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By Raja V. Ramani, Robert L. Frantz

"The House/Senate Joint Conference Committee has instructed the Bureau of Mines to have the Advisory Committee on Mining and Mineral Resources Research review on an annual and simultaneous basis each generic mineral technology research center (GMTC). In order to accomplish that review promptly and uniformly, committee members have revised and approved an in-depth questionnaire. That document formed the basis of their review. The information provided by that questionnaire was an important factor in their recommendations concerning the future direction of the program; a presentation was made at the last National Plan Update.The comprehensive nature of the questionnaire and the scope of the information contained therein make it an excellent retrospective of the Center. Having a clear vision of where the Center has been and knowing where it is now will help guide it into the future. It is felt that such a detailed view of the Center's facilities and research program will be of value to Center personnel and Advisory Committee members.Each aspect of the questionnaire has been examined, answered in detail, and documented throughly. With the completed questionnaire as a guide, this volume examines the research program, Center personnel presently active on GMTC projects, number of graduate degrees granted with GMTC support, GMTC publications, degree of individual interaction, technology transfer, the reference center, GMTC equipment and facilities, and any envisioned plans for future research. It is hoped that this volume will serve as a review of the years 1984-1988, the first four years of the Center's operation."

Aug 31, 1989

By Raja V. Ramani, Robert L. Frantz

"In response to the U.S. Bureau of Mines (USBM) Request for Proposal (RFP) for "" the establishment of a Generic Mineral Technology Center (GTC) in Respirable Dust,"" the Mining and Mineral Resources Research Institutes (MRIs) at The Pennsylvania State University (PSU) and West Virginia University (WVU) in association with participating MRIs at Massachusetts Institute of Technology (MIT), and the University of Minnesota (UMN) have prepared the comprehensive research program described herein. Michigan Technological University (MTU) joined the Center as an affiliate after its inception. This program was developed with recognition of the stated objective of the Federal Mine Safety and Health laws which is to "". . . permit each miner the opportunity to work underground during the period of his entire adult working life without incurring any disability from pneumoconiosis or any other occupation-related disease . . . .""Exposure to respirable contaminants in mine atmospheres has long posed a serious hazard to miners. The control of these hazards, some of which can have sudden and catastrophic consequences and some others, slow and long enduring, has been a major concern for labor, management and the government. This concern has manifested itself in four mechanisms of control -- (1) regulatory control through minimum standard setting by the passage of mine health and safety laws, (2) engineering control through design and operation of mines according to the best recommended practices, (3) interaction of dust and lung control through periodic physical examinations, wearing personal protection devices, etc., and (4) legal and social control through workman's compensation laws for occupation related health deterioration."

Aug 31, 1989

By R. Karl Zipf, Z. T. Bieniawski

"A set of fracture profile photomicrographs is presented for fractures generated under mixed mode loading of the Pittsburgh coal. The fractal dimension is used· to characterize the irregularity of these profiles and a tentative relationship is presented between the fractal dimension and the fracture toughness. Surface roughness appears to depend solely on the stress intensity and no other dependence was observed with fracture loading mode, loading rate· or specimen orientation. Observations of crack bifurcations.in fracture profiles can indicate crack growth direction whereas direct surface observations generally cannot in materials such as rock and coal.1 INTRODUCTIONThe production of fine fragments of material as a result of some loading event occurs in many industrial processes. In crushing and grinding, the efficient production of fine fragments is the desired end result; .however, in coal cutting, the production of fine fragments may lead to high levels of respirable dust in the immediate atmosphere with the danger of human lung diseases. Two of the most important sources of fragments in the 1 to 10 micron size range during a cutting process are 1) severe crushing in a zone near the loading tool and 2) subsequent shearing along major crack surfaces that form the larger fragments during material reduction. These and other sources of fine fragments generation are discussed by Roepke (1984) and Zipf and Bieniawski (1986). The physical character of the nearly created major crack surfaces is believed to have a strong influence on the amount of fine fragment generation that occurs during subsequent shearing movement. When the major large fragments initially form, they are ""locked"" in place by the irregular character of the new fracture surface. Only after some relative motion has occurred between fragments are they actually liberated, and the net result is the formation of additional fine fragments. The fine fragmentation is not necessarily limited to the shearing of high points from the macrocrack surf ace since material remaining in the wake of the crack tip is damaged to a substantial depth below the actual crack surface."

