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The National Institute for Occupational Safety and Health (NIOSH) conducratory and field tests to evaluate the effectiveness of dust collector bags for reducing dust liberation and operator exposure from a roof bolter?s dust collection system. The laboratory tests evaluated the bag?s effectiveness to contain dust and the effect on canister filter loading in both a bag and bagless condition. The dust emissions from the collector?s exhaust were also measured in each condition during laboratory testing and show that nearly 100% of the test dust fed into the collector was captured by the dust bags. Loading and pressure drop on the dust collector?s canister filter is greatly decreased when using the bags, enabling longer periods of drilling without filter removal/cleaning. The field results showed that, even though dust standards were met, respirable dust in exhausted emissions was reduced around the bolter. Laboratory and field results show that benefits from use of the bags are realized in all areas of operator exposure.

Jan 1, 2008

By Michael Michaylov

INTRODUCTUCTICN The coal seams at Bobov dol basin are highly prone to spontaneous combustion in Bulgaria. The risks of endogenous fires (SPONCOM) exist mainly in gob area. During the last 15 years three different technologies for preventing and fighting SPONCOM have been applied in underground mines of this basin: pulp from hard material and water, foam and inerting with nitrogen. On the basis of experimental application of these technologies as well as theoretical and experimental research a new technology - Foam Pulp Technology (FPT) was worked out. It is very effective in difficult to reach places in a gob. BACKGROUND AND THE NEED OF FPT Application of the three methods mentioned above showed advantages as well as some disadvantages, allowing determination of their effective application scope depending on geological and working conditions. Their advantages can be summarized as follows: - Foaming: high viscosity at low density, which allows forming a thick layer; good surfactant wetting properties; excellent effective cooling during evaporation in high temperature zones. - Pulping with mixture of solid particles (e.g., fly ash) and water from surface installation: easy to apply in a mine; low operational and energy costs due to gravity transport from the surface to the gob: good ecological results because the waste material is returned back underground. - Inerting with nitrogen: volumetric action which doesn't restrict the thickness of treated coal pile; easy to apply in a mine; controllable nitrogen delivery depending on fire hazard conditions. Main disadvantages of the same three methods are: - Foaming: rapid disintegration due to intrusion into heterogeneous and porous media and high costs due to the need of frequent large volume foam flows (short foam's life); - Pulping: inapplicable for coal piles with high thickness which is of great importance in the cases of seams with ununiform hypsometry (rapid and frequent changes in a seam configuration) and/or great volumes of coal or ore piles particularly heated to a high temperature; strong dependence on gob floor declination; water draining of the working face area which impedes the movement of supports and chain conveyor's. - Inerting: relatively high costs hardly depending on the rate of face advance (fig.1) in comparison with the other methods; it is difficult to ensure sufficient oxygen at the exit end of the face. This problem is crucial in faces with a high level of methane emissions; accelerating of the oxidation and spontaneous heating of the pile after turning off the nitrogen supply. Inerting should be applied again at higher capacity of nitrogen supply (fig.2) and what is more important, it shouldn't be

Jan 1, 1995

By Rustu S. Kalyoncu

Rainbow colors of roofing granules, adorning the roofs of buildings from single family units to largest office buildings, have their origin in the roofing shingles as burlap soaked with tar appearing as early as the 1700s. Dusting of talc and mica on the coated surfaces, to keep roofing from sticking to itself in storage, represents an early improvement to the original construction product. Sometimes, colored, natural mineral dusts were added as color pigments within the dusting material, for initial color. Prolonged exposure to sun caused the asphalt to become brittle, and it eventually cracked and leaked. Search for solutions to cracking and subsequent leaking problems eventually led to the use of crushed mineral granules on asphalt coated shingles. This provided the impetus for further growth in the asphalt roofing industry. Application of a layer of crushed mineral on the asphalt coating minimized the coating deterioration from exposure to ultraviolet light, thus significantly improving the shingle life. In the 1900s, screened waste from slate quarries was the most commonly used granule in asphalt roofing products. Records indicate the use of coarse slate screenings for asphalt roofing as early as 1906. As the asphalt roofing industry further developed, other naturally colored minerals, such as silica sand, quartz, mica, feldspar, talc, slag, granite, rhyolite, and oyster shells were used on roofing surfaces. Later on, a number of manufactured granular materials, such as crushed brick and tile, fire clay, and white porcelain were used. The first artificially colored roofing granule was produced in 1914 by running molten slag into a solution of alkaline metal silicate, which was absorbed by the porous slag. Various colors were obtained by adding pigments to the silicate coating and by subsequently heat treating the granules. In 1922, another technique was developed in which green slate granules were saturated with copper sulfate solution and heated to 760°C to form copper oxide. Since then, many other granule coloring processes have been patented, one of the most significant being the sodium silicate coatings introduced around 1975. Granules as used in construction (specifically roofing materials) are defined as natural or synthetic-mineral grains smaller than gravel and larger than sand in particle size. They are used primarily for protective and decorative purposes on the weather- exposed surface of asphalt composition roofing. Development of artificial coloring techniques has made it possible for the roofing industry to provide asphalt roofing shingles in a wide variety of colors complementing the color and style of buildings. Roofing granules, as we see today, are the products of long technological evolution.

