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A comprehensive understanding of the effects of autoclave configuration (batch, semi-batch, continuous) on the residence time necessary to achieve a target conversion is a prerequisite for design of commercial scale autoclaves. Particle size distribution, mineral and reagent concentrations, temperature and mixing also influence the conversion. This paper outlines the bases of using test data to predict performance of commercial scale autoclaves. Recommendations for coordinating test program design with selection of scale-up method are provided. Examples are given to illustrate the different levels of engineering effort needed to meet corresponding levels of design optimization and accuracy.

Jan 1, 1998

By R. R. Beebe

Marcona Corporation produces about 3.5 million long tons of iron ore pellets annually on its two travelling grate pelletizing machines at San Nicolas, Peru. During 1969, these pellets will be shipped to customers in four marketing areas--Japan, the United States, Europe, and South America. All of these sales are on the open market, and product quality is a major concern. Typical chemical, structural, and quality test results for Marcona pellets are given in Table 1. [ ]

Jan 1, 1969

By Clement K. Chase

Since the dam of cyanidation leaching techniques for precious metals, certain manganese-bearing silver ores have been a problem due to low silver extractions. Since simultaneous occurrence of silver and manganese is common in nature, this situation has made many otherwise attractive silver deposits uneconomic in the past. Several older techniques have been useful but at $1.29 per ounce of silver, the economics were unfavorable. With the new look in silver prices and some improvements in processing technology, neglected silver districts offer new promise.

Jan 1, 1981

By L. Yuan, R. A. Thomas

"Atmospheric monitoring systems (AMS) have been widely used in underground coal mines in the United States for the detection of fire in the belt entry and the monitoring of other ventilation-related parameters such as airflow velocity and methane concentration in specific mine locations. In addition to an AMS being able to detect a mine fire, the AMS data have the potential to provide fire characteristic information such as fire growth — in terms of heat release rate — and exact fire location. Such information is critical in making decisions regarding firefighting strategies, underground personnel evacuation and optimal escape routes. In this study, a methodology was developed to calculate the fire heat release rate using AMS sensor data for carbon monoxide concentration, carbon dioxide concentration and airflow velocity based on the theory of heat and species transfer in ventilation airflow. Full-scale mine fire experiments were then conducted in the Pittsburgh Mining Research Division’s Safety Research Coal Mine using an AMS with different fire sources. Sensor data collected from the experiments were used to calculate the heat release rates of the fires using this methodology. The calculated heat release rate was compared with the value determined from the mass loss rate of the combustible material using a digital load cell. The experimental results show that the heat release rate of a mine fire can be calculated using AMS sensor data with reasonable accuracy.IntroductionFires at different stages generate different gases and smoke toxicity hazards. When fires occur in underground mines, a significant amount of toxic gases and smoke enter the mine ventilation system and are carried throughout the mine ventilation network, increasing the hazard potential for personnel even if far away from the actual fire. Although fires that develop to the point of rapid flame spread pose imminent hazards, fires in their smoldering, pre-flaming stages can also contaminate the mine atmosphere with debilitating levels of smoke and toxic gases.The most important parameter for evaluating the fire hazard in mines is the heat release rate (HRR), which is directly related to the rate at which heat, smoke and toxic gases are produced and transported by the ventilation system and which provides an indication of the time available for escape or firefighting (Babrauskas and Peacock, 1992). The HRR is also an important input parameter to mine fire simulation models."

Jan 6, 2017

By J. J. Peshel

As per the current conceptual design presented by the Department of Energy, the exploratory shaft facility (ESF) becomes a part of the repository if the Yucca Mountain site is found suitable for repository development. Therefore, the design of the ESF should be compatible with the performance requirements for the repository. The construction methods selected should limit to the extent practical, the degree and the extent of damage to the surrounding rock mass. The ESF construction and operation should be compatible with the site data gathering activities, such as geological, thermomechanical, hydrological and geochemical testing.

