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By W. J. Pennstrom, J. R. Arnold

Gold Fields installed what was the mining industry's first commercial gold electrowinning/replate circuit at Ortiz in 1981. Its highly successful operation since that time provided the design basis for a similar circuit at Mesquite, which was started in early 1986. These circuits produce plated gold foil suitable for direct shipment to a refinery or melting directly into bars. Detailed descriptions of the electro- winning and replate circuits are given and advantages and disadvantages are discussed.

Jan 1, 1988

By H. M. von Seebach, M. P. Trubeljal, L. G. Austin

Six US coals and a crystalline quartz were tested in an instrumented laboratory high-pressure grinding rolls machine equipped with 100-mm-diam. rolls. The machine was choke-fed to maximize the capacity. As expected, the specific capacity decreased with increased grinding pressure for each material tested. Among the six coals, there were significant differences in the critical angle of nip, the effective feed porosity and the variation of strain at the gap relative to the grinding pressure. Although a precise correlation was not obtained, the overall effect of these factors was that, at a given grinding pressure, the specific capacity increased as the Hardgrove grindability index of the coal increased. The relationship between the specific capacity and the grinding pressure for a given coal was independent of feed size down to 150 µm. However, smaller feed sizes produced anomalous results, and the flow within the feed hopper was restricted.

Jan 1, 1996

By William C. Cooley

Modern tunnel boring machines are subject to excessive cutter wear and bearing failures when used in hard and abrasive rock. In very hard rock, the high cost of cutter and bearing replacement, combined with slower excavation progress, make it more economical to drive tunnels by conventional drill and blast methods. The use of high pressure water jets to break rock provides a promising alternative. Experimental data indicate that the specific energy (the energy expended per unit volume of rock broken) decreases as the water jet pressure increases. Continuous jets are generally limited to pressures below 100,000 psi, whereas pulsed jets from a water cannon can attain much higher pressures. Therefore, the Federal Railroad Administration of the U. S. Department of Transportation has sponsored the design (Ref. 1 & 2) and the fabrication and testing (Ref. 3 & 4) of a water cannon to determine its effectiveness in rock disintegration at very high pressures. This paper reports the results of laboratory tests with pulsed jets against large rock samples at pressures of 125,000 to 650,000 psi and field tests against dolomitic limestone and granitic gneiss at pressures near 450,000 psi. Although initial tests were made with a small nozzle, operating at off-design conditions (Ref. 4), this paper only covers results with the full-size nozzle, including 55 laboratory test shots and 67 field test shots.

Jan 1, 1974

By H. V. Scotland

Lafarge Corporation's Texas Quarry, in Baltimore MD, achieved a substantial expansion of pit reserves by removing an inactive underground mine. The daylighting program, designed, and completed in 1997, open pit mined more than400 meters of room and pillar workings which were originally developed to recover high brightness Calcium Carbonate. The project proved to be a challenge throughout its course as the pit plan was modified and successful daylighting techniques were developed to remove the mine without adversely affecting the safety of the operation, quality of the stone recovered, or negatively impacting the surrounding community. The design parameters and techniques developed and implemented at Texas may prove of interest to other operators as they are faced with daylighting opportunities. This article will detail the challenges we faced and the solutions which made the project a success.

Jan 1, 1999

By R. M. Wheeler

For years the blasting industry has recognized eight milliseconds as the minimum delay time interval required between charges in order for them to be considered to fire independently of each other. However, computer analyses of seismic recordings made of several surface mine blasts reveals that this time interval may not always be sufficient for adequate vibration separation to occur. In some situations a combination of short delay periods and low frequency vibrations can result in waveform reinforcement. Various analyses of seismic recordings obtained from single hole detonations can be used to predict delay intervals that may enhance or reduce blast vibration effects.

Jan 1, 1987

By D. A. Kramer

Seawater and natural brines accounted for about 51percent of U.S. magnesium compounds production during 2004. Dead-burned magnesia was produced by Martin Marietta Magnesia Specialties from well brines in Michigan. Caustic-calcined magnesia was recovered from sea-water by Premier Chemicals in Florida; from well brines in Michigan by Martin Marietta and Rohm and Haas; and from magnesite in Nevada by Premier Chemicals. Intrepid Mining and Great Salt Lake Minerals recovered magnesium chloride brines from the Great Salt Lake in Utah.

Jan 1, 2005

By R. D. Doepker, P. L. Drake

The dissolution of metals from various metal- mine tailings has been studied through a series of submerged tailings batch tests at US Bureau of Mines laboratories. Tailings selected for this study included both reactive (as determined by column leaching studies) and benign tailings. Metal mobilization in aerated (97% saturated with oxygen) samples appeared to be consistently greater than metal dissolution from stagnant (79% or 70% saturated with oxygen) waters. In the early weeks of the study, sulfate concentrations increased with solid-liquid contact time, while calcium dissolution remained early constant. Metal concentrations varied in relation to solid-liquid contact time and aeration. Leachate pH appeared to be nearly independent of solid-liquid contact time for basic tailings. Reactive tailings having both a submerged and a surface component demonstrated increased metal mobility.

