Search Documents

By J. Richard Tonry

In portland cement manufacturing, the raw materials axe changed to clinker in the burning operation. Generally the rotary kiln is used for this purpose and involves many processes, including pelletizing and nodelizing. This transformation is called clinkering, and is analyzed as now generally practiced in cement making, from the raw material to the resulting clinker.

Jan 1, 1963

By Chester A. Rowland, David M. Kjos

INTRODUCTION Mineral ore comminution is generally a feed preparation step for subsequent processing stages. Grinding, the fine product phase of comminution, requires a large capital investment and frequently is the area of maximum usage of power and wear resistant materials. Grinding is most frequently done in rotating drums utilizing loose grinding media, lifted by the rotation of the drum, to break the ores in various combinations of impact, attrition and abrasion to produce the specified product. Grinding media can be the ore itself (autogenous grinding - primary and secondary), natural or manufactured nonmetallic media (pebble milling) or manufactured metallic media - steel rods, steel or iron balls, or a combination of autogenous media and steel balls (SAG milling). This chapter covers rod and ball mills utilizing manufactured metallic grinding media. MILL DESIGN The interior surface of rod and ball mills exposed to pulp and/or grinding media are protected from wear and corrosion by rubber, metallic or a combination of rubber and metallic wear resistant materials. Rod and ball mills essentially draw constant power, thus are well suited for use of synchronous motors with power factor correction capabilities as drive motors. A net of approximately 120 to 130 percent of running torque is required to cascade the charge in these mills. The pull-in torque is about 130 to 140 percent with the pullout torque to keep the motor in-step (in-phase) generally in excess of 150 percent. When rod and ball mill are started across-the-line the starting and pull-in torques result in inrush currents exceeding 600 percent which possibly result in high voltage drops. To deliver 130 percent starting torque to the mill the motor design must take into account the maximum anticipated voltage drop. Motor torque decreases as the decimal fraction of the voltage available squared. E.g., a motor rated 160% starting torque with a 10% system voltage drop will deliver 160% x or 129.6% torque to its output shaft When it is not possible or practical to start a fully loaded synchronous motor across-the-line it is possible to utilize the motor's pull- out torque to start the mill. By using a clutch, normally an air clutch. between the motor and the mill, the motor is brought up to synchronous speed before the clutch is energized. If the motor has an adequate amount (175 or greater) of pull-out torque the pull-out torque starts the mill without major disruptions on the electrical system. Since the energy release at initial cascade of the mill charge is an inverse function of acceleration time, a minimum acceleration time of 6 to 10 seconds or more is recommended to prevent damage to the mill or the mill foundation. Economics at the time of plant design and mill purchase determine the drive to be used. The simpliest drive is the low speed synchronous motor with speeds in the range of 150 to 250 RPM connected to the mill pinionshaft by either an air clutch or flexible coupling. Using a speed reducer between the motor and pinionshaft permits using motors having speeds in the range of 600 to 1000 RPM. In this speed range, if power factor correction is not required induction motors can be used; squirrel cage where there is no restriction on inrush current; slip ring where a slow start and low inrush current is required. Air clutches can also be used to ease starting problems with squirrel cage motors. In some areas of the world induction motors and starters are less expensive than synchronous motors at a sacrifice of motor efficiency and power factor correction. Dual drives, that is two pinions driving one gear mounted on the mill, become economical for ball mills drawing more than 3500 to 4000 horsepower (2600 to 3000 kilowatts). Further developments of the low frequency, low speed synchronous motors with the rotor mounted on the mill shell or an extension of one of the mill trunnions could improve the cost picture for these "gearless drives", making them practical for large ball mills. The percent of critical speed, which is the speed at which the centrifugal force is sufficiently large to cause a small particle to ad- here to the shell liners for the full revolution of the mill is given in mill specifications. Critical speed is determined from the following: Where D is mill diameter inside liners (specified in meters). Cs is critical speed in RPM. When D is specified in feet