Jan 1, 1991

By S. K. Kawatra, J. E. D. McDonald, S. C. Roache

"The formation of geopolymers from mine tailings using cold-bonding processes is known to be possible. Numerous cold-bonding methods exist, but the hydrothermal processes involving high temperatures and pressures in the presence of steam have been found to be the most ideal. This paper presents the results of successful preliminary studies to apply hydrothermal bonding processes to mine tailings agglomerates. Particle-size analysis revealed the particle size of the tailings waste to be 80 percent passing at 35 µm. The compressive strengths of the tailings pellets were shown to increase with time in the curing vessel, closely approaching the 400 lbf of standard iron ore concentrate pellets. These strengths are sufficient to allow use of the tailings pellets as aggregate materials for asphalt and cement. Additional applications may be possible, including reprocessing to extract more valuable materials and usage as agglomerated road-bed materials, backfills for building foundations, and replacements for sand and lime in cement.IntroductionMine tailings are a waste byproduct of ore concentration and are available in large quantities across the world. Despite their abundance, they have received little attention or consideration for beneficial use. One reason is that the chemical nature of the material is not well known. Another factor that has hindered direct usage is the fine particle size. This raises the questions: what is the composition of the tailings, and how can such fine solids be beneficially used? Because the mining industry produces concentrates, the tailings may be treated as concentrates and processed in the same fashion, but it would be inefficient to consider full sintering or induration conditions for materials that have little ore content. To achieve sustainable operation, the development of technologies to use these tailings is necessary. Mine tailings should not be considered waste, and an “out of sight, out of mind” mentality does not represent a sustainable solution for the future.One iron ore mine in Michigan is estimated to have accumulated more than 400 million metric tons of tailings during its last 30 years of operation, with an additional 180 million metric tons accumulated before the ore body is depleted. These mine tailings currently have no practical use, largely due to a scarcity of knowledge of their true physiochemical nature. It is thought that lack of quality control of the waste material prevents its use, but variability in the unprocessed ore prevents a consistent waste stream composition. The fact that the tailings are available in such great quantities makes them an extremely attractive resource. However, developing a sustainable, low-cost means of repurposing the mine tailings waste as a construction material may only be completed once the tailings are physically and chemically understood. Due to the high silica content of the material studied, cold bonding was determined to be the most viable method for processing the tailings into a usable product."

Jan 1, 2016

By Andrew J. Neale, Chelvan Veloo

P.T. Freeport Indonesia currently operate a 600,000 t/d mining and 125,000 t/d milling operation in the remote highlands of Irian Jaya, Indonesia. The isolated location and generally difficult working conditions make for challenges not encountered in most North American operations. In spite of this, the mill technical groups have been able to develop and maintain a highly effective level of plant wide automation. This has been achieved through the appropriate selection of available technologies and the implementation of innovative management practices. This paper provides an overview of the control systems currently installed and focuses on those practices which have resulted in the long term success of process control at Freeport.

Jan 1, 1997

By Jacob Petersen, Jon J. Kellar, Samuel Kessinger, Kiran Green

Belle Fourche Shale was processed and characterized for use as a clay-based ceramic. The shale was wet sieved to produce particles that were ± 150 μm. X-ray diffraction (XRD) revealed that the -150 μm material was enriched in clay content compared to the unprocessed materials, whereas the oversize material was enriched in quartz compared to the undersize sample. Particle size analysis was performed on the—150 μm sample, which showed that the median particle size was around 10 μm. Scanning electron microscopic (SEM) analysis further confirmed the small plate size, which appeared to be primarily layered clay particles. Next, the -150 μm particles were rolled into a green body, dried at room temperature, and fired at 998°C. The fired piece was analyzed by XRD and contained 6 wt% hematite, 55% quartz, 19% microcline, and various other minor amounts of minerals. When fired at 1152 ℃, mullite was found with increasing hematite compared to the 998 ℃ firing. A multi-spectral analyzer was used to quantify the color change of the 998 ℃ fired (orange) to the 1152 ℃ fired (red) samples. Micro-computed tomography (Micro-CT) of the unfired body exhibited very few large pores, while the piece fired at 998°C also exhibited few and small pores, the overall porosity of the fired body increased. Microhardness data, obtained from the aforementioned samples, resulted in Vickers Hardness (HV1.0) values of 70.8 HV1.0 (998 ℃) and 485.7 HV1.0 (1152 ℃). Three-point bend testing was performed, giving an average strength of 23 MPa on pieces fired at 998 ℃. The average bending strength of the samples fired at 1152 ℃, was 55 MPa.

