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By K. L. Boyd

"Can the ever-increasing tonnages of ore and waste being mined today be accommodated simply by using bigger and better crushers? This paper reviews the latest primary crushing and large cone crusher designs. It highlights how—in addition to using the larger crushers now available—maximizing the utilization percentages in each of the four stages of the rock size reduction circuit will assist in meeting the larger production requirements of existing and new mining operations. Its goal is to help consultants and operators select the optimal equipment and custom-designed items in the material handling flowsheet from the mine to the mill, maximizing operating hours per year. INTRODUCTION Are larger crushers the answer to meeting the demands of existing or new mining projects for increased tonnage? Boyd (2002) predicted that larger crushers for primary and fine crushing would be beneficial and contribute to the further development of mineral processing. Larger crushers for primary and fine crushing applications are now available. The rock size reduction process from the mine to the selected milling process facility has not changed since man first broke a rock to get at the interesting mineralization within. The rock size reduction process circuit from the mine to the mill can be summarized in four stages: • Stage 1: Mining (rock breakage and fragmentation) • Stage 2: Pre-screening (scalping) • Stage 3: Primary crushing • Stage 4: Fine crushing (secondary, tertiary and quaternary) Plant throughput and ore delivery schedule will form the basis for flowsheet design and equipment selection. Once the project design criteria and the mine plan have been established, the circuit’s utilization percentage (percentage of hours when the circuit is being utilized) can be optimized for each of the four stages. The mining and process departments are the key stakeholders in the selection of the final comminution circuit, and both departments should be familiar with and contribute to the design of the circuit. This paper focuses on the four stages of a rock size reduction circuit from the mine to the mill, equipment selection, various ore and waste handling flowsheets, and improvements in crusher station design, all with the purpose of maximizing availability and plant utilization percentages. What is a large tonnage? From 1907 to 1914, the American Panama Canal excavated 300 million tonnes of material in 7 years (History of the Panama Canal, Wikipedia). Today’s large mining operations can move the same material in 10 months, using large crushers or multiple crushers for ore processing and large crushers and a mixture of truck haulage and conveyors for handling the large waste tonnages. Some examples include:"

Jan 1, 2017

By Steve Kral

MINExpo INTERNATIONL 2000 was a good place for companies to introduce new products, technologies and services to the mining industry. Caterpillar took that a step further. The company hosted a one-day preview of its mining products at its Tinaja Hills Training and Demonstration Center near Tucson, AZ. About 30 members of the trade press spent the day at Tinaja Hills before heading on to Las Vegas for MINExpo INTERNATIONAL 2000. Dozens of Caterpillar professionals provided the editors with a first-hand look at Caterpillar’s mining trucks, loaders, excavators, road graders, water trucks and engines. In addition, these Cat experts explained the intricacies of each piece of equipment, the latest technology that led their improvement and their value to the company’s mining customers.