Jan 1, 1998

By Maria S. Adusumilli, A. Bhaskara Rao

ABSTRACT The presence of gold in lateritic crusts over mafic and ultramafic volcanogenic complexes in / and greenstohe belts, has called the attention in several parts of Brazil and also in Australia. Recent studies reveal the variety of structures and mineralogy of such crusts, and their importance in correlation with host(bed) rock types, as exploration guides, specially for greenstone belt metallogeny. The expected nature of growth of plates and/or nuggets in such crusts is under detailed study, and is considered as possibly due to dissolution and reprecipitation phenomenae of disseminated-fine-low grade ore in the host rock, in this investigation, laterite geochemistry, though incipiently discussed todate, is of fundamental importance and significance. Lateritic gold can be classified texturally as: dusty and diffused, fine, thin platy, taDular, and nuggets. Such gold is pure, and is often restricted to nodular (pisoliths, ooliths, concretions) forms or the matrix, that constitute the crusts or lateritised gravel beds which have an essentially goetnitic nature. Further this gold is recovered directly by mining the crusts or the adjoining placers with the metal derived from them. The thickness and extension of laterite crust zones is extremely variable depending oh the paleoclimatic conditions, and is conditioned to the favourable lithology and its structural expression. However, the "growth" of gold in these laterites will be conductive , without doubt, to several small scale mining activities, specially in the developing countries and regions limited to latitudes 309N and 309S.

Jan 1, 1987

By Ryne Goodnough

INTRODUCTION The Wyodak Mine is located in the northern Powder River Basin of Wyoming and is thought to be the oldest continuously operating coal mine in the United States, having recorded yearly production since 1923. The mine has expanded over its 80-plus-year history from an underground room and pillar operation to a modem surface snip mine. Currently, the mine feeds four on-site power plants using conveyors, has a filly automated truck load-out, and ships coal by rail to nearby Wyoming power plants. Annual production of 4.8 MTFT is accomplished on a single-shift basis with 53 fill-time production, maintenance and administrative personnel. In 1990 a decision was made to modernize the coal feed system to the power plant complex with modular conveying equipment. The project involved constructing coal storage silos, overland conveyors, feeder breakers and modular conveyors to follow the mining benches. Total project cost in excess of $25 million was used to construe or commission: A 2,150-TPH 48-inch overland conveyor with horizontal curve A 2,150-TPH 48-inch plant feed conveyor 13 shuttle conveyors, each 150 feet in length 2 front-end loaders equipped with large coal buckets 2 crawler-mounted feeder breakers with compatible discharge conveyor 1 high-lift shuttle conveyor with adjustable discharge height 1 high-angle conveyor 2 4,500-ton coal silos with automated truck load- out capabilities. Conceptually, the plan was to develop 33 MTONS of reserve adjacent to the plant complex and use front-end loaders to tram ROM coal to in-pit feeder breakers. The primary crushing would reduce coal to 6-inch minus and feed through a series of shuttle conveyors to an overland supply conveyor. The overland conveyor would feed the secondary crusher, and the crushed product would be moved to any of four storage silos using conveyors. The in-pit crushing and conveying system is a unique fit for the power plants and provided many interesting challenges for the coal mine to overcome. System integration, maintenance windows, equipment availability and the like had a major role in engineering the system to a power plant complex having no emergency coal stock- pile and limited plant storage. In crediting the designers and operators, the in-pit conveying system at the Wyodak Mine has delivered coal to the power generators since 1994 with little or no downtime. ENGINEERING CONSIDERATIONS Yearly production for the mine is based on 3.5 MTPY which requires about 1,550 TPH on an 8 hour, one-shift- per-day, 5-days-per-week basis. Considering efficiencies for starting and stopping, crew transport, loader trams, and operational delays, a nominal conveyor feed rate of 2,150 TPH or 72% system utilization was used in engineering design application. This ton-per-hour basis is used to size and commission the remaining components of the in-pit system. Coal quality requirements also played a role in equipment selection. The mine reserve grades vertically and coal from Upper and Lower benches needed to be mixed in any given proportion. This required equipment to be filly variable and capable of producing all or part of the 2,150-ton-per-hour requirement. Bisecting the 80-foot- high coal face for quality required construction of a high lift module capable of reaching a single overland conveyor 40 to 50 feet above the pit floor. Designers built a high-lift, adjustable and portable module specific for this application Having two bench systems capable of each producing the required feed for the power plants required computerized control processes to control on-line production. RSLinx, RSLogix, and RSView were chosen as the communication and control software, and a Data Highway Plus serves as the communication backbone. Each of the two in-pit benches are controlled with a data center equipped with Allen Bradley 5-40 processors. This

