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It had been more than a decade since this many booths were occupied at an SME Annual Meeting, but at the 2010 meeting in Phoenix, AZ 630 booths were sold to 470 vendors from the entire spectrum of the mining and minerals industry. Exhibitors such as Metso, FLSmidth, West-Tech, ABB, NIOSH, Eriez and Resource West took their usual prominent places on the exhibit floor and were joined by newcomers such as tunnel boring machine manufacturer Herrenknecht AG, Frontier Kemper, the International Society of Explosive Engineers and more than 100 other first-time exhibitors. On the floor, one could find everything from a new pair of boots to a new career in the recruitment pavilion where some of the biggest companies in mining (Barrick Gold, Freeport-McMoRan, Newmont Mining, etc..) set up shop. The following is a look at some of the companies and products that were on display at the 2010 meeting. For information about displaying at the 2011 annual meeting in Denver, CO, Feb. 27 to March 2, contact exhibits@smenet.org.

May 1, 2010

By Lim Thi Duong, Du Duy Bui, Thuat Ngoc Pham, Chuc Ngoc Pham, Que Anh Nguyen, Hoa Anh Bui, Chi Thi Ha Nguyen, Hoan Thanh Nguyen, Bac Quang Nguyen, Kien Trung Nguyen, Dung Trung Doan, Nhiem Ngoc Dao

The microstructures and kinetics of a rich iron ore ( TFe = 65.84%) of Na Rua mine, Vietnam, used for the iron production were investigated in this study. Thermal behaviors of iron ores were well-examined by heating microscopy, thermogravimetric analysis, and differential thermal analysis. After being pelletized and then oxidatively fired at 500–1200 °C for 2 h, the pellets fired at 1200 °C (P1200) displayed a hard and dense structure with a decent compressive strength of 317.9 kg/pellet whereas those fired at 500 °C (P500) had a soft and spongy structure. The reduction of iron pellets conducted in a flow of a 60–100% CO2/ Ar gas mixture at 900–1100 °C showed significantly higher efficiency than the reduction using coal. The spongy pellets showed superior performance for the reduction in the CO/Ar gas mixture compared to the dense ones, compatible with the production of sponge iron. When mixed with an amount of coal, P1200 designed for iron production in the blast furnace demonstrated an impressive reduction activity compared to P500 and previous studies. The kinetics of pellet reduction was determined by the diffusion of substances through the solid product layers having the mathematical model of 1 − 2 3 f − (1 − f )2∕3 = kt . The microstructures of pellets during the oxidative firing and reduction were also examined by X-ray diffractometry; scanning electronic microscopy; energy-dispersive X-ray spectroscopy; and Brunauer, Emmet, and Teller method.

Jun 7, 2022

By MYRIAM FRANCOEUR, JOHN R.R. BOWLING, ADAM MCFADDEN

As duct-fan systems push the envelope of power, length and cost, their design calls for a more comprehensive technoeconomic analysis to ensure they deliver the expected results without failure and cost overrun. This work explores the numerous factors to include in the design of an extensive (semi-)rigid duct-fan system. Besides delivering a given airflow, the system must satisfy component limitations and power constraints during its lifetime. We evaluate the assumptions underlying the positioning of in-line booster fans in a long gapless duct-fan system and propose a strategy for specifying the location and blade pitch of successive booster fans to prevent system failure due to a partial vacuum.

Oct 1, 2022

By Mahmud Esad Uluer, Aaron Noble

Respirable coal mine dust (RCMD) is one of the biggest occupational health hazards for underground coal miners. Coal extraction is a main source of RCMD. To prevent challenges related to RCMD from developing, it is vitally important to limit airborne RCMD and stay within the regulatory limitations for mine operators. The flooded-bed dust scrubber (FBS), mounted on a continuous miner, is one of the most widely used dust mitigation technologies in room-and-pillar mining, but it is limited by technical challenges, the most notably being the potential to clog. In this study, the impact of mesh design and surface modification on system efficiency is examined using different vibrating, liquid-coated, stainlesssteel mesh panels in a laboratory-scale FBS.

