiltration observations, progress of the grouting work, and its potential application to the remainder of the Milwaukee project.

Jan 1, 1987

By Rob Dorey

The disposal of mine waste continues to be one of the main controlling factors in the economics and feasibility of project development. Particular to gold and precious metal mining, waste disposal is further complicated by the environmental and political implications of the use of cyanide. Regulatory compliance criteria have partially dictated and can be anticipated to further dictate the approach and methods of tailings disposal. To develop practical, economic, and environmentally acceptable tailings disposal systems within these criteria requires the use of common sense approaches and the application of available technology. Waste disposal is typically considered during the pre-feasibility stages of project evaluation. At this time, the main emphasis is on the economics and practicality of extracting the metal values from the ore. Frequently, the result of this is that the nature of the tailings and the ability to dispose of the tailings is prejudged. It is also frequently the case, however, that during the feasibility stage and project permitting, the requirements for tailings disposal become paramount.

Jan 1, 1998

By Thomas J. Martin, James W. Martin, Paul F. Martin

The conveyor belt is the basic building block of a broad range of material handling applications in modern mining systems. The mining plans and site conditions dictate basic system requirements but this is only a part of total design evaluation. The total system in the typical mining situation can encompass all the activities from the excavators at the mining face to the processing plant, site loadout facilities and/or a power plant. The number of alternative configurations which must be evaluated including subsystems and components is limited only by analytical time and creativity. The constraints and issues which must be addressed continue to expand, driven by reliability, environmental impact and cost competitiveness. All of the system requirements must be translated into specifications for costing, final design and construction.

Jan 1, 1993

By Oscar Letelier Gonzalez

The goal of mine planning is to determine "the best" strategy to exploit an ore deposit during its workable life. Such strategy must be consistent with the objectives of the company and must be subject to the contraints imposed by economical, physical and geological conditions. Mine planning process may be broken down into three categories, according to the planning horizon: Long range, Short range and Operational. The shorter the scope of planning, the higher the level of details and the lower the degree of freedom associated to each plan. A long range plan defines the economic limit of mining at the mining life end of the deposit; it also can be used as an aid in the evaluation of the economical potential of a mineral deposit and as a guide for short range plans.

Jan 1, 1979

By James J. Anthony

High-angle in-pit conveying is an idea that is being seriously studied by a number of important mining companies in North America. Its application in coal, iron ore, and copper mining is expected to reduce mine operating costs considerably compared with the conventional discontinuous methods, such as truck haulage, which are fuel, labor, and maintenance intensive. Therefore, a mine introducing high-angle in-pit conveyors will gain a competitive advantage over mines which continue to use conventional haulage. While the capital outlay for in-pit conveyor systems obviously varies depending on pit depth, the angle of incline, and the capacity required, it generally will not exceed that of truck haulage when all Factors are taken into consideration. These factors include the cost of excavation, as measured in relation to the volume of minerals mined, the cost of building truck ramps and roads, and the capital outlay for the trucks and maintenance facilities. In many cases, in Fact, the capital outlay will be less than for truck haulage. This cost advantage will best be realized by new mines, whereas in existing producing mines the switch from truck haulage may involve the abandonment of a substantial capital asset.

Jan 1, 1983

By J. A. Marts, R. C. Gilmore, Jr. Bogin, S. A. Saki, J. F. Brune, J. W. Grubb

"Colorado School of MinesResearchers at Colorado School of Mines (CSM) have developed computational fluid dynamic (CFD) models to study gas distributions and explosion and fire hazards in longwall gobs. In underground coal mines, methane continuously emitted from surrounding strata mixes with air from active mine workings and may form explosive gas zones (EGZs). Some western United States coal mines are also prone to spontaneous combustion (spon com). Insight into oxygen concentrations within the gob is crucial for assessing spon com hazards and mitigation strategies. Nitrogen injection used in conjunction with progressive gob sealing can reduce EGZs and spon com hazards by forming a dynamic seal that separates the methane in the gob from the air that ingresses from the face. This paper describes CFD modeling simulations studying the formation of such dynamic seals by optimizing the nitrogen injection locations. The impact of nitrogen on oxygen ingress and formation of EGZs is discussed. Optimum nitrogen injection quantities and injection locations were determined. Dynamic seal formation is most effective if the headgate nitrogen injection locations are split between the first crosscut inby the face and a second location about 300 m (1,000 ft) further inby. INTRODUCTION Underground longwall coal mine ventilation systems are designed to dilute hazardous gases and to provide breathable air to miners working in the area. Methane gas is liberated as the mining process extracts the coal and disturbs the surrounding strata. Methane mixes with the ventilation air and often produces explosive gas zones (EGZs) within longwall gobs (Brune 2013). Past CFD modeling research of underground coal mine ventilation systems has shown the effects of face air quantity on EGZs (Worrall 2012) and nitrogen injection to control spon com (Balusu et al. 2005; Ren et al. 2012; Ren et al. 2011; Smith and Yuan, 2008; Yuan and Smith, 2014). Other modeling approaches include network ventilation models of oxygen ingress (Dziurzynski and Wasilewski, 2012), and coupled Linear Network CFD algorithms (Wedding 2014). In a project sponsored by the National Institute for Occupational Safety and Health (NIOSH), CSM researchers are using Fluent®, a CFD software package by ANSYS, Inc., to model gas compositions and flows in underground longwall gobs. Figure 1 shows a progressively sealed gob with a U-type ventilation system in a three entry development. As the longwall advances, seals are constructed along the headgate in the crosscuts between the center entry and the gob. Additional gob isolation seals are built to block off the headgate entries inby the face. Nitrogen is injected through the seals in the first two crosscuts on the headgate side and at the first crosscut inby the face on the tailgate side, as shown in Figure 1."