Aug 31, 1989

By Raja V. Ramani, Robert L. Frantz

"The U.S. Bureau of Mines (USBM) established on August 15, 1983, a Generic Mineral Technology Center (GTC) for Respirable Duet within the Mining and Mineral Resources Research Institutes (MRIs) at The Pennsylvania State University (PSU) and West Virginia University (WVU) in association with participating MRIs at Massachusetts Institute of Technology (MIT) and the University of Minnesota (UMN). The primary goal of the Center is to reduce the incidence and severity of respirable dust disease through researching and advancing the fundamental understanding of all aspects of respirable duet associated with mining and milling and the interaction of dust and lungs. Other Center activities include the training of engineers and scientists, graduate students and undergraduate students through their respective institutions, and the technology transfer to the industry. The Center also serves as the reference center for publications in the respirable dust area.Exposure to respirable contaminants in mine atmospheres has long posed a serious hazard to miners. The control of these hazards, some of which can have sudden and catastrophic effects and some others, slow and long enduring consequences, has been a major concern for labor, management and government alike. This concern has manifested itself in four primary mechanisms of control -- (1) regulatory control through minimum standard setting by the passage of mine health and safety laws, (2) engineering control through design and operation of mines according to the best recommended practices, (3) interaction of dust and lung control through periodic physical examinations, wearing personal protection devices, etc., and (4) legal and social control through workmen's compensation laws for occupation related health deterioration.The stated objective of the Federal Mine Safety and Health laws is to ""... permit each miner the opportunity to work underground during the period of his entire adult working life with-out incurring any disability from pneumoconiosis or any other occupation-related disease ....""Significant progress has been made in lowering the dust levels in mines since the inception of the Bureau's respirable dust research program. It is generally agreed that mines are less dusty today than they were a decade ago. However, the most serious hazard for workers in the mining and minerals processing industries is still the exposure to respirable dust, and solutions to the problem of respirable dust disease remain to be found."

Aug 31, 1989

By R. V. Ramani, R. L. Frantz

"The U.S. Bureau of Mines (USBM) established on August 15, 1983, a Generic Mineral Technology Center (GTC) for Respirable Dust within the Mining and Mineral Resources Research Institutes (MRls) at The Pennsylvania State University (PSU) and West Virginia University (WVU) in association with participating MRis at Massachusetts Institute of Technology (MIT) and the University of Minnesota (UMN). The primary goal of the Center is to reduce the incidence and severity of respirable dust disease through researching and advancing the fundamental understanding of all aspects of respirable ~~9t associated with mining and milling and the interaction of dust and lungs. Other Center activities include the training of engineers and scientists, graduate students and undergraduate students through their respective institutions, and the technology transfer to the industry. The Center also serves as the reference center for publications in the respirable dust area. IntroductionExposure to respirable contaminants in mine atmospheres has long posed a serious hazard to miners. The control of these hazards, some of which can have sudden and catastrophic effects and some others, slow and long enduring consequences, has been a major concern for labor, management and government alike. This concern has manifested itself in four primary mechanisms of control -- (1) regulatory control through minimum standard setting by the passage of mine health and safety laws, (2) engineering control through design and operation of mines according to the best recommended practices, (3) interaction of dust and lung control through periodic physical examinations, wearing personal protection devices, etc., and (4) legal and social control through workmen's compensation laws for occupation related health deterioration.The stated objective of the Federal Mine Safety and Health laws is to"" permit each miner the opportunity to work underground during the period of his entire adult working life without incurring any disability from pneumoconiosis or any other occupation-related disease ."" Significant progress has been made in lowering the dust levels in mines since the inception of the Bureau's respirable dust research program. It is generally agreed that mines are less dusty today than they were a decade ago. However, the most serious hazard for workers in the mining and minerals processing industries is still the exposure to respirable dust, and solutions to the problem of respirable dust disease remain to be found."

