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By Crystal Poon, Paul Matlashewski, John Morkeh, Kathryn Dorfschmidt, Jose Carvalho, Chad Williams

Rockfall hazards are ubiquitous in mining environments making their control critical for safe mining operations. The complex processes involved in rockfall events necessitate a probabilistic modeling approach with well-calibrated material properties. The controls designed to mitigate rockfall hazards need to be reliable, efficient, and safe to deploy to meet the constraints present at an active mine. This paper presents an innovative solution to rockfall at Rio Tinto’s Bingham Canyon Mine. The solution incorporates the site-specific calibration and creation of a predictive rockfall model with the design, field testing, implementation, and monitoring of the rockfall controls.

By D. Saramak

The proposal of the nip zone angle determination in HPGR crushing process is presented in the paper. Knowledge of the nip zone angle value, in turn, makes it possible to determine the real maximum pressing force in the high-pressure comminution. Two methods of determination of this maximum pressure were proposed and verified. The first method is based on the roll?s geometry, and the change of the HPGR chamber?s volume together with the roll rotation, while the second one considers the outlet gap width impact. Results of the nip zone angle calculations according to both methods are similar and show convergence with the real operating conditions. The verification was carried out in a piston-die press, and experimental results show that methodology of the nip zone angle determination presented in the paper has its practical confirmation. A proper determination of the nip zone border makes it possible to calculate the comminution probability of given type of material and is a basis for the HPGR crushing process modeling and optimization. Keywords: HPGR, comminution, nip zone, ore processing

Sep 1, 2012

By Tim Grain Joseph

This paper considers the duty cycle of an electric cable shovel and correlations with measured passive seismic responses of the underfoot oil sand material in-pit. It has been observed that the cyclic activity during operation of any shovel in the oil sands environment causes the material to deteriorate and provide a less than ideal footing for this large item of equipment, whose dead weight approaches 1500 tons with a footprint of merely 75 square yards. Consequences are manifest in the form of carbody and side frame cracks, and associated downtime, maintenance activity, cost, and subsequent loss of availability. The objective of these considerations, as part of the Oil sands Equipment Interaction Program (OsEIP); currently a joint venture between Syncrude Canada Ltd., JPi Ltd., Caterpillar Inc., P&H MinePro and the University of Alberta; is to identify and provide feedback to the manufacturer and end user adverse shovel - ground conditions. This would enable the manufacturer to incorporate greater knowledge into the design process and the end user to direct operations in an enhanced proactive maintenance stance.

May 1, 2002

By E. G. Bailey

The bituminous coal industry faces a real problem, if it desires to retain the position in the power-generation field to which it is economically entitled. More power is probably produced today for electrical energy, for steam-driven and steam-heating industries and processes, for transportation by rail, water, highway and air, collectively, than ever before, and yet the total bituminous coal production has decreased about 38 per cent, from 575,000,000 tons in 1926 to 357,500,000 tons in 1934. It is not the intention of the writer to recommend coal as a fuel for automobiles and airplanes, but rather to point to these forms of transportation as being responsible in a very measurable degree for reducing the coal consumed by railroads. Petroleum products may still further reduce consumption of locomotive fuel through the extension of the use of Diesel-driven trains. Oil-burning steam-driven locomotivcs are replacing coal in some places, where railroads operating high-speed passenger trains are willing, temporarily at least, to pay a premium for the fuel that is low in ash and produces less smoke and practically no cinders. In the navy and ocean-going passenger ships, oil is so firmly established, and has such definite advantages over coal as formerly fired, in steaming radius, in ease of bunkering, cleanliness, and reduction in firing labor, that very outstanding developments in the handling and burning of coal will be rcquired in order to replace oil. For freighters on the Great Lakes, coal is the logical fuel, but there is great and immediate need of radical improvements in its use, else that market also may be lessened. It is not within the scope of this paper to discuss in detail bituminous coal for either locomotive or marine use, but, rather, generation of power in stationary plants, consisting of electrical generating stations and that very large group of miscellaneous industrial plants, such as paper, rubber, textile, steel and other industries that use electrical, mechanical, and steam power, derived from either hydro or some form of fuel.