Jan 1, 1994

By Gerard P. Hand

The use of graphite in industrial applications is one of the oldest in the world. Yet, it is one of the fastest-changing technologies today. Graphite was first used centuries ago in developing writing instruments and as a raw material in crucibles used in melting metal. Today, graphite is used in some of our most demanding industries. These include aerospace, electronics and automotive applications. Graphite usage has historically been split between the natural and synthetic forms. Figure 1 shows the breakdown of natural graphites and synthetic graphites used. The usage of natural graphites and synthetic graphites is split fairly evenly, although the applications are quite different. Figure 2 shows the breakdown of applications using natural graphite. The largest application is the refractory industry. This includes refractory brick and plastics, crucibles, shrouds and other refractory parts. This main application uses roughly 50% of all natural graphite. The refractory industry is an important application for natural graphite. However, the refractory markets have been struggling for several years. As demonstrated in Fig. 3 (Semler, 1996), the production of refractories in tons per year has declined by more than 32% during the last 25 years. Refractory prices have actually risen on a dollar per ton basis during that same period as the product mix has shifted to the value-added side. Raw material and production cost increases, inflation and other related costs have kept profitability at low levels for the industry. Furnace linings that once lasted 1,000-2,000 heats now last 8,000-12,000 heats. This means that tonnage requirements have gone down and quality requirements have gone up for graphite suppliers. Therefore, new opportunities and applications must be developed if the graphite industry is to grow. Synthetics are the other major forms of graphite. There are two forms of synthetic material currently used. One is the traditional type. It is made from the turnings of graphite electrode production. The second was developed in the mid-1970s in response to a shortage of conventional synthetic graphite. This occurred by a breakthrough in thermal technology. This new technology purifies, desulfurizes and graphitizes petroleum coke on a continuous basis at temperatures of more than 2,500° C (4,532° F). This product is called desulfurized petroleum coke (Desulco). It now accounts for about half of the synthetic type material used in the United States. Figure 4 shows the breakdown in the use of synthetic types of material by application. The largest requirement is for use as a carbon addition in iron and steel. This is followed by alkaline batteries and friction materials. Current technological opportunities New opportunities for graphite products are now being developed. These new areas are made possible due to the advances in graphite thermal technology. The ability to purify and modify graphite and carbon products is the key to future growth in the graphite industry. New, higher-purity, more consistent graphite products are leading to enhanced performance in current applications. They are also opening the door to new applications.

Jan 1, 1997

By L. W. Swent

Dr. Emrick, honored guests, distinguished speakers, ladies and gentlemen, I am Langan Swent, Vice President for Environmental Affairs and Occupational Safety and Health, of Homestake Mining Company. Today, I appear on behalf of the American Mining Congress, as chairman of its uranium mine health subcommittee. The American Mining Congress is a trade association of several hundred members, which include the producers of a large proportion of the nation's uranium. I've been asked to make a statement of principles for the uranium industry. There are two types of principles that apply to industry in general, and specifically to the uranium industry. Some have external origins and apply regardless of what industry does or thinks. Others are generated by industry itself and serve as goals for the industry. I'll discuss some of each type. I'll limit my statement to those principles related to the subject of this conference--radiation hazards in mining. I won't take your time trying to explain some of the unrelated principles that we must all contend with, such as Parkinson's Laws, Murphy's Law, and the Peter Principle. First and foremost, industry has a sincere interest in the well-being and health of its employees. There are two basic reasons for this. One is a basic respect for human lives, especially those of people we see and work with every day. No one in management wants to carry the lifelong burden of blame for a life lost due to poor working conditions. Most uranium and other mining is done in small communities. Production workers, maintenance workers, service workers, shift bosses, foremen, superintendents and managers all live in the same community. They attend the same churches. They serve together in civic activities. Their children go to the same schools. If one employee in such a community loses his life due to poor working conditions, those remaining know in a daily and intimate way the resulting personal tragedy, usually of a bereaved widow and fatherless children. This sad experience makes the community, including industry management, intensely sensitive to the need for maintaining good working conditions in the mines. But what about the segment of industry that does not live in the mining communities? Corporate and owner's offices are frequently hundreds of miles from the communities where the mining takes place. Many of these people are not personally acquainted with the workers, and there are few close personal ties between the two communities. The distant staff are, however, still human beings and motivated by the same basic human respect for life. Mr. Manuel Gomez of MSHA and a member of the planning committee for this conference summed this point up expressively when he told me: "No one group has a corner on compassion." In addition to compassion, there is another factor. In both communities the basic assignment to everyone is to produce profits. In carrying out this assignment, supervisory and management people are acutely aware of the high cost of illnesses and accidents. Their objective of maximizing profits is advanced significantly by minimizing illnesses and accidents at the mines. A business that has illnesses and accidents generally suffers from poor employee morale and high employee turnover, both of which detract from profits. Next, I would like to talk about what industry has done in the field that is the subject of this conference. We have worked at all sorts of methods to reduce exposure of employees since the exposure standards were first introduced and then lowered. Other speakers will go into details of technology, and I'll simply comment on exposure results. These are best shown in Table 1. The table shows the average WL to which miners in U.S. underground uranium mines have been exposed since 1937 through 1980. The trend of decreasing radon daughter concentrations throughout the period is obvious. Figure 1 presents this data graphically and shows the trend at a glance. This record begins in 1937 when uranium, as such, really wasn't being mined or sought. The concentrations given by the U.S. Public Health Service were for a few small vanadium mines which carried uranium as a by-product. A few years later, when the Manhattan project to develop the atomic bomb was begun, these mines became the first U.S. uranium mines and the vanadium became the by-product! The radiation hazard then also received attention and the average concentrations began to decline. As knowledge of the reality of the hazard spread, conditions improved. The search for uranium in the U.S. turned up new and larger ore bodies that had to be mined by large underground mines. These mines involved ventilation planning from the beginning, and when they came into production in the late 1950's they lowered the average concentrations greatly. Then in 1960 the American Standards Association adopted a standard setting 1 working level as a satisfactory condition, and several action levels up to 10WL, at which point removal of people from exposure was called for. As a result of the uranium producing states governors' conference in December 1960, state mine inspection agencies, in the early 1960's, began to adopt and enforce the ASA standards. As a result, average concentrations again declined. In 1967, the Federal Radiation Council recommended an annual limitation of 12 WLM per individual. This represented a great change in the methods of

