Search Documents

Early experiences suggested autogenous mills were difficult to operate and consumed substantially more energy than conventional rod/ball mill circuits. As our understanding has increased and the technology has matured this perception has changed to the point where most new comminution circuits are ag/sag based. In addition many operators have replaced existing conventional circuits with this technology. The JKMRC has been studying ag/sag mills for over 20 years. During this time it has amassed what is probably the single largest and most detailed data base of pilot and full scale mill operations in the world. This has been used to help develop and refine its cur- rent commercially available mathematical model of ag/sag mills. A decade of its application has greatly helped simplify both design and operation of ag/sag milling circuits as well as helping to promote the effective use of recycle crushing, secondary crushing and closed-circuit operation. This paper describes the development of ag and sag milling in terms of our understanding and the evolution of the technology. In addition the application of mathematical modelling and simulation in designing and operating efficient circuits is described with the aid of practical examples.

Jan 1, 1998

By P. Clifford

FIPR-sponsored research will playa critical role in enhancing the competitiveness of the Florida phosphate industry as ore grade declines and environmental restrictions tighten. FIPR's program seeks to improve surface mining and pipeline transportation while reducing the energy cost for pumping phosphate matrix. The development of a reliable on-line analyzer and a modern process control strategy will result in improved processing efficiency. Significant improvement in overall efficiency will also be realized as the industry adopts column flotation technology. Economic acidulation of high-Insol rock will allow the industry to adopt simplified flotation flowsheets thereby reducing operating costs. Various applications of phosphogypsum would save the industry millions of dollars in constructing and closing gypsum stacks.

Jan 1, 1998

By Jan M. Andersson

This paper will discuss the background information about rock cutting tools used for soft ground excavation, their history and evolution. A brief review of the current state of the art manufacturing technology will be presented and some parameters related to the material used in the drag and conical type pick cutters and their impact on their life and performance will be explained In addition, the selection procedures for choosing the right bit for excavation of a particular geological formation will be reviewed A set of guidelines will be provided for initial selection of the tools for various machines and rock formations. The methods for estimation of the tool life in various materials and the influencing parameters along with limitations of the rock cutting tools will be discussed as well.

Jan 1, 1998

By D. R. Spears

Conventional round tank thickeners have been widely used in the mining industry for many years. The mining industry was well satisfied with the ability of conventional thickeners to improve minerals beneficiation operations. However, development of improved flocculants (the polyacrylamides) made possible much more rapid settling rates, since polyacrylamides produce large flocs rapidly (unlike starch or inorganics). Traditionally considered to be a slow operation if maximum underflow density was achieved, and therefore there was some justification for the expense. Thickeners required large volumes to permit sufficient time for settling. The oversize not considered a drawback but the initial capital cost was. In high rate thickeners, a bed of thickened material is allowed to build around the feedwell, even above the bottom of the feedwell. The slurry is fed directly into the bed at a velocity that allows the material to be evenly dispersed over the thickener area This more efficient use of settling area allows a higher solids throughput per unit surface area (rise rate). In this paper, high rate thickener rise rates and polymer consumption are compared.

Jan 1, 1998

For over 50 years R W Miller & Co Pty Ltd operated old coal properties abandoned by former owners as uneconomic, some of which dated back to the last century. The companyÆs ability to survive with what were relatively poor quality coal resources required a small efficient management organisation. In 1970 R W Miller was involved in negotiations with other coal companies through coal sales contracts to develop private coal areas under the provisions of the old Coal Mining Act (1906) and these efforts led to the development of Lemington colliery. At the same time development of the Ironbark colliery holding near Newcastle commenced. In 1971, R W Miller approached the New South Wales Government for a resource replacement area to prospect for coal in the Upper Hunter Valley. Authorisation No 33 was finally granted on 30 September 1975, but the company found the area was inaccessible as most of the surface was owned by the Australian Army. Later R W Miller was granted Authorisation 66 of 2167.5 hectares at Mount Thorley near Singleton on 1 November 1976. The development of this coal mining project coincided with the second OPEC oil crisis in 1978 and a short-term boom for coal resources and the unrealistic expectations generated by the boom. This paper gives a broad outline of the development of the Mount Thorley project between 1976 to 1986 including the feasibility study and the many governmental and industrial delays that resulted in a three-year time overrun in the project development period.