Jan 1, 1991

By C. H. L. Bastos

A physical and chemical characterization study was carried out on 483 kaolin samples from 2.9 km2area at the Para Pigmentos mine along the Capim river, northern Brazil. The samples obtained from cores, drilled with regular spacing of 100 m, were evaluated using grit percentage, particle size distribution (psd), brightness, leachability, magnetic response and viscosity. These parameters were correlated with each process step in the plant and also the physical and chemical properties of the ore and finished product. Cluster analysis was performed and four main groups of kaolin were identified. These were then related to their performance at the various process steps and the quality of the initial product. These groups are well defined by plotting grit X “psd” and TiO2x “psd” in scatter plots.

Jan 1, 2004

By C. L. Karr, E. J. Gentry

Researchers at the U. S. Bureau of Mines have developed a control algorithm to efficiently manipulate chaotic systems. The control, based on both fuzzy logic and genetic algorithms, prescribes actions that drive the chaotic system to acceptable regions of state space. The use of fuzzy logic enables a person who has limited experience with a chaotic system to establish a set of rules for manipulating the problem environment, and a set of membership functions that define terms used in the rule-set. Genetic algorithms are search algorithms based on natural genetics, and are used in the control algorithm to select membership functions that provide for a suitable level of control. The Bureau-developed algorithm controls the computer simulation of a ball bouncing on an oscillating table, a system that exhibits chaotic behavior.

Jan 1, 1993

By P. Somasundaran, C. C. Harris

The power consumption of stirred-media mills was studied using an approach developed from work on stirred reactors. Evaluated were the relationships of factors such as stirring speed and impeller and tank dimensions on the torque required to rotate disc and pin impellers immersed in dense particulate media. Data collected under carious experimental conditions were analyzed. The results were summarized and presented in the form of characteristic plots, general equations and dimensionless group correlations involving power and modified Reynolds numbers. Special attention was directed towards the rheological properties of the media, which was considered a non-Newtonian liquid, and hence the equation of power-law liquids was employed. A procedure for estimating the parameters of effective viscosity and scale-up guidelines (with respect to power consumption) are proposed.

Jan 1, 1996

By Edward (Ted) M. Dowey

Shaft 26B of New York City’s Third Water Tunnel was constructed by Frontier-Kemper Constructors, Inc. of Evansville, Indiana. The 176.8 m (580 ft) deep shaft will serve as the construction shaft for the Manhattan spur of Water Tunnel No. 3. Twelve m (40 ft) of over-burden was supported by a rectangular cofferdam. This shaft was excavated in 13 months, through 164.6 m (540 ft) of rock, using 24,040 kg (26.5 tons) of explosives. Concrete lining cycles included the installation of stainless steel pipes embedded in the lining as the shaft advanced. A total of 635 m (2,084 linear feet) of stainless steel pipe was installed.

Jan 1, 1997

A roof rating system has been devel¬oped for upper seam damage prediction during mul¬ti-seam mining based on structural and geologic conditions in the upper seam. Two primary consid¬erations -geologic and spatial - form the basis of the classification system. It includes factors commonly found in geomechanics classification systems as well as factors which are peculiar to multi-seam mining, such as those which define the two adjacent seams and the innerburden. This rating system has been applied to numerous case studies to form empirical relationships for quan-titatively predicting potential upper seam damage based on anticipated subsidence and strain values and vertical movements.

Jan 1, 1988

By C. D. Breeds, F. E. Valencia, J. H. Pye

The "FIRST AUTOMATIC SHOTCRETE TECHNIQUE" (F.A.S.T.) system, provides safe, efficient methods of remotely lining, shafts/raises. Two systems are available; one system will be used to shotcrete a 3.04m (10-ft.) diameter ventilation raise at a mine in Mexico; the other system incorporating remote control and sensing devices will to used to shotcrete ventilation raises from 2.75-4.9m (9-16 ft.) in diameter. This paper describes development of the system, from idea to field use.

Jan 1, 1981

By Jihong Xue, Jialin Wang, Della Valle Nicola

Experience of Hard Rock TBM excavating soil in Wanjiazhai Yellow River Diversion Project tells us that selection of Hard Rock TBM to excavate soil in case that rock dominates overall length of tunnel, could be a compromise among tunneling speed, cost and quality. Risk of this operation could be greatly reduced with a detailed study of the geomechanical characteristics of the soil and, if the characteristics are suitable, money and time can be saved by using Hard Rock Double Shield TBM.