Jan 1, 1981

By Paul L. Russell

Introduction As the US and world population increases, so does the problem of supplying expanding energy needs. Early requirements worldwide were mostly met by abundant forest vegetation. Man's large scale use of minerals-energy resources is a fairly recent development. It occurred only during the past 200 years. Coal was the first mineral fuel to be used extensively. It was not a large factor in US energy production until the beginning of the 19th century. Petroleum and natural gas use is about 125-years-old. Electricity generation by falling water is about a century old. Atomic energy is only about 30-years-old. Extensive use of it is still in the future. Solar energy is in its infancy. Other energy sources such as wind, peat, and geothermal energy are minor and primarily of local importance. There were three main features of the fuel supply picture during the past 125 years. By 1900 coal replaced wood as the principal energy source. Since 1900, oil and gas have captured many coal markets. And after the mid-1970s, there was a resurgence of coal usage. (Figs. 1 and 2). Wood Until the advent of mineral fuels for energy, the major global energy source was wood. But populations increased and became centered in towns and cities. The problem of a sufficient energy supply first developed as nearby, easily obtained wood was exhausted. This problem became more acute as industries such as shipbuilding, smelting, and pottery making, became more widespread. Results of wood use as an energy source and building material are starkly evident in areas of the world where civilization is oldest. Entire forests were consumed and have never been replaced. In the US, wood supplied 90% of all fuel requirements until about 1850; and more than 50% until after 1880. By 1900, wood still supplied 20% of all energy uses. In the mid-1970s, energy costs increased, due largely to the oil embargo. This increase resulted in an increased wood demand for domestic heating. While large quantities of wood were being used, its share of the total energy market was still less than 3%. By 1983, wood was becoming increasingly scarce and more costly near most large US cities. Wind Wind powered ocean vessels for many centuries. Sailing ships were still common in 1900. Windmills provided an early, cheap energy source and continue to be used today on farms. Design and development of windmills for electricity generation is being conducted. Interest in wind power is growing worldwide where availability of wind currents warrants the investment. Also, US regulation requires power companies to "buy back" electricity generated by windpower in excess of that used by the windmill owner. Coal By the 1600s, England was producing, 900 kt/a (1 million stpy) of coal for heating and other uses. The first coal-fired blast furnace for iron smelting was developed in 1621. Coke-making was developed in 1755, and Watt invented the steam engine in 1769. Illuminating gas made from coal was introduced in London in 1800. During this same 200-year period, France and Germany developed coal production, but on a smaller scale than England. US, bituminous coal was mined near Richmond, VA, as early as 1748. Major bituminous coal-producing states in the early period were Pennsylvania, Virginia, Ohio, Kentucky, Illinois, and Maryland. West Virginia replaced Virginia as a major producer, when that state was formed in 1863. As the US expanded west, new coal deposits were found and exploited. Indiana, Alabama, Tennessee, Iowa, Kansas, Missouri, Washington, Colorado, Wyoming, Arkansas, Oklahoma (Indian Territory), Montana, New Mexico, and Texas had significant coal mining operations by 1900. Today the eight major coal producing states are Kentucky, West Virginia, Pennsylvania, Illinois, Ohio, Virginia, Wyoming, and Montana. These states accounted for about 80% of all coal (lignite, bituminous, and anthracite) produced in the US during the past several years.

Jan 8, 1984

By L. M. Cenegy

Introduction The formation of scale is common in gold ore processing plants. A working definition of such scale is: "A hard, tightly adhering deposit formed in place by the precipitation of calcium-bearing mineral compounds from water." The most common scale found in gold processing plants is calcium carbonate (CaCO3) although calcium sulfate (CaSO4) is occasionally a problem. The problem of scale in carbon strip circuits Carbon strip circuits present a particularly challenging scale inhibition problem. Many of the factors that tend to promote scaling are present in these systems. For example, carbon strip circuits are run at high temperatures and high pH levels and require long batch cycle times. Tortuous paths are encountered by the strip solution circulating through heat exchangers, pipes and elbows, causing transient pressure drops throughout the system. Severe conditions such as these cause the water to possess a high scaling potential and may lead to the breakdown of some of common types of scale inhibitors. Formation of scale Natural waters contain dissolved minerals and gases that promote scaling. One of the contained gases, carbon dioxide (CO2), is an important factor in scale deposition. Carbon dioxide dissolves in water to yield carbonic acid according to the following reaction: [CO2 + H2O - H2CO3 (carbonic acid)] Carbonic acid rapidly dissociates to yield bicarbonate and carbonate ions depending on the pH of the system: [H2CO3 -s H+ + HCO-3 (pH range 6-10) HCO3 -a H+ + COO (pH range > 9)] In gold cyanidation processes, lime is added to raise the pH of the mill solution to 10 or above to promote cyanidation of the gold and to eliminate the possibility of hydrogen cyanide (HCN) formation. Lime contributes both hydroxyl ions (OH--) and calcium ions (Ca++) to the solution. The normal scale forming reactions in mill water systems were described by Beasley (1973) as: [HCO-3 + OH -s C03 + H2O Ca++ + C03 -a CaCO3] Factor affecting scale deposition According to Linke's (1958) solubility tables, the solubility of calcium carbonate in carbon-dioxide free water is only 13 mg/dm3 (13 mg/L) at 25° C (77° F). Scale deposition occurs when the concentration of calcium and carbonate ions in the solution exceeds the solubility of calcium carbonate. This occurs, in most cases, when the water has undergone some chemical or physical change. Some typical changes that might occur that lead to scale deposition are discussed below. Temperature An increase in temperature can greatly increase the tendency to form calcium carbonate scale. Studies by Miller (1952) have indicated that calcium carbonate is less soluble at higher temperatures. Hence, high temperatures promote scaling. For this reason, scale is often noticed on heat exchangers, autoclaves and other high temperature surfaces. Pressure A decrease in pressure may lead to an increase in the tendency to form calcium carbonate scale. Fulford's (1967) work has shown that scale is more soluble at high pressures. Hence, scale is likely to be prevalent in pump suction lines, elbows, baffles and other areas that produce turbulence and subsequent pressure drops. Change in pH Calcium carbonate scale is pH dependent and tends to form more readily at high pH. Any event that causes an increase in pH, such as the introduction of lime or caustic, would tend to initiate scale formation. Since most gold recovery operations are run at a pH above 10, the tendency to form calcium carbonate scale is always great. The use of scale inhibitors to prevent calcium carbonate scale Many products are commercially available to inhibit the formation of calcium carbonate scale. Some of the more effective types include phosphonates, as well as acrylate and maleate-based polymers and copolymers. Many of these products function by means of threshold