Sep 26, 2023

By J. R. Koehler

Yield pillar-based gate road designs oftentimes fail to provide mine operators with adequate ground control because of the unknowing misemployment of "critically" sized pillars. A "critical" pillar is one that is too large to either yield nonviolently or yield before the roof and floor sustain permanent damage, but is too small to support full abutment loads. To demonstrate the critical pillar concept, a field study of a tapering gate road was conducted by the U.S. Bureau of Mines at the Sunnyside Coal Mines, Sunnyside, UT. Extreme pillar stresses and associated coal bumps characterize the response to first panel mining of a 16.8-m wide critical design. Significantly lower pillar stresses, early yielding of the pillar and adjacent panel rib, and an absence of coal bumps suggest that a narrower 12.2-m-wide design more closely approaches proper yield pillar dimensions. Probehole drilling of several 1 O.6-m-wide pillars revealed low stress levels and substantial pillar and panel rib yielding prior to abutment onset, indicating a properly functioning yield pillar design.

Jan 1, 1995

By Z. Yu

The effect of particle size on coal dewatering has been well recognized However, there are no systematic studies on ultrafine coal dewatering. The results discussed last year revealed the effect of flocculant type and coal wettability on the filtration of ultrafine coal In this paper, the differences in dewatering between -25 µ m ultrafine and -500 µ m fine coal with addition of flocculants, surfactants and oil-emulsions in vacuum filtration are further investigated Significant differences were observed in the reduction of the cake moisture. The utilized emulsions were found to be very powerful and promising filtration aids for both ultrafine and fine fractions of hydrophobic and hydrophilic coal

Jan 1, 1995

By J. W. Leonard

Gravity based coal/mineral preparation plants must be operated to yield products of a quality satisfactory to existing markets; but, because of historic control problems, recovery is frequently sacrificed to achieve quality resulting in losses of valuable product. Plant control has ranged from intuitive in-plant spot quality judgments made by various operators to gross methods involving such devices as density gauges, floats, grab-sample on-the-spot sink-float tests, etc. Millions of tons of quality coal/minerals are lost to refuse each year, because of the historic lack of a continuous and dependable control system. The result is both serious economic as well as environmental losses. While the economic losses are obvious, less obvious environmental losses, in the case of coal, result from the misplacement of more ignitable quality fuel to refuse banks. A control system capable of supplying a market-grade coal/mineral product, while continuously minimizing product losses to refuse, has until recently escaped technology.

Jan 1, 1991

By Rick Bearce, Minsu Cha, Mike Mooney, Yuanli Wu, Lisa Mori

"Proper soil conditioning is critical for effective earth pressure balance (EPB) TBM tunneling. Chamber pressures can reach 3-5 bar yet the vast majority of testing is performed under atmospheric conditions. This paper illustrates how pressure influences foam stability and conditioned soil behavior, and how atmospheric test results must be viewed in the context of expected chamber pressures. Torsional shear strength, compressibility and abrasivity of foam conditioned sand were found to be ideal when the void ratio was above the ASTM-determined maximum void ratio, achieved by sufficiently expanding the soil grain structure with foam, herein when the foam injection ratio at pressure exceeded 45%. Otherwise, the engineering properties of foam conditioned sand were not ideal, i.e., appreciable torque and abrasivity, low compressibility. INTRODUCTION Proper soil conditioning is critical for effective earth pressure balance (EPB) TBM tunneling. The formation soil at the cutterhead must be transformed into a highly compressible, low shear strength and low permeability medium within the excavation chamber to allow effective EPB performance. This behavior must be maintained for a certain residency time while the soil is in the chamber and screw conveyor. The vast majority of published studies on conditioned soil behavior have been performed under atmospheric conditions (Quebaud et al., 1998; Bezuijen et al., 1999; Psomas and Houlsby, 2002; Vinai et al. 2008; Thewes et al., 2012; Peila, 2014); however, the desired soil behavior must occur under chamber pressures that can reach 5-7 bar. The influence of pressure on conditioned soil is significant and is dramatically different than behavior under atmospheric pressure (Williamson et al., 1999; Mori et al., 2015). This paper illustrates how pressure influences conditioned soil behavior and how atmospheric test results must be viewed in the context of expected chamber pressures. The influence of pressure on foam bubble size (including with time) is shown through digital image analysis. The influence of pressure on foam half-life is also investigated. The compressibility, shear strength, and abrasivity of conditioned soil under pressure is presented and explained in terms of density, soil and air compressibility and porosity."