Sep 1, 2024

By B. M. Eiter

The impact of fatigue is seen not only in its effect on the job performance of haul truck operators but also on the health of the operator and the productivity at the mine site. Its impact can even extend outside of the mine site to the health and well-being of the surrounding community (Fourie et al., 2010). In this paper, a case study of a small, surface mining organization is presented. The goal is to highlight the fatigue risk management system implemented at the studied mine site. Mine safety personnel who were interviewed discuss the changes made to the infrastructure of the mine, to administrative areas such as the number of shifts and the use of vacation time, as well as the implementation of new technology into haulage vehicles. This paper reviews how these changes are supported in the research literature.

By F. J. Sotillo

Mining in Peru is mainly concentrated on metallic and polymetallic ores of gold, copper, lead, zinc, silver, tin, iron, etc. However, little has been done to develop extensive and rich non-metallic or Industrial Minerals deposits with the exception of some silica and phosphate deposits. This paper presents the characterization and metallurgical studies for the development of a feldspar deposit. These studies showed that the special characteristics of the ore, such as high porosity, high Al2O3 content, low clays content, and sized material allowed us to obtain commercial products applying relatively simple and low cost concentrating unit operations. The characterization studies showed that the feldspar products contained no quartz and about 90% of albite (NaAlSi3O8). The 14x40-mesh size fraction product analyzed 5.91% Na2O, 22.56% Al2O3, 65.73% SiO2, 0.65% K2O, 6.50% CaO, and 0.40% Fe2O3; whereas, the 40x150-mesh size fraction product analyzed 6.22% Na2O, 24.30% Al2O3, 60.80% SiO2, 0.91% K2O, 7.06% CaO, and 0.54% Fe2O3. These products could be used for manufacturing glass, ceramics, refractory, and filters in different applications. In addition, Middlings, could be used as insulation material due to its porosity (bulk density of 0.828 Kg/dm3), analyzing 4.46% Na2O, 15.7% Al2O3, 67.2% SiO2, 2.57% K2O, 3.94% CaO, and 4.24% Fe2O3. The material showed a sphericity of 0.77, a roundness of 0.68, and acid solubility of 13.3025% on only washed and 2.72% effective for clean material suitable for use in these applications. No selective accumulation of the valuable mineral was observed at any specific size fraction. However, iron and titanium bearing impurities trended to concentrate in fine fractions (minus 70 mesh -212 µm-). Metallurgical studies demonstrated that this feldspar ore required sizing at 14x40 mesh and 40x150 mesh to render commercial products. In the case of the 14x40-mesh size fraction, the process involved magnetic separation, gravity separation, and flotation for feldspar (direct flotation) using a blend of primary and condensate amines. However, the reverse flotation for mica-biotite and iron bearing minerals was also possible using petroleum sulfonate. The metallurgical process for the 40x150-mesh size fraction required magnetic separation and reverse flotation of iron and titanium bearing minerals, the feldspar being reported in the sink material. Commercial products from this feldspar deposit for glass, ceramics, refractory, and filtration; and for the manufacturing of insulation material were obtained.

Feb 23, 2014

By K. Papke

Nine western states contain significant barite deposits, but most deposits are in Nevada, which has been the principal western producer for more than three decades. Nevada produces about 85% of the total United States production, but about one-half of the barite consumed in the country is imported. Approximately 95% of the barite is used in drilling muds. Sharply decreased oil and gas drilling, starting in early 1982, severely depressed the domestic barite industry. Other problems for western barite include long distances to the areas of major drilling, high railroad-freight rates, and increased barite imports. Bedded deposits, formed by submarine exhalative processes, account for almost all western production, and reserves are large.

