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By O. M. Arafat, J. A. Finch

Since its development, the functional performance equation for ball milling (McIvor, 1988) has facilitated a new understanding of industrial circuit cause and effect relationships, leading to significant strides in operational performance. Success stories of this approach to plant circuit performance improvement are now too numerous to list. Finch and McIvor (circa 1986) also discovered that the functional performance mill grinding rate at the size of interest was the same cumulative grinding rate that is calculated from mill feed and discharge size distributions using a first-order rate equation. By calculating these cumulative grinding rates for all screen sizes, a complete ball mill model is generated (as