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By J. A. Herbst

It is widely recognized that Semiautogenous Grinding (SAG) circuits require the use of effective process control techniques to achieve their full processing potential and to protect them from the harmful effects of overloads and grind-outs. This requirement is even more essential as the variability of the ore being processed increases. The new Chino Mines Company concentrator located near Santa Rita, New Mexico started operation in June of 1982. At least eight major rock types are mined and milled. Ore hardness, feed size, and specific gravity are quite variable. Typical feed rates per grinding line are 850-900 tph but extremes of 260-1200 tph have been encountered. Normal feed rate variations of between 400 and 1100 tph are encountered on a weekly and sometimes daily basis. Feed size varies with rock type from a maximum of eight inches for the harder ores to two inches for the softer ores. One somewhat unique characteristic of the Santa Rita ore body among major copper mines is the wide variation in ore specific gravity. Specific gravities of the major rock types range between 2.7 and 3.6. The specific gravity variations are due to large changes in magnetite concentration throughout the pit. The result of this is large variations in SAG mill throughput which can have a harmful effect on downstream ball milling and flotation performance. Due to these wide fluctuations in ore characteristics, it was recognized soon after startup that successful operation of the grinding circuit and the plant at large was dependent upon the development of an effective automatic grinding control strategy. Research at the University of Utah has suggested that control based upon critical but difficult or costly to measure variables would improve automatic control performance. A project team made up of the Chino process control staff, Kennecott's Process Control department and the University of Utah Metallurgy Department was established to assess these concepts at Chino. This paper describes the development and on-line plant implementation of an Extended Kalman Filter that uses simple models of the SAG milling process, to predict the volumetric loading, the rock mass, the water mass, and the ball mass within the SAG mills at Chino. The on-line estimation of these parameters is the first step in the development of an integrated SAG mill/ball mill control strategy which is hoped to L eventually maintain the grinding circuit at its maximum capacity, while balancing the grinding load between the SAG and ball mills. Examples of long term estimation with the models and filter are shown for typical operating conditions as well as a SAG mill overload and grind-out.

Jan 1, 1983

By C. R. Kuhn

From 1968 to 1975, most work in surface modification of inorganic materials involved silane coupling agents. A silane coupling agent can be described simply as an oganosilicon chemical having a general formula RSi-X3 wherein the R group is attached to a silicon in a thermally and hydrolytically stable manner, and X is a hydrolyzable group usually having an alkoxy functionality. About 1975, Kenrich Petrochemicals brought into the market place titanate coupling agents. Titanate coupling agents usually consist of one alkoxy group and three functional groups attached to a central titanium atom. Zircoaluminates became available in about 1982. Zircoaluminate organometallic coupling agents, which vary principally in their respective organofunctionalities, arise from a basic technology in which two different types of organic ligands are selectively bound to a low-molecular weight zircoaluminate backbone.

Jan 1, 1995

By D. P. Gold

Major sources and reserves of Cb/Nb, Ta, REE, Y, Sc, Zr, Hf, Cu, apatite and vermiculite may be concentrated in primary and secondary minerals associated with different stages and depths of emplacement in carbonatite complexes and kindred alkalic intrusive rocks. Exploration targets include: apatite and pyrochlore (Nb) in the plutonic and hypabyssal core and ring-dikes: bastnaesite (REE), strontianite, barite and fluorite in hydrothermal veins and cone-sheets (subvolcanic setting): thortveitite (Sc,Y) and vermiculite in metasomatized aureoles (fenites): high grade eluvial deposits of apatite and pyrochlore, and secondary REE, Nb, Ti. and V-minerals in supergene and weathered zones.

Jan 1, 1991

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 R. S. Kalyoncu

Materials demands by the advancing process technologies, desire for higher performance and durability, and improved efficiency in combustion processes, such as applications in heat engines, heat exchanges, and batteries have added to the driving force fueling R&D efforts for the development of components with the combined characteristics of metals and non-metals. These new materials involve refined and specialized microstructures that can lead to improvements in the performance characteristics and durability new technological applications require. Fabrication and sintering methods, once believed to be sufficient, alone, have been found to be inadequate in the manufacture of such advanced components. Realization of the importance of the starting powders has led to efforts to produce materials of ultrahigh purity and ultrafine particle size with very narrow particle size distributions. Such powder characteristics are essential for the fabrication of components with high density and with the desired mechanical, electrical, or magnetic properties called for by the specific application. Novel ultrafine and ultrapure powder preparation techniques are discussed and effects of impurities on the powder characteristics, particle size and morphology, sintering behavior and properties of the finished product are elucidated.

