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By J. W. Merks

Spreadsheet software is an effective tool for simulating dynamic stochastic systems such as mineral processing plants. The two-product formula is used to show how to set up a Monte Carlo simulation in a spreadsheet template and how to calculate variances of dependent variables. The key to a reliable and realistic simulation model is to obtain unbiased estimates for all independent variables and variances in the set that defines the stochastic system. Monte Carlo simulation is also a powerful tool for optimizing sampling procedures, for applying sensitivity analysis and for designing and evaluating experiments.

Jan 1, 2000

By R. Wild

[When a blast furnace has a certain defined burden and is operated under fixed conditions of blast temperature, etc., the fuel efficiency is determined by the extent to which the reducing gases can remove oxygen from the burden in the furnace stack. This is determined by two distinct factors: 1) The uniformity of gas-solid contact, and 2) The ease with which oxygen can be removed from individual pieces of burden. This latter is often called burden reducibility. When burdens were poorly prepared the first factor was by far the most important and a study of the reducibility of individual lumps was of rather academic interest recent years good burden preparation with emphasis on sized material has led to greatly improved gas distribution in the stack, and thus the second factor has become much more important and there has been a marked increase in interest in methods of measuring reducibility.]

Jan 1, 1964

By C. D. Anderson

A variety of processing technologies exist for recovery from both primary and secondary sources of rhenium. Currently, there are no known primary rhenium deposits, thus, the method in which primary rhenium is produced is dependent on the commodity of which it is a byproduct, e.g., copper, molybdenum, uranium, etc. In addition, focus on the recovery of rhenium from secondary sources, such as alloy scraps and catalysts, is continually growing. This paper presents a review of both primary and secondary processing technologies for the recovery of rhenium. Key Words: Rhenium, Ammonium Perrhenate, Extractive Metallurgy

Feb 27, 2013

By B. Jensen, B. K. Abraham, G. J. Tuck, A. D. S. Gillies

A dust concentration meter has been developed with Australian coal industry support for the measurement of total airborne dust concentrations capable of causing explosions in underground coal mines. The instrument, The University of Queensland Dust Meter (UQDM), measures the effective dielectric constant of a mixture of coal dust and air that is drawn between the plates of a capacitor, the capacitance of which is measured by a ratio-transformer bridge and synchronous detector system. This technique measures small changes in capacitance to approximately 1 part in 106. The unique design of the capacitor sensor permits a precise volume of coal dust and air mixture to be sampled. This arrangement overcomes difficulties inherent in optical dust measurement. The meter is portable, battery powered, incorporates data logging and has intrinsic safety approval. The operation of the meter is discussed. The system is designed to monitor dust concentrations along a coal mining face and provide concentration profiles leading to the development of suppression strategies. If data from underground tests are available, the meter's potential to contribute to establishing safe working conditions underground will be discussed. Other areas of potential application of the measurement technique are also examined.

Jan 1, 1993

By J. Litsenberger, T. E. Marshall, L. Burke, R. Melville, A. T. Iannacchione

Excessive levels of horizontal stresses cause ground fall hazards in underground mines in the Appalachian Basin. At an underground stone mine in Pennsylvania, a modified stress control mine layout is reducing the hazardous conditions associated with excessive horizontal stresses. A microseismic monitoring system is in place to measure levels of rock stability and provide information on the effectiveness of the design technique. The microseismic data is supplemented with frequent and extensive mapping of roof falls and roof rock damage. Findings to date show that the stress control layout provides more stable conditions and thus a safer environment for the mine workers.

Jan 1, 2001

By Steve Crewdson

High tonnage hoisting of materials by vertical conveyors through deep shafts is a relatively new concept in mining that is proving to be effective. The development of the Pocketlift® belt by Metso Flexowell, located in Moers, Germany, enabled the installation of a deep shaft vertical conveyor in 2002. This application followed years of design and operational experience gained in medium-depth shafts around the world. The design, manufacture, installation and operational experience of an 1,818 tonnes capacity, 273 meters vertical lift, Pocketlift® belt system at the White County Coal Pattiki 2 Mine is the subject of this work

Jan 1, 2004

By Vernon F. Swanson

The expansion of a fluidized bed of carbon depends on fluid velocity, fluid temperature (viscosity) and particle size of the carbon. This paper presents a mathematical model which can be used to calculate the necessary fluid velocity. It will allow the design of sufficient freeboard in the column to accommodate expected operating conditions. Although this paper is keyed towards the use of activated carbon in precious metals adsorbtion from water solutions, the model is.valid with any fluid. Additionally, the method of calculating the required suspension velocity in CIL or CIP pulps is described.