Jan 1, 1936

By G. L. Oldright

NEARLY all of the present schemes for treating complex (i. e. lead¬silver-zinc-copper) ores are based on the idea that lead holds, and will hold for some time, the strongest economic place from the viewpoint of supply and demand of all the non-ferrous metals. Copper, it is thought, will come back to its own when European affairs are stabilized, although at that time competition from Chile, Peru, and Katanga, in particular, will be more severe than in pre-war days. The future for silver and for zinc is uncertain. New uses are developing for zinc, and the market has remained better than many expected, but the stabilization of world markets will bring in foreign competition instead of relief. The cost of producing zinc from simple zinc ores, by the retort process, will, from the nature of the labor required and the increasing cost of fuel, increase steadily. As a result, the small producers of purely zinc ores around Joplin are shutting down their mines, even with a good market price for zinc; on the other hand, the producer of lead from complex ores, in the Rocky Mountain states, is confident of a profit from the sale of his lead, and is seeking means to make the zinc in his ore pay some part of the cost of treatment. However, the tonnage costs for mining and ore dressing are much higher in the Rocky Mountain states, as may be seen by comparing tax-return statements from the various states. Even before the recent drop in the price of silver, many mines were operating on a very slender margin of profit; labor and supplies cost more. Mining at greater depth has shown most orebodies to grow increasingly more complex, so that improvements in mining and ore-dressing practice have not been sufficient too compensate for the additional expense involved in beneficiating these ores. The smelters have had to meet the same general economic situation, so they can only give

Jan 3, 1924

By E. G. Bailey

The bituminous coal industry faces a real problem, if it desires to retain the position in the power-generation field to which it is economically entitled. More power is probably produced today for electrical energy, for steam-driven and steam-heating industries and processes, for transportation by rail, water, highway and air, collectively, than ever before, and yet the total bituminous coal production has decreased about 38 per cent, from 575,000,000 tons in 1926 to 357,500,000 tons in 1934. It is not the intention of the writer to recommend coal as a fuel for automobiles and airplanes, but rather to point to these forms of transportation as being responsible in a very measurable degree for reducing the coal consumed by railroads. Petroleum products may still further reduce consumption of locomotive fuel through the extension of the use of Diesel-driven trains. Oil-burning steam-driven locomotivcs are replacing coal in some places, where railroads operating high-speed passenger trains are willing, temporarily at least, to pay a premium for the fuel that is low in ash and produces less smoke and practically no cinders. In the navy and ocean-going passenger ships, oil is so firmly established, and has such definite advantages over coal as formerly fired, in steaming radius, in ease of bunkering, cleanliness, and reduction in firing labor, that very outstanding developments in the handling and burning of coal will be rcquired in order to replace oil. For freighters on the Great Lakes, coal is the logical fuel, but there is great and immediate need of radical improvements in its use, else that market also may be lessened. It is not within the scope of this paper to discuss in detail bituminous coal for either locomotive or marine use, but, rather, generation of power in stationary plants, consisting of electrical generating stations and that very large group of miscellaneous industrial plants, such as paper, rubber, textile, steel and other industries that use electrical, mechanical, and steam power, derived from either hydro or some form of fuel.