Mar 1, 1989

By J. M. Mutmansky, C. Lee

"IntroductionRecognition of Coal Workers' Pneumoconiosis (CWP) as a major occupational disease has affected various aspects of the coal mining industry in the United States as well as in almost all major coal producing countries, Regulations related to the control of coal mine dust forced mine operators to modify their mining and ventilation practices. As the coal production record of the last 15 years shows, this had both direct and indirect impacts on the productivity and production costs.To identify the causes of CWP, many research efforts have been made throughout the world. Most of these studies were epidemiological in nature, attempting to pinpoint exposure and seam variables that affected the incidence of the disease. Other studies have been oriented toward the elemental and mineralogical composition of the coal dust in the mine atmosphere and in the miners' lungs. These studies indicate that there may exist some relationships between the characteristics of the coal mine dust and the prevalence of the disease. Some of the variables that are thought to affect the occurrence of CWP are the mass of the dust in the working place, the rank of the coal, the existence of certain trace elements, the free silica content of the coal, and the existence of other minerals in the respirable dust. A more complete description of these previous research studies has appeared elsewhere (Mutmansky and Lee, 1984).The behavior of particles in the human lung is known to be governed by their aerodynamic diameter, which is defined as the diameter of a hypothetical spherical particle with unit density that exhibits the same settling velocity as the given particle. Because of this fact, the aerodynamic size distribution of coal mine dust is one of the parameters to be determined along with the other physical, elemental, and mineralogical characteristics. The objective of this paper is to establish a strategy for providing coal mine respirable dust samples for characterization purposes using instruments that classify according to the aerodynamic diameter. In addition, several findings concerning characterization methods will be presented"

Mar 1, 1989

By R. Karl Zipf, Z. T. Bieniawski

"Researchers at The Pennsylvania State University are engaged in a project to understand the mechanics of respirable size fragment formation in coal. The project is based on the premise that a thorough understanding of the fundamental mechanics of fine fragment formation may lead to techniques for reduction and better control of coal dust problems in mines. Presently, it is believed that the mode of fracture propagation which can range from pure tensile to pure shear or any mixed mode in between and the loading or displacement rate can influence the amount of respirable size fragments that are generated on new fracture surfaces during the fracture propagation process The essence of any coal cutting process is one of mixed mode fracture propagation. To study the crack propagation process, a unique mixed mode testing rig was designed and fabricated. This rig is capable of applying loads to a prenotched test specimen that range from pure Mode I (tensile mode) to nearly pure Mode II (shear mode) or many mixed mode loading combinations. It is also possible to apply different loading or displacement rates to the test specimen. With this rig, it is possible to create new fracture surfaces via the different fracture modes and under various loading conditions.These new fracture surfaces are examined with a scanning electron microscope (SEM) to characterize the amount of structural damage and respirable size fragment formation that occurs during the fracture process. Initial observations suggest that the amount of fine fragment formation and the new fracture surface appearance is related to the fracture initiation conditions, particularly the fracture mode and the loading rate. Mode II loading and higher loading rates seem to generate more structural damage and respirable size fragment formation that Mode 1 loading at slower rates.With the mixed mode test rig, the mechanics of fracture initiation for a single crack can be controlled to better understand its influence on respirable size fragment formation. Such understanding may lead to methods which characterize the tendency of specific coal seams to produce undesirable fine fragments during the fracture process, or it may lead to rational recommendations and design guidelines or coal mining machines which inherently produce less dust.IntroductionAs part of a larger effort to reduce the incidence of coal workers pneumoconiosis (black lung) in coal miners, researchers at The Pennsylvania State University are engaged in a project to understand the fundamental mechanics of fine fragment formation in coal. This project is part of a com¬prehensive research effort within the Generic Mineral Technology Center for Respirable Dust which is jointly administered by The Pennsylvania State University and West Virginia University.The principal source of the coal dust in underground mining is the cutting operation. The U.S. Bureau of Mines (USBM) and various European research organizations have conducted investigations into the mechanics of coal cutting for many years. These studies of airborne respirable dust (ARD) formation have concentrated on empirical studies of the various cutting parameters and their effect on ARD for¬mation. The parameters study include depth of cut, cutting speed and bit spacing.(1,2) Other studies investigated the effect of symmetric and asymmetric bit wear and various bit geometries and designs (3-5) Roepke(6) summarized the principals of proper coal cutting to minimize dust formation by recommending to ""cut at maximum depth (maximum advance rate) at all times, at minimum RPM, with the fewest possible bits, having the lowest possible included tip angle."" Most coal in the U.S. is mined with the continuous mining machine which inherently cannot meet these design recommendations.(3)It is recognized that respirable size dust particles are formed and/or liberated by a fracture process. One extremely interesting and useful study performed very early in the USBM dust re"