Jan 1, 1992

Although there was a significant improvement in the world economy, recovery in the iron and steel industry followed its traditional pattern and lagged the general economic recovery in 1983. World crude steel production increased from 645 Mt (711 million st) in 1982 to 664 Mt (732 million st) in 1983, an increase of less than 3%. Domestic iron and steel production showed a modest increase over 1982. Weekly raw steel pro¬duction levels ranged between 1.5 and 1.75 Mt (1.6 and 1.9 million st) for the last 10 months of 1983, compared with less than 1.25 Mt (1.4 million st) for the last half of 1982. The peak was 2.5 Mt (2.7 million per st) per week in 1978-79. This how level of steel operations kept most pelletizing and sintering operations at curtailed production levels. Extended shut-downs of pellet plants were also common. Pressure by management to reduce operating costs has continued with an increasing emphasis on maintaining quality and efficient unit productivity. With the extended decline, there have been significant personnel reductions in both operating and headquarters staffs. Many companies are anticipating a long-term how growth period in the iron and steel sector. Pelletizing Domestic pellet production showed a slight increase last year to about 34 Mt (38 million st), less than 50% of total capacity. What is indicative of the inevitable is the announced intention to chose down facilities, such as US Steel Corp.'s Atlantic City ore operations pellet plant at Lander, WY, and the recent aborted move by US Steel to purchase National Steel with the apparent intent to chose the National pellet plant in Keewatin, MN. There is excess domestic pellet capacity that will not be needed. The question is what form attrition will take. South American pellets can be brought into the Chicago area at a cost competitive with Great Lakes plants. This raises the possibility that imported pellets can, in fact, displace domestic pellets at almost any US steel plant. The need to re duce total production costs at domestic pelletizing plants is crucial. Efforts to reduce fuel costs for pelletizing have focused on re placing natural gas or fuel oil with coal. More recently, petroleum coke has become available at an attractive cost, but systems must cope with its higher sulfur con tent, which limits its potential The direct firing of grate-kiln systems with pulverized coal hay been fully proven. The use of solic fuel in the straight-grate process however, is still being developer and no straight-grate system i running on solid fuel alone. The further development o coal-water slurry systems may provide a suitable fuel for both systems. It would appear, how ever, that the same ash quality restriction would hold for coal water systems as for direct-firin systems. So, the choice is based of the relative cost and convenience of a wet-grinding system with additives, compared with a dry-grind direct-fired unit. The high-temperature (two stage) heat recuperation system installed at US Steel's Minnta plant (Step III) has provided the fuel savings anticipated, any modification of additional in durating lines is planned. Other operators are hooking at similar heat recuperation improvement. Another area of potential cost savings has been in the reduction of bentonite requirements. A CCI's Tihden plant, major improvements have been made in this area. Progressive bentonit reductions were achieved over several years from the 8- to 9-kg (16- to 18-lb per st) range to the 5-k (12-1b) level by progressive moisture reductions and chose attention to operating practice. Further reductions were achieve by raising bentonite specifictions. In this instance, the wate plate absorption test specifia

Jan 5, 1984

By A. P. Grobbelaar

Andalusite is a member of the sillimanite group of minerals consisting of andalusite, kyanite, and sillimanite. These minerals are the structural polymorphs of Al,Si05 (the anhydrous silicate of aluminium) and although chemically similar, they differ in physical properties due to their different crystal structures. For further information on the sillimanite group, see the chapter on Kyanite and Related Minerals that follows. The minerals are generally the products of the metamorphism of alumina-rich sediments and are found in schists, gneisses, or hornfelses, which have undergone either regional or thermal metamorphism from their original form. Sedimentary deposits may also form since the minerals are chemically and physically resistant to breakdown. When heated to a sufficiently high temperature the sillimanite group minerals convert to mullite with a resultant volume expansion and the liberation of silica. Due to the stability of the mullite formed, its high hot strength and resistance to chemical and physical erosion, they are widely used in the manufacture of refractories and special ceramics (Table 1). The reaction can be represented as follows: [ ] The worldwide use of these minerals depends to a large degree on their availability (Fig. 1). Andalusite, with its lower conversion temperature and the lowest volume expansion on being heated is the natural choice as a raw material to produce energy-saving refractories without prior calcination. The Republic of South Africa holds by far the largest minable andalusite deposits of the world, estimated at some 70 Mt of known in situ reserves. The only other large commercial production of andalusite comes from France, with known reserves of about 5 Mt. Potential new deposits are known from China, Ireland, Australia, and South America. World consumption of andalusite in special performance refractories has risen from less than 10 ktpy in 1960 to nearly 300 ktpy in 1990, which is due to cost effectiveness in many industrial applications compared to other conventional refractory products. Andalusite-based refractories have traditionally been used in Europe, South Africa, and the Far East; usage in America was limited in the past due to relatively high delivery costs and availability of other local refractory minerals. However, there is a significant trend towards greater use of andalusite in North America, thus opening new markets and replacing other traditional refractory raw materials. GEOLOGY Andalusite occurs in metamorphosed rocks of clay-like com- position, as in the andalusite-hornfelses in thermal aureoles (contact metamorphism), formed under conditions of high temperatures and low stress, and in regional metamorphic rocks, such as the andalusite-schists. These schists are mostly unconnected with definite igneous intrusions but were presumably also formed at high temperatures and under low stress. Andalusite can also appear in alluvial deposits associated with the primary deposits. At depths of 10 to 20 km, temperatures of up to 450°C might be expected. Another result of increasing depth is an increase of pressure due to the load of the rock cover. The load stresses involved in metamorphism is generally believed to lie in the range 0 to 10 000 bars. During contact metamorphism the increase in temperature is brought about by the injection of magma. The temperature reached in the country rock at some distance from the igneous body will always be less than the initial temperature of the intrusion, which is presumably less than 1 200°C, and will vary with time and distance from the contact. A simple metamorphic reaction involving dehydration of an aluminous sediment can be: [ ] At higher temperatures sillimanite would form at the expense of andalusite, while kyanite would be the mineral formed at higher pressures, as can be seen in the phase diagram of A12Si05 (Fig. 2).