Jan 1, 1936

By Jianmin Qin, Raja V. Ramani, Wilson Miola

The number of underground work entities operating under reduced dust standards in U.S. coal mines has been increasing since the start of the decade of the 80s and is currently approaching 10,000. The concern for controlling the quartz levels in airborne respirable dust in coal mine has manifested itself in several improvements in equipment selection and operation, face ventilation practices, and dust control procedures. At the same time, fundamental studies have been initiated on determining the source-sink relationships of the airborne quartz dust. The P-7 method is the prescribed method for the determination of quartz in the respirable airborne dust samples from coal mines. Questions have been raised on the reliability of the P-7 infrared spectrometry method for quartz analysis in powders. No specific method has been defined for quartz determination in bulk samples from the mine. In a recent study on the relationship between quartz in the airborne dust and that in the materials being mined, both infrared (IR) and x-ray diffraction (XRD) methods were used on a suite of samples from several coal mines. These samples encompassed airborne respirable dust samples, airborne total dust samples, the oversize fraction from the respirable samplers, ROM samples, channel samples, and chip samples from the face, roof, and floor materials. In this paper, the sample preparation and analysis procedures for the samples are discussed. The data, analysis results, and comparisons of the P-7 and XRD results are presented. The quartz percent determined for the same sample by the two methods are different. In 85% of the samples analyzed, the quartz percents determined by the XRD method are higher than those obtained by the P-7 method. However, there is a strong linear relationship between the results from the two methods. Further, the XRD method indicates an average of 20 percent more quartz than that from the P-7 method. The reasons for the differences in the results and the need for additional studies are explored.

Jan 1, 1991

By O&apos, R. G. Meara, M. M. Fine

One of the principal activities of the Bureau of Mines connected with the recent war was to help to increase the supply of strategic and critical minerals. Fluorite was one of the most critical of the nonmetallic minerals because of the increased demand for it as a flux in basic open-hearth and electric steel furnaces and as a raw material for the production of artificial cryolite used in the aluminum industry. Wartime developments in the technology of hydrofluoric acid, such as the use of the anhydrous acid as a catalyst in production of high-octane gasoline and the use of organic fluorides as carriers for insecticides, also increased the demand for acid-grade fluorite. † In 1943 the consumption of acid-grade fluorite was advancing at a more rapid rate than production, and was only slightly less than production during the latter half of the year.' The outlook for the postwar market for fluorite is encouraging Steel production is expected to remain high until the domestic demand for commodities not manufactured during the war is satisfied. The uses for hydrofluoric acid are expected to increase under the impetus of war-initiated research. In consideration of these and other factors some authorities predict a postwar demand for fluorite equal to about 60 to 75 per cent of the wartime production.1,2 Others believe that the postwar fluorite industry will be permanently expanded over its prewar status3 Acknowledgment This paper is one of many reporting on various aspects of the Bureau of Mines program directed toward the more effective utilization of our mineral resources. The program has been under the general supervision of R. S. Dean, Assistant Director, since July 1942. The scope of the paper falls in the province of the Metallurgical Branch, whose activities embrace the separation of difficultly beneficiated ores, the production of pure metals from domestic deposits, the exploitation of marginal ore reserves, the recovery of secondary metals, and the improvement of present industrial metallurgical practice. The investigation was initiated at the request of Mr. J. H. Steinmesch, vice-president and general manager, Minerva Oil Co., Eldorado, Ill. His hearty cooperation and helpful suggestions, and those of Mr. 0. E. Anderson, mill superintendent,

Jan 1, 1947

By Roy E. Thomas

Soon after the Waelz p1an.t for the fire concentration of low-grade zinc ores was put into operation in the early part of 1929 at Katowice, it was found that the conveyor equipment for transporting the hot residue from the furnace dust chambers was inadequate. Hand tramming with water cooling was used for a time, but that method was injurious to the workmen as well as costly. The problem was to find some practical mechanical means of conveying flue dust at temperatures of from 450" to 600°C. as it was drawn from the dust chambers. After considerable preliminary investigation it was decided to install pneumatic equipment for conveying the hot materials to a central mixing plant, where it would be mixed with slime and from which it would be returned to the furnace feed hoppers. The first pnenmatic equipment was installed in 1930, and has been in successful operation since that time. The pneumatic method of transportation has shown a considerable saving in operating costs over the former methods of dust handling and a decided improvement in working and hygienic conditions at the plant, through the elimination of the dust hazard. Additional pneumatic equipment mas installed in 1933 for conveying the furnace fume from the baghouses to the roaster plant. At the same time pick-up lines were provided for collecting the cleanings from the vertical and horizontal cooling pipes that are between the furnace dust chambers and the baghouses. The latter installation has practically eliminated a dusty and costly hand-tramming operation. A third extension was made to the pneumatic system in 1938 for conveying 'the zinc-lead-cadmium fume from the roaster-plant baghouses and flues to a new re-treatment plant for secondary products. The success of pneumatic conveying at the Waelz plant was the determining factor in the decision to install another pneumatic unit at the Saeger zinc-roasting and sintering plant. The new unit at Saeger was installed early in 1938 for the transportation of flue and Cottrell dust, small amounts of flotation concentrates to the sinter machines, and