Jan 1, 2016

By J. L. Kohler

The knowledge-based expert systems (KBES) is a potentially powerful technique to the mining engineer in traditional areas of mine design and operations, as well as in the emerging areas of mining automation and robotics. Since KBES is still experimental in many respects, caution must be exercised as this "high tech" tool is developed and applied to mining. The objective of this paper is to demystify expert systems by introducing the elements of KBES, discussing the strengths and weaknesses, and identifying some areas of application in mining, based on the authors' experiences.

Jan 1, 1986

By T. B. Acton

There are two types of ore transportation systems in use at Newmont's Magma Copper Co. San Manuel mine in Arizona-rail-mounted, box-type rotary cars and the newer rail-mounted, bottom-dumping ASEA cars. Though the cost per car for the ASEA units greatly exceeds the cost per rotary car, the advantages of the ASEA units, including much faster dump times, have made the ASEA system a successful alternative at the San Manuel mine. The rotary system of ore transportation has been in use at San Manuel since production began in 1956. The system employs 7.9-m3 box-type cars to transport ore by rail to shaft pocket areas. A rotating dumping mechanism turns three cars at a time upside down to empty them, and returns them to an upright position. Trains of 15 cars each are dumped in about six minutes. Each 15-car train is pulled by an 18-t rated trolley locomotive. There are about 400 rotary cars in service at San Manuel and the system is used for the majority of ore haulage. This well-proven rotary method was instrumental in achieving the December 1977 world record of 272 Mt hoisted from an underground copper mine. Magma Copper Co. began using ASEA cars in late 1977. Designed by ASEA of Sweden, the cars are built for San Manuel by Kasper-Hall Manufacturing Co. in Tucson. The cars basic design feature is a hinged floor that opens at the side as the car is pulled through the dump. As it passes over the dump, a fifth wheel attached to the hinged floor (opposite the hinges) travels along a rail in the dump. This rail dips down into the pocket and then returns to track level. As the fifth wheel travels along the rail, the car floor opens, the car dumps, and the floor is then returned to track level. As the car is dumping, the body remains suspended over the pocket by wheel rollers attached to each side of the dump. Trains of 10 cars each are emptied in about 45-50 seconds. Each ASEA train is pulled by an 18-t rated trolley locomotive, adapted at San Manuel to allow it to pass through the ASEA dump. At minimal cost, "wings" are welded to each side of the locomotive. These wings suspend the locomotive over the pocket as the train passes through the dump. Advantages of the ASEA System Major design characteristics of the ASEA and rotary systems are shown in the accompanying table. The comparison points out some of the following advantages demonstrated by the ASEA system. • Faster dumping-An ASEA train dumps in 50 seconds, while a rotary train takes at least six minutes. There is no stopping or starting when dumping an ASEA train. The train enters the dump area, dumps, and leaves in one continuous motion-in contrast to rotary trains which must stop and start five times to dump. With the rotary system, three cars are spotted in the dump mechanism by remote control. When the cars are in place, the train operator activates the dump, the cars are turned over, and then returned to an upright position. This process is repeated until all 15 cars in the train are emptied.