Jan 1, 1992

By Stephen J. Navin, Francis P. D. Navin

Long-distance movement of various materials by conveyor is becoming common; therefore, it is no surprise that conveyors are frequently found in very long tunnels. In such long tunnels, there is a continual controversy between the tunnel operator's requirement for a maximum of clear space for the conveyor and vehicles and the investor's wish to make the minimum capital investment for excavation. This analysis shows that the question becomes more pressing as the tunnel becomes longer. The result given in this paper is a straightforward method by which an economic and operational optimal tunnel width may be selected for any specified tunnel length. Detailed computational formulas are developed relating costs of construction, vehicle operation, vehicle accidents, and conveyor downtime to both tunnel width and length.

Jan 1, 1985

By M. Josick Comarmond, Paul L. Brown, Greg P. Timms, A. Ian M. Ritchie, John W. Bennett

Geochemical kinetic models have only become available in recent years and their utilisation in the prediction of effluent chemistry from sulfidic waste rock piles is even more recent. The models used to date, however, have incorporated some questionable assumptions. This paper shows how geochemical, mineralogical and physical field data have been coupled to remove some ill-founded assumptions in the construction of a geochemical kinetic model. Further, the paper discusses a comparison between the observed effluent chemistry from a waste rock dump at the Rum Jungle copper/uranium mine in northern Australia with model predictions. In general, there is good agreement between the two, although an anomalous result is discussed.

Jan 1, 2000

By Richard B. Muter

In determining the layout or combination of unit operations to be utilized in a modem preparation plant, several factors must be taken into account. Among these are the washability data, size consist data, the particular market or markets for the coal, the mining method used, the degree to which the coal must be prepared, expected fluctuations in raw coal and markets, and the overall economics of the process. In addition, there are the health and safety aspects of coal utilization and preparation. Chapter 1 of this book discusses the characteristics of coal and coal markets, while Chapter 2 deals with the design of preparation plants. Once the unit operations for a particular plant have been decided upon, these arrangement may be depicted by using a flowsheet. A coal preparation plant flowsheet is a two-dimensional graphical representation of the sequence of operations, the arrangement of machinery, and the flow of materials for a particular coal cleaning operation. The flowsheet is usually qualitative in nature, becoming more quantitative as material balances, water balances, numbers and sizes of various pieces of equipment, etc. are added. The usual convention in preparing a flowsheet is to show the feed flowing from left to right, starting at the top left and working down as in an all-gravity process. Various symbols are used for each unit operation as depicted on a flowsheet, and Fig. 14-37 is a compilation of the commonly accepted international standard symbols for each unit operation. Fig. 14-38 through Fig. 14-40 are flowsheets of various coal cleaning processes as published in the January 1976 issue of Coal Age. Each process has its own unique features which, among others, depend upon the coal being cleaned, the coal market, and the mining operation. Fig. 14-38, for example, is a flow diagram for a jig plant preparing steam coal from two strip mines located a few miles apart. In addition to the jig washer, cyclones are used to treat the finer size coal. Fig. 14-39 is a flowsheet of a heavy media plant using a heavy media washer for + %-in. (+6.3-mm) coal, froth flotation for -28 Tyler mesh (-0.6 mm) material, and dewatering phase units (dwp) for Y, in. x 28 Tyler mesh (6.3 x 0.6-mm) cleaning of steam coal. In addition, thermal drying, centrifuge drying, and the use of vacuum disk filters and thickeners for dewatering are depicted. Fig. 14-40 is a flowsheet of a plant producing metallurgical coal. In addition to the heavy media and froth flotation circuits, a tabling circuit is also employed. These flowsheets are intended to give the reader an example of how the various unit operations for coal cleaning may be linked together. Figs. 14-41 and 14-42 illustrate the conversion of block diagrams into an IS0 prescribed set of symbols.