Jan 1, 2004

By Leslie C. Thompson

The heap leach process used for recovering gold from oxide and sulfide ores is operated as a closed circuit system in which the cyanide process solutions are continuously recy­cled. In a well-designed operation there is little or no dis­charge of cyanide to the environment. Spent leached ore residues are water washed to remove most of the trace cyan­ides and precious metals remaining after completion of cyan­ide leaching. After the washing step, small amounts of cyanide, metal-cyanide complexes and nitrates remain in the residue. Most of the cyanide and nitrate residue constituents exist in the pore water of the spent ore rather than in the solid mineral fraction. More than 90% of the complexed cyanides in a freshly washed ore residue are present as free cyanide or weakly complexed metal-cyanides. Natural volatilization and decom­position rapidly remove most of these easily dissociable cyanides from the spent ore. Only the stable, strongly com­plexed metal-cyanides, such as gold, cobalt or the ferrocyan­ides and other constituents such as nitrates have a long term persistence in the spent ore residue (Towill et al). Despite washing and natural removal mechanisms, spent ore has the potential to act as a point source of com­plexed cyanides and nitrates for soil and groundwater con­tamination if inadequately contained (Huiatt et al). The groundwater contamination is caused by the leaching of the soluble cyanide compounds and nitrates from the pore water of the residue.

Jan 1, 1990

By Scott D. Kinsala, Patrick T. Flynn, Andrew T. Rosol

During calcination of diatomaceous earth, cristobalite is formed in varying percentages. Also, during efforts to recycle products containing natural diatomaceous earth, various heat treatments are used which may or may not result in the formation of cristobalite. The ILO (International Labor Organization) Encyclopaedia of Occupational Health and Safety states that conversion begins at 450'C and in the presence of a flux, is complete at 800'C. Due to the potential adverse health effects associated with crystalline silica, a more thorough understanding of the time/ temperature relationship is needed. Tests performed under controlled conditions do not substantiate the claims made in the ILO Encyclopaedia.

Jan 1, 1991

By LeRoy D. Poindexter

TWO-INCH TO MINUS #100 MESH IN ONE GO The need to reduce mineral ore to a very fine mesh economically has been a timeless problem in the mining industry. With this as the specific and we.l.l focused objective, the Cyclone Crusher has been designed and is being manufactured. Utilizing space age technology from such military projects as piercing steel plate with plastic particles, the Cyclone uses the physical principles of centrifugal force. Through a combination of very high G-forces and asymmetrical loadings between a cone and anvil, particles are pulverized to very fine mesh gradation. Just how fine the final product will be, of course, is dependant on a number of factors. The machine setting, the feed rate, the gradation of the in feed material, the molecular structure of the material, and the original fracture planes of the material all affect the end result.

Jan 1, 1992

By L. F. Nicolai, W. J. Schlitt

Lateral migration of leach solution in heaps and dumps is attributed to two phenomena. One is site-specific anisotropic conditions that exist on a macroscopic scale on the surface or within the rock piles. The second is associated with a random walk phenomenon that causes dispersion of solution, especially at gradients in flow or hydrostatic pressure. The latter phenomenon is a general condition that will occur in any leaching operation. Its effects are modeled by computer analysis and are compared with available field data on heap leaching. Under appropriate assumptions, the observed 58° angle of solution dispersion can be reproduced by the model. The combined effects of both anisotropy and random walk are also discussed. Finally, the impact of lateral solution flow on actual leaching operations is considered.

