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By M. S. Klima

A 25-mm diameter dense-medium cyclone was tested to investigate the effects of geometry and operating conditions on cyclone performance when processing -150 I'm coal. The emphasis was on examining those variables (e.g., flow rate and inlet velocity) which impact the separation kinetics (specifically the number of g's and the mean retention time) and the occurrence of apparent bypass. Apparent bypass, indicated by partition curve "tails", results from the short circuiting of the feed coal to one or both of the product streams and represents a loss and/or contamination of the clean coal. This paper presents the results for this series of tests.

Jan 1, 1993

By C. J. Newman

Production levels at the Kidd Creek copper operation increased during the 1980's by expansion of both the smelter and refinery and by major modifications to equipment which was causing bottlenecks. As a result, there was a significant reduction in the unit cost, some manpower reductions and hence a significant increase in productivity. In the last two or three years, there have been no major expansion projects leading to unit cost reductions and yet these have still been attained. This has been achieved by the development and implementation of various techniques designed to maximize the inherent potential of the operators and maintenance employees. This paper will initially describe the operation but will then place emphasis on employee involvement through such methods as idea awards, incentive schemes, loss control and continuous improvement programs. Organizational changes are discussed, particularly with reference to changes from the traditional operator role to one which encompasses maintenance skills and to cross-training of maintenance employees into multi-discipline fields. The effect of these changes are discussed by a review of the salient plant parameters of safety, production levels, cost and quality.

Jan 1, 1993

The 250 metric tonnes of gold and 360 000 metric tonnes of copper recovered from the Mt Morgan Mine in Central Queensland justify its fame. The mine ceased operation before the advent of three-dimensional computer graphical modelling of orebodies became common practice in mine planning. The Mount Morgan Mine records however remain and are the database for this study. The Mount Morgan project takes ore deposit modelling one step further by examining the relationship between grade distribution within the orebody and key geological features, as a tool for exploration and development.The Mount Morgan gold and copper mineralisation is shown to be strongly lognormally distributed. The deposit has been split into three areas, using geological boundaries, each with different geostatistical characteristics. Important features include: the spatial relationship of near-vertical, high grade shoots with a ring dyke thought to be related to the North Dyke; separation of the high grade eastern stopes from the others along the Andesite Dyke; and lack of concentrated mineralisation along the Slide Fault.Recognition of these features is useful to those currently exploring the Mount Morgan district for similar style deposits, by stressing the importance, or lack thereof, of the geological features.

Jan 1, 1993

By Byron Belew, Juris R. Harlamovs, D. B. Dreisinger, John L. Watson, G. A. Kordosky, Thomas O. O’Keefe

Unwanted impurities, present in raw materials, are often coextracted along with desired constituents during leaching. Due to its abundance and ease of extraction, the presence of ferric iron in leach solutions, solvent extraction circuits, and subsequently in electrowinning circuits, has always been a problem. In the case of zinc hydrometallurgical processing, iron is frequently an impurity in leach solutions. Purification of such solutions by solvent extraction, using di (2-ethylhexyl) phosphoric acid (D2EHPA) in a kerosene diluent, results in ferric ions being readily extracted along with zinc into the organic phase. Ferric iron has proven difficult to strip from the organic phase, but it is known that ferrous iron may be easily stripped from D2EHPA, and hence a process to effect reduction of iron present in the organic would have great potential. This research investigated a process to directly reduce ferric to ferrous iron in the organic phase, and to strip the ferrous iron using a dilute acid solution. The process utilized metallic zinc as the reductant and a low concentration sulfuric acid stripping solution. The results of the laboratory tests illustrated that iron could be readily removed from the organic phase by simultaneous direct reduction and acid stripping. The reductive stripping process was subsequently utilized in industry at the laboratory and pilot plant levels. The results of the industrial tests were encouraging and demonstrated the potential of this novel concept.