Jan 1, 1944

By M. M. Fine, R. G. Meara, O&apos

One of the principal activities of the Bureau of Mines connected with the recent war was to help to increase the supply of strategic and critical minerals. Fluorite was one of the most critical of the nonmetallic minerals because of the increased demand for it as a flux in basic open-hearth and electric steel furnaces and as a raw material for the production of artificial cryolite used in the aluminum industry. Wartime developments in the technology of hydrofluoric acid, such as the use of the anhydrous acid as a catalyst in production of high-octane gasoline and the use of organic fluorides as carriers for insecticides, also increased the demand for acid-grade fluorite. † In 1943 the consumption of acid-grade fluorite was advancing at a more rapid rate than production, and was only slightly less than production during the latter half of the year.' The outlook for the postwar market for fluorite is encouraging Steel production is expected to remain high until the domestic demand for commodities not manufactured during the war is satisfied. The uses for hydrofluoric acid are expected to increase under the impetus of war-initiated research. In consideration of these and other factors some authorities predict a postwar demand for fluorite equal to about 60 to 75 per cent of the wartime production.1,2 Others believe that the postwar fluorite industry will be permanently expanded over its prewar status3 Acknowledgment This paper is one of many reporting on various aspects of the Bureau of Mines program directed toward the more effective utilization of our mineral resources. The program has been under the general supervision of R. S. Dean, Assistant Director, since July 1942. The scope of the paper falls in the province of the Metallurgical Branch, whose activities embrace the separation of difficultly beneficiated ores, the production of pure metals from domestic deposits, the exploitation of marginal ore reserves, the recovery of secondary metals, and the improvement of present industrial metallurgical practice. The investigation was initiated at the request of Mr. J. H. Steinmesch, vice-president and general manager, Minerva Oil Co., Eldorado, Ill. His hearty cooperation and helpful suggestions, and those of Mr. 0. E. Anderson, mill superintendent,