Jan 1, 1983

By M. Ribeiro, P. So, P. Wong

Electrowinning is a process by which metals, such as copper or nickel, are recovered from aqueous electrolyte solutions resulting from the extraction of the metal ion from an acidic or basic leach solution. The electrolyte or “pregnant” solution is customarily forwarded to an electrowinning "tankhouse." In the tankhouse, the metal ions are deposited on cathode plates by electrodeposition and then recovered from the cathode plates. Other processes may be employed with other metals, such as nickel, zinc, among others, to produce an electrolyte from which their respective metals are obtained. During the electrowinning (electrodeposition) stage, elemental metal is plated out at the electrowinning cathode and oxygen evolves at an insoluble anode. The evolution of oxygen gas forms bubbles which entrain strong acid electrolyte, carrying it into the air above the electrowinning tank in the form of a fine mist or spray when the bubbles break. An acidic mist is generated above the electrolyte. This mist or spray then spreads throughout the electrowinning tankhouse. The acidic mist is corrosive and a health hazard and can cause extreme discomfort to the skin, eyes, and respiratory systems of tankhouse workers, especially during hot weather conditions. Polyfluoroalkyl based products (PFAS) have been widely applied as anti-misting agents in the electrowinning of metals in an acidic electrolyte. Functionalized PFAS compounds, however, have come under increased scrutiny by the EPA due to their impact on human health and the environment. There remains need for improved acid mist suppression agents for electrolysis and electrodeposition, particularly for products free of fluoroalkyl components.

Feb 1, 2023

By L. J. Warren

Recent research at the Parker Centre in Pe1ih, Western Australia, has provided opportunities to reduce gold production costs by: reducing lime costs in the carbon-in-pulp process, understanding the mechanism of selective extraction of gold over copper using ammoniacal cyanide, and increasing throughput and improving overflow clarify in thickeners. This paper reviews the work of these three Parker Centre project teams, and highlights those instances where the results have been applied to plant practice.

Jan 1, 1998

By Lewis Gordon, Alan Morrow, Aundra Nix

At the ASARCO Mission Mill, a multivariable, predictive controller was used to optimize parallel grinding circuits, improving throughput and product size. Using a dynamic model of the grinding circuit developed from on-line testing the software manipulates 4 variables to control 14 quality and constraint variables in each circuit. Traditionally, model-based control in grinding is difficult due to ore changes. This is addressed via a novel method to predict mill overload and automatic model switching.

Jan 1, 2000

By A. Mai, J. S. Wakeman

The progress results of a pilot plant study on the effects of ball top size and other mill operating parameters are reported. Test series on taconite and quartzite crude ores using a 1.7-m diam primary mill in closed circuit with a vibrating screen indicate clear trends on the improvements of mill throughput and power consumption when using larger diameter balls. Possible effects on mill liner and ball consumption as well as future research plans are discussed.

Jan 1, 1987

By Y. Luo, S. S. Peng

Several issues deserve further attention to improve subsidence prediction accuracy. These include: subsidence initiation and development over a setup entry area; subsidence development after face stop; and subsidence over chain pillar. An intensive subsidence monitoring program has been carried out over several longwall panels. A large amount of subsidence data has been collected, analyzed and solution techniques developed. In this paper, some of the measured data. data analysis techniques and the developed prediction methods are presented.

Jan 1, 1992

By Andrew F. McKown, Lewis L. Oriard

Advances in explosives engineering are moving forward in several different aspects. These include improvements and new development in explosives products, the application of these products to blasting technologies, and the study of the peripheral effects of the use of explosives, such as ground vibrations and airblast. Topics of special interest in the last several years include new explosives and detonators, cap timing, explosive casting, high-speed photography, perimeter and slope control, air decking and mathematical modeling of blasting processes.