Jan 1, 1991

By F. P. de Kock, P. West-Sells, B. Wassink, D .. B. Dreisingerl

During the cyanide leaching of gold ores containing copper minerals, aurocyanide (Au(CN)f) is produced and typically recovered using activated carbon. However, free cyanide, as well as cyanide associated with cuprous cyanide complexes, are generally not recovered from the barren liquor. This results in a significant economic penalty in high cyanide consumption due to the dissolution of copper. 1\vo different configurations of a novel method for the treatment of barren liquor streams for cop­per recovery and cyanide recycle are described. Recovery of copper and cyanide is affected using solvent extraction (XI 7950). Loaded organic is stripped with a high copper, high caus­tic solution which is electrowon to produce copper metal. Depleted electrolyte is treated with sulfuric acid to recover cyanide which is returned to the leaching circuit. Results of benchscale and mini-pilot plant experiments are presented.

Jan 1, 1996

By Prescott Greene

AVAILABLE MACHINES Machines discussed in this section include only rubber tire mounted kerf cutting machines of a self¬propelled electrically powered design. Such machines handle bars up to 4.6 m (15 ft) in length, cutting kerfs of from 115 to 191 mm (4.5 to 7.5 in.). The basic design concept of all machines currently in production is very similar. The chassis features dual driving wheels on the cutter-bar end, fixed directly to the main frame. The steering wheels on the outby end of the frame are articulated in some manner to keep all four wheels on the floor over uneven bottom. Machine power for tramming, and all other functions except powering the cutting chain, is furnished from a pump motor that drives the specific pump or pumps required by a given machine. The cutter chain is driven through a mechanical drive train from a separate electric motor having no duty other than driving the chain. The general arrangement of a cutting machine is shown in Fig. 1; two types of machines, with their specifications are shown in Figs. 2 through 5. A hydraulically powered cable normally is included to eliminate the need for manual cable handling and make this a one-man machine. A bug duster, though optional, is needed for most applications. The bug duster is an hydraulically driven scroll conveyor located directly behind the cutter chain drive sprocket. Its function is to move the cuttings away from the sprocket to prevent them from packing up in this area and consuming a lot of machine power to further pulverize them. Available machines vary from models 610 mm (24 in.) high that can cut horizontally only from 203 mm (8 in.) below ground line to 229 mm (9 in.) above, to machines 1143 mm (45 in.) high that can cut in any plane from 178 mm (7 in.) below the ground line to 3.7 m (12 ft) above it. Most currently manufactured machines fall in the 17 200 to 20 400 kg (38,000 to 45,000 lb) weight range, but can be dis¬assembled for underground installation where weight and size are a problem. Maximum teardown results in all pieces having a weight of 5400 kg (12,000 lb) or less and a size allowing passage through a 1.2 x 2.1-m (4x7-ft) opening. Further reduction in either size or weight of the parts becomes a serious problem. Machines currently being manufactured are avail¬able for use with power supplies of 250 v dc; 500 v dc; 440, 550, or 950 v ac (60 Hz). Also available are machines for use on 415, 500, and 950 v 50 Hz. De¬signs to allow operation on other voltages of either 50 or 60 Hz can be made available without any serious problems. As of September 1977, a typical medium-seam ma¬chine without the extra options needed for unusual conditions, but fully equipped to operate, was selling for about $185,000. CAPABILITIES Materials That Can Be Cut The problem of deciding before a machine is put on the job whether it can work effectively is an old one that has never been completely solved and probably

Jan 1, 1982

By N. R. Joshi, A. D. Agate

It is estimated that more than 80% of phosphate rock output in the world is used for fertilizer production. In India, there are only a few high-grade deposits of phosphate ores; therefore, most of the requirement for phosphatic fertilizers is satisfied with imported DAP (diamino phosphoric acid). Due to the drain on foreign exchange reserves, this import-dependent, essential commodity is in short supply in India and, therefore, is sparingly used by farmers. In addition, of the added phosphorus, normally 80% becomes unavailable to plants because phosphorus complexes are formed in soil, causing deleterious effects on plants. In our laboratory, this problem was tackled by using a bacterial consortium of phosphorus-solubilizing bacteria. It resulted in the speeding up of seed germination and increasing available phosphorus in the soil by 14%, over a period of 80 days. To use the low-grade deposits of phosphatic rocks available in India near Hirapur, Madhya Pradesh, India, which contain high amounts of iron, beneficiation through microbial means was used for phosphorus removal. Beneficiation was achieved partially through removal of extra iron by oxidizing ferrous iron from the ore by a Thiobacillus species after removal of impurities containing both silica and iron, instead of sieving and cleaning the ore using different techniques. This resulted in a cleaner ore, with nearly 70% of such impurities removed. The factors for beneficiation technique were standardized at the laboratory level and are being used for scaling up of the process. Thus, the beneficiation of phosphatic rock from Hirapur will be an important first step of phosphorus production in India.