Jan 1, 1947

By J. G. Peacey

"Canada has a special place in non-ferrous pyrometallurgy because it is the only country in the western world that is a significant producer of all the major non-ferrous metals; aluminum, copper, lead, magnesium, nickel and zinc. This large non-ferrous pyrometallurgy industry has developed because of Canada's abundant mineral wealth and energy resources. Table I summarizes the number of primary non-ferrous production facilities in Canada and their share of western world production.Production of non-ferrous metals is a mature, capital intensive business and its basic processes have been in use for many years. Nevertheless, these processes have continued to evolve in response to changing needs and external pressures; such as the energy crisis of the early seventies; historically low metal prices in the early eighties and the continuing pressure to reduce plant emissions and improve in-plant working conditions. Canada's major metallurgical companies: Alcan, Cominco, Falconbridge, Inco and Noranda have played a leading role in pioneering new process technology and continue to meet the difficult challenge of keeping their operations competitive in the global metals market. This paper will try to give an overview of the major developments in non-ferrous pyrometallurgy, largely from the Noranda and Canadian perspectives, highlighting the current status of process technology and possible future directions.AluminumCanada has the world's second largest aluminum smelting industry and its capacity has expanded rapidly in recent years with the completion of several large projects in Quebec. The location and capacity of the Canadian aluminum smelters are given in Table 2. All these plants use the Hall-Heroult process, that was invented over a century ago but over the last twenty years considerable improvements have been made to increase productivity, reduce power requirements and emissions.The developments in aluminum cell technology can be illustrated by the experience at Noranda Aluminum. In 1971, Noranda Aluminum started its first pot line using Kaiser's P69 prebake cell, which was considered, at that time, the best available technology. The P69 cell was designed primarily for high productivity, operating at 150 000 amps and high current density to produce just over tonne Al per cell-day. The P69 cell is a simple design, typically operating at about 88070 current efficiency and 15 800 kWh/tonne Al. When Noranda Aluminum decided to expand in 1980, the Alcoa 697 cell was selected as it then represented the most proven, stateof- the-art technology. This cell is similar to that installed at Alcan's new Grande Baie and Laterriere smelters and is designed to operate at 180000 amps and 93070 current efficiency, producing about 25070 more aluminum per pot-day than the P69 cell using about 15070 less power. The 697 cell has a much more sophisticated cell design, with very good balancing of the magnetic field giving a flat metal pad and allowing efficient operation at the higher amperage. Alumina is fed via point feeders that provide an almost continuous feed allowing close control of the alumina level in the bath and the use of low-ratio bath composition, giving much higher current efficiencies."

Jan 1, 1991

By RICKARD HANSEN

With vehicles frequently found in underground mines and tyres being a major fuel item, the risk of tyre fires will be severe underground. This study presents an in-depth analysis of tyre fires on mining vehicles to increase the knowledge of the risk, applying data from full-scale fire experiments and CFD simulations. It was found that the wheelhouse of the loader caused an increase in the flame tilt angle of approximately 10%, decreasing the flame impingement and heat flux downstream. The flame temperature of the drilling rig tyre was found to be approximately 7% higher than the loader tyre, increasing the risk of igniting adjacent fuel items. The construction of the wheelhouse/mudguard will contribute to a longer flame length by creating a fuel-rich environment. The CFD simulations predicted higher flame tilt angles for the drilling rig case for higher flow velocities, indicating the influence of a varying wheelhouse/mudguard construction and tyre geometry on the flame tilt angle. The construction of the loader resulted in a flow behaviour, where the short distance to the front mudguard/tyre and the separation of flow directly downstream of the protruding construction led to fire gases being steered past the front mudguard/tyre. In the drilling rig case, the longer distance to the front mudguard/tyre led to fire gases being directed towards the body of the vehicle after passing the area with flow separation. An increased knowledge of the tyre fire risk on mining vehicles and mitigating measures would improve the fire safety in underground mines.

Feb 10, 2022

By Raelly Laurinda Araujo da Silva

As ligas de alumínio são utilizadas mundialmente em inúmeras atividades. Com o aumento da competitividade, existe a necessidade de melhoria constante no processo produtivo. Essas melhorias têm como objetivo reduzir custos e melhorar o desempenho dos componentes e têm sido realizadas pela aplicação de novas técnicas e pelo desenvolvimento de novas ligas/composições. O processo squeeze casting é um processo inovador dentro dos processos de fundição, no qual o metal vazado no estado liquido é solidificado sob pressão dentro de uma coquilha metálica fechada por um punção. Neste contexto, o presente trabalho buscou analisar a influência da aplicação de diferentes pressões no processo de squeeze casting na modificação estrutural da liga de alumínio do tipo AlSi1Mg0.5Mn. Os resultados indicam que o aumento da pressão na liga gera uma taxa de transferência de calor mais elevada que reduziu o tempo de solidificação modificando a microestrutura.