Jan 1, 1988

By J. B. Malcolm

The discovery of tungsten-bearing quartz outcroppings in Vance County, N. C., by the Hamme brothers in 1942, made international news in the mining industry and was, in fact, one of the major ore discoveries made in the U.S. during the last 25 years. Operations began at the Hamme mine in 1942, but after 16 years of successful operation, the mine was closed down in 1958 under adverse market conditions. By that time, it had produced nearly 20 million lbs of metallic tungsten. Because of the square-set timber mining method then in use, mine operating expenses were high, actually representing 78% of the total operating expenses at the property. In timber work alone, 160 men were employed. Approximately 500,000 bd ft of timber were placed monthly at a direct supply cost of $1.00 per ton of ore mined. Late in 1959, following a slightly improved position in the tungsten market, company management decided that, by changing the mining method, the operation could be economically feasible. The major premise in this decision was that a reduction of from 25 to 30% of the mining costs could be achieved by the conversion of the mining method from square-sets to horizontal cut and fill. Reopening of the mine began in February 1960, Full production has now been reached and overall mine productivity has been doubled.

Jan 1, 1962

By R. Adams

Zirconium is the 20th most abundant element in the Earth?s crust and it most often occurs in the form of silicate (as zircon), less often in the oxide form (as baddeleyite or caldesite). Historically, the world?s production of zircon was entirely derived from mining and processing beach sands or heavy mineral sands that were being exploited primarily for their titanium content, i.e., to generate TiO2 feedstocks that would be used for making titanium pigments and, to a lesser extent, titanium metal. Zircon was then regarded as a byproduct, with the sharply fluctuating prices typical of a commodity where the supply is essentially involuntary and not truly responsive to market demand. However, in recent years, zircon has shown considerable mining investment appeal in its own right. Projects have been planned ? and some have already come to fruition ? based mainly on the zircon potential of the deposit. Booming Chinese demand for zircon to meet the requirements of the ceramic and zirconium chemical sectors has been a major factor causing zircon prices (f.o.b. Australia) to surge from US$674/t ($611/st) at [ ] the end of 2005 to beyond US$2,400/t ($2,177/st) by the end of 2011.

Jan 1, 2012

By J. O?Hanlon

The 4500 m3 blast furnace at the Redcar Works of ESC operates or, a burden of sinter and pellets, both materials being produced within the works. The early history of the furnace was given to the AIME Ironmaking Conference in 1981(1) when the burden was 65% superfluxed minter and 33% acid pellets. While ironmaking performance was adequate, it was felt that there were advantages to be gained by the use of fluxed pellets. For example, Kobe Steel had reported (2) that the rise of 30-50% dolomite fluxed pellets had enabled them to achieve better furnace permeability, higher gas utilisation, and enhanced ore/coke ratios. It appeared probable to BSC that the use of magnesia-bearing fluxed pellets would give a burden which had compatibility of softening and melting properties, i.e., fluxed sinter and dolomite pellets would result in a thinner cohesive zone because of closer matching of softening and melting temperatures, with consequential benefits on furnace stability and efficiency.

Jan 1, 1983

By F. D. Mendes, A. H. Martins

The high copper grade in the Igarapé Bahia (Brazil) gold-copper ore restricts the direct application of the classical cyanidation process. Copper oxide and sulfide minerals react with cyanides in solution, causing high leach-reagent consumption, raising processing costs and decreasing gold recovery. According to studies, a feasible solution would be to pretreat the ore to remove copper minerals prior to cyanidation. The goal of this experimental work was to study the conditions for the removal of copper from the Igarapé Bahia gold-copper ore by sulfuric acid leaching, applying a statistical approach to the experimental design. By using the Plackett Burman method, it was possible to select the variables that exhibited the largest influence on copper extraction at the sulfuric acid leaching stage. These variables were leach solution temperature, stirring speed, sulfuric acid concentration in the leach solution and ore particle size. The individual effect of these variables and their interaction influences on the experimental response were analyzed by applying the replicated full-factorial design method. Finally, the selected variables were optimized by the ascending-path statistical method, which determined the best leach experimental conditions for maximum copper extraction. The optimized leaching conditions resulted in a copper extraction of 75.5%. Keywords: Copper, Gold, Extraction, Sulfuric leaching, Optimization