Jan 1, 1994

By Dirk van Zyl, S. Chander

Minerals have been critical to human society from the earliest and their use has been intertwined with the development of civilization. In the Western World, the mining, processing and extractive metallurgy associated with ores was first described in detail by Agricola in the 16th century. He considered these collective activities to be the most necessary and the most profitable of professions, and wrote, "without doubt, none of the arts is older than agriculture, but that of the metals is not less ancient; in fact they are at least equal and coeval, for no mortal man ever tilled a field without implements. In truth, in all works of agriculture, as in the other arts, implements are used which are made from metals, or which could not be made without the use of metals; for this reason the metals are of the greatest necessity to man." Ours is still a materials-dependent society that relies heavily on minerals for raw materials. Today our dependence on minerals is exceptionally great. To meet the need for fuel and non-fuel minerals in a representative year, in the United States alone, about one billion tons of coal and 2.7 billion tons of ore are mined. These mineral products are essential for fertilizers, for construction materials, metals and alloys, for manufacturing household and industrial items, for transportation, and for the generation of electric power. It is instructive to consider the diversity of uses found in our society for a single mineral product - silver, for example. Experts believe that in the past 5000 years we have mined about a million tons, or 31.9 billion troy ounces of silver. In 1988, 133 million troy ounces of silver were used in the Unites States. Most of the silver used was for techno- logical, medicinal and industrial purposes, Table 1. X-ray films, for example, carry comparatively large amounts of silver to lessen patient's radiation exposure. Silver does not prevent tooth decay, but each year about two million troy ounces of silver is used for dental work in the United States. In small quantities it is used in medicine. No metal - not even copper conducts heat and electricity so efficiently as silver. Silver wires lace solar cells, and silver oxide batteries power hearing aids, calculators, submarines and satellites. Hardened with tungsten or molybdenum, miniature discs of silver pass current from wire to wire in cars, telephones and computers. A dish- washer timer alone may have 50 such electrical contacts, which open and close without excessive heat or friction. Silver is an important component of solar reflectors, since no other material reflects light so well or uniformly. In our personal lives, silver remains in high esteem to adorn our tables, provide precious objects and jewelry. In many parts of the world, silver in the form of coins, jewelry and bullion is used for financial independence and security against the vagaries of paper currency. In India, silver is used in its purest form as thin foils to decorate sweets and other edibles. It is obvious that this mineral product, silver, is of great value and utility in our society. Minerals and Environment The benefits of minerals do not come without problems. Much of the silver, for example, lies locked up in copper, lead-zinc or precious metal ores; to extract it creates vast quantities of waste material. On the average, in order to recover one ounce of silver about a quarter ton of ore must be mined. To meet the world's annual demand for silver, approximately 100 million tons of waste is generated every Year. The problem with silver is repeated with all minerals. Conversion of mineral ores into usable materials necessitates the generation of large quantities of waste products that create tremendous disposal problems. In addition to waste material discarded during mining, wastes may be generated during processing as gases, liquids or solids that must be subsequently converted into forms more acceptable for disposal. Associated with the handling, treatment and management of waste products are a number of environmental problems. Environmental problems are not new to the minerals industry. In his Geographia, Strabo (63 B.C. - 20 A.D.), gives an account of the conditions of labor under which men

Jan 1, 1992

By P. R. Taylor

The ability to process complex precious metal sulfide concentrates containing antimony and arsenic in an economic and environmentally safe manner is an important problem facing the mining industry in the United States. Preliminary experiments have been performed to evaluate the possibility of treating a complex sulfide concentrate to recover antimony and precious metals while fixing the arsenic and sulfur as calcium arsenate and calcium sulfate. The process involves: • the oxidation of the antimony and arsenic minerals in the presence of soda ash (to collect the sulfur dioxide and to keep the antimony and arsenic from forming volatile compounds), •the selective leaching of the arsenic from the roast calcine with a heated caustic solution, •the precipitation of the arsenic and sulfate with calcium hydroxide and/or calcium chloride, •the reduction of the residual antimony (collecting the precious metals), •fuming of the metal to form a marketable antimony oxide, and •crucible reduction of the residue to obtain a gold and silver dore. Batch experiments, using synthetic concentrates of stibnite and arsenopyrite, were performed to evaluate the first stage of this process. Variables studied included mixture weight fractions, temperature, gas flow rate, oxygen partial pressure, and time. All of the off gas dust and sulfur containing gases were collected and analyzed. The roast solid residues were subjected to arsenic leach tests, and the leach solutions were subjected to arsenic and sulfate precipitation tests. Introduction The ability to treat a precious metal ore containing appreciable amounts of antimony and arsenic is dependent upon the characteristics of the ore. For some ores, selective flotation can be used to separate the antimony and arsenic minerals, which are then treated separately. Unfortunately, many ores are not treatable in this way, and the concentrates obtained may contain appreciable contamination (which limits the ability to make acceptable grade antimony products). If we consider the added value of the precious metals in the concentrate, then it is worthwhile to evaluate the potential for new methods to treat these types of concentrates. In addition, the environmental difficulties associated with arsenic disposal must be taken into account in any proposed process. If there is appreciable arsenic present, then it must be either recovered as a marketable product or placed in an insoluble form. The problem addressed in this research program has become increasingly important as the precious metals mining industry is encountering more ores of this type. A large deposit of this type exists in Idaho where the antimony occurs primarily as stibnite, with minor amounts of kermesite and tetrahedrite (Cooper, 1951). The gold appears in association with arsenopyrite with minor amounts of other arsenic minerals. Flotation has been used to obtain an antimony concentrate. The concentrate, however, is contaminated with appreciable amounts of arsenic and also contains precious metals. If the ore or concentrate contains appreciable amounts of base metals, then the recovery process becomes much more difficult. There are a number of other known deposits of this type in Alaska, Canada, Montana and elsewhere. The objective of this research program was to develop a fundamental understanding of the oxidation and leaching chemistry of the arsenic and antimony minerals so that technology may be developed to treat these ores in an economic and environmentally safe manner. Wendt (1949) and Koster and Royer (1940) discussed the possibilities of oxidative roasting of stibnite concentrates containing arsenic. Wendt describes a process used at a smelter in Czechoslovakia (in the 1930s) where roasting was carried out in rotary furnaces at 723° K (500° C). Most of the arsenic was removed as fume, as well as 25% of the antimony. No sulfur dioxide containment was described. The oxide fume from the furnace went to a heated caustic water leach, where the arsenic was preferentially dissolved and then precipitated with calcium chloride as calcium arsenate following solid-liquid separation. The antimony oxide was sold, and the solid oxide discharge from the rotary furnace was sent to a blast furnace where the antimony metal, containing the precious metals, was recovered. The metal was fumed to obtain antimony oxide, and the precious metals were left in the residue and collected with copper. The copper