Jan 1, 1993

By Lee W. Saperstein

The Research Council of SME, at its Annual Meeting in Reno, NR, in February 1993, held a Research Forum on Technology for the Future. The Forum's purpose was to find out from the members, particularly those from industry, their opinions on research needed in the mineral industries. Panelists were selected for their breadth of knowledge and connections. Many panelists, in turn, solicited opinions from additional contacts. A similar effort is underway with mineral-oriented schools. A parallel mission has been undertaken by the American Mining Congress (AMC) through its Committee on Technology. In particular, AMC is concerned that the needs of industry be transmitted in a timely way to federal agencies, especially the US Bureau of Mines. This article reports to the SME membership the principal findings of the Research Forum. The article is derived from a full report that is available from SME. Many of the calls for research made during the Forum can be clustered into five broad categories. These categories are discussed in the following sections of this article. However, since the time of the Forum, many reviewers of the full report have noticed that fundamental research was not given much emphasis. The Research Council points out that the Forum was organized around industrial needs. There is a call to the academic and research community to organize a similar Forum. The Council emphasizes that this is not the last word on research needs and that the membership is urged to continue to give ideas and opinions to the SME Research Council. There will be an opportunity at its next meeting during the SME Annual Meeting in Albuquerque, NM, Feb. 22, 1994, for open discussion of this report. Because the opinions were intentionally confined to representatives from industry, the problems portrayed and the solutions sought are from the vantage of an operator. It comes as no surprise that many of the espoused research desiderata seek more efficient or cost-effective outcomes for the various mining activities discussed. The order of the Forum was a straightforward set of mining activities: exploration, evaluation, mining and processing.

Jan 1, 1993

By R. Gong, R. Bhaskar

A coal mine study was conducted to evaluate the effectiveness of a compressed-air, foam spray system installed under a continuous miner boom and directed to cover the pan and the gathering arm. The study's objectives were to evaluate the foam, underboom sprays' effect on: • the respirable dust concentration in the ambient air, and • the quartz concentration in the airborne, respirable dust. The foam generation and delivery system's engineering design is described in the paper, followed by descriptions of the mine and the dust sampling strategy. The data were analyzed to study the foam's effects on respirable dust and quartz concentrations at the continuous miner cab, the face return and the intake. The data indicate reductions in the dust's quartz content, ranging from 19.7% to 64.6%, in eight of 11 comparisons of the foam vs. no foam cuts. In addition, airborne intake dust reductions were observed in eight of 11 comparisons.

Jan 1, 1993

By Lynn E. Bowman

Efficient filtration of fine kaolin particles plays a crucial role in the processing of raw kaolin to a marketable product. Filtration can often be the rate-controlling step of the whole process. Consequently, plant production depends on the rates being achieved in filtration. To alleviate the bottleneck in production, Nalco Chemical Co. initiated a reagent development program to chemically enhance the performance of the filtration units. Filter aids of different classes were assembled and evaluated in bench simulations. These included reagents whose primary mode of functionality were coagulation, flocculation, thickening and combinations of each. This article discusses the development and application of a new reagent that improves the filter production rate with minimal impact on filter cake percent solids. Plant data indicate that this reagent can increase production rates by as much as 35% on clays of varying particle size, as well as clays that are calcined. The reagent's impact on solids content, re-slurrying characteristics, Brookfield and Hercules viscosity and drying is within the standards set by plants that evaluated and now use this product.

Jan 1, 1993

A major high grade zinc deposit, Dugald River has fine-grained and complex mineral associations which provide considerable metallurgical challenges for both mineral dressers and downstream processors. A long history of metallurgical testing focusing on mineralogy and flotation concentrate production has shown that while separate lead and zinc concentrates can be produced at saleable grades, high levels of iron, and particularly manganese, are likely to place constraints on the marketing of zinc concentrate produced from deeper zones where coincidentally lode development is at its maximum. Testwork has focused on characterising the flotation response of ore types ranging from banded and stringer sulphides to brecciated ores in a variety of sulphide matrices. A high level of variability with lower than expected metal recoveries has been indicated across some of the higher grade brecciated ores. However, the dominant slatey breccia has generally provided the best results. Heavy media preconcentration testwork has been moderately encouraging and at this stage, although value adding downstream of concentrate production on-site is not seen as an economic option processing developments are being monitored on a broad front. Providing satisfactory means can be developed for handling manganese during downstream processing of the concentrate, it is not difficult to see a world-class operation emerging from the resource in the medium-term Future.

Jan 1, 1993

By Ximeng Zhu

In the transpassive region, about 0.4 to 0.8 V (SCE), aggressive oxidation of pyrite occurred. The reaction products in this region were Fe(III) oxide, sulfate ion and partially oxidized sulfur intermediates. The growth kinetics of the reaction product film, resulting from transpassive oxidation of pyrite were studied using chronoamperometry measurement with both stationary and rotating disk electrodes. The effect of electrode rotation speed, solution pH and temperature were examined. Potentiostatic measurements were well correlated by a paralinear rate equation, suggesting the formation of an intermediate passive film, associated with the simultaneous dissolution of the outer layer of the film. Activation energies of 66.17 kJ/mole (15.83 kcal/mole) and 38.67 kJ/mole (9.25 kcal/mole) were obtained for associated parabolic and linear rate constants respectively, at an applied potential of 0.6 V.