Jan 1, 1988

By I. Douni

In the last decade there is a growing interest from the society about the rational use of raw material resources and the minimization of the environmental impact of production processes and products when they reach the end of their life cycle and are disposed in the environment. In order to respond to this societal request industrial and scientific community have made considerable effort to optimize the environmental performance of the production processes and products and also to develop the necessary tools to quantify the environmental impact over their entire life cycle. In this framework the methodology of Life Cycle Assessment (LCA) has been developed about fifteen years ago and since then it has become a widely acceptable tool to quantify and assess the environmental impacts. The application of the LCA methodology can significantly assist the mining and mineral processing sector in the development of a strategy concerning the rational exploitation of raw material resources, the management of solid and liquid wastes and the optimization of the metal and mineral production processes. In this paper the work that is currently being done in the Laboratory of Metallurgy of the National Technical University of Athens concerning the Life Cycle Analysis of the production processes of basic metals, as copper, nickel, lead, zinc, aluminum etc is presented.

Jan 1, 2003

By F. Schreiter

"One method to increase the exploitation rate of a mine is the use of backfill with residual materials in exploited areas. The backfilled material is meant to support both, the walls of galleries and pillars as well as the roof of mining openings. With increasing depth, the exploitation rate diminishes fast, thus the application of backfill in order to change the layout of the mine is crucial for economic success. In result of using backfill, it is possible to change the layout of the working area with a higher ratio to excavated areas and less area occupied by pillars. Thus it is possible to boost the output of a mine by using backfill. Setting the criteria for the selection of the best possible materials and whose improvement, it is useful to know about their qualities and handicaps. The Mining Department at TU Bergakademie Freiberg is analyzing the parameters of residues from different processing methods, accrued in plants of different potash mines and blending different residues for optimization of material attributes. These were significantly characterized by basically parameters like the size and the distribution of different diameters of the grain material. INTRODUCTION The chair for underground mining methods at TU Bergakademie Freiberg is tasked with the sufficient and sustainable supply of economics with raw materials. The steady high demand, the rising prices and the finiteness of the deposits are reasons for the need of an optimized economic utilization of natural deposits, a continuous improvement of mining technics and technology. From an ecological and economical position the best possible utilization of the resources has to be achieved. Many mining operations are by reasons of the deposit not able to haul valuable minerals only, they have to haul a mixture of valuable minerals and waste rock. This hauled combination is given into the processing plant for separation and enrichment of the valuable mineral. The residuals of the processing are commonly dumped to a waste rock pile. For minimizing the size of such a waste rock pile and also minimizing the ecological footprint of a mining operation the only way is minimizing the quantity of accruing waste rock material. Both, optimization of economic utilization and also minimization of waste rock dumps can be realized in one by backfill with processing waste rock material in mined out areas. Especially in mines, mined by room and pillar method, smaller dimension of the pillars are sufficient for safety and stability. By the way less valuable minerals have to be leaved back in the mine and the mine outcome is increasing."

Jan 1, 2015

By Kim A. Lapakko, David A. Antonson, Jon R. Wagner

This study examined the potential of mixing rotary kiln fines (RK fines), a waste product generated when limestone is converted to lime (CaO), with acid producing mine waste to provide 1) short-term mitigation by neutralizing acid produced by iron sulfide oxidation and 2) long-term mitigation by facilitating the passivation of iron sulfide mineral surfaces. Five loadings of RK fines were mixed with 75 g of Duluth Complex rock to produce neutralization potential (NP) added: acid potential (AP) quotients of 0,0.11,0.22,0.66 and 1.1. The mixtures were subjected to wet-dry cycling laboratory testing for 585 weeks. The rock alone produced acidic drainage, with pH decreasing below 4 after about 20 weeks of reaction and ultimately reaching the approximate range of 3.3 to 3.5; sulfate release did not decrease over time. The RK fines elevated pH and inhibited sulfate release for time periods which increased with the mass of RK fines present. The pH of drainage from the 0.11 quotient (NP added1AP) loading decreased below 6.0 after 75 weeks of dissolution and decreased to 3.6 after 117 weeks, at which time the reactor was terminated. The duplicate 0.22 quotient loadings of RK fines decreased below 6.0 after 95 and 170 weeks. The former was terminated after 117 weeks, and the latter reached a minimum pH of 2.8 after 512 weeks. Drainage pH from the 0.66 quotient decreased below 6 after 581 weeks. For the drainages which acidified, the cumulative calcium release prior to pH decreasing below 6.0 was 92 to 103 percent of that initially present as calcium carbonateloxide in the RK fines. The pH of drainage from the 1.1 quotient typically remained above 8.0 throughout the period of record. Sulfate concentrations in the drainages decreased while the neutralizing fraction of the RK fines was present, but increased after this fraction was depleted.