Jan 1, 1994

By Dominique Francois-Bongarcon

The world mining industry is facing a severe recession. Thus, it is time to recall the value of geostatistical methods which were formerly developed as a money-saving and productivity-increasing tool. The situation has worsened, but the techniques of geostatistics have dramatically changed. Up to millions of dollars can be saved during exploration with simple use of variograms; then, during reserves estimation with kriging methods; and finally, with the parameterization of reserves, when evaluating a project and optimizing its global mining parameters.

Jan 1, 1983

By Frank H. Skelding

A new, large mine is about to be born. Many years and millions of dollars have been invested in exploration. An orebody has been found and proven. All necessary political and legal work to establish rights and conditions for development are complete. The feasibility studies are favorable. Financing has been arranged. Board approval has been given to proceed. The time has come to engage a contractor to design and build the new facilities in a location, as is the common case today, far re¬moved from the centers of advanced technologic development where the minerals will ultimately be used. A select list of Engineering and Construction (E&C) companies is asked to prepare proposals. At this point the common viewpoint among mining companies is that the company's sole remaining problem, a major one to be sure, is to select qualified contractors to design and build the project at the lowest cost and shortest time possible so that production can start generating a return on investment. The purpose of this discussion is to explore the viewpoint of the large E&C contractor toward such projects. It differs in important ways from that of the client mining company and it is these differences and the reasons for them that must be understood by the client if severe difficulties and misunderstandings with the contractor, starting at the beginning of contract negotiation and continuing through design and construction to final startup are to be avoided or minimized. Often enough, the difference is in degree, not kind, which only serves to obscure the fact that a difference exists.

Jan 1, 1975

By Ihsan Berk Tulu, Haochen Zhao, Deniz Tuncay

This paper proposes a new method to estimate the percentage of load carried by the gob in underground coal mines using a new parameter that introduces the site-specific overburden geology. The new parameter was defined as the total strong layer thickness (tstr) that represents the strength and stiffness of the overburden with a single value. Twelve field measurement case studies from 11 different U.S. longwall mines with different overburden geologies were used to develop the new methodology. 2D numerical models of these case studies (and additional parametric runs with different panel widths) were verified against field measurements such as surface subsidence and stress. Statistical analyses using the model results were conducted for a loading model with the new tstr parameter as one of the variables. The new methodology was found to have a coefficient of determination (R2) of 85% when compared to the field measurements and the parametric models. The method was then tested for practical implementation for pillar design. The percentages of load carried by the gob as estimated by the new method were implemented into the LaModel program, that is commonly used in the coal industry. The results obtained from LaModel were compared to the available field stress measurements, and the new method implemented into LaModel was found to give successful results.

Jul 18, 2022

By James R. Hindman

Vermiculite is the mineralogical name generally applied to a group of hydrated, trioctahedral ferromagnesian aluminum platty or micaceous silicate minerals. In microscopic particles the mineral as mineral is differentiated from montmorillonite by a higher Si:AI ratio of approximately 3:l and a higher layer charge and higher cation exchange capacities. Commercial vermiculite, the vermiculite which is mined, beneficiated, and discussed in this chapter, is an important industrial mineral which is formed by the alteration of macroscopic particles of biotite and iron-bearing phlogopite. In natural form it has the size and shape of mica, while possessing the ion exchangeable properties of zeolites and some clays. Within the internal structure of vermiculite lie water molecules, which when rapidly heated to high temperature, transform into steam causing the vermiculite particles to increase in volume. This process of thermal exfoliation produces a lightweight product which finds use in various construction products, agriculture, horticulture, and other industrial applications. In exfoliated form it has the low density and biological inertness of expanded perlite, while maintaining a chemically active surface. Most of the uses of vermiculite are for the thermally exfoliated material. In addition, the cation exchange potential of vermiculite and its layer-silicate structure are properties which can be used as the basis for numerous products including intumescent coatings and gaskets, inorganic films, and the treatment of nuclear and other toxic waste. When chemically and physically modified, it possesses some properties common to organoclays and synthetic compounds. In high purity concentrates and manufactured products, these properties can be altered and optimized in applications to produce superior performance. GEOLOGY Mineralogy Vermiculite was first described as a mineral by Thomas H. Webb in 1824. Webb believed vermiculite to be a variety of talc and described its diagnostic property of thermal exfoliation thusly: "If subjected to the flame of a blowpipe, or that of a common lamp, it expands and shoots out into a variety of fanciful forms, resembling most generally small worms having the vermicular motion exact." Observing that with one exception, all commercial vermiculite has formed by the alteration of iron-bearing phlogopite, a simple definition of vermiculite might be the alteration product of trioctahedral micas, macroscopic particles of which display marked exfoliation when heated rapidly to temperatures above 374°C (the critical temperature of water). The first vermiculite described was found near Worcester, MA, but it was later pointed out by Brush (1866) that vermiculite had been known for some time in Japan as a children's novelty. Because the techniques for mineral analysis were somewhat primitive com- pared to those routinely available today, and because the structure and crystal chemistry of the micas and related minerals were not widely understood, the early literature generated at least 20 "new" minerals which were nothing more than variations in the color and chemistry displayed by vermiculite. Trade names such as Dugarlite, Mandolitem, Strong-LiteTM, and Zonolitem are sometimes used to denote commercial vermiculite, thermally exfoliated vermiculite and their products. Vermiculite particles resemble mica and vary in color from colorless through tan and green to black, depending on the chemical composition. Most physical and optical properties are close to those of biotite, with perfect basal cleavage, hardness between 1.5 and 2.5 Mohs, and specific gravity between 2.2 to 2.8. Fine-sized particles will feel talcose, especially when wet. However, for commercial vermiculite the diagnostic test is that of thermal exfoliation. Vermiculite can display a wide range of compositions, depending on the composition of the original mica and the change of chemistry during weathering and ion exchange. Chemical data for some commercial vermiculites are given in [Table 1]. There are numerous analyses for vermiculite given in the literature, and the analyses of vermiculites from commercial deposits will fall within the range indicated by the average analysis in the table. Many analyses separate the adsorbed water (H2OP) from crystalline water and water as hydroxyl (H20+). The basis of separation of adsorbed water is generally considered to be 100°C. However, hydrate water within the vermiculite interlayer begins to be lost at 75°C and lower. Therefore, measured water content and loss on ignition are combined in the table as H20[total].