Jan 1, 1998

An appropriate scale-up methodology is very useful for ball mill design and optimization of the grinding circuit. To date, the scale-up is based on the selection and breakage function method using lab mill data. However, a major drawback of that approach is that the charge motion in a lab mill is vastly different from that in a large industrial mill. Therefore, in the methodology proposed here, first the energy of individual collision in the mill is computed employing the discrete element method (DEM). Then the breakage of particles as a function of collision energy is studied in a separate experiment. Together, this information constitutes what is known as collision energy based population balance method. The appropriateness of this method is shown for 38-cm ball mill.

Jan 1, 1998

By M. A. Evanto

Since the late 1970's, the Roof Control Division (RCD) of MSHA's Technical Support has been performing linear analyses for the enhancement of miners' safety. This remote sensing process uses Landsat data to predict areas of potentially hazardous ground conditions in underground mines. To date approximately 700 analyses have been completed by the RCD, with nearly 75 being performed with the current equipment, software and methodology which was updated in early 1995. While success is difficult to measure, requests for linear analyses continue to come from large and small mining companies which suggests the industry's acceptance of the process.

Jan 1, 1998

By N. A. Warner

To filly secure the environmental and social acceptability benefits of making a sulphide smelting facility and its ancillary sulphuric acid plant or other means for fixing sulphur, a virtually zero gas emission operation, it will be necessary to utilise exclusively technically pure oxygen. The strategy proposed for preventing the smelter from overheating involves highly efficient energy transfer by promoting sulphur trioxide formation at a relatively higher temperature than normal. A closed-loop gas circuit uses an eductor system actuated by the process oxygen to recirculate sulphur trioxide and unconverted sulphur dioxide back to the smelter, the endothermic dissociation of sulphur trioxide becoming a major contributor to the removal of excess heat. The only gases leaving the system relate to the bleed of nitrogen impurity introduced in the tonnage oxygen.

Jan 1, 1998

By James A. Finch

"I offer a personal view of what the next 30 years holds for mineral processing. Re-stating that mineral processing will remain a vibrant industry in raw material production, growth opportunities in waste management are identified. The processing sequence familiar now (mining -mineral processing -extraction) will become more interwoven. In situ processing (i.e., milling underground) will evolve from concept to demonstration. Opportunities to exploit physical properties altered in chemical (pyro-and hydro-) processing will present themselves. In primary grinding, the path to AG/SAG milling will progress with little deviation but opportunities in regrinding are wide open. Flotation will see the trend to designing bubble/particle reactors accelerate simultaneously with a vigorous response from mechanical cell suppliers. Gravity separation remains a bastion of the lone inventor but I anticipate that the new lines will come from the waste management business. I finish by examining the ""research cycle"", identifying growth in small ""high tech"" companies and university research centres.IntroductionI have been asked to offer a personal view of""where we are going in mineral processing?"". Gazing into crystal balls is quite a cottage industry as we approach the end of the millennium. Academics are often asked to assume the role of visionary, I presume because it is considered in their mandate, to reflect and philosophize (or, less charitably, because they are considered to have the time). Since this is the 30th Annual Canadian Mineral Processors Operators Conference, I am tempted to suggest the next 30 years as my frame of reference. This is about equivalent to one engineer's career or, given it takes typically 15 years to go from concept to realization in mineral process engineering (Napier-Munn, l 997a), about 2 ""invention cycles"". With this length of cycle, much that is familiar now will remain so over the 30 years.Research and development (R&D) is in response to need. The overarching need in mining is to find new ore bodies. Process developments cannot compensate for a depleting deposit or a declining commodity price. Mineral processing R&D is characterized by incremental gains, aimed at pushing the mine down the cost per tonne league table. Breakthroughs are the exception (flotation at the turn of the century was one). This must be kept in mind when trying to predict the future in our business."

Jan 1, 1998

By J Shillabeer

Paste backfill has been adopted by many underground mines in North America and a growing number elsewhere. Paste offers a number of advantages. This paper suggests wider applications of paste technology to surface tailings disposal and water management. Advantages include improved overall stability, potentially easier permitting, smaller water inventory and earlier reclamation. It may be feasible to use the same plant to prepare backfill and to dispose of surplus tailings. Example cost models are given to illustrate potential applications.