Mar 1, 1989

By R. L. Grayson, S. S. Peng

"Abstract. Sampling of respirable dust and analyses of samples have been partially completed for a longwall panel. Physical and compositional properties which have been characterized include:l. Respirable mass concentration, 2. Mineral composition,3. Particle size distribution by mineral,4. Particle shape distribution by mineral,5. Particle angularity distribution by mineral, and6. Respirable size distribution.Analytical techniques used in the characterization of samples are described, and results are reported with emphasis placed on relationships between the various characteristics and worker locations. Details of existing mining conditions, equipment arrangements, dust control methods and operating system parameters are presented.INTRODUCTIONThrough the work of many researchers worldwide, the health of coal miners in modern societies is now protected from dangerous exposure to respirable coal mine dust. A vast amount of research culminated in the exposure-response model of Jacobsen, et al. (1971) whi3h has been used to establish the 2mg/m exposure limit in the United States. According to the model, exposure to respirable dust for 35 years at this level or less would prevent the occurrence of a clinically significant case of coal workers' pneumoconiosis (CWP). The exposure limit, of course, must be adjusted whenever greater than five percent free silica exists in the respirable dust.The Jacobsen model was built around a mass concentration exposure, which showed the highest correlation with incidence and progression of CWP. As Morgan; et al. (1973) noted, howev.er, the quantity of respirable dust inhaled is not the only significant factor. It is noted that although mass of respirable dust correlates highest with the incidence of CWP, it is not a causal factor. Indeed, the insidious processes causing the disease occur on the cell-particle scale, requiring microscopic investigation."

Mar 1, 1989

By S. P. Sandoval

The U.S. Bureau of Mines investigated the separation of aluminum from copper dump leaching liquors using a supported liquid membrane. Aluminum was selectively transported through porous polypropylene impregnated with di (2-ethylhexyl) phosphoric acid in an aliphatic diluent. The effects of variables, such as solution composition, temperature, and extractant concentration, were measured with a three-level fractional factorial experimental design. Experimental results were used to derive equations for predicting transport rates for aluminum, iron, and copper. The major variables influencing aluminum transport were solution temperature, feed solution pH, aluminum concentration in the feed solution, and extractant concentration. Copper and iron transport rates were almost zero when aluminum transport rates were high. Measured aluminum transport rates under the best conditions of 55° C, pH 3.0, 16 g/L A13+, and 65 pct extractant solution confIrmed the predicted value of 210 f.'g/(cm2.h). Transport rates for iron and copper were less than 5 ug/(cm2.h) under these conditions. Aluminum was recovered from the stripping solutions by sparging with gaseous hydrogen chloride to crystallize aluminum chloride hexahydrate, which was calcined to alumina. Sparging crystallization regenerated the stripping acid for recycle.

Jan 1, 1989

By R. J. Dippenaar, J. C. van den Berg

This paper describes an investigation into the prereduction of hematite fines in a fluidized-bed reactor as a means by which they can be prepared for direct smelting in a transfered-arc plasma furnace. A single-stage fixed fluidized bed reactor using the in situ gasification of coal was employed. It is shown that the hematite is reduced to magnetite at 1000 QC, the degree of reduction being limited by the inherent shortcomings of a single-stage reactor in which both the gasification and the reduction reactions have to occur. Methods by which the degree of reduction can be increased are suggested. The gasification process was studied in some detail, and three different reducing agents are compared. The dominating effect of the Boudouard reaction on the behaviour of the fluidized bed is clearly illustrated. Non-coking coals of high reactivity are best suited to this process, a finding that would complement the trend away from coke as a metallurgical reducing agent.