Jan 1, 1992

By R. A. Deju

The Basalt Waste Isolation Project of the U.S. Department of Energy is a part of the National Was re Terminal Storage Program. Its mission is to assess the feasibility of siting a nuclear waste repository in the basalt formations which underlie the Hanford Site of the U.S. Department of Energy. The progress in all program areas is summarized in this paper. Activities conducted to date have led to the identification of possible repository candidate sites within the Hanford Site.

Jan 1, 1981

By Richard H. Johnson

The Castle Mountain Mine (CMM) is located in the eastern por­tion of San Bernardino County, Southern California, 70 miles south of Las Vegas. The CMM is a joint venture between Viceroy Gold Corp. (75% and operator) and MK Gold (25%). The CMM initially started gold production with an 8,000 tpd cyanide heap leach operation in February, 1992 when the first ore was crushed and delivered to the leach pads. Even during construction and commissioning, design work was under way to engineer and construct a 1,200 tpd Mill circuit to process the higher grade fraction of the ore through use of pulp agglomera­tion. The need for a grinding circuit became evident with the quantity of high grade material delineated during drilling and the amount of visible gold that the geologists were finding in the drill core and R.C. cuttings. Viceroy did not want to stack the higher grade ore on the heap, and it was clear that permitting a tailings pond would, at best, be a long drawn-out affair. An alternative to a tailings facility had to be found.

Jan 1, 1996

By Alexander N. Winchell

"Location. The Cuyuna iron district extends from the region of Kimberly, near the Center of Aitkin County, Minnesota, south-westward through Deerwood, Ironton, and Brainerd, across Crow Wing and Todd counties, across the Mississippi River, and for an unknown distance farther southwest in the same direction. It is known that the Huronian rocks, in which the ores of the Cuyuna district are found, reappear near the western border f Minnesota, but no ores have been found in this region. The district has a length of more than sixty miles, but the more important portion as now known 'is confined to Crow Wing County in an area which is less than thirty miles in its longest dimension. The commercial headquarters for the district are in the city f Brainerd, on the Mississippi River.History. The discovery of iron ore in the Cuyuna district was accomplished with no aid from surface outcrops, but solely through the use of the dip needle. The mantle of glacial drift overlying the iron formation varies from twenty-five to 359 feet in thickness, and it was by means f the magnetic attraction of the iron bearing rocks that their presence was discovered with the dip needle by Cuyler Adams, about 1895. The general geologic map of Minnesota, published by the State Geological Survey in 1909, showed the extension of the Huronian rocks of the Mesabi district passing through this area. Two years later, Leith published a sketch showing the hypothetic extension of the iron bearing formation through the same area. The first drilling was done in 1903, near Deerwood, Minn., by Cuyler Adams, and exploration was continued to the present time in increasing amount. The Northern Pacific Railway extends throughout the length of the district and affords an easy outlet for the ores. The Soo Line Railway completed a spur into the district in 1910. Both roads carry the ore to the docks at Supe¬rior, Wis., the average haul being about ninety miles. Shipments began in 1911, the Kennedy mine being the first producer. By 1918, the number of shippers reached twenty-seven, with a total output of nearly two and one-half million tons for that year."