Jan 1, 1994

By R. A. Holmes

Although manganese is a metallic element and is widely dispersed in nature, it never occurs except as a compound in combi¬nation with other elements. Use of such compounds in the production of glass is known to have occurred in early Egypt. The dioxide of manganese was considered a compound of iron until 1774 when C.W. Schule first recognized it as an element. In the same year, a Swedish mining engineer, J.G. Gahn, became the first to isolate manganese. In 1856 development of the Bessemer process of steelmaking gave economic importance to manganese, and later, in 1882 Robert Hadfield discovered the benefits of high manganese steels. GEOLOGY Physical Properties Elemental manganese is a silver-gray metal, resembling iron but harder and more brittle and used primarily in alloys (both ferrous and non-ferrous) and a wide variety of chemical compounds. Some of the physical properties of manganese include: melting point¬1 245°C; boiling point-2 150°C; density at 20°C-7.43 g/cm3; specific heat at 25.2°C-O.115 cal/g; latent heat of fusion-63.7 cal/g; hardness on Mohs scale-5.0; linear coefficient of thermal expansion from 0 to 100°C-22 x 10-6. Mineralogy There are over one hundred minerals that contain manganese. These minerals vary from those with compositions that are pre¬dominantly manganese to those having only minor percentages of manganese. Distribution of Deposits Manganese ore deposits are found worldwide and were formed in various geological environments, but only a rather limited num¬ber of deposits have high grade manganese ore in sufficient quan¬tities to be mined and utilized economically on an industrial scale. It is worth noting the fact that almost all of the significant deposits can be classified into two types of deposits: marine chemical sed¬imentary deposits, and residual (secondary) enrichment deposits. There are, however, a much larger number of geological types but these are not of commercial significance at this time. Sedimentary deposits are the most common and are usually stratiform or lenticular. Manganese minerals were formed by a chemical process during the deposition of marine sediments. They usually contain manganese oxides and carbonate minerals, some¬times interbedded together or with other sedimentary rocks such as limestone or shale. Examples of this type of deposit are the Russian ore bodies of Nikopol and Tchiatoura, as well as the Kalahari deposits in South Africa and deposits of Groote Elyandt in Aus¬tralia. Residual deposits were formed in a different way: by alteration of existing manganese deposits or by concentration of the manga¬nese minerals when other minerals were washed away by weath¬ering or ground water processes. The Nsuta deposit in Ghana, the Amapa deposit in Brazil, the Moanda deposit in Gabon, and nodules in the residual clays of the US Southern Appalachians are examples of this type of geological process. In the case of the Ghana and the Amapa deposits, this is only true for the outer layers of the deposit containing oxide minerals, the inner part being comprised of car¬bonate minerals including manganese carbonate, probably from marine origin. Some sedimentary and residual-type deposits have been metamorphosed, giving rise to small high grade ore bodies. These deposits are regionally metamorphosed, occurring in mar¬bles, slates, quartzites, schists, and gneisses. Some of these deposits, such as the Franklin, NJ, deposit are rich enough to be commercial without secondary enrichment; however, most of the exploitable deposits have been secondarily enriched. Due to the diversity and complexity of manganese deposits, both with respect to deposition and chemistry, a wide range of impurities are almost invariably present in the ores. Table 1 shows that the reserves (i.e., a measured resource that can be economically and legally extracted) are estimated at 814 x 106 tons of contained Mn, which equates to more than a 100 year supply at the current level of production. The reserve base is made up of the marginally economic reserves and sub-economic re¬sources and are some 4.5 times greater than the proven reserves. Also apparent from study of Table I is the fact that some 75% of manganese reserves are found in two countries, the USSR and South Africa. On the other hand, North America (i.e., the United States and Canada) have few significant deposits. The largest deposit, or at least one of the largest, in the United States is located at Chamberlain, SD. This deposit is sedimentary