Jan 1, 2000

By James R. Arnold, John O. Marsden

Introduction Metallurgical accounting practices have been revolutionized over the past 15 years by the introduction of low cost personal computers and easy- to-use spreadsheet software. The Chimney Creek metallurgical accounting system takes full advantage of these advances. Data is provided by a PLC-based process control system, IBM data logging, operator logsheets and assay results from an automatatic plant sampling system. The data is organized and stored in an IBM PS/2 system using Lotus 123 and customized accounting programs to provide a comprehensive information management system. Metallurgical accounting for gold plants should ideally provide information for the following: a) Gold production accounting b) Day-to-day process control and operation c) Metallurgical evaluation and process optimization The Chimney Creek system provides all of these while overcoming specific accounting problems presented by SAG milling a coarse feed, grinding in cyanide and dump leaching run-of-mine material. Process description Gold Fields' Chimney Creek mine is located 47 miles northeast of Winnemucca, Nevada, at the northern end of the Osgood Mountains. Ore is processed by a combination of dump leaching and milling processes. The dump leach operation treats approximately 2.0 million tons per year of low grade ore (0.030 oz/ton). Run-of-mine ore is top dumped in 40 foot high pads. The use of three solution ponds for leaching enables an intermediate solution to be recirculated to the leach pad to reduce the pregnant solution flowrate and increase gold tenor of solution to the carbon-in-column (CIC) recovery circuit. Gold recovery is approximately 65% by this method. The milling process employs a SAG mill-ball mill grinding circuit to treat 900,000 tons per year at an average grade of 0.19 oz/ton. The ore is crushed to minus 12" in a jaw crusher prior to feeding the SAG mill. Cyanide is added to the grinding circuit to start gold dissolution as early as possible. After grinding, leaching of the ore is continued in a unique two-stage counter current decantation circuit 1 with 12 hours of leaching between stages . 85% of the soluble gold is recovered from the first stage thickener overflow in carbon columns (CIC). The second stage underflow is treated in a scavenger carbon-in-pulp (CIP) plant. Ultimate gold recovery is over 95%. Loaded carbon from both the dump leaching and milling processes is pressure stripped by hot cyanide solution and gold is recovered from the resulting solution by zinc precipitation. The precipitate is retorted for mercury removal and smelted into bullion. The plant flowsheet appears in Figure 1. Data collection Data for daily metallurgical accounting is obtained from three sources: a) Plant sampling b) Process control system c) Operator logsheets All of the data collection for metallurgical accounting is based around the 12-hour shift operating schedule. Sampling All critical sampling for gold production accounting is performed by automatic samplers (Figure 2). Heath & Sherwood two-stage sampling systems are used for sampling all slurry streams (cyclone overflow, CIP feed and CIP tails). The automatic sampler consists of a pneumatically operated primary sample cutter and a continuous rotary secondary splitter. The cyclone overflow and CIP tails are the most critical samples since these are used to calculate gold into and out of the plant on a shiftly basis. The CIP feed sample gives additional information concerning intermediate dissolution and recovery

Jan 1, 1990

By A. J. Barry

This report presents observations made by Bureau engineers regarding hydraulic-powered roof supports that are currently being used or have been used on nearly all operating longwalls in the United States, A comparative summary of specifications for various types of powered supports with a brief description of the mine conditions has been compiled to enable mining engineers and mine operators to readily evaluate the differences in design data. Some of the support data furnished in the field may vary from those listed in manufacturers' brochures because of the trend to customize various support components to meet specific mine conditions. A method of estimating support requirements for different assumed operating conditions is presented. Similar computations for specific mine conditions may be used to make preliminary estimates of support requirements.

Jan 1, 1969

The contribution of minerals to the growth and development of the United States is best demonstrated by the uses which have evolved during the past two centures. During pre-Revolutionary days the colonies were essentially agricultural in character, producing cotton, tobacco, rice, indigo, grains and flour, fish, livestock, dairy products, and timber. Shipbuilding was the major manufacturing industry. In 1763, the total value of exports for Virginia, Maryland, New York, Pennsylvania, and Massachusetts was £2,722,000, of which £55,000, or 2 percent, was for "copper ore, and iron in pigs" (3)1 and £49,000 was for 21,000 barrels or hogsheads of "pot-ash." The value of 75 ships built for sale in 1763 by the colonies was £61,500.

Jan 1, 1976

By A. Leppala

Scope of the Courier 300 System The fact that reliable on-stream analysis is a prerequisite for effective flotation control is hardly disputed today. Nevertheless, up to now no system has been available that includes all the equipment necessary for successful analysis. However essential an on-stream analyser is in itself, reliable and accurate assaying can only be assured after techniques for sampling, handling the slurries and computing the X-ray data have been developed for the purpose. The Outokumpu Company's Courier 300 System is a complete package that can be installed and handed over with the key. It includes the equipment needed for sampling and handling the slurries. It has been developed from the start to meet industrial demands. Obviously an on-line system must comply with far stricter standards than one designed for a laboratory. Assays are computed by an Outokumpu 316 digital data processor, which is an integral part of the system and controls its entire performance. The computer software is programmed as a standard package, including a highly advanced new model for assay computation. Analysis output is available for a process computer, report typewriter:, and recorders. The package also includes calibration for slurry assays at our pilot installation before delivery. A complete Courier System can analyse up to 4Z slurries and six elements in each slurry. Thanks to its modular design, it can be dimensioned initially to the customer's requirements and is easy to expand later at low cost. Being a mining company itself, Outokumpu has been able to utilize its own long experience in non-ferrous metallurgy - an important factor contributing to the success of the Courier system. History of the project and present installations The first on-stream analyser was installed at Outokumpu'a Pyhasalmi Con¬centrator at the end of 1967, after several years' development. Since then,