Jan 1, 1920

"Replacing the century old rail tunnels that run beneath the Hudson River and carry about 200,000 passengers per day between New York to New Jersey has been a high priority for many years. But after Superstorm Sandy hit the east coast of the United States in 2012, the urgency to replace the tunnels increased dramatically. The Hudson Tunnels project is one of nine projects that make up the larger $30 billion Gateway Project. The Gateway Project has been called the most urgent infrastructure program in the country and the Hudson Tunnels is the most critical part of the project, as it will build a new rail tunnel under the Hudson River and rebuild the existing and deteriorating North River Tunnel that connects New York and New Jersey.“Superstorm Sandy proved the level of resiliency of the tunnels, which was not very good,” Amtrak deputy chief engineer structures James Richter told attendees of the George A. Fox Conference in New York City on Jan. 23. Age and corrosive salts deposited by flood waters from the storm in 2012 have affected interior concrete and copper wiring in the tunnels. “Since then, things have been deteriorating and getting less reliable.”Richter, along with Mohammed Nasim, senior director engineering design, both with Amtrak, spoke at the 2018 George A. Fox Conference where more than 350 tunneling and underground construction professionals attended the conference at the Graduate Center of the City University if New York to share insights about the complexities many of them face on daily basis.Under the theme of “Managing construction of complex underground projects: Strategies for tunneling in populated areas,” the one-day conference featured presentations from some of the top minds in the tunneling and underground construction industry. The presentations touched on everything from the highly technical challenges of constructing tunnels through changing geology while working beneath cities and rivers, to navigating the complex financial issues and contracts that come with the projects that have many stakeholders.All of those challenges, and more are part of the Hudson Tunnels project. It is one of the best examples of the full complexities of a complex tunnel project, with the added pressure of securing funding from state and federal government entities under an increasingly tight deadline."

Jan 3, 2018

By N. Abdel-Khalek, A. Youssef

The tailings from beneficiation of Florida phosphate ore contain considerable phosphate values. These tailings are currently discharged into large disposal areas. More than three million tons of P2O5 are discarded with the phosphatic slimes (clays) in Florida each year. These phosphatic clays not only create one of the most difficult disposal problems in the mining industry, but also represent a tremendous loss of P2O5. As the quality and quantity of Florida’s phosphate reserves diminish, recovery of phosphate values from these wastes becomes more vital. This will also significantly lengthen the life of these important phosphate resources. Thus, it is the goal of this study is to recover more than 80% of the phosphate values in phosphatic clays. A systematic study to characterize samples taken from inactive disposal area has been conducted. The data suggest that natural segregation takes place in the settling pond. In other words, coarser particles settle closer to the feeding point of the pond. Flotation tests were conducted using the +325 mesh fraction of samples obtained from sites close to the feeding point (sample# A) and further from that point (sample# B) and (sample# C) which is even further away from the feeding point. The results show the following: Sample# A gives the highest grade and recovery, followed by that of # B and then of # C. There is a great potential to upgrade sample# A where concentrates of high grade (68.9-70.1 % BPL or 31.5- 32.1% P2O5) and recovery (~86.6-95.4 %) can be obtained under the investigated operating conditions (1.0 – 2.0 kg/ton sodium silicate and 1.5—3.0 kg/ton collector mixture of fatty acid and fuel oil). The mineralogical and chemical analysis of all samples is presented in this paper for comparison. Only in this paper, the flotation data of (site # A) are discussed below.

Jan 1, 2002

A new fluid bed lime calcining plant is converting high quality limestone into quicklime at the Cape Lime facility in Vredendal, South Africa. The plant was supplied by Metso Minerals. Cape Lime, established in 1946, operates two limestone and dolomite mines in South Africa. The high quality Vredendal limestone deposits are suitable for the production of lime for water treatment and for manufacturing precipitated calcium carbonate.

Jan 1, 2003

By Morgan M. Sears

The stability of gateroad pillars is crucial in deep-cover longwall mining, especially during transitions to wider panel layouts. This study evaluates the transition from a 700-foot to a 1,000-foot panel layout with an inter-panel barrier in a deep-cover longwall mine in Southwestern Virginia to identify a configuration that enhances stability and reduces operational risks. Using the LaModel program, three pillar configurations were simulated to assess their performance based on stress distributions and pillar safety factors. These included the previously used 4-Entry Yield-Abutment-Yield layout, the current 3-Entry Yield-Abutment layout with a 220-ft inter-panel barrier, and the proposed 3-Entry Yield-Yield layout with a 320-ft inter-panel barrier. The findings of this study suggest that the proposed 3-Entry Yield-Yield pillar layout is more effective in managing stresses in deep-cover mining environments. By optimizing pillar placement and improving load management, this layout could positively impact mineworker safety and health. The study underscores the importance of advanced simulation tools in developing innovative solutions to address the challenges of modern longwall mining operations.