Jan 1, 2003

By James E. Lawver

During 1981 the Florida phosphate industry produced more than 43 million metric tons of phosphate rock - about one-third of the entire world production and also generated nearly an equal amount of waste clay and waste clay-sized product that requires dewatering and disposal. The material balance of solids and water for a typical Florida phosphate mining operation is shown in Figure 1. Historically, the industry has impounded clay waste (about 60% below ground and 40% above ground) in earthen dams, often as large as 800 acres and occasionally greater than 60 ft. high. The dams have served the triple purpose of: 1. Dewatering initial 3% solid waste clay for process water re-use. 2. A reservoir system to minimize water discharge from the mining area and to capture and store rainwater thus minimizing deep well pumping requirements. 3. The ultimate densification and storage of waste clay.

Jan 1, 1983

By James L. Evers

Introduction There is a continuing search by government and industry for new mining methods that increase production, improve the working environment, reduce labor intensity, enhance recovery effectiveness, improve the reclamation process, streamline the flow of material, and reduce the unit cost. Hydraulic extraction and transport methods have outstanding potential in several of these areas. For example, hydraulic fragmentation produces a significant reduction in respirable dust. The inherent simplicity of hydraulic mining equipment and the resulting high reliability are recognized. Tool wear can be virtually eliminated. There is great flexibility in the size, shape, and orientation of the mineral deposit that can be mined. The cutting, gathering, and transport operation can be controlled remotely, providing more safety for workers. The threat of tool sparking and the resuiting dust or gas ignition are also eliminated. Although hydraulic mining was introduced in the US before the turn of the century, it has not gained the degree of acceptance found in other countries such as the Soviet Union, China, Germany, and Canada. The Hydraulic Mining Research program, initiated by the US Bureau of Mines in 1958, and the subsequent research by others has provided much of the basic technology required to spur the development of these methods into a viable extraction alternative. This article updates the development of hydraulic mining in the US. Particular attention is paid to monitor mining, the long-wall hydrominer, borehole mining, and the semi-autonomous mining system. Whenever the particular mining method is also being developed in other parts of the world, a brief description of the world-wide state of the art is given. Finally, allied studies designed to optimize these mining techniques are described. Hydraulic Monitor Mining Since 1958, the US Bureau of Mines (USBM), the Department of Energy (DOE), and other government agencies have funded more than a dozen programs to investigate the potential of hydraulic monitor mining. For this method, water is directed on the coal face from a monitor nozzle. Sufficient velocity is used to cause local fragmentation (Fig. 1). Coal particles are washed from the face to a trough. They are then flumed to a collection point. Oversized particles are directed through a breaker and then into the troughs. Monitor field tests were conducted in the 1960s in bituminous and anthracite coal at the following locations: • Rosylin No. 9 mine, WA (Nasiatka and Badda, 1963); • Rosylin No. 10 mine, WA (Price and Badda, 1965); • Sugar Notch mine, PA (Buch, 1964); • Thomson Creek mine, CO (Palowitch and Malinka, 1964); and • West Lebanon, PA (Fowkes and Wallace, 1968). In 1975, Ingersoll-Rand Research Inc. was awarded a two-year USBM contract to develop a continuous coal mining system using water jet fragmentation and

Jan 10, 1984

The Cutoff grade optimization is very critical to the open pit production scheduling. In case of single mineral deposits, algorithms have been developed for determining cutoff grade policy that maximizes the net present value (NPV) of yearly cash flows. For deter-mining the cutoff grade policy for projects with two minerals including stockpiles the problem becomes much more complex. The purpose of this paper is to present fundamentals of a generalized cutoff grade optimization algorithm that will maximize the NPV of a project subject to mining, milling, and marketing constraints. Benefits of the methodology developed are demonstrated on three different case studies.

Jan 1, 1997