Jan 1, 1971

During the second quarter of 1983, the economic recovery showed further strength abetted by the performances of consumer spending, residential investment, and the slowing down of inventory reductions. Real gross national product (GNP) increased from the first to second quarter at an annual rate of 9.2 percent, compared with 2.6 percent from the fourth quarter of 1982 to the first quarter of 1983 and an overall 1.9- percent decrease in 1982. Total industrial production increased 1.8 percent in July, and productivity as measured by output per man-hour increased 1.3 percent between 1982 and the first quarter of 1983 (table 1). Especially noteworthy .was the performance of real consumer durable goods expenditures, which increased at an annual rate of 32.0 percent from the first to the second quarter (about half of the increase consisted of automobile sales) and real consumer spending, which increased between these periods at an annual rate of 9.7 percent. Residential investment increased at an annual rate of 76.1 percent between the first and the second quarters,1/ and private housing starts by about 38,000 units in both March and May.

Jan 1, 1983

By Edward E. Johnson

The U.S. economy made significant progress in 1984. The current-dollar gross national product (GNP), the market value of the Nation's output of goods and services, increased almost 11 percent over that of 1983 to slightly more than $3.66 trillion (table 1), and the real gross national product increased almost 7 percent.2/ Such rapid growth in real GNP has not occurred since the early 1950's. Real final sales increased only 5 percent during 1984, and real business inventories increased $24.8 billion ($57.9 billion in current dollars). Total employment of 106.7 million was an all-time record, and the unemployment rate declined from 9.5 percent in 1983 to 7.4 percent in 1984. During 1984 the U.S. dollar showed great strength on international markets, contributing to large current-dollar negative net exports of goods and services (-$62.5 billion) and even larger negative net exports of merchandise (-$107.6 billion). The strong dollar and the substantial increase in net imports of goods and services helped reduce U.S. inflationary pressures and provided a major source of loanable funds for financing domestic private investment.

Jan 1, 1985

By D. G. Willard

The U.S. Department of Interior, Bureau of Mines has evaluated the potential resource and annual availability of cobalt from 27 deposits or districts in 11 market-economy countries. More than 95 pct of primary cobalt production from market-economy countries, mainly byproduct output from copper and nickel operations, was analyzed. Approximately 1,200,000 mt of cobalt is potentially recoverable at the demonstrated resource level. Very large additional resources exist, especially in laterite deposits, but are at the inferred level. The producing operations evaluated in this study are expected to produce about 19,000 mt of cobalt in 1989, significantly less than the available capacity of about 31,000 mt. More than 14,000 mt per year of cobalt is produced from copper-cobalt deposits in Zaire and Zambia, of which 11,000 mt can be produced at a copper price of $O.60jlb or less with a O-pct discounted cash-flow rate of return (DCFROR). Approximately 4,400 mt of cobalt is produced annually from nickel-cobalt deposits in six countries, of which about 1,800 mt (in Canada and Brazil) could be produced at a nickel price of $1.50jlb or less at a D-pct DCFROR. Approximately 200 mt per year of cobalt is produced from a cobalt mine in Morocco. Most of the evaluated nonproducing operations and prospects that could potentially produce cobalt as a principal product or byproduct would require a total cost (including a 15 pct-DCFROR) significantly exceeding January, 1989 market prices of the principal commodities. Principal-commodity dependence, transportation routes, cobalt toxicity, and other issues that could affect the availability of cobalt are addressed herein.

Jan 1, 1991

By C. H. Schack

Extractive metallurgy techniques currently employed to recover silver from primary ores and secondary scrap were reviewed and evaluated to identify and delineate metallurgical problems whose resolution would increase the supply of silver from domestic materials. The survey revealed that practically all primary silver is recovered by froth flotation concentration of various types of ores, followed by smelting and refining of the separate lead, copper, and zinc concentrates. Silver losses during the complex processing are, with rare exception, inconsequential. Furthermore, any silver production gain from base metal ores, which contribute about two-thirds of the total primary silver, is directly dependent in improvement in the market for the base metals. Statistical data on new and old silver scrap are wholly inadequate to make reliable conclusions about scrap processing problems and the possibility of increasing the recovery of silver from the many forms of secondary silver- bearing materials. The available information indicates (1) that efficient silver reclamation practices are employed by the larger users of silver, and (2) that recovery of additional secondary silver involves solution of problems of collection rather than of processing. Several possibilities exist for limited increases in silver production from primary ores by improvement in metallurgical practices. Specifically, research is needed to (1) solve the problem of recovering silver from the copper ores of the Copper Range district, Michigan; and (2) devise economically feasible methods for recovery of silver from presently marginal or submarginal ores that because of grade, location, and frequently complex nature cannot presently be exploited by conventional techniques.