Feb 1, 2025

By Michael J. Shulman

Outcrops of the Nubian Sandstone Series cover approximately 180,000 km2 in southern Egypt. Within the series, oolitic iron ore beds occur. The only comprehensive information available on stratigraphy of the iron beds is for the area east of Aswan, otherwise information is exiguous, sparse or unreliable. Based on this low level of information, the iron potential of the Nubian Sandstone Series was assessed and an exploration strategy formulated specifically tailored to the assessment. The area covered by the Nubian was divided into five regions, each comprised of 100 cells. A spatial distribution, i.e. negative binomial, was assumed adequate to describe the number of targets per cell and was indirectly calculated using a compound poisson distribution. Estimate of the only unknown parameter - the average number of targets per cell - implicitly/explicitly incorporated available geologic and economic information into the assessment. A probability distribution for the number of targets per region was then derived from the cell probability distribution. An allocation model based on the regional probability distribution assessment as well as on an estimate of the exploration effectiveness and on the exploration budget determines the optimal time to be spent in each region.

Jan 1, 1986

By Mike Wardell-Johnson, Chris Campbell-Hicks, Craig Bitmead

Faster, simpler, cheaper and more accurate cyanide ex­tractable gold procedures are now available for grade control assay. Cyanide 'bulk leach extractable gold' or BLEG assays have previously been seen as desirable, due to the large sample size that can be treated, but not in common use due to the 24hr total assay time required. Sample sizes from 50g to several kilos can now be accurately assayed in less than 4 hours total time with the larger sample size increasing accuracy, without loss of precision, while greatly reducing the 'nugget effect' or coarse gold bias. Typical assay size is 200g, equivalent to 4 x 50g Fire Assays or 10 x 20g Aqua Regia Assays. Ongoing modifications and refinement of the procedures and reagents used also indicate applicability to the treatment of coarse gravity gold where substantial savings in both capital and operating costs for these circuits are possible. The successful use of this cyanide assay at the Bannockburn and Windine Well operations are cited to-gether with a compre­hensive comparative testwork program by Newcrest. Testwork at Gidgee and Lynas Gold operations is currently being initiated. Other operations using the method include Red Dome and Kidston; with Placer(Granny Smith) and PMA's Palm Springs operations to commence shortly.

Jan 1, 1995

By Terry S. Maio

In 1978, Ozark Lead Company made the decision to expand the capacity of its mine/mill complex by 33%. The objectives of the expansion were to (a) increase mine' production capacity by 1816 tonne/d(2000 TPD), (b) increase lead metal pro¬duction by 21,790 tonne/y (24,000 TPY) and to (c) construct new facilities and/or modify exis¬ting equipment to accomodate the increased pro¬duction. The intent of this paper is to give a brief explanation of the equipment installed and the overall production and metallurgical benefits-realized from this expansion. The expansion was completed in the second half of 1980 with all equipment debugging and fine tuning completed by the first' quarter of 1981. The concentrator modifications and improvements were basically restricted to four areas: (1) materials handling, (2) automation: of the mill grinding circuit, (3) the increase of flotation capacity, and (4) concentrate dewatering.

Jan 1, 1983

By Edmund H. Warner

Any city dweller who has walked alone along a remote mine passageway has to be impressed by the eerie silence - the total absence of noise except for ones own breathing and scuffing of boots on the bottom. An underground mine can have tremendous contrasts, from complete silence to the ear piercing clatter of percussion drills working on the mine roof. Noise in underground mining machines is both useful and detrimental. Without characteristic noises that are recognizable to miners, operators would have a more difficult job operating their machines. Noise serves as a warning of approaching machinery, and changes in noise give indication that breakdowns may occur. But excessive noise is a health hazard. In recognition of this fact, our Congress included noise exposure as a part of the "Coal Mine Health and Safety Act of 1969". As Fig. 1 indicates, allowable noise exposure is established by specifying a time duration permitted at different noise levels. This is the well known "Walsh-Healey" criteria which governs noise exposure in many industries.