Jan 1, 2015

By Sathit Tandanand

Geological differences among various coalfields restrain the applicability of subsidence prediction using existing European methods. To modify these methods for domestic conditions, the Bureau of Mines, U.S. Department of the Interior, developed a method of assessment to evaluate the lithological effects on subsidence in the Northern Appalachian basin by examining data collected from 16 longwall panels in the coalfield. The assessment is partially completed, and the results to date show that the ratio of maximum subsidence to the extraction thickness, known as the subsidence factor, can be expressed in terms of the width-to-depth ratio by a simple exponential equation which has a coefficient tentatively considered as the subsidence index. This index varies with the lithology of a particular site and can be expressed in terms of the percent distribution of weak and strong rocks in the overburden.

Jan 1, 1982

By Paul Javor

Optimization of a process is achieved by selecting, 'from all the known options, the most beneficial method of obtaining a product. It is rare that the optimum process is arrived at by conventional methods, because of the great amount of time required for developing and comparing all the options. On the other hand, it is now possible, by means of an optimization program based on special mathematical formulas involving an algorithm and implemented by a computer, to plot the optimum process realizing considerable savings and in a reasonably short time. The flow sheet arrived at in accordance with the optimization program described in this paper investigates and develops all the possible options and, with the aid of the computer, makes it possible to select the most economical ore beneficiation process. The options in an ore beneficiation process are all the possible trajectories that can be traced through the particle sizes to which the ore is reducible in the extraction of its valuable minerals. Although an ore can have a wide range of composition and several valuable minerals that can be extracted, this paper is concerned with the special case in which only one mineral is extracted from the ore and in which the maximum allowable percentage of impurities in the end product is defined.

Jan 1, 1971

By Randy Ynchausti

ERIC GUTIERREZ, Knowledgescape: Our next speaker is Randy Ynchausti. He's the director of development, Knowledgescape systems division, of EIMCO Process Equip- ment Company. The title of Randy's talk is "An Expert Control System for Phosphate Beneficiation." RANDY YNCHAUSTI: System integration. How does the systems integrator survive when caught between plant engineers, plant management, and third-party engineering firms, and stay within the budget of the corporate goals? I'm not sure that anyone knows how to do all of that on one project. Results are critical when we talk about how systems integrators work with operating people, how the operating people want systems integrators to work with them, and how both groups work together so that at the end of a project, you have been provided with solutions that meet your needs and solve your problems at a fair price. How does the integrator's role change when working with different types of professionals, such as plant managers, plant engineers, engineering firms, or other system integrators? Finally, what is the dynamics of people working with machines and providing services and solving needs? The average number of employees per pound of copper processed has decreased significantly during the past 15 years. I would dare to generalize and say that the average number of employees per whatever unit of measure we have in whatever industry we work in has decreased over the last 15 years. From a system integrator's perspective, there are some clients who lack a bit of internal expertise as corporate downsizing occurs, and that's one reason why we go out to system integrators or third-party vendors and buy things from them to solve our problems. Downsizing really amounts to savings, but more than that, I think Brian expressed this and I agree with him, it also amounts to a cost. Unfortunately, most of us count the savings and none of us count the cost in that approach. It's easy to count the savings, which is one reason why we count it so quickly. Maybe that also accounts for why we set our pencils down so quickly after we get that dollar value. Maybe we should pick that pencil up every once in awhile and refigure the expense, the cost to us, and determine what we're going to pay during the next year or two or three in losing that expense, or that staff. A broad experience base accumulated over projects at various plants helps system integrators to provide services to clients. This experience enables the system integrator to

