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By B. Hagemeyer

The trend to higher solids paper coating and to neutral/alkaline papermaking is causing an above average growth in the use of calcium carbonate as both a paper coating and a paper filling pigment. These developments are expected to continue well into the 1990s. Thus, calcium carbonate will account for a somewhat larger percentage of total paper pigment volume. Nevertheless, overall growth in paper tonnage coupled with an increase in filler pigment percentages will create a demand for larger quantities of other pigments as well. Kaolin will continue to be the dominant paper pigment by far, with continued growth though at a somewhat slower rate than calcium carbonate.

Jan 1, 1986

By Vincent R. Bovino

Introduction Only a person fresh from an information vacuum could not know the status of this nation's economy. The inability of the US to compete in the world marketplace is manifested in many industries, from shoes to computer chips, from cars to copper. What industry will next fall prey to world competition? Perhaps the question should be, what insustry will next fall prey to declining productivity? American industry is being forced into an era where the focus must be on productivity, quality, cost control, and competition in the world marketplace. It is approaching a change that could rival the American Industrial Revolution. The future of the US is bright only if it can increase productivity by trying different and new ways to manage its businesses and people. Unlike the easy successes during the 60s and 70s, success in the decades ahead will depend on an ability to compete in the world market. Any operation can achieve unlimited productivity by developing the resources within its employees. As an industry, mining has harvested the earth's resources. As an industry in trouble, it now has to learn to tap human resources to release the energy and creativity in each person. Recently, I worked with a mining operation to reopen a mine and implement a different management approach. The extensive changes resulted in a 50% reduction in cash cost of producing silver (from $0.40 to $0.19/g or from $12.50 to $6 per oz). Thus, an unprofitable mine became an attractive business venture without technological changes or significant capital infusion. The operation is union-free, in spite of being in a highly unionized area. The mine implemented a real productivity improvement process called "gain-sharing." Employees now recognize their individual success is tied to the success of the business. They recognize the day of the free lunch is over for mining employees. This paper will explore three areas related to productivity: • some of the unspoken "whys" of the mining industry's paralysis and how management has caused unproductiveness in mining operations; • major components of a productivity improvement process; and • characteristics common to companies with successful productivity plans. Unspoken whys When things go wrong, everyone tends to point a finger at someone, anyone. This industry has blamed every conceivable person, corporate group, government agency, foreign government, and private group for its failures. The fault finger will not work anymore. Nobody is listening. It is a characteristic of winners in management to assume responsibility for less than acceptable performance. Excellent people tend to blame others less for problems. Everyone involved in mining should shoulder part of the blame for the industry's illness. Is the problem low prices or our high operating costs? To regain our status in the world marketplace and increase our productivity, we need to painfully and honestly talk about our mistakes.

Jan 3, 1986

By A. G. Journel

Accurate prediction of recoverable reserves are key to the development and planning of a mining operation. Recovery functions for tonnage, quantity of metal and ore grade are defined and two approaches for their estimation are proposed. The indicator kriging (IK) approach draws on the data rank orders, whereas the multi-gaussian (MG) approach relies on a grade multi-variate distribution hypothesis. Although based on different premises, both approaches yield remarkably similar--and accurate--estimates for recoverable reserves.

Jan 1, 1984

It was shown previously that chalcopyrite could be floated without using a collector when the ore samples were treated with small amounts of sodium sulfide (Na2S). The role of this reducing agent was considered to be one of a cleaning agent to remove the hydrophilic surface oxidation products. It was later found, however, that the collectorless flotation could be obtained only under slightly oxidizing conditions. This might suggest that collectorless flotation is not due to the clean surface but to the elemental sulfur which may be present as an incipient oxidation product. Therefore, a search for the presence of elemental sulfur has been made by means of ESCA, mass spectrometry, and solvent extraction followed by W spectrophotometric analysis. On the basis of these results, the mechanisms of collectorless flotation are discussed.

Jan 1, 1983

By V. W. Smith

For the past 50 years, the primary crushing of stone at the Dolase Bros. Co. Richards Spur Quarry. 13 miles north of Lawton, Oklahoma, has been accomplished by a Traylor 42-inch gyratory crusher. The production capacity of the primary system, consisting of a feeder, grizzly, and the gyratory crusher, was approximately 2100 tons per hour. Shot-down scone was hauled from the working face about one mile to the feeder by a fleet of Caterpillar Model 773's and WABCO 60- and 65-ton trucks. In order to maintain production, nine to ten trucks and four Caterpillar Model 992 front-end loaders were required to be operational at all times.