Jan 1, 1994

By C. S. Thompson, P. A. Ciullo

Pyrophyllite is a naturally occurring hydrous aluminum silicate with the molecular formula SiO,,AI,,(OH), or, as more commonly expressed, the oxide formula A120,~4Si02~H20. Pyrophyllite is rarely found in deposits as the pure mineral and is often intimately associated with quartz, sericite, kaolinite, and diaspore. These associated minerals, to a large degree, help determine the most appropriate commercial application for a given pyrophyllite ore. Structural similarities plus the generally soft platy nature of pyrophyllite has in the past caused it to be included with talc in applications and production data. The Minerals Yearbook, published annually by the US Bureau of Mines (USBM), still reports on talc and pyrophyllite together, although admitting that they do not share the same uses. Pyrophyllite has also at times been considered a clay mineral because of its structure and chemistry. The refractory properties of pyrophyllite have been known for nearly 200 years, but it has only been in the past 60 to 70 years that a variety of applications have been developed to exploit the unique characteristics of this mineral. Worldwide, pyrophyllite is a component of refractories, whiteware, foundry mold dressings, pesticides, paint, plastics, rubber, cement, fiberglass, and soap. Historical Overview The most salient refractory features of pyrophyllite are its low coefficient of thermal expansion, high thermal conductivity, low moisture expansion, and good resistance to corrosion by molten metals and basic slags. One of the first recorded uses of this mineral was as firebrick in Japan in the early 1800s. This followed its discovery in 1797 on Mount Omotoyama at the site of the present Mitsuishi mine. In addition to firebrick, sawn blocks of ore were used for carvings and in the manufacture of slate pencils and signature seals. The Mitsuishi mine is still one of Japan's largest. By the mid-1800s, refractories were being made in Japan from roseki (a pyrophyllite-bearing ore) for the construction of metal melting furnaces. The mineral did not get its name until 1829 when R. Herman, testing a sample of supposed talc from the gold-quartz veins at the Berezovo deposit in the Urals, showed that it was actually an aluminum silicate and designated it pyrophyllite. This name was derived from the Greek pur for fue and phullon for leaf, in allusion to the effect of heat in causing separation of the laminae in foliated varieties (Mellor, 1927). The exact date of the discovery of pyrophyllite in the United States is uncertain, but it is believed that the talc and soapstone deposits noted in an 1827 report on the geology of the slate belt of North Carolina were actually pyrophyllite occurrences (Olmstead, 1827). Pyrophyllite was first used in North Carolina on a local basis in the early 1800s. Blocks were sawn and cut for use as stove linings, mantels, chimneys, fireplaces, and gravestones. This was the material of choice because it did not shrink when heated, but cut easily and hardened as it weathered. Pyrophyllite crayons were sold commercially by local gold miners for steel marking and as tailor's chalk from about 1800 until 1922. It was during this period that pyrophyllite was discovered near the town of Hemp (later renamed Robbins), NC. The large quantity of scrap resulting from the sawing of crayons at this deposit prompted the construction in 1921 of a grinding plant. The ore scrap was ground to fine granules and sold to asphalt producers to prevent shingles from sticking together. By the mid-1930s, milled pyrophyllite from North Carolina was also being successfully utilized by the ceramics industry in whiteware for its low cost and ability to shorten firing time. Also during the 1930s, pyrophyllite was first used in kilncar furniture in the United States. Canada was another early entrant in the pyrophyllite business. Mining at the Foxtrap deposit on the Avalon Peninsula of Newfoundland began in 1904, with ore shipped to the United States. Production from this deposit was mostly sporadic in the ensuing years until 1956 when mining began for shipment and captive use in US tile manufacture. This production has remained continuous and still essentially captive to the present. The Foxtrap deposit is currently the sole commercial source of pyrophyllite in Canada.

Jan 1, 1994

By M. Rieber

In July 1985, as the U.S. copper industry contracted and the Mexican industry expanded, a trans border pollution agreement was signed which included smelter air pollution control in the "Gray Triangle": Cananea, Nacozari and Douglas. Since then the Douglas smelter has been closed, a year earlier than initially required; though its new smelter is operating, S02 collection and acid disposal at Nacozari is yet to come; and the Cananea smelter has been un-touched. Nacozari and Cananea copper mining have expanded while a reduced U.S. copper industry has rationalized to a point of fragile profitability. As a paradigm of U.S. copper competitiveness, this paper attempts to explain the differential fortunes of copper in the two countries, to project the future of the smelter agreement as a function of acid disposal, and to consider the consequences of the politicized application of smelter pollution control in Arizona.

Jan 1, 1988

By Ibrahim S. Balbaa, J. Terry Strack, James G. Hopkins

A microwave system for continuously reactivating carbon, used in gold processing, has been demonstrated at a gold mine in Ontario, Canada. The pilot unit produced reactivated carbon at a rate of 12 kg/h. Comparisons with the mine's existing reacti­vation kiln indicate that microwave reactivation technology has several clear advantages over conventional regeneration kilns. Upon completion of the original study, the microwave reacti­vation technology was further developed. An advanced rotary type microwave system that can be scaled up to reactivate car­bon at a rate of 120 kg/hr was designed and smaller pilot-scale equipment was commissioned and tested. Under an agreement with OHT, Harper International Corporation will manufacture, supply, and market the new technology. In addition to carbon reactivation, the rotary microwave system can be used in many other heating applications such as ore treatment, ceramic pro­cessing, and cleaning of minerals.

Jan 1, 1998

By Y. Topkaya, R. E. Johnson, B. R. Palmer, Bruce E. Kurtz, Anatoli Omelian, John I. Choi

This paper relates to hydrometallurgical studies on the recovery of soluble aluminum values from aluminum-bearing ores, i.e., Georgia clays. At least 50% of the soluble alumina values were recovered by leaching the calcined clays from aqueous solutions, comprising simultaneously contacting a stream containing an effective amount of a reducing agent such as sulfur dioxide and a stream containing an effective amount of an oxidizing agent such as chlorine gas for a time sufficient to dissolve alumina. The recovery of alumina from this aqueous slurry of the calcined clay by leaching with sulfur dioxide and chlorine gas showed much better results than that by leaching with concentrated sulfuric acid and/or concentrated hydrochloric acid at 100O C. The leaching reactions between the aqueous slurry of the calcined clay, chlorine gas, and sulfur dioxide were strong exothermic reactions for several hours, requiring no external heating.

Jan 1, 1993