Jan 1, 1993

Studying the ore textures in a discrete orebody is a novel approach to estimating liberation potential of the ore minerals present. As part of a PhD thesis, this project aims at classifying and quantifying the textures of the Hilton North orebodies, and at estimating their liberation characteristics.

Jan 1, 1993

By Edmonds W, Giles C. W, Webb R. J, Gum J. C

Gold production from The Granites - Tanami Goldfield during 1993 is expected to exceed 8 t, eclipsing that of the traditional Northern Territory gold mining districts of Tennant Creek and Pine Creek. This is the result of dedicated and successful exploration, and the consequent discovery of new orebodies such as those at Dead Bullock Soak.Following granting of access to regional exploration areas in 1988 and identification of favourable host rocks in the Schist Hills area, North Flinders Mines (NFM) began a methodical exploration program of detailed geological mapping, rock chip sampling, costeaning and various types of drilling. The first resource of 600 000 t of 3.3 g/t gold was announced in mid-1989. This has grown progressively with systematic exploration to the currently published resource inventory of 6.6 mT @ 5.4 g/t, (as at 31.12.92) contained in six separate orebodies within the Dead Bullock Soak Mineral Lease at Schist Hills.

Jan 1, 1993

By Charles L. Kimbell

The final 26 tables of this chapter, tables 25-50, extend and expand the statistical series on production that was started in the 1963 edition of the "Area Reports: International" volume of the "Minerals Yearbook" and that was subsequently updated and expanded in the 1965 and 1967-89 editions. Continuing the practice started in 1989, a column has been included in each of these tables providing a 5-year average for 1986-90, inclusive. This should provide a clearer picture more rapidly of the role of each major producer over the 5-year period. The listing order of major producers, however, continued to be, as in past years, in descending order of rank in the year of review, 1990. With the inclusion of silver and uranium in the 1988 edition of this chapter, this group of tables now includes each of the crude minerals that ranked from 1st to 19th in 1983 terms of value of their output (as well as four others of lesser rank). These 23 crude mineral commodities accounted for 93% of the estimated value of world crude mineral production in 1983. In addition, world output of five key downstream products-aluminum, steel, cement, nitrogen in ammonia, and refined oil-are included because of their significance as products.

Jan 1, 1993

By Soldenhoff K, Levins D, Collier D, Day A, Secomb R, Brown S, Tapsell G, Bellingham A, Quan C

Bench and pilot plant studies were carried out at ANSTO to develop a process for rare earth recovery from the Mt Weld deposit near Laverton, Western Australia. This paper describes the development of the flowsheet, which is similar to conventional monazite processing, but with the introduction of several innovative steps to account for the complex rare earth mineralisation and the presence of specific gangue minerals. A unique feature of the flowsheet is the recovery of cerium by solvent extraction from a sulphate leach liquor. The process was tested continuously by the operation of a pilot plant at ANSTO's Lucas Heights Research Laboratories, Sydney in the first half of 1992. The plant, designed to treat 100 kg per day of beneficiated ore, confirmed the viability of the process, with rare earth products from the operation satisfying stringent buyer specifications.

Jan 1, 1993

The Mobile Miner MM130 was delivered to Broken Hill in February 1992. During March the machine was extensively trialled on the surface to test manoeuvrability, climbing ability and muck handling prior to being trammed underground in April. The first cutting test on 30 April 1992 provided promising results. The machine has undergone continual development since it arrived in Broken Hill with aims of ensuring reliability and achieving performance goals. The paper gives a detailed account of recent performance comparing this with the predicted Performance.

Jan 1, 1993

By S B. Richardson, R E. Danell, D Mead, N T. Moxon

Explosives provide a very concentrated source of energy which is often well in excess of that required to adequately fragment the surrounding material. Blast design, environmental requirements, production requirements and the lack of detailed insitu geological data generally limits the degree to which the explosive energy distribution within the blasthole can be significantly altered using, for example, different explosive formulations or variable loading techniques. However, increased flexibility can often be exercised over a blast through the use of air-decks.