Jan 1, 1986

By Mike Horn, Keith Meade, Marvin L. Smallwood

Technological changes in programmable logic controllers (PLC)'s and the need to improve the architecture of Mine Wide Monitoring Systems (MWMS) has resulted in the design of a PLC based system at the Virginia Division of Island Creek Coal Company. The system which is presently in the installation phase, is a joint effort of Island Creek Coal Company, Westinghouse Electric Supply Company and Mining Controls Incorporated. The system uses an ethernet based network for graphic display of system data operating under the Genesis software package. Telemetry for the system utilizes the Seimens/Westinghouse L1 network operating over two twisted pairs. Remote telemetry uses fiber optic links and modems operating over standard telephone lines. 500 and 2000 series PLC's provide distributed data processing for the system with hierarchial processing operating under the Genesis software on the ethernet network for individual mine site monitoring along with the remotely located division office monitoring. System control and data acquisition is provided for underground MWMS operations and on the surface for a vast methane gathering system that is used for degasification of the mines and collection of pure methane for sale to the Columbia Gas Company as natural gas. The inability of industrial MWMS companies to keep up with the vast changes in technology, along with economic considerations associated with expanding the existing MWMS created the need for the development of the PLC based system to replace the older industrial monitoring systems.

Jan 1, 1993

By Gordon R. Wicker, Peter V. Avotins, Steven S. Ahlschlager

Laterite ore slurries exhibit Bingham plastic behavior and can be characterized by the magnitude of their yield point and Bingham viscosity. These two parameters are affected by ore composition, solids concentration, and temperature and are used to predict the pressure drop in pipelines and heat transfer coefficients in shell-and-tube heat exchangers. In cycloning of laterite slurries, the calculated cut size is corrected by factors obtained from the rheological parameters.

Jan 1, 1979

By T. S. McGahey

The southeastern region of the United States has long been a major market area for coarse and medium particle size natural ground calcium carbonate fillers. The primary market for calcium carbonate in the southeast traditionally has been as fillers in building materials such as carpeting, joint cement and roof shingles. In these applications the economic value of the calcium carbonate in the final product is weighted more toward lessening the cost of the final product, as opposed to contributing any desirable physical characteristics. For example, in carpet backing applications the calcium carbonate filler does little more from a physical standpoint than add weight and body to the backing adhesive. The important factor in the use of calcium carbonate in carpet backing is that it can be used at high loading levels to replace the more expensive latex binder, thus lessening the cost of the final product. It is estimated that calcium carbonate producers in the southeast sell in excess of 200,000 tons (181,436,000 kg) annually for use in latex compounds for carpet backing applications.

Jan 1, 1986

By D. M. S. Bhatia

The intimate association of iron formation and massive sulfide deposits has been documented by many investigators (McAllister, 1960; Hutchinson, 1972). In a classic example of such an association four distinct facies (oxide, carbonate, silicate, and sulfide) were identified in an Algoma type iron formation occurring in Paleozoic rocks, but exhibiting physical features (banding) and chemical composition (SiO2 + A1203 + Fe2O3) typical of Precambrian iron formations. The geochemical variation of the iron formation was studied by analyzing 62 samples for Si, Al, Fe, P, S, and CO2. Following a model proposed by James (1954), the geochemical and mineralogical variation of the iron formation can be used as an excellent tool for the exploration of massive sulfide deposits.

Jan 1, 1981

By Frank Littlewood

Research over a period of ten years resulted in the development of an efficient automatic ore feed regulator for mill grinding circuits. The facilities that a large mining company gave the inventor made it possible to develop the control apparatus under actual mill operating conditions. The Littlewood Regulator automatically determines the optimum power input at which a mill should operate, and controls the rate of ore feed to maintain this optimum power for any predetermined operating conditions. It is to be noted that the optimum power varies with many factors such as ball, rod, and mill liner wear, therefore the regulator is designed to automaticall keep itself properly calibrated. To efficiently control the rate of ore feed of a mill grinding circuit the regulator analyzes and interprets all power changes of the mill motor. The critical electrical measurements for this type of control are made possible by a patented device that has the ability to detect and integrate minute changes in power. In ball mill operation the small but significant changes in power serve to select the rate of ore feed in accordance with the rate at which ore accumulation takes place within the mill, and in rod mill operation they serve to select the rate of ore feed in accordance with the degree of rod spread.