Oct 30, 2017

By Leiner Novaes Arêdes

Na CSN, parte das bobinas laminadas a quente destinadas a produção de laminados a frio e zincados eram processadas na Linha de Preparação de Bobinas a Quente (LPBQ), com o objetivo de aplicar laminação de acabamento para melhorar o aplainamento destes materiais e facilitar o processo nos equipamentos posteriores. Principalmente devido a melhoria apresentada na qualidade da matéria prima oriunda do LTQ, foi possível flexibilizar as regras que determinam a obrigatoriedade de LPBQ em materiais para laminação a frio e zincagem. Com tal flexibilização, é possível diminuir a produção de placas curtas no LTQ, aumentando a produtividade do mesmo e aumentando a entrega de BQ com tolerâncias mais restritas de aplainamento (BQ com LA). Há ainda um grande ganho logístico e de lead time na produção do material. Atualmente evita-se processar na LPBQ grande volume de material para o fluxo de laminação a frio, recozimento e zincagem. A produção de placas curtas no LTQ por falta de disponibilidade de corte em LPBQ foi praticamente eliminada.

Jul 30, 2018

By Bronwynne K. Williams

"In deriving flotation kinetic models, the froth phase was, until recently, either ignored or treated entirely empirically. The behaviour of the froth is now known to be usually important and sometimes dominant in determining flotation performance. Hence numerous methods have been developed for sampling the flotation froths and models incorporating the effects of the froth behaviour have been derived.Such models will assist in determining more accurate estimations of the kinetic parameters utilised in the designing of industrial scale plants thus reducing the incurred costs of over designing. In particular, improved models for batch tests may lead to more effective use of batch testwork for prediction of continuous plant behaviour. A more detailed model is thus proposed which allows for a more realistic approach to the flow distribution in the froth phase.PROPOSED MODELThe batch flotation process is split into two stages in time, namely before the froth begins to overflow and after. The assumptions made, and hence the calculations, are different for each stage.The air enters the slurry at t=0 and generates froth. The superficial velocity of the air through the cell is given by go. It is assumed that the rate of froth breakage (gb) is constant during the first stage. The froth rises with a uniform net velocity throughout the cell and no mixing is assumed to occur.After the froth begins to overflow, the velocity distribution of the gas is modeled by segmenting the froth phase as shown in Figure 1. A model for bubble breakage rate or measurements of froth velocity allows one to obtain the volumetric rate of concentrate froth production. The entrained water and associated particles and a drop-back mechanism are also allowed for in the model."

Jan 1, 2003

By Oliver C. Ralston

The growing popularity of perlite (sometimes spelled pearlite) as a raw material for thermal expansion into pumicelike products in the Western States has prompted a preliminary investigation of the properties of such material and the problems that want solution to put a perlite industry on a firm foundation. The Bureau of Mines is undertaking the gathering of data and the solution of these problems, and the following paper records some of the available information. and the promise of the material, with some comparisons of advantages of the various competing lightweight aggregates that can be made from siliceous volcanic glasses and rocks containing entrapped or dissolved water that causes their expansion on' quick heating to their softening points. This new industrial rock has caught the fancy of the mineral industry in the western States because it has Fume advantages over natural pumice. Chemically, it is typified as rhyolitic in composition, and one may find obsidian, rhyolite, pumice, pumicite, and perlite from the same vant and contemporaneous in origin. The material need not be rhyolite but should be a siliceous or acid lava and contain 2 to 5 percent water still in "solution" in the rock. On quick heating to the softening temperature the material puffs, due to conversion of the contained eater into bubbles of steam. Slow heating causes gradual release of the imprisoned water by decrepitation and. cracking and-results in, very little puffing. Perlite is often in the form of ovoid volcanic bombs formed by explosive eruption of large masses of lava into the air, where they, quickly cool, with escape of little of the contained water, exceptt perhaps for a hollow interior. Since they cool in layers they have an onion-type structure and a pearly luster from interference of light between the. layers, which is' the origin of the name "perlite." Perlite may occur in intruded flows that have been quickly cooled and partly expanded but retained most of their magmatic water content. Obsidian may be the same lava cooled quickly under conditions that prevented crystallization of feldspars and other minerals, leaving the volcanic glass that may or may not retain all of the original contained water.