Jan 1, 1989

By III Kimball

For many years, Arizona merely shadowed EPA's environ-mental regulation of mining operations and waste. During this period, Arizona generally assisted EPA in the implementation of federal programs and enacted environmental laws patterned closely after their federal counterparts. A growing public concern about protecting water quality, particularly groundwater quality, eventually caused the State to depart from this pattern.

Jan 1, 1989

By William Petrul

Image analysis studies were performed on mill products from laboratory flotation tests of the Zn-Pb ore from the Faro deposit in Yukon, Canada, to determine mineral liberations at specific grinds and to predict recoveries at optimum flotation conditions. The minimum and optimum grinds for liberating sphalerite and galena were predicted from size analysis data for the minerals in large ore pieces, and determined by image analysis studies of the mill products. The determined optimum grinds are about 2 Tyler mesh sizes larger than predicted because sane of the fine grained sphalerite and galena occurs in interstices between coarser grained pyrite and is liberated when the pyrite grains are broken apart. Materials balance calculations were performed on the analyzed values for the liberated and unliberated sphalerite and galenaa to determine their distributions in the mill products. The laboratory flotation tests recovered 74% of the sphalerite and 83% of the galena in Zn and Pb concentrates respectively. The mineral evaluation study indicates that the optimum recovery for sphalerite and galena are 85 and 83% respectively. The company is currently recovering 80% 'of the sphalerite and 82% of the galena.

Jan 1, 1989

By C. A. Rhoades

A major contributor to the problem of short life expectancy for blade-type conveyor belt cleaners is uneven wear along the blade edge. Uneven wear results in the formation of channels in the blade edge, which allow material to be carried back between the blade and the belt. In an effort to reduce the uneven wear problem, the U.S. Bureau of Mines has studied the mechanisms responsible for effective belt cleaning. From this study emerged a design for a cleaner blade that would greatly reduce uneven edge wear. The design consists of a standard cleaner blade incorporating air passages that allow for the expulsion of air along that part of the blade edge in contact with the conveyor belt surface. The results of 18-h tests indicated that the expulsion of air on the blade edge prevents scratches from developing into deep grooves. These tests showed that effective blade cleaning life can be extended 25 times using the pneumatic cleaning blade, compared with solid metal cleaning blades.

Jan 1, 1989

By Gerald M. Ellis

Exploration for gold .deposits on Hispaniola has taken place sporadically over the years but has expanded in the past decade. There are veintype, disseminated, alluvial and elluvial deposits. Investigations were previously undertaken in Haiti by combined Haitian, Bureau of Mines, and UN geological teams at Grand Bois Limbe(Milot) and Cap Coq areas. Later studies were conducted at the Miches and Moncion districts. Gold occurrences were reported in quartz, silicic-barite veins and gossans. An important deposit ?at Pueblo Viejo is? a disseminated type where extraction is taking place in the oxidized zone. Exploration by Japanese and West German firms with local geologists are described in this paper together with Pueblo Viejo, Miches, Restauracion, Milot, and Meme ?areas where occurrences are known. Copper deposits with associated gold va1ues are also described. These include vein deposits in Central Cordillera and disseminated deposits at Terrier Rouge and Blondin.

Jan 1, 1989

By G. J. Melvin

Mines the world over tend to face a common range of problems. They begin life by trying to determine if there is sufficient product, usually under tons of earth, of sufficient quality to justify the operation. Once such a determination is made the mine must then be planned and brought into operation. Once operating most mines find that they are far away from suppliers, using very expensive equipment. Hence the three most common mining problems are, what does my ore body look like and how can it best be mined, how can I get sup- plies to my mine in the most cost effective way, and how do I control the vast dollars required to keep it all operating. Mincom started life by providing technical mining software to address the first of these problems and was very successful, particularly in the coal mining industry. However the company soon realized that if it was to become a significant provider of mining industry software it must also address the other major problem areas. Hence started what is now Mincom's largest business which is the provision of fully integrated mine management software with strong emphasis on materials and maintenance management to control costs. Mincom not only supplies the software but also provides a comprehensive implementation package using its own staff of experienced mining industry specialists. This papaer highlights some of Mincom's international implementation experiences.