Jan 1, 1993

In process industries, time-dependent random fluctuations of raw material characteristics and mass flow rates in bulk material or pulp flows cannot be always prevented for different reasons, eg because of the geological situation (no uniform formation of the deposit) or/and because of technological reasons (segregation in bunkers or on stockpiles). Since a long time, there has been practical experiences that such fluctuations can have negative consequences, eg: ò fluctuations of the final products characteristics, ò higher expenditure for process control, and ò worsening of technological characteristics (recovery, sharpness of separation etc). In the literature, there can be found a lot of details as to, eg the improvement of the sharpness of separation in a jig in dependence on the raw material blending (Kubitza, 1981; Gathen, 1983) or the decreasing flotation recovery with increasing raw material characteristics fluctuations in iron and potash ore processing plants (Bubnova, 1978). Up to now, however, these consequences of random fluctuations, eg on the separation efficiency were not predictable theoretically. It could be shown by means of the general model for mechanical macroprocesses (Graichen, 1989), that the reduction of input fluctuations passing a blending facility can be calculated in this way. In this example, the steady state of the process is the wanted one, but, in general, the model is able to describe also non-steady states of the process regarded. On the other hand, the general model of mechanical macroprocesses has been used successfully for modelling separation processes, eg cross-flow and air classification (Molerus, 1969; Neesse, 1991; Senden, 1979; Tichonov, 1973). That is why it was tried to model the influence of input fluctuations on the separation efficiency, that means, the impact of non-steady states - as a consequence of random fluctuations - on a separation process. The models discussed in the literature are related nearly exclusive to the steady state of the process. The reasons for that lie in the (relative) simplicity of the models and the fact that the steady state is aimed at by means of blending processes under practical conditions - because of the advantages mentioned above. These models cited have proved to be superior to other models, since the basic general model for mechanical macropocesses makes possible the consideration of turbulence acting in the process unit and influencing the separation process essentially. This is valid also for modelling the turbulent cross flow classification, applied to mechanical classifiers and hydrocyclones, where the correspondence between the separation characteristics (cut size, separation sharpness) calculated and determined experimentally is much better than for other models.

Jan 1, 1993

By Charles T. Staniek

Following a dragline relocation at Agrico's Fort Green phosphate mine in 1986, the recovery plant experienced a significant decrease in flotation performance. Through weeks of trial and error testing, we discovered we could restore recoveries by conditioning feed at pH's higher than we had used historically. The higher pH's essentially increased flotation cell kinetics, although we still do not understand the exact mechanism at work. Armed with new-found appreciation of pH modification, we initiated a program to determine the optimum modifier for us, from both a performance and environmental perspective. Environmental considerations were important because ammonia, the standard industry modifier, is a plant nutrient and higher usage rates could affect the quality, of our recycle process water. This paper describes the research and development work spanning a 3 year period that culminated in making a major change in our reagent suite when we replaced ammonia with soda ash on a permanent full-time basis.

Jan 1, 1993

By Bret E. Leisemann

The geomechanical environment in which highwall mining must operate represents a hybrid between surface and underground operations. Mine design must take into consideration the complexities associated with unsupported spans, pillars with extreme aspect ratios and the instability related to the interaction between coal extraction and the highwall stability. The rock mass adjacent to the highwall, and for a significant distance in, is affected by lateral stress relief and blast damage. This paper describes a rigorous site investigation program aimed at providing some of the input parameters for the design of highwall mining layouts at the Moura Mine and focuses upon defining the nature and extent of the relaxed zone behind the highwall. The combination of borehole imaging and C factor analysis allows delineation of blast damage and relaxation of the rock mass immediately adjacent to the highwall excavation, as well as the more subtle relaxation effects deeper into the rock mass. This has led to the formulation of a proposed geomechanical model for the relaxed zone for direct input into highwall instability analysis and mine design.

Jan 1, 1993

By S. N. McIntosh

Column bioleaching was evaluated by the U.S. Bureau of Mines as a means of recovering manganese from a low-grade ore from the Three Kids deposit in Southern Nevada. Manganese was solubilized from the ore using indigenous heterotrophic microorganisms. Diluted molasses medium was provided as nutrient for the microorganisms. The medium was recirculated through the ore bed until the sugars were spent. Two methods were evaluated to recover manganese from the sugar depleted bioleaching solution: (1) adsorption with a weak cation exchange resin followed by stripping and precipitation techniques, and (2) direct precipitation of the manganese using ammonium carbonate. Both methods removed up to 95 pct of the solubilized manganese from the medium as a carbonate salt. After manganese removal, the medium was replenished with fresh molasses and recycled back through the column. More manganese was effectively leached. This process of manganese solubilization and recovery followed by replenishment and recycling of the medium was repeated until 98 pct manganese was extracted from the ore.

Jan 1, 1993

Potential hlghwaJl mining reserves in Australia are large, but geotechnical and operating conditions are quite different from those where highwall mining has evolved in the USA. In order to achieve safe and effective resource recovery, equipment and procedures should be developed to penetrate 250 m in the Australian mining environment. This paper identifies key auributes to be incorporated in such machinery and methodology. These suggestions are intended to promote discussion on innovations to satisfy Australian requirements for highly productive, safe and environmentally acceptable techniques.

Jan 1, 1993