Jan 1, 1946

By C. Gerow

THIS paper is entitled "Some" problems, rather than "The" problems, met in selling coal, since the problems to be met in selling any commodity have to deal with an infinite number of circumstances and conditions. These are believed to be more varied in the case of coal than probably any other commodity. This is due, perhaps, to the fact that coal has been one of the basic materials in the guiding of industrial and national achievement for the past two hundred years. During this time its use has developed from a most haphazard one to uses involving all modern scientific methods, which, rather than simplifying matters as regards the marketing of coal, have added many fresh problems, and these vary according to the particular market served. Since the concern of this paper is primarily the selling of Nova Scotia coal, it is proposed to deal chiefly with some of the specific conditions met in the markets presently served by this coal. For the purpose of discussion, these markets may be considered as divided into three main groups, namely, the Maritime market, the Quebec market, and the Ontario market. THE MARITIME MARKET First of all, let us consider the Maritime market. This is a market which has been regularly served by Nova Scotia coal since coal mining became the first industry in Cape Breton, slightly over one hundred years ago. Conditions as applying to the use of coal have naturally tended to adjust themselves to the characteristics of the coal most readily available, and, therefore, marketing problems are fewer in the Maritimes than in districts where many coals of varied characteristics are offered. Up to recent years, the problems involved were chiefly those of providing satisfactory service insofar as de-liveries were concerned. However, with the speeding-up of manufacturing processes and the necessity of reducing costs to a minimum, users of coal have become interested in obtaining coal that will give the most economical service. It is, therefore, now of importance that the salesman should have full knowledge of the particular conditions applicable to each customer's use in order to deal to the best advantage.

Jan 1, 1936

By Laszlo Valentyik

Heavy media separation (HMS) is one of the most widely used gravity methods in the mineral industry. The feed is separated, according to the specific gravities, into two products; float (light) and sink (heavy) particles. The universal acceptance of the process is due to simplicity, efficiency and robustness for ease of control. However, if optimum separation is desired during the operation of heavy media plants, a delicate balance of a number of variables is essential. Among the variables, the two which are generally the most frequently checked and controlled are specific gravity and consistency of the medium. The latter is a function of the settling rate of the media. The medium is generally made up of finely ground ferrosilicon, magnetite, galena, shale, quartz sand, clay contaminants and water. The frequently present clay in the medium acts as a stabilizing agent, since the coarse heavy medium solids (called media) would quickly settle if they were mixed only in water. Clay concentration of the medium varies between 3-7% by height (1,2). Although clay is essential for reasonable media stability, clay concentration greater than 7-8% imparts too high a viscosity to the medium, and the feed cannot accurately stratify and therefore separate into the required products. To be on the safe side, plant operators clean the medium from most of the clays, and would rather work at a lower stability than have a very viscous medium on their hands. The most recent advance in the area of consistency control rlas made by the introduction of atomized (spherical) ferrosilicon (3). This extended the upper limit of the use of ground ferrosilicon from 3.3 to approximately 3.6, broadening the range of the optimum operating conditions. A viscosity control method was also worked out by the use of low cost additives which lower viscosity while retaining a favorable low setting rate (4). Recently (5) polymers have been successfully used in oil well drilling muds then the requirements were mainly to suspend and transport cuttings during the periodic shutdowns and dril1ings respectively. The rheological properties of these polymer suspensions are such that they present an infinite viscosity to