Jan 1, 1999

By Keith S. Liddell

he selection of mill design parameters to suit the applica­tion requirements can result in quite different operating parame­ters for each generic type of application, even though the basic mechanical layout of the mills may remain similar. The selection of the type and size of grinding media is very important to efficient and cost-effective operation, and to ensuring that the milled product achieves the required properties. Accordingly, the grinding media selection is seen as an integral part of the mill design. Consideration of the requirement for classification is important in order to achieve the optimum mill and circuit performance. This can lead to the circuit feed not being classified for a steady feed with minimal slimes and a low size reduction ratio. Feed containing on-size particles would be deslimed by open circuit classification. Closed circuit classification is performed where the feed fluctuates. The rheological characteris­tics of the circuit feed slurry can have an influence on mill performance, and needs to be allowed for. A common misconception frequently encountered is the belief that "a mill is just a mill". This is not the case with stirred types of mills, since the operating parameters selected for the mill can have a large effect on the product characteristics. For example, horizontal shaft high speed stirred mills have a com­pletely different grinding action to vertical shaft low to medium speed stirred mills, which results in large differences between the surface area produced at a given product size (Liddell, 1986). Hence, it can be misleading to apply test results or design procedures obtained from one type of mill to other types for scale-up. The Metprotech stirred mill, as applied in the mining and minerals industries, is a low to medium speed vertical shaft mill. The basic design has been discussed previously (Liddell, 1989). Currently, the largest mills that have been manufactured have an installed power of 400 kW. The largest chamber volume at this power is 6000 litres, containing IO t of grinding media. It is intended that the installed power will increase up to lMW as applications requiring larger sizes arise.

Jan 1, 1995

By Ruari Soutar-Dawson, Fisher Wang, Alan Boylston, Michael Denzel

Vertical stirred mills are increasingly used for fine grinding applications in the mineral processing industry due to their high energy efficiency. Thus, modeling power draw is of great interest proven by the effort in previous work including analytical models. In this contribution the development of a DEM-CFD coupled model is presented to determine power draw under different operating conditions. These include grinding media filling level, shaft speed and fluidization as well as changes in grinding compartment configuration. An extensive test program on an especially equipped test mill is initiated to validate the model.

Feb 22, 2026

By J. P. Barbosa, R. V. V. Araújo, R. B. E. Trindade

Bromide stabilizes the auric or aurous ion by forming a stable complex in acidic aqueous solution. The oxidizing agent normally used for the process is bromine, which is a corrosive liquid with high vapour pressure. This is, in fact, the main reason why it has not found acceptance yet as an industrial oxidant for gold. Ferric ion with hydrogen peroxide and/or sodium hypochlorite have already proved to be effective oxidants for the dissolution of gold from a rotating disc in a bromide-containing aqueous solution. In the present work, preliminary tests with four selected ore samples were tested to evaluate the dissolution of gold with the same system already tested with the rotating disc (Br-/Fe3+/H2o2/NaCIO). Compared to the conventional cyanidation, results were superior in one instance only. The major obstacle seems to be the maintenance of a suitable potential to allow the complex formation. However, the studied system may be interesting, is in some situations it may yield better results than conventional cyanidation; therefore, further investigation seems to be worth doing.