Jan 4, 1980

By Paul Gilmour

"The principal role of the geologist is to recognize the existence of phenomena before trying to explain them" - B.M. Keilau, 1825; A. Holmes, 1965 Some important groups of mineral deposits in the layered rocks of orogenic belts or greenstone belts occur in horizons characterized by the presence of exceptional amounts of silica, iron and carbon, with more or less significant amounts of manganese. Generally, the rocks involved are well banded. In practice, these five physical features - four compositional and one geometric - are found with many lithological guises. Iron formation, in the full, modern sense of the term (James, 1954), quartzite, ferruginous quartzite, chert, jasper, "tetsusekiei" (Horikoshi, 1969), tuffaceous jasper ("purple porphyry" - Anderson and Creasey, 1958, p. 36), ferruginous or graphitic shale, argillite, slate or schist, and hematitic tuff are but a few of the more familiar of the names that have been assigned to these rocks. Widely acknowledged and well-documented examples of metallic deposits found in such sediments include concentrations of iron and manganese and stratabound, polymetallic, massive pyritic sulfides. Less familiar examples include occurrences of asbestos (Miles, 1953; and Coetzee, et al., 1976), antimony (Coetzee, 1976), and perhaps stratabound deposits of Au-Cu-U-W-etc., such as Aitik in Sweden (Mining Magazine, 1975; and Nilsson, 1979) and Olympic Dam in South Australia (Roberts and Hudson, 1983). The case of gold is intriguing. An association between gold and iron formation has been identified at several famous deposits and districts, such as Yellowknife, N.W.T. (Morton, 1979), Homestake, S. Dak. (Sawkins and Rye, 1974), Vubachikwe, Zimbabwe (Fripp, 1976) and the Barberton district, R.S.A. (Hammerbeck, 1976). Yet a critical reading reveals the existence of many other hitherto unsuspected examples. The purpose of this note is to draw attention to that omission and the apparent explanation for it. It is not hard to detect the two most probable reasons for the discrepancy between reality and the record.Most occurrences of gold are associated, not with the familiar banded iron formation or interbedded magnetite and chert (technically, the magnetite-banded variety of the oxide facies), but with the enigmatic carbonate, sulfide and silicate facies of iron formation and/or with rocks evidently related to iron formation. All too commonly, the unfamiliar facies of iron formation have been identified by field and mine geologists and not a few researchers as products of regional metamorphism and hydrothermal alteration, as mafic igneous rocks, or as conventional sediments, ie., without regard to their intrinsically ferruginous nature. The justification for these two complementary assertions is largely to be found in the recognition of a characteristic suite of metals and minerals in gold deposits known to be associated with iron formations. Although, from a geological standpoint, a lithological association is more important than a mineralogical assemblage, the latter is the more likely of the two to be diagnostic. This arises from the different natures of mineral and rock classifications, The identification of a mineral or an element is a matter of fact. Owing to the genetic component inseparable from petrographic nomenclature, viz., "igneous": a rock (believed to have been) derived from a melt, the identification of rocks depends on inferences or conclusions about their mode of formation - conclusions that are commonly debatable and, all too often, involve subjective judgements. This is especially prone to be true, if - as at many of the gold occurrences in question - the host rocks have been metamorphosed and/or "altered". In the notes that follow greater weight has accordingly been assigned to elemental and mineralogical than to host rock composition. In other words, if, in a given gold occurrence, the suite of metals and minerals present conforms to the standards of the subject class, whereas the names assigned to host rocks do not, the latter will be viewed as suspect.

Jan 1, 1985

By H. O. Harju

In July 1968, P.T. Inco Indonesia was granted a Contract of Work to explore and develop the nickel laterite resources on the southeastern peninsula of the island of Sulawesi. Since 1970, exploration has centred on the deposits at Soroako as the site for initial project development. This paper describes the exploration methods used to evaluate these rather unique laterite deposits, the geology of which is described in the first section of this volume.