Jan 1, 1971

By Z. Jin, D. DePaoli, P. Zhang

"Phosphate beneficiation in Florida generates more than one tonne of phosphatic clay, or slime, per tonne of phosphate rock produced. Since the start of the practice of large-scale washing and desliming for phosphate beneficiation, more than 2 Gt of slime has accumulated, containing approximately 600 Mt of phosphate rock, 600 kt of rare earth elements (REEs) and 80 million kilograms of uranium. The recovery of these valuable elements from the phosphatic clay is one of the most challenging endeavors in mineral processing, because the clay is extremely dilute, with an average solids concentration of 3 percent, and fine in size, with more than 50 percent having particle size smaller than 2 µm, and it contains nearly 50 percent clay minerals as well as large amounts of magnesium, iron and aluminum. With industry support and under funding from the Critical Materials Institute, the Florida Industrial and Phosphate Research Institute in conjunction with the Oak Ridge National Laboratory undertook the task to recover phosphorus, rare earths and uranium from Florida phosphatic clay. This paper presents the results from the preliminary testing of two approaches. The first approach involves three-stage cycloning using cyclones with diameters of 12.4 cm (5 in.), 5.08 cm (2 in.) and 2.54 cm (1 in.), respectively, to remove clay minerals followed by flotation and leaching. The second approach is a two-step leaching process. In the first step, selective leaching was conducted to remove magnesium, thus allowing the production of phosphoric acid suitable for the manufacture of diammonium phosphate (DAP) in the second leaching step. The results showed that multistage cycloning with small cyclones is necessary to remove clay minerals. Selective leaching at about pH 3.2 using sulfuric acid was found to be effective for removing more than 80 percent of magnesium from the feed with minimal loss of phosphorus.IntroductionFlorida phosphate ore, or “matrix,” as it is called locally, contains three different mineral groups that have to be separated from each other: (1) phosphate minerals, (2) clay minerals and (3) quartz, or sand. As mined, the phosphate and sand particles are embedded in compacted mud, or clay-balls. Before separation can begin, all of the particles must be liberated from the matrix of mud. The very first unit operation in the beneficiation process is to disaggregate the various particles. This actually starts while the matrix is flowing through the multimile pipeline from the mine to the beneficiation plant. While in the pipeline, the matrix is exposed to shear forces as it passes through the various centrifugal pumps along the pipeline. These intense shear forces cause a significant percentage of the sand and phosphate particles to be liberated from the clay-balls by the time they arrive at the plant. Once they reach the plant, the first goal is to finish disaggregating the clay, and follow that by making a size separation at 1 mm. This processing is conducted in the washer, consisting of a large rotating trammel screen and a few stages of log washer, screens and hydrocyclones. In all of the currently operating beneficiation plants, the washer is a large structure that receives the matrix, screens it and then discharges a pebble phosphate product sized larger than 1.0 mm and a slurry of liberated clay, sand and phosphate particles that are smaller than 1.0 mm."

Jan 1, 2017

By G. L. Oldright

Nearly all of the present schemes for treating complex (i. e. lead-silver-zinc-copper) ores are based on the idea that lead holds, and will hold for some time, the strongest economic place from the viewpoint of supply and demand of all the non-ferrous metals. Copper, it is thought, will come back to its own when European affairs are stabilized, although at that time competition from Chile, Peru, and Katanga, in particular, will be more severe than in pre-war days. The future for silver and for zinc is uncertain. New uses are developing for zinc, and the market has remained better than many expected, but the stabilization of world markets will bring in foreign competition instead of relief. The cost of producing zinc from simple zinc ores, by the retort process, will, from the nature of the labor required and the increasing cost of fuel, increase steadily. As a result, the small producers of purely zinc ores around Joplin are shutting down their mines, even with a good market price for zinc; on the other hand, the producer of lead from complex ores, in the Rocky Mountain states, is confident of a profit from the sale of his lead, and is seeking means to make the zinc in his ore pay some part of the cost of treatment. However, the tonnage costs for mining and ore dressing are much higher in the Rocky Mountain states, as may be seen by comparing tax-return statements from the various states. Even before the recent drop in the price of silver, many mines were operating on a very slender margin of profit; labor and supplies cost more. Mining at greater depth has shown most orebodies to grow increasingly more complex, so that improvements in mining and ore-dressing practice have not been sufficient to compensate for the additional expense involved in beneficiating these ores. The smelters have bad to meet the same general economic situation, so they can only give

Jan 1, 1924