Jan 1, 1977

By L. B. Hales

Expert control of grinding and flotation plants has been successfully used in the minerals industry since the 1970?s. The earliest of these systems were written in a hard-coded fashion in FORTRAN, BASIC or Pascal. Second generation systems were built using the first experimental expert system shells that were being developed in the artificial intelligence community. Later systems were deployed in expert system shells designed for real-time processing plants that also included the ability to model the process with neural network models and optimize setpoint selection through the use of genetic algorithms. Significant performance increases have been achieved using these systems, but in general, they suffer from the static nature of their rules and to a degree the process models also. Typical improvements quoted in the literature suggest throughput rate increases of 4 to 8 percent and recovery increases of 1 to 4 percentage points. In over 30 years of designing and installing expert systems we have never seen performance numbers less that these but have often seen numbers in excess of the high values. However, once the system has been installed and tuned up the performance usually does not improve much thereafter. Granted, the initial increases in throughput rate and recovery are significant but a question always lingers, that is, can the expert strategies be modified further to squeeze a little more improvement out of the system. The answer to this question is a resounding yes, however a complete understanding of what we do well as designers and operators of expert control systems is required as well as how we can improve upon our best practices is required to move us from the performance plateau we have been on for a number of years to a new higher level of performance.

Jan 1, 2009

By J. K. Ahlness

The Bureau of Mines investigated technologies for determining the integrity of in situ leach mining wells. A self-contained trailer-mounted well integrity testing system (WITS) was designed and built to enable rapid testing of well casings for leaks as required by environmental regulations. The WITS utilizes two inflatable packers to seal off the entire casing length or any portion thereof. Water pressure is built between the packers to the desired test pressure, and the presence or absence of casing leaks is determined by monitoring the pressure drop between the packers. A winch and steel cable are used to run the packers in and out of the well. The WITS underwent an industry field test at the Irigaray in situ uranium leaching mine near Buffalo, WY. A total of 37 wells with an average depth of 225 ft (69 m) were tested at an average rate of four wells per 8-h shift with a two-person operating crew. This represents a 75-pct time savings and an 83-pct labor savings compared to the rigid-pipe method previously used at the mine, with which a three-person crew tested an average of one well per shift.

Jan 1, 1986

By R. E. Lund

The design, operation, and performance of an integrated pilot plant for recovering zinc and copper from a complex sulfide ore are described. Metallurgical processing comprised selective sulfate roasting in a fluid bed, leaching in a weak sulfuring acid solution, recovering copper by cementation with scrap iron, air oxidation to remove soluble iron, more-or-less conventional purification for removal of impurities deleterious to zinc electrolysis, recovering zinc by electrolyzing solutions, and recycling spent electrolyte to the sulfating roaster. The effects of several feed preparation and roasting variables on the sulfation response of zinc, copper, and iron are set forth, together with the electrolyzing characteristics of the zinc solutions.

Jan 1, 1962

By C. J. Pritchard, R. E. Gundersen

I commend the authors on examining an interesting method of shaft lining and attempting to improve safety in a dangerous environment by remotely installing the shaft lining. It is important, though, to not trade off shaft lining safety for long-term mine safety by lining an intake shaft with combustible material. In many operations, the mine utilities are installed next to the lining of the intake shaft, supplying a possible ignition source if damaged or overloaded. Although the polyurethane studied in the paper is of relatively high density, no mention is made of the flame retardency of the samples. When exposed to heat, small amounts of polyurethane will melt and bum but are extinguished when the heat source is removed. If large surface areas of combustible polyurethane - a tunnel or mine shaft- are exposed to ignition heat sources that are not removed or extinguished early, an uncontrollable, fuel rich fire may result with high carbon monoxide levels, low oxygen concentrations, and greatly increased burning rates that can have devastating effects on the ventilation system and miners' safety. Although these heavy polyurethanes lend themselves to a "pouring" application around the annulus of the shaft liners and is a continuous process, past experience with atomizing and frothing polyurethane spray systems indicates a high degree of maintenance and operator attention to the nozzle1 delivery system. This may require more miner's time to be spent in the shaft maintaining the foam system, negating some of the safety advantages of the system. If polyurethane foams are to be used in mines, they must be of the highest quality available in terms of flame spread, heat emitted while curing, and contaminants emitted while curing and spraying. In addition, employees must be given adequate training and be thoroughly informed in all aspects of polyurethane foam safety procedures. As witnessed by our fellow miners in South Africa, we can accept no less.

Jan 1, 1991