Jan 1, 1970

By Graham A. Mathieson

The precise definition of an ultimate or economic pit has, over the years, received much attention in the literature on the subject of mine planning. Unfortunately, relatively little has been published in the area of pit sequencing and scheduling--an aspect which is typically of much greater economic significance both during the life of a mining operation, as well as in the evaluation of an exploration project. This paper discusses an overall mine planning methodology with emphasis on the design of an optimal sequence of pit expansions or phases. Although the concepts given are not new, it is hoped that some practical suggestions will be made. The paper will also describe graphical techniques which have been found useful in comparing the merits and impacts of alternate planning strategies and production schedules.

Jan 1, 1982

By G. L. Mowrey

In addition to developing various types of coal interface detection systems, the U.S. Bureau of Mines is actively involved in developing a coal rib thickness monitoring system for high wall mining applications. One particular system that appears to show promise uses a ground-penetrating radar system to detect the coal-air boundaries of coal ribs. Based on preliminary laboratory and field tests, results indicate that this method can be applied successfully in highwall mines to maintain a constant rib thickness. The coal seam should be relatively clean in the vicinity of the antenna (e.g., have minimal partings or dirt bands) for best results.

Jan 1, 1995

By M. Hodgson

The redox reactions that occur on pyrrhotite and pentlandite in contact with oxygenated deionized water were examined using voltammetry. Reactions were put forward in which both minerals were progressively hydroxylated to form thermodynamically metastable surface intermediate products. These intermediates were modelled as metal deficient sulphides where a sulphurous layer was coordinated onto the remaining metal sites via polysulphides. Prior to hydroxylation pentlandite exhibited changes in the surface stoichiometry which were not related to pH effects. The formation of polysuiphide-sulphur intermediates were believed to promote collectorless; flotability for the two minerals. Microflotation tests (0.3 g samples) verified that the surface potential and particle size affected the flotation response, excessive oxidation inhibiting the minerals' flotability. Larger scale tests using ore samples (30 g) confirmed that the extent of pulp oxidation, particle size distribution and the presence of frothers affected the flotation response, the findings being in accordance with the postulated model for the hydrophobic species generated on the pentlandite and pyrrhotite surfaces.

Jan 1, 1985

By Thomas H. Koenning, James R. Boulton

The coal mined by Cyprus at the Shoshone mine near Hanna, WY is highly susceptible to spontaneous combustion. Spontaneous heatings have occurred in the gob of several of the longwall panels and, in some cases, following roof falls. Prevention and detection methods have evolved over the years as more has been learned about the occurrences. Seal design and construction have progressed to reduce air leakage into the gob. Pressure balancing has been successful as a supplement to good workmanship in reducing leakage. Early heating detection has improved as knowledge has been gained. Prior methods of detection relied upon thermocouples detecting a temperature change. Later a gas chromatograph was used to analyze gob gas samples. Initially the products of combustion (POC) were relied upon for detection. Most recently, lack of oxygen depletion in the gob has been used as an early warning of problems. Examples are presented to illustrate the evolution of spontaneous combustion control at the Cyprus Shoshone coal mine. Methods have been developed which minimize the oxygen concentration in the gob and reduce the potential for spontaneous combustion.

Jan 1, 1997

By Norman F. Schulz

The technical excellence of separation achieved in a mineral concentration process, or any other process where two constituents of any kind are physically separated from each other, is expressed uniquely and quantitatively by the Separation Efficiency: ES = (R ? Rg) where R is the percentage of the valuable constituent and Rg the percentage of the waste appearing in the concentrate. The Separation Efficiency meets all the usual requirements of a true efficiency and is independent of the nature of the process used. It can be visualized as the percentage of the feed material that, in effect, actually undergoes complete separation while the rest of the feed is distributed randomly and unchanged into the two separation products.

Jan 1, 1969

By James M. Barker

No commodity agreements now exist for sulfur and a lack of reference to sulfur commodity agreements exists in the literature. Law (1975) made a passing reference to sulfur as one of a group of commodities where "there have been additional control efforts of various types." Clearly, sulfur was a candidate, at least conceptually in the past, for some form of commodity agreement and the following discussion centers on the world sulfur market of the early 1980's in this context. GENERAL THEORY OF COMMODITY AGREEMENTS The upsurge in demands for commodity agreements seen in the last decade or so stems largely from agitation by the less developed countries (LDC) for better economic treatment by more developed countries (MDC). Several economic factors, real or imagined, adversely affect the LDC's as follows (MacAvoy, 1977): 1) variable demand in MDC's causes wide fluctuations in commodity prices which hurt the economies of commodity producers, who are often LDC's although consumer economies may also benefit from more predictable prices; 2) a general decline of commodity prices relative to the price of manufactured goods which hurts commodity producers in their balance of trade while their stocks and overcapacity rise; 3) instability of LDC economies enhanced by the above factors lowers internal stability, inhibits foreign investment, and retards economic growth; and 4) a lack of self respect when dealing with developed countries o, following the OPEC lead, LDC producers want the stature related to cartel market power.