Jan 1, 2000

In the early days of minimal environmental protection awareness and unreasoning economy development pressures, little attention was paid to growing environmental concerns in Fuxin colliery, especially the air pollution problem due to the long term mining activities. In order to determine air quality concentration levels, a new technique for synthetic assessment of ambient air quality by using the extension of matter-element method is proposed in this paper. The air pollutants data such as Sulphur Dioxide (SO2), Carbon Monoxide (CO), Nitrogen Oxides (NOx), Total Suspended Particulates (TSP), Particulate Matter (PM10), and dustfall collected at four different air quality monitoring stations located in four districts of Fuxin colliery is used. The results obtained indicate that TSP, PM10, dustfall and SO2 are the predominant pollutants. Other pollutants such as CO and NOx are also detected in Fuxin colliery. The air pollution comes mainly from industrial emissions, mining activities and the abandoned gangue stockpiles. Compared to those applied to other mathematical assessment methods, it is demonstrated that the extension of matter-element model is quite appropriate for air quality assessment.

Jan 1, 2006

By Julius Rubinstein, Victor Badenicov

The development of column flotation is the most significant achievement in the area of mineral processing in the last few decades. The high efficiency of column flotation allows a reduction in process time, a decrease in the number of cleaner stages and in the volume of the circulating load in the flotation circuit, and, as a result of this, an increase in consistency and reliability of operations. Unique multisectional column flotation apparatuses were developed. Such designs have a number of essential advantages as compared to monocells. A change from monocells to multisectional column allows to provide favourable conditions for separation of particles of various floatability. To attain that aim particular hydrodynamics and aeration regime is established in each section of the column, operational variables being adjusted according to the floatability of the material. Therefore in multisectional column machines the material-apparatus feedback can be established, process variables optimized depending on the characteristics of the floated materials. This concept forms the basis of column designs we have developed. For the first time column cell with alternating slurry Rows (combination of co- and counter-current flows) were developed and commercialized . Successful operation was reported of the new generation of columns with cell volumes of 10 to 80 m3 and the height of 4-6 m in copper, molybdenum, antimony, tungsten and nickel ores and coal slurry processing at different plants. Operation experience of these cells showed their considerable design and operational advantages and verified the proposed options and relationships. The new apparatus is provided with a pneumohydraulic aerator allowing to control bubble size distribution, the service life of the aerator is not less than two years. A multilevel flotation model was developed and used to work out a technique of column design and process parameters calculation. A method of the apparatus design parameters calculation based on laboratory test results (scaling up) was worked out. The method is based on flotation macro and micro-hydrodynamics simulation.

Jan 1, 1995

By Steve Kral

The power industry throughout the world is in the midst of a significant transition that will result in a major restructuring. Deregulation of utilities in the United States is continuing, resulting in increased competition among power providers. The traditional ways that electric power is globally bought, sold and delivered will also change. However, according to the Department of Energy's (DOE) Pat Godley, one thing is clear: "Those who provide the power during the 21 st century will be those who are willing to change - those who are willing to accept new ways of doing business and willing to employ new technologies." Godley is assistant secretary of fossil energy with DOE. Her comments came during the opening remarks at the Fourth Annual Clean Coal Technology Conference, held in Denver, CO, Sept. 5-8, 1995. The conference was sponsored by DOE and the Center of Energy and Economic Development. Under the theme "Global Opportunity," more than 300 coal and utility executives spent three days discussing the new face of the electric-power industry throughout the world and the new, mostly clean coal technologies (CCT) that will be available to power providers.