Jan 1, 1989

By W. K. Tolley

The Bureau of Mines is testing super critical fluids as solvents to selectively extract valuable components from complex matrices. Materials recovered during supercritical fluid extraction are often highly purified. Using laboratory apparatus designed specifically for supercritical fluid research, Bureau re-searchers have measured the solubility of titanium tetrachloride (TiCI4) in supercritical, liquid, and gaseous carbon dioxide (C02), CO2, a commonly used supercritical fluid, is inert, inexpensive, and nontoxic. Supercritical CO2 formed a single phase with TiCl4 at 45° C and 1,500 psig. When the solution was heated at constant pressure beyond 55° C, TiCl4 precipitated from the fluid. Results showed that TiCl4 solubility in supercritical CO2 is not controlled by the vapor pressure of the solute.

Jan 1, 1989

By Larry J. Hughes

Ground-based electrical geophysical techniques have be valuable for three indirect exploration strategies: "tracer" sulfide mineralization, 2) mapping structure with or controlling mineralization, and 3) mapping proven to 1) mapping? associated alteration zones. When sulfide mineralization is associated with gold, it often can be mapped using induced polarization (IP). This technique can detect pyrite in amounts as small as 0.2% by volume, and in some cases can distinguish pyrite from anomalies due to graphite and clays. A case history illustrates mapping sulfides in a shear zone. Structure and alteration mapping are often the domain of controlled source audio-frequency magnetotellurics (CSAMT) due to the superior lateral resolution and depth penetration of this technique. Typical CSAMT targets include silicified sediments and volcanics, faults, brecciated zones, argillic alteration, clay and graphite horizons, and certain lithologies. Examples of mapping silicification and mapping epithermal alteration are presented in CSAMT case histories over Cannon mine in Washington and Hishikari mine in southern Japan. In our experience, four things are needed to use geophysics effectively in precious metals exploration. First, the explorationist must correctly identify the exploration stage at which the geophysics is most useful. Second, the explorationist must clearly define the types of "tracer" mineralization, host geology, or alteration which need to be defined by the geophysics. Third, the right electrical technique needs to be applied to the problem to provide the best chance of success. Fourth, the explorationist must be willing to commit adequate finances to do the geophysics properly. With careful adherence to these principles, geophysics can greatly enhance exploration success while reducing the total cost of exploration.

Jan 1, 1989

By Kavetsky A

In surface mining operations, the ease with which a muckpile may be dug is a dominant factor in mining efficiency. Within broad limits, this is largely dependent on muckpile shape and looseness within a muckpile. Moreover, prediction of grade boundary movement and subsequent dilu- tion is of interest to most open cut mines. Such a predictive tool would enable blast design changes to be made to reduce mixing of certain grade regions. At the very least, a good knowledge of post-blast region bound- aries can reduce layout of the grade boundaries and decrease grade dis- crepancies between pit and plant. The model presented in this paper is able to consider various options for a production blast and predict consequent muckpile shapes and grade boundary movements in a three dimensional manner. The overburden geometry, hole patterns, hole inclination and charge distribution are all explicit model inputs. The model divides the rock mass into blocks and calculates a velocity for each block. Three controlling parameters are used in the model, which are related to the explosive energy per unit length of blast hole, energy attenuation of the rock mass and inter-row delay, respectively. The output of the model is a 3 dimensional muckpile shape (contour or any cross section) and a contour map of grade distribution within the muckpile. The model parameters are site specific, since their values depend on the rock condition and explosive-rock interaction which varies from site to site. In order to "tune" the model to a particular site, parameter values must be found which reproduce an observed muckpile profile shape from a given blast design. This calibration of the model requires at least one surveyed muckpile profile shape from a production blast. The model parameters which best reproduce that shape are found by a pattern search technique, and may then be used to predict the effect of changes in blast design on muckpile profile shape and grade boundary movement.