Jan 1, 1979

By Gene M. Handel

Today the world is heavily dependent on petroleum for its energy. In the United States, over 75% of the primary energy used comes from petroleum. Other developed countries are similar. The less developed countries have a lower dependence on petroleum just as the United States did through the early 20th Century. However, these less-developed countries look upon petroleum as one of the primary energy sources for the economic growth required to improve their standard of living. So everyone considers petroleum an essential ingredient in the recipe for the good life. But there is a substantial problem with this recipe, and it is finally getting general recognition. Petroleum is a finite resource, and the world is using it up at a rapid, accelerating rate. Though it won't be exhausted for many decades, the early warnings of ultimate limits have already appeared. The suppliers of the incremental production in the Middle East have threatened to restrict increases in their production rates. And, of course, the short term embargo of four years ago clearly demonstrated the economic impact of reduced access to petroleum as a primary source of energy. World petroleum production will probably peak in. 10 to 15 years and then start declining. When that happens, economics--the allocation of scarce products (also known as the dismal science for obvious reasons)--indicates that the price of petroleum will escalate in real terms. So that's the situation today. We have a serious and growing problem facing us that could substantially alter the quality of our life over the next 25 years. Recognition that the society may face a period of lowered expectations after a long period of upward mobility will be a painful experience, but it is certainly not the moral equivalent of war. And, besides, we have time to take positive actions to avert the most serious consequences. When we consider alternate energy sources, the possibilities are almost endless: coal, oil shale, tar sands, solar, fission, fusion, wind, tides, biomass, etc. Actually, the list is endless because new possibilities are continually being proposed. Of these possibilities, coal uniquely stands out as an attractive substitute for petroleum. Coal can be, and is, burned to generate electricity and provide heat. It can be liquefied to supplement the liquid fuels from petroleum, and it can be gasified for use as synthetic natural gas. Unlike exotic alternate energy such as solar and fusion, coal has successfully been used commercially to produce synthetic fuels. But, the technology does need to be refined and modernized. Thus, coal's role is not to be "America's Ace in the Hole," but to bridge the transition from primary dependence on petroleum for energy to the utopia of renewable sources of energy. But don't be mislead by the prophets--those renewable sources of energy are going to be very, very expensive when they are invented.

Jan 1, 1978

By J. Andres, M. Cross

"Freeport-McMoRan’s Sierrita operations has two natural gas-fired molybdenum roasters for converting molybdenum disulfide into molybdenum trioxide. When these roasters were compared to other similar units within the company during a benchmarking exercise, it showed that increased throughput from the roaster units at Sierrita was possible. A team of site metallurgists, technical experts from other sites, and engineers from the Climax Technology Center was formed to study the potential in more detail. The team investigated many parameters in the roaster, including temperature profiles, roaster chemistry profiles, rabble and drop hole patterns, and operational strategies. The results of these studies and the associated throughput improvements are described in this paper. INTRODUCTION Molybdenum, a vital component for the steel industry, is typically found in nature as molybdenum disulfide (MoS2). MoS2 is typically recovered via flotation processes and is purified through leaching processes. While molybdenum disulfide is a commercial product, it is not the form of molybdenum that the steel industry requires. They require molybdenum in the form of molybdenum trioxide, MoO3. There are multiple ways to refine molybdenum disulfide into molybdenum trioxide. The primary method is the oxidation of molybdenum disulfide in a multiple hearth roaster. The chemistry of converting molybdenum disulfide to molybdenum trioxide is very favorable at increased temperatures, oxidizing the molybdenum through a range of exothermic reactions to ultimately produce MoO3. The chemical reactions that occur in molydenum roasting occur in three zones. These three zones correspond with four different reactions."

Jan 1, 2015

By S. Bahrampour

One of the basic requirements for designing an optimized rock support for an underground opening is having reasonably enough geological information. It is often financially impractical to obtain detailed geological information about the rock surrounding the excavations. The geological and geotechnical information which are obtained during the construction phase are also usually inadequate and need periodic operation stoppage. Penn State University- J.H. Fletcher & Co. joint venture is to improve the existing instrumented roofbolter so that the 3D geological and geotechnical map of the rock mass surrounding the underground working can be generated real-time as the data is being collected. This information will also be used to design appropriate support for different sections of mines. In this paper, recent results in improving the performance of the measurement while drilling system will be discussed. Moreover, updates related to borehole probing methods for estimating the properties of the rock masses will be presented.

Feb 23, 2014

By J. Hilgers

Metal prices are often predicted by relying on time trend projections of various economic indicators or even the trend in price itself Thus, time is the underlying explanatory variable acting through at best, a limited selection of economic variables. The price prediction method described in this paper differs from this by analyzing hundreds of economic variables to develop a few principle components that automatically capture the fundamental changes in the economy and delete duplicate or irrelevant information. This leaves a few principle variables to describe a state-space representation of the economy which can then be used for prediction. Forecasts of the price of a metal are then made based on these principle variables.

Jan 1, 1995