Jan 1, 1995

By Adrian E. Scheidegger

Recently, a new theory of the subsidence of rock masses has been advanced by Litwiniszyn and coworkers, which is based on the notion that the individual rock particles perform random walks. It is shown in the present paper that the final equations of the random walk theory can be justified from general principles of statistical mechanics in which no specific theoretical model of particle behavior has to be made. The theory appears to account appropriately for subsidence phenomena.

Jan 1, 1966

By Ludovico Sebastiao Costa, Luis Albano Tondo, Bonzi Yokomizo Santos, Nelson Roberto Garcia Munhoz

This paper focus on the productivity, cost efficiency and training programmes that have enable RPM to rank as a world class operation in production efficiency and safety achievements. The first step was to commit all senior managers to implementing the NOSA Industrial Safety System based on Management by Objectives. This focused the workforce in a specific, results-driven direction which greatly promoted subsequent performance improvements. The early operations concentrated on increasing throughput via process simplification and removal of bottlenecks. Efforts were simultaneously directed to environment, health and safety as a means to improving the quality of operations. In the last two years, improvements in mining and in-tailings dam management have further improved the cost competitiveness of RPM such as to assure its future in treating the remaining CTBl ore reserves. Promissing progress is being made in developing a viable process to exploit a remaining large resource of B2 mineralisation.

Jan 1, 1993

By Alexander Filimonov, Yury Bloshteyn

The development of a high-efficiency control system for mine ventilation is a complicated scientific and engineering problem. As a result of high-costs and difficult conditions involved in experiments for the development and investigation of mine ventilation systems, simulation is a critical task in cost reduction and productivity. The paper presents the description of a universal simulation model for controlled aerodynamic processes in an Underground ventilation Network (UVN). The high-efficiency programming tool to design and investigate mine ventilation control systems (MVCS) is also suggested.

Jan 1, 1991

By K. T. Mau

Hawaii is located approximately 2,500 miles from the mainland, but has basic needs for its thriving developing community. Cement is one of these needs Cement production in Hawaii is not without handicaps. The necessary raw materials are practically non-existent except for limestone. Even at that, the available limestone is marine in origin, coralline in nature and amorphous in characteristics - unlike calcite which is normally the calcium carbonate source for cement manufacture. There is no clay or shale for the argillaceous portion of cement raw mix. Hawaii being volcanic in origin is too young geologically for clays and shales to evolve and whatever there is, most likely is washed into the ocean.

Jan 1, 1982

By Zhiyuan Ma, Yong Liu, Xianjin Lyu, Jianfang Lyu, Jikui Zhou

A stable and continuous leaching process for niobium and tantalum extraction from ferrocolumbium tantalum (FT) was developed. The effects of initial concentration of HF and H2SO4, grinding fineness, leaching time, and temperature on the leaching rate of Ta, Nb, Fe, and Si were studied. Experimental results show that the leaching rates of Ta, Nb, Fe, and Si were enhanced by the increase of acid concentrate, fineness, leaching time, and leaching temperature. The optimum process conditions are HF initial concentration of 5 mol/L, H2SO4 initial concentration of 2.5 mol/L, − 74 μm percentage of 65%, leaching time of 20 min, and leaching temperature of 25 °C. Continuous leaching of FT was carried out by feeding ore and acid every 20 min. By leaching with HF − H2SO4 for 4 h, then adding appropriate amount of HNO3 into the solution and keeping for another 1 h, a high Nb extraction rate of 99.8% was achieved. The established method provides a promising technique for the high-efficiency separation of niobium and tantalum from FT.

Jun 5, 2022

By Ivan Hunter, Gary Johnson

In many comminution circuits based on SAG mills, an operating cost penalty is incurred in terms of high unit power consumption. By the addition of a crusher to the circuit, to crush part of the so­called critical size fraction extracted from the mill charge, the power efficiency of the circuit can be significantly improved. Dominion Mining has now incorporated pebble crushing into three of its comminution circuits. The improvements in circuit performance have in all cases been significant, and in some cases dramatic.

Jan 1, 1991