Jan 1, 1965

By Harold J. Barnett

In January 1948 , the Secretary of the Interior directed that a study be made of energy resources and requirements that would provide a basis for continuing appraisal of the adequacy of the Department's programs in the energy field . That this instruction was timely has been demonstrated by the increasing interest being evidenced by Congress , industry , labor , and the public in the future of the energy segment of our national economy . Several studies of individual energy sectors have appeared . Various legislative proposals have been made in Congress for obtaining more information on this subject . Substantial interest in energy projections is not , of course , a recent innovation . Energy availability and consumption are strategic factors in peacetime prosperity and growth and in our national defense as well . The past generation's literature of earnest public discussion and of legislative consideration of matters involving energy projections is very extensive . This is an exploratory study produced in the Program Staff of the Office of the Secretary of the Interior in the first half of 1949 and revised recently to take account of certain of the preliminary energy data from the 1947 Census of Manufactures and critical comments . It is offered at this time solely as a technical contribution in economic research technique . As the Bureau of Mines has recently undertaken to revise this preliminary study , critical and other comments are invited .

Oct 1, 1950

By F. Channier

The paper provides the most recent information on the construction of the AP60 phase 1 plant of Jonquiere which is due to be commissioned and started up in the first quarter of 2013. HSE management on site by RTA, and cooperation with local equipment manufacturers and contractors of the Saguenay-Lac Saint Jean region are highlighted in this section. The AP60 phase 1 Jonquiere plant aims to demonstrate of the AP60 technology at an industrial scale and allows the further developments of the AP60 cell. The advantages of the AP60 cell technology in terms of productivity, power consumption and environmental footprint are also briefly presented in the paper.

Jan 1, 2011

The Arctic is a region of special economic, geopolitical, research, socio-ethnic, and defense interests of both Russia and other countries of the Arctic zone. Introduction of innovation technologies at ore-processing factories is a direct responsibility of the state and this problem should be solved on the basis of coordination of interests of different stakeholders. The task of elaboration of scientific principles of rational state regulation in the North is very topical. Innovations require considerable investments first of all from private capital. However as an investment object innovations are not attractive for investors as they require large expenditures for long-term projects, and they are connected to high risks because market incentives form striving to get quick profits of private companies and result in a certain behaviour strategy while innovations need ?long money?. Under such conditions without state regulation of investment and innovation activities development of the mining sector in the Arctic practically has no prospects. At innovation development of mining enterprises economic growth is provided at the expense of active state innovation activities. The elaborated strategy of ore-processing enterprises should correspond to the modern paradigm of the ore-processing industry development which is not only for extraction of minerals but also for multi-profile structure having comprehensive use of the resources on the rational basis intended for rational complex utilization of mineral resources of the AZR which by the definition includes maximally full use of the whole aggregate of resources on the economically rational basis with obligatory environmental with resource reproductive and socio-economic functions and deterrents. The main principle of creation of innovation technologies is to obtain more products of higher quality with minimal costs. This allows increasing ?productivity of the resources? several times. This principle makes increasing productivity of the resources the most important and in this case efficiency of use of the resources brings extra profits at the expense of lack of new costs such as payment for protection and utilization of wastes. According to the economic theory only ratio between demand and supply is able to fix optimal proportions in economy and to give necessary signals for investment activities of mining enterprises. In this context market for minerals and increase of mineral resources productivity do not create incentives for investment activities without which neither sustainable economic growth nor solution of macroeconomic tasks are possible. Nevertheless countries should not reject this idea in spite of economic efficiency of the enterprises. Extraction degree of useful components and especially oil in the Arctic zone is one of the lowest in the world. This can lead to crisis of oil industry and other mining sectors. The reason for that is lack of a state policy of realization of innovation technologies in the mining sector in the Arctic.