Jan 1, 1985

By R. Q. Honaker

Dense medium processes are used to clean over 50% of the coal that is fed into preparation plant facilities worldwide. The dense medium is formed using ultrafine magnetite which is recovered after the cleaning step using drain-and-rinse screens and magnetic separators. Despite the high efficiency of the recovery system, magnetite losses of around 0.5 to 1.0 kg/ton are common. Considering the recent escalation of magnetite to around $300/ton, an alternative source of magnetic material from coal combustion bottom ash has been investigated. A relatively low cost recovery system has been developed. Dense-medium tests using the bottom ash magnetics revealed a high level of efficiency as indicated by probable error values around 0.03 over the range of medium densities investigated. The results from both the recovery and coal cleaning efforts will be discussed in detail.

Jan 1, 2009

This paper presents the results of an experimental study undertaken to demonstrate the feasibility of using silica sand as a grinding media in stirred ball mills for ultra-fine coal grinding. Laboratory batch as well as bench scale continuous tests indicate that the use of silica sand can reduce the energy consumption by 50% and more over its steel media counter-part. Moreover, this approach has been found to eliminate the disadvantages observed with grinding using steel media such as high replacement cost, contamination of coal through media wear, greater degree of coal oxidation due to higher slurry temperature and greater level of noise dissipation. Additionally, coal-sand attrition system reduces the manpower time required which is often spent towards cleaning and storing of steel media in inert atmosphere to avoid rust and corrosion problems.

Jan 1, 1991

By O. T. Rämö, E. Suikkanen

Episyenites are sub-solidus, quartz-depleted alkali-feldspar-rich rocks. They form veins and lenticular bodies in granitoid rocks and migmatites in a late- to post-orogenic or anorogenic setting. Leaching of quartz is usually a response to a flux of weakly saline hydrothermal solution in circulation cells above cooling intrusions, where sufficient fluid-rock ratios and thermal gradients are achieved. Fluid Si-undersaturation is achieved by rapid cooling within the field of retrograde Si solubility or by temperature and pressure increase outside retrograde conditions. Some quartz may also be consumed in metasomatic reactions and in response to pressure fluctuation in sealed episyenite bodies. The small size and overall rarity of episyenites imply that conditions for episyenite formation are not commonly encountered in the crust. In addition to quartz depletion, episyenites record complex histories of metasomatic alteration and hydrothermal mineral growth. Nearly all episyenites have undergone Na-metasomatism, which may have led to the formation of nearly monomineralic albitite, and which is occasionally followed by late K-metasomatism, phyllic alteration, and argillization. Depending on the effectiveness of later compaction, recrystallization and vug-filling episyenites may preserve the macroscopic porosity formed by quartz dissolution and brittle deformation. Vuggy episyenites can act as significant sinks for metals carried by crustal fluids and host many significant U, Sn, and Au deposits worldwide. Rare earth-critical syenitic fenites around alkaline intrusions share mineralogical and genetic traits with episyenites.

By O. T. Rämö, E. Suikkanen

Episyenites are sub-solidus, quartz-depleted alkali-feldspar-rich rocks. They form veins and lenticular bodies in granitoid rocks and migmatites in a late- to post-orogenic or anorogenic setting. Leaching of quartz is usually a response to a flux of weakly saline hydrothermal solution in circulation cells above cooling intrusions, where sufficient fluid-rock ratios and thermal gradients are achieved. Fluid Si-undersaturation is achieved by rapid cooling within the field of retrograde Si solubility or by temperature and pressure increase outside retrograde conditions. Some quartz may also be consumed in metasomatic reactions and in response to pressure fluctuation in sealed episyenite bodies. The small size and overall rarity of episyenites imply that conditions for episyenite formation are not commonly encountered in the crust. In addition to quartz depletion, episyenites record complex histories of metasomatic alteration and hydrothermal mineral growth. Nearly all episyenites have undergone Na-metasomatism, which may have led to the formation of nearly monomineralic albitite, and which is occasionally followed by late K-metasomatism, phyllic alteration, and argillization. Depending on the effectiveness of later compaction, recrystallization and vug-filling episyenites may preserve the macroscopic porosity formed by quartz dissolution and brittle deformation. Vuggy episyenites can act as significant sinks for metals carried by crustal fluids and host many significant U, Sn, and Au deposits worldwide. Rare earth-critical syenitic fenites around alkaline intrusions share mineralogical and genetic traits with episyenites.