Jan 1, 1998

By H. Appiah

Small scale mining (SSM) has been going on for a long time in Ghana. SSM was legalized by the PNDC Law 218, 1989. Since then there have been numerous gains from the SSM industry. The SSM is organized locally by the concession owner who engages people to work for the gold which he buys. Small scale miners (SSMs) use crudely made sluices in Ghana and, therefore, their production falls below what is expected. The SSMs work in groups and not as cooperatives, as they do in Brazil and other Latin American countries. Legalization of SSM has curbed gold smuggling considerably because a gold marketing entity is available. SSM poses certain environmental problems like pollution of water bodies and soils by mercury and indiscriminate digging of pits.

Jan 1, 1998

By Andrew Neale

ERIC GUTIERREZ: With that, we'll go ahead with the final speaker of the day, Andrew Neale. Andrew has a master's of science degree in mineral processing from the University of Alberta. He worked at the Falconbridge in Sudbury area, also at Brenda Mines, and then he became part of the Brenda Process Technology group in British Columbia. He joined Freeport in late 1993 in Indonesia, and was involved in process control and automation. He is now the senior manager of metallurgy in New Orleans. He's responsible for designing Freeport's new 100,000-ton-per-day expansion concentrator, which is currently being commissioned. Please welcome Andrew. ANDREW NEALE: With the ongoing explosion in digital computing power, there seems to be no limit to what can be modeled, simulated, and controlled in the mineral processing plant. However, at each stage of development of a control system, it is necessary to complete a cost-benefit analysis for justifying the move to a higher level of control. Incremental improvements in plant performance, while often significant, must be weighed against the costs of implementation and long-term maintenance. This presentation will provide examples of what the author believes are misplaced or misguided process control efforts and make a case for the KISS principle as applied to process control.

Jan 1, 1998

By Yanske TR, Lane WL

The Doc Run Company and its predecessors have been mining for over 130 years utilising the room and pillar mining method. This method has left approximately 20 per cent of the orebody in the remaining pillars. The original design and planning for the mines did not include extensive pillar extraction. This paper summarises the introduction of the pillar extraction and backfill techniques which have been implemented since 1991. These techniques include the use of low cost fill walls up to 20 in in height and the use of stinger trucks for topping off the fill. In conjunction with these accomplishments, much experience and confidence has been gained in the use of numerical modelling as a method of predicting pillar stability as the mining of pillars progresses. These advances have led to pillar extraction hecoming a major portion of the overall production and have added to the mine life of Doe Run's six operating mines.

Jan 1, 1998

By J. M. Mutmansky, R. A. Jankowski, M. A. K. Mohamed

"SYNOPSISKnown health hazards associated with the breathing of respirable dusts, particularly silica dust, during mining are becoming a great concern in many parts of the world. The search for effective and low cost dust control methods for underdeveloped countries will help in improving the productivity and keeping the mine environment safe. This article addresses the problem by providing suggestions concerning the easiest and most cost effective methods to control respirable dust in mining and mineral processing operations. INTRODUCTIONMedical BackgroundLung diseases caused by dust in mining operations have been recognized by mankind since the time of the Roman Empire. The writings of Pliny the Younger on natural history reported on maladies associated with dust in mining in the first century AD. However, no significant advances in controlling the lung diseases of miners came about for many centuries. The effects of mineral dusts were further described by Georgius Agricola in his sixteenth century book on mining (Agricola, 1556). After the appearance of Agricola""s book, lung diseases were more readily recognized, but the nature and severity of the ailments associated with mineral dusts could not be readily interpreted.In 1896, the discovery of x-rays by Roentgen advanced the diagnosis of lung diseases and the knowledge of what causes these diseases. In addition, the discovery allowed medical personnel some method of judging the extent and severity of the lung diseases in human beings. During the ensuing years, the term 'pneumoconiosis' became the common term to describe any of the diseases of the lung in which dust particles deposited in the lungs caused fibrous tissue and loss of some of the respiratory function. However, little in the way of social remedies for the diseases resulted until much later. Society was still not ready to act decisively to reduce the causes of lung disease due to the dusty conditions in the work place.Social action against lung diseases did not occur in the United States (US) until the 1930s. At that time, a tunnel driven through a sandstone mountain near Gauley Bridge. West Virginia, caused the death of several hundred workers due to acute silicosis, a severe form of pneumoconiosis caused by silica (Seaton, 1975). Dust conditions in this tunnel were quite bad, causing many of the workers to be subjected to extremely high silica dust concentrations. The severity of the disease in many of the workers became known to the public and prompted the US Congress and many of the states to enact laws to reduce the dust levels."