Jan 1, 2014

By Cris Sideco

This paper describes the concentration processes of the Sullivan. Concentrator, including crushing , transportation, sink-float, grinding , flotation and dewatering. Handling of hot muck has had a deleterious effect on most of the processes, resulting in significant operating problems and poorer metallurgy. These problems are described -in detail. THE SULLIVAN CONCENTRATOR is situated in Kimberley, high up in the Purcell Range of the Selkirk Mountains, at an elevation of 3,600 feet, approximately 4 miles from the Sullivan Mine (see Fig. 1). The original plant went on stream on August 23, 1923 at a designed capacity of 2,500 tons per day. This has been increased in stages to its present rated capacity of 11,000 tons per day. The latest stage was in 1949, when several major projects, including the underground crushing plant, the sink-float plant and the installation of a rod mill, were completed. Some 112,800,000 tons of ore have been treated in this concentrator to November 1975. The plant started on a 48-hour/ week schedule, but was reduced to 44 hours/week in October 1946 and down to 40 hours/week by the end of 1949. Except for a 6-month period in 1952 when the mill operated continuously, the 40-hour/week, Monday to Friday schedule was in effect.

Jan 1, 1977

By J P. van Dyk

A new crude ilmenite beneficiation process was recently proposed that allowed for the preparation of a smelter grade ilmenite from ilmenite with elevated chromium content. Magnetising roasting was not utilised in the process. As part of this circuit an ilmenite low susceptible reject stream was produced that had a low magnetic susceptibility. In this article a magnetising roasting process was investigated to beneficiate this material. Tests were conducted on material produced by pilot scale simulations on a typical South African East Coast heavy mineral reserve. The results obtained were compared to those published in literature for crude ilmenite. The small-scale experiments were used to define approximate operational limits for the oxidising roasting of a low susceptible ilmenite low susceptible reject stream, although industrial roasting conditions may differ significantly from those obtained in laboratory units. In a next phase these results will be confirmed on pilot plant scale.

Jan 1, 2001

By A. S. Macfarlane

"SynopsisMetal accounting and reconciliation is an increasingly important governance issue in all mining operations, in that it is required, from a risk management perspective, that the company is in control of its product throughout the whole mining value chain. Reconciliation is a grossly misunderstood term. It means different things to different people, and therefore one of the purposes of this paper is to ensure a holistic and integrated understanding of ‘reconciliation’.Previously, where reconciliation was done, it was often for internal control purposes and loosely applied, sometimes with a low degree of confidence and understanding of the underlying parameters and their natural variability.In most mining operations, issues such as dilution, stope performance, and recovery are critical to profitability and long-term value, and thus understanding and control of these key value drivers is essential, not only from the governance perspective, but also from the perspective of maximizing shareholder returns. In order to implement a system for metal accounting and reconciliation, it is important that the cause and effect of these value drivers is understood, and that a systematic control system be established.While a number of off-the-shelf solutions exist for this work, it is the contention of this paper that a full understanding of the metal flow, its variability, its underlying loss potential, and its control points is necessary before a systematic approach to reconciliation can be undertaken.The paper also advocates that this approach should ensure that the reconciliation system clearly addresses the reconciliation needs, within a consistent framework. Such a framework has been developed by AMIRA, in terms of a metal accounting code. However, up until now, this code has been aimed at plant processes, whereas this paper shows how the concept can be extended to cover the full reconciliation requirements for a base metal mine.IntroductionReconciliation is defined as ‘the process of finding a way to make two different ideas, facts, etc., exist or be true at the same time’. In terms of a mining process, this refers to the comparison of measures and estimates along the value chain, and at different points in time, in order to track and optimize metal recovery. This leads to the notion of having a system in place for accounting for the metal. The University of Cape Town defines metal accounting as ‘… the estimation of (saleable) metal in a mine and subsequent process streams over a defined time period. Comparisons of estimates, from different sources over a specific time period, are called reconciliation.’Traditionally, metal accounting has consisted of geological reconciliations of mineral resource to mineral reserve conversion, mine planning reconciliation related to the reconciliation of long-term plans to short-term plans, grade control reconciliation of head grades to sampled or block grades, and mine survey reconciliation of tonnage discrepancies and mine call factors. In addition, metallurgical reconciliation has tended to be based on metal balancing, followed by some commercial metal accounting that links dispatched product to sales quality, quantities, and revenues. Miners disparagingly refer to this plant process as ‘millmatics’."