Jan 1, 1998

By Michael J. Martinson

Mine ventilation has been evolving as a separate field of study since the middle of the nineteenth century, and some practitioners might assert that mine ventilation has come of age as a discrete field in the last decade or two. Certainly the extensive literature now available on many facets of the subject, international congresses, the phenomenal upsurge of interest in mine ventilation in the United States of America since the passage of the 1969 Federal Coal Mine Health and Safety Act, and the existence of a virile mine ventilation society in South Africa with its own monthly journal all point in this general direction; on the other hand the lack of a rational design philosophy for ventilating mines suggests that mine ventilation may still be on the threshold of maturity. To generalise, many mines are still ventilated simply to comply with arbitrary statutory regulations, or with some ill- defined notion of reducing the risk of injury associated with the atmospheric environment in mines. Hazards in this category include oxygen deficiency, toxic gases and particulates, pathogenic gases and aerosols, explosive gases and dusts, and extreme climatic conditions. Although many mines are ventilated to abate the risk of a specific injury, there is inevitably a spectrum of latent and patent atmospheric hazards in every underground mine. The writer (Martinson, 1976) has previously drawn attention to the dearth of material on mine ventilation design in textbooks and technical journals, and to the overly simplistic approach sometimes adopted in the limited work published on the subject. The available material undoubtedly contains useful technical data and persuasive views, but seemingly could not be used to demonstrate the rational engineering approach to mine ventilation design advocated in the present paper. The range of papers presented at the 1975 and 1979 Congresses, and the diverse interests and affiliations of delegates, emphasize the multidisciplinary nature of mine ventilation. Easily recognisable topics include: Fluid mechanics Thermodynamics Heat transfer Flames and combustion Aerosol physics Radiation physics Geophysics and geomechanics Occupational diseases Epidemiology Industrial physiology Despite these heterogeneous connections there can be little doubt that mine ventilation is fundamentally an engineering field and not an off-shoot of some other branch of applied science. The distinction is important because mine ventilation has essentially developed as a form of ad hoc trouble- shooting, and in the process mining engineers have relied extensively on the assistance of experts drawn from other fields. Thus historically there has been limited scope for the application of rational design techniques, and personnel enlisted from scientific disciplines may not have had any previous experience in the intricacies of engineering design.

Jan 1, 1980

By William Petruk

Performance assessments are carried out to monitor operations, to evaluate performance and to identify processing problems. The assessment involves collecting and analyzing representative samples from critical points in a flowsheet and interpreting the data. Sample analysis techniques include chemical analyses, mineralogical investigations, mineralogical analyses, and materials balancing. Chemical analyses provide the lowest cost assessment and should be used liberally, particularly in monitoring a process. Materials balances performed on chemical assays for a suite of samples are used as a first step in evaluating a process. Mineralogical investigations are more expensive than chemical analyses but need to be used only at the beginning of mining and metallurgical operations and as a second step in assessing processing problems. Quantitative mineralogical analyses combined with materials balancing provide the most complete performance assessment, but the procedure is expensive. On the other hand, the assessment has the potential of a large payback when carried out where warranted.

Jan 1, 1991

By T. V. Subrahmanyam

Unlike coarse particles (40-50 µm), the fines (<10 µm) have low collision efficiencies with gas bubbles in flotation process. Among the alternative methods for recovering the fines are their aggregation with coarse particles (carrier flotation) and flocculation of the fines alone (shear-flocculation), prior to flotation. In any case, hydrophobic aggregation is the mechanism involved though the technique is known by different names in literature. This paper deals with theory and state-of-the-art of particle aggregation. To illustrate the dependence of aggregation on particle hydrophobicity, charge and, in turn, the sheer force, the results of quartz-DDACI and galena-xanthate systems are considered. In the flotation of complex ores selectivity is achieved by chemical control and aggregation of particles of the same species is analogous to that; however, more work is necessary on ores for a better understanding of the pulp chemical aspects from the view point of selectivity in aggregation. For a few ores, the results of earlier workers confirm improved recoveries of fines by aggregation prior to flotation.

Jan 1, 1997

By J. R. Walls

The United States potash industry had its beginning in the early Colonial days. Potash was initially manufactured by leaching of hardwood ashes in large iron pots. Production of potash was recorded as early as 1631 in New Hampshire, and in Maine a few years later. According to the census of 1850, the production of potash was America&apos;s most thriving chemical industry and, at that time, 569 plants were reported producing potash from wood ashes. Interest in potash was so great prior to the 1800&apos;s that the very first United States patent, signed by George Washing- ton, was granted for the production of potash on July 31, 1790. A new era for the production of potash began when potash was discovered by the analysis from a brine well in 1839 near Stassfurt, Germany while exploring for salt. The predominant use of potash at that time was in the chemical industry rather than agriculture. The discovery, by Justice von Liebig in about 1858, that potash salt contributed greatly to the essential plant food in soil opened up an enormous potential market for a suitable potash material.

Jan 1, 1985

By G. E. Vaninetti

During its modem era, the southern Powder River Basin (PRB) in Wyoming has grown from meager origins in the early 1970s to become one of the most important coal-producing regions in the United States. In 1993, production and sales of southern Powder River Basin coal exceeded 190 Mt (209 million st), or about 20% of the US coal industry. Despite the remote location of the PRB relative to its potential markets, most coal industry observers anticipate continued strong growth to meet utility compliance plans for Phases I and II of the Clean Air Act Amendments (CAAA). This article is an overview of supply and demand issues concerning the marketing of southern PRB coal. It reviews the events leading up to the recent run on spot coal and offers a forecast of demand and prices.

Jan 1, 1994