Jan 1, 1998

By S Harvey

An inrush of water or mud into an underground mine, or sudden subsidence above mining voids represent low probability but high impact risks in underground mining. About two such incidents involving multiple fatalities or loss of production are reported each year worldwide. On average, Australia experiences one such incident every three to four years. This paper reports the development of a Standard that is intended to eliminate fatalities due to inrushes and subsidence.

Jan 1, 1998

The Australian industrial relations system is in a state of constant change. We are undergoing a transformation from a compulsory arbitration and an award based system to one which is fundamentally rooted in the concepts of enterprise bargaining. This is true both at the State and Federal level. The structural changes which facilitate the movement away from the predominance of Awards to enterprise agreements has been fostered by both sides of the political spectrum and is a cornerstone of their respective industrial relations platforms.In determining what form or combination of forms of industrial instrument(s) should apply to the individual enterprise, employers must have regard to the viability and sustainability of each form in the changing industrial climate. In particular employers should have regard to the needs and agendas of their employees and unions which may purport to represent Them.

Jan 1, 1998

By Kenneth N. Han

Ammonia has been found to be an effective leaching reagent for gold, silver and platinum group metals in the presence of appropriate oxidants. Electrochemical and kinetic aspects of the dissolution of elemental gold in ammoniacal solutions have been investigated. The cathodic reaction of aurous di-ammine on the gold cathode has been investigated first. From this investigation, the standard electro-potential of the cathodic reaction .and hence. the Gibbs free energy of formation of the aurous di-ammine were established. The solubility of gold in ammoniacal solutions was also examined in relation to ammonia concentration, temperature and concentration of various oxidants. The anodic reaction of the gold disk in ammonia? in the presence? of various oxidants including oxygen, ozon, hypochlorite, hydrogen peroxide, cupric and cobaltic ammine, and iodine was also examined and the results have been discussed. Excellent dissolution yielding of gold and many other metals, typically better than 95% recovery in 1'-2 'hours of leaching at a temperature ranging 80°C to 190°C has been observed. Test results of the dissolution of gold from elemental state as well as other sources including sulfidic ores and scrap are presented.

Jan 1, 1998

By G. A. Eltringham

Mining and extraction methods in the copper industry use basic technologies developed over a period of almost 150 years. Paradigm shifts in the industry have been rare, yet human involvement in the activities has changed dramatically. Clearly defined extraction paths have become more blurred as economic considerations broke down the barriers that had encouraged specialization. What had been a labor-intensive industry unfettered by environmental restrictions was forced to change. Better productivity and "cleaner" operations resulted in much higher capital costs on a plant basis. Many of the changes were truly innovative in the same spirit as in the mining revolution of the first decade of the twentieth century. What role will innovation play in the next 20 years as lower-grade, mixed-metal orebodies are exploited in more remote locations?

Jan 1, 1998

By D. A. Swanson

Predicting when and at what rate seepage will occur from waste-rock facilities is becoming an integral part of permitting and closure at mines situated in dry climates. Such predictions require development of a conceptual framework that accurately describes how water will percolate through a waste-rock facility. Also needed is a detailed hydrological characterization of the waste-rock facility, including measurement of the hydraulic properties of the waste rock and any potential cover materials. This paper presents a conceptual framework describing unsaturated water flow in a waste-rock facility and describes methods for characterizing the hydrology of a waste-rock facility in a dry climate. The methods are designed to collect site-specific data to support accurate and defensible predictions of long-term seepage rates.

Jan 1, 1998

By M. C. Roberts

In assessing the future markets for a mineral from a producing district, three key aspects must be considered: 1) the future growth in markets, 2) the competitiveness of the district in terms of production costs and reserve adequacy, and 3) the competition from alternative sources of supply. This paper will focus on the first issue by developing a method of predicting the demand for phosphate from the trends in the major markets for phosphate products, primarily the fertilizer and agricultural markets. The paper will show how broad changes in the final end use markets for phosphate products have evolved over time and how this has affected the needs for phosphate rock. These trends are then projected into the future to make an assessment of future phosphate requirements.

Jan 1, 1998