Jan 1, 2015

By R. E. Eyre

ALTHOUGH the idea of roasting zinc concentrates in suspension had intrigued investigators for a number of years, no commercial application of a process appeared successful until the development of the "Cominco" process. The efficiency and high capacity of this process may be judged by the fact that nearly all other electrolytic plants and many zinc retort plants in the world use this method. A furnace of the Cominco type can roast without special preparatory treatment and without supplementary fuel, mineral sulphides such as zinc sulphides and iron sulphides containing varying amounts of moisture at any desired rate ranging from one-half up to full capacity. The full capacity of a unit is in general about three times that of a multiple hearth furnace of the same size. The latest type of "Cominco" furnace can be built for capacities from 25 to 500 tons per day. The quality of the calcine is subject to positive control and may be

Jan 1, 1961

Paper and paperboard manufacturers need to quantify the carbon footprint and environmental impact of their products to satisfy market, social and government demands. Coated paper products contain minerals, such as kaolin and calcium carbonate, at significant levels; some coated paper grades have mineral contents as high as 45% by weight. Some uncoated paper has no mineral content, but most uncoated paper contains some mineral to improve appearance, process efficiency and cost. Super-calendared paper grades can contain levels of mineral up to 35% by weight. This paper describes how to calculate the carbon footprint of kaolin and calcium carbonate minerals used for white pigments. The carbon footprint of these minerals strongly correlates to the primary energy sources, final product form and energy used to calcine kaolin and lime. Kaolin and calcium carbonate pigments have a favorable impact on the carbon footprint of paper and paperboard products by directly substituting for fiber and by reducing the energy needed for paper making. Key words: Kaolin, Calcium carbonate, Paper production, Carbon footprint, Lifecycle analysis

Jan 1, 2010

By C. A. Ingram

The Cigar Lake ore body is a high-grade uranium deposit situated within water-saturated sandstone. In order to extract the uranium ore remotely, ensuring minimal radiation dose to workers, and also to access the ore from stable ground, the Jet Boring System (JBS) was developed. This method of mining involves drilling a pilot hole up through a frozen ore body and utilizing a high-powered water jet to mine out cavities. During the mining process an ultrasonic sensor will be used to provide feedback to the operator, who is located beneath the ore body, as to the dimensions of the cavity. However, more precise data is required to determine final shape, volume, and location of the cavity for mine planning purposes. Selecting a device that will provide sufficient range data in the challenging environment will be vital to optimizing the mining process. Major issues include fog build up and flying debris during mining, and an environment that is wet, dark, and cold A test cavity has been designed and constructed at the Saskatchewan Research Council (SRC) so that a study comparing three different technologies, as prospective candidates for the survey system, can be conducted. The devices being evaluated include a Senix ultrasonic sensor, an MDL Cavity Auto-Scanning Laser System (C-ALS), and a MESA Time of Flight (ToF) camera. The ultrasonic sensor is known to provide range data in foggy conditions but has low accuracy. The C-ALS has been developed for surveying remote cavities but is expensive and does not provide reliable data in fog. The ToF camera provides a high volume of data in a short time period, with potential to provide accurate information in extreme conditions, but has not been tested in a mine cavity application. Iterative closest point (ICP) registration is applied in an attempt to create a 3D point cloud from the scan data and to also compute rotation and translation of the ToF camera. This paper presents an overview of the challenges involved in conducting a survey within a JBS mined cavity, the analysis used to determine the suitability of each device, and the data collected from the test cavity.

Aug 1, 2013

By Charles E. Dunne

One of the most frequently asked quesitons is: "Where is copper (price and usage) going?" I will not attempt to forecast either the future price of copper or the future growth of the copper industry; rather I would like to discuss the current trends experienced in the smelting and refining terms and conditions for sales and/or purchases of copper concentrates. A brief review of contract language and terms, together with a review of the common jargon, I believe, would be helpful. To accomplish this review, I will first list what I consider the four basic parts or sections of a basic ore contract and then illustrate basic terms with calculations.

Jan 1, 1984