Jan 1, 1995

By Alena Conrads, Markus König, Markus Scheffer, Markus Thewes, Hannah Mattern

"INTRODUCTION In recent years, the development of tunnel boring machines has revolutionized the tunneling industry. The general structure of a tunnel boring machine (TBM) can be described as a multi-component system. To achieve high performance rates, machine elements have to perform reliably. Performance losses and interruptions of the construction process should be prevented or at least, reduced to a minimum. In order to achieve high advancing rates, cutting tools must be in good condition at any time. Furthermore, failure of individual tools might result in increased and faster wear of remaining structural components. For this reason, maintaining and replacing cutting tools is crucial to prevent project delays due to insufficient boring performance. Precise prognoses concerning the prevailing geology are infeasible and thus, efficient scheduling of maintenance actions is challenging. The intention of this work is to analyze different approaches of TBM maintenance in soft ground. Different strategies are analyzed by the use of a simulation approach. Cutting tool condition is regarded as performance limiting factor. The maximum operation time of the cutting tools is determined using the “Soil Abrasivity Index”. A case study serves to show the effects of different maintenance strategies on total project duration. SCHEDULING OF MAINTENANCE ACTIONS Scheduling maintenance actions of single and multi-component systems concerns numerous fields of industrial production. Concentrating on mechanized tunneling in soft ground, cutting tool maintenance represents the most common reason for intermission of advance (Köppl 2014). In literature, time-based and condition-based maintaining techniques are widely discussed. The following section outlines the principles of time- and condition-based policies. Furthermore, examples for their applications in recent research are given. Time-Based Maintenance In general, the time-based maintenance approach assumes that the failure behavior of the system components is predictable. Maintenance actions are scheduled according to predefined intervals (e.g., hours, days, weeks). A detailed analysis of preventive repair times or interval forms the basis for maintenance decisions. For this approach, an adequate quantity and quality of data is fundamental. Numerous studies deal with the analysis of time-based maintenance for production equipment. In fields of mechanized tunneling, unplanned machine downtimes restrict the applicability of time-based maintenance approaches. Thus, this paper mainly focuses on condition-based maintenance."

Jan 1, 2016

By R. A. Pindred, M. P. Lam

Cyanide is a conventional lixiviant for gold extraction but its' toxicity is a major concern for the environmentalist. There are many alternative non-cyanide lixiviants, such as thiourea, thiosulphate, chlorine and hypochlorite etc., which may reduce environmental sensitivity. This paper will discuss the leaching characteristics of gold in hypochlorite leaching solutions. The dissolution of gold in a hypochlorite solution not only depends on the concentration of the hypochlorite but also on other variables, such as hydrochloric acid, sodium chloride and temperature. The dissolution rate of gold in hypochlorite solution is much faster than other lixiviants. Due to the interference of impurities, gold extraction from an ore under ambient conditions requires large quantities of reagents. However, refractory gold ores may be successfully pressure oxidized in an autoclave at reasonably low reagent levels. Gold extraction to the pressure oxidation leach solution is rapid and complete in one stage, thus eliminating the need for further cyanidation.

Jan 1, 1990

By C. Klauber, H. G. Linge, W. G. Jones

The carbon-in-pulp process for gold processing depends on the adsorption of dissolved Au(CN)2- from solution onto activated carbon. Our work shows that coconut and peat based carbons have the same mechanism and kinetics of adsorption. There is no contribution to the bonding from carbon-oxygen functionalities on the carbon surface, as has been invariably supposed in all previous theories for the mechanism of the reaction. It is shown that Au(CN)2- is reversibly adsorbed intact on, and parallel to, the graphitic planes of the carbon. The physiochemical basis of the measurement of carbon reactivity for gold adsorption is discussed.

Jan 1, 1989

By G. Barbery

In Mineral Processing, the objective of most processes is the separation of mixtures of minerals, which are originally associated in composite particles. Feed preparation processes grinding for instance, which take place before beneficiation or separation processes do not usually break particles at the boundary between mineral phases. They produce composite ("middlings") as well as liberated particle. It is therefore necessary, in a particulate system, to determine the proportion of particles which are liberated as well as, ideally, the size distribution of minerals which remain associated in composite particles. Up to now, there has been a lack of experimental techniques to characterize completely composite particulate systems. Heavy liquid separation which is commonly used to obtain information of this type can only be applied to simple binary cases for which one mineral has a low density (lower than e.g 2.8 ). The technique which is proposed in this paper involves the measurement of parameters on polished sections of particles mounted in a matrix, and the use of mathematical transformations to reconstruct in three-dimensions the information obtained from these measurements .

Jan 1, 1977