Jan 1, 2003

By Bob Gordon, Allen Furth, Dan Dobbels

A 4.8 m (16 ft) diameter hard rock tunnel was driven through granite bedrock to create the 1.7 kilometer (1.1 mile) long Hampton McCloy Retention Tunnel for the city of Richmond, Virginia. During the work the tunnel encountered narrow seams of partially decomposed granite that were not self supporting and could be dealt with using ribs and lagging. However, as the tunnel approached the receiving shaft, it encountered a large seam of highly decomposed rock, alluvial deposits and running sand which resulted in soil loss into the machine. As a result of this condition, a jet grouting program was quickly developed to allow the tunneling to continue. This paper will describe the manner in which jet grouting was used to solidify and stabilize the decomposed bedrock, alluvial soils, and running sand to allow the TBM to continue tunneling.

Jan 1, 2003

By B. E. Davis, D. A. Stanley, C. E. Jordan

A prototype expert advisor was developed by the U.S. Bureau of Mines to systematically offer advice on the control of a Florida phosphate operation. The PC based system receives input from remote sensors for circuit parameters such as feed rate, reagent addition, and pH and from operator entered information such as the quality of the concentrate and tailings in each of the coarse, fine, and amine flotation circuits. The computer evaluates the information using rules obtained from industry representatives and Bureau flotation experts. Recommended actions and questions are displayed to quickly guide the operator to a problem within the flotation circuit and suggest a solution. This process control system could provide more uniformity among the flotation operators and also serve as a trainer for new operators. In addition, it represents a step toward fully automated systems for phosphate flotation.

Jan 1, 1990

By A. Venkatachalam

Spinel ferrites, like NiFe2-2x Znx Ti4 O4 Fe CO1.5 Ge0.5 Tix O4, Ga1-x Fex Ni CO O4, Nil-x Fex Mn2 O4 have been prepared using the respective metal oxides in Stoichiometric quantities, by the ceramic method. The oxides were homogenized in acetone medium, pelletifed by using poly vinyl acetate as the binder. They were fired at 1000°C for 100 hours for compound formation. Chalcogenide spinels such as Zn1-x Cux Cr2 Se4 where 0=x=l and Cu1-x Fex Cr2 Se4 where 0=x=0.3 have been prepared by using 99.99% pure elements and then fired at 1000°C in quartz ampoules under vacuum conditions. X-ray diffraction studies of these compounds indicated a single cubic spinel phase. DC resistivity studies of the compounds were taken between 300-700K using LCR bridge by two probe technique. Thermo-electric power measurements were taken between 300-500K for all the compounds. Initial susceptibility studies have been carried out using a low field (0.506) and from which the nature of magnetic dimains and Curie temperatures were determined. Magnetic hysteresis measurements were carried out at 300K and at 80K, using alternating current hysteresis loop tracer, at 2K02 field. Mossbauer spectral measurements were carried out using Co57 source embedded in a copper matrix and an absorber containing 0.3 mg/cm2 of the sample. The spectra has been fitted by Mossfit Program. The catalytic effect of the spinel ferrites NiFe2-2x Znx Tix O4 where 0=x=1 has been studied by using the model reaction of decomposition of H2O2 at temperatures from 40°C to 70°C. It was found that the spinel oxides were found to possess poor catalytic activity.

Jan 1, 1990

By Klados. T.

MSC.Software assessed the performance of the drive end and non-drive end bearings on a ball mill using the finite element method. The assessment included the effect of mill and pedestal deformation on the performance of the bearings. Oil film thickness, oil pressure distribution and power requirement were of interest. A solution approach coupling a structural solver to a Reynolds equation solver was specifically developed for the project. Results showed that the deformation of the bearing surfaces had a significant influence on the performance of the bearings. For example, for the non-drive end bearing, the minimum oil film thickness computed for the deformable bearing surfaces was significantly lower than calculated for the non-deformable case. The results also showed that cavitation was likely in both the drive end and non-drive end bearings (severe negative pressures were obtained in both bearings). Other design variations were also assessed, e.g. a case with a modified radial clearance which improved the results.

Jan 1, 2006

By Silvia H. M. Grimaldi, Afonso H. Martins

The scope of this experimental work was to study the yttrium extraction and stripping behaviour in a solvent extraction system with mono(2-ethylhexyl)2-ethylhexylphosphonic acid (IONQUEST 801) in a chloride system The study was performed for only one contact between organic and aqueous phases The experiments were carried out according to a factorial design. Due to the statistical analysis and its experimental proof, the optimum conditions for maximum yttrium loading into the organic phase of the extraction stage were 16 minutes for time of contact between phases, 980 rpm of stirring intensity and pH=2.3 for the aqueous phase of the sovent extraction system. The optimized experimental conditions by the statistical approach for the stripping stage were: time of contact between phases equal to 20 minutes, 1050 rpm of stirring intensity and 1.75 M HCI into the stripping aqueous solution.

Jan 1, 1995

By Clement K. Chase, Manuel Lastra, George M. Potter

Heap leaching for gold-silver recovery in the western United States has been widely applied. Advantages, disadvantages, and requirements of the method are discussed, as well as heap building, recovery systems, agglomeration applications, and safeguards against freezing. A list and review of current heap leach operations world-wide are presented, together with obvious opportunities for application of this innovative technique in new areas.

Jan 1, 1983