Jan 1, 1989

By David Seymour

Newmont Gold Company (NGC) located in Northeastern Nevada has been processing carbonaceous and sulfide refractory gold ores through a chlorination circuit prior to cyanidation. A "Flash Chlorination" pilot plant was installed in 1987 in an effort to obtain higher chlorine utilization efficiency and increase gold extraction. The Flash Chlorination process oxidizes organic carbon and sulfide sulfur. It also deactivates preg-robbing carbon, making the ore amenable to cyanidation. Significant recovery improvements were observed using this new process. This scheme has also been instrumental in the processing of higher than normal grade ores at economic chlorine levels. The Flash Chlorination pilot plant has been successfully treating carbonaceous ore on a production scale since April 1988. This paper summarizes laboratory and pilot plant optimization test work, using conventional and statistical methods.

Jan 1, 1989

By Tom Plouf, Deepak Malhotra

INTRODUCTION The U. S. mining industry experienced a severe recession in the early 1980's. This resulted in the realization that the domestic mining industry had to compete on a global basis and only the strong or the low-cost producers would survive. The economic viability of a mining company not only depended on maximizing mineral recovery but also on its ability to do so at minimum cost. Companies had to become more productive not only by cutting costs, but also by developing and/or evaluating new technologies in existing or new plants. Several innovative concepts, including in-pit crushing and conveying, fine crushing, improved classification equipment, flotation, column flotation, pressure filtration, etc., have been developed in recent years. This paper addresses the impact of new flotation concepts and equipment on mill design. MILL DESIGN PHILOSOPHY Modern mill design, especially for large capacity plants, has its foundation in minimizing capital and operating costs. Capital costs can be minimized by minimizing the various components of the capital cost: infrastructure, equipment, instrumentation, structural, initial spare parts costs, etc. All these costs are minimized by simplifying the mill design and/or process flowsheet. The simplified process flowsheet, where applicable, consists of a single stage primary crusher followed by a semiautogeneous - ball mill grinding circuit to produce feed for a flotation circuit. Multiple flotation circuits have been eliminated in most cases. These concepts minimize the cost and encourage the use of large capacity equipment while maintaining optimum metallurgical recovery. The philosophy of mill modernization/modification is generally driven by the desire to increase the mill capacity within the limits of the existing mill building. This need is facilitated by using large size flotation equipment and eliminating multiple parallel flotation circuits in order to minimize capital and operating costs. Conventional flotation machine development has paralleled this mill design philosophy. FLOTATION CELL DESIGN Since froth flotation has been the most widely used separation process for over half a century, one would expect that it would be possible to design and select flotation machines for specific applications based on scientific principles. But this has not been the case. Best judgment, experience and personal prejudice have played a key role in equipment selection. These factors, along with the difficulty of evaluating new concepts in commercial plants, has slowed progress in implementation and commercialization of innovative ideas and/or equipment. Conventional Flotation There have been no major technological advances in conventional flotation cell design in recent years. A recent flotation cell survey indicates that 'larger flotation cells are still the order of the day.”(1) A comprehensive review of design of flotation machines indicate that they have been mechanically redesigned and are generally simpler and easier to maintain and less expensive to manufacture. (2,3) The approximate chronological development of conventional cells from the 25 cubic foot cells to the 3000 cubic foot cells, which were recently installed at the Copperton concentrator of Utah Copper, is given in Table 1. Larger flotation cells are the obvious choice for new plants or plants looking for expansion because of the following reasons: • They have lower capital cost per unit volume • Installation costs are generally lower because fewer units require less space • Maintenance costs are lower because of fewer mechanisms • Power requirements (HP/ton dry feed) are generally lower • with increased flotation cell size as illustrated in Table 2 [Table 1. Conventional Flotation Cell Size Development Year Individual Cubic Cell Size, Feet 1925 25 1935 50 1960 100 1965 300 1970 500 1975 1,000 1980 1,500 1985 3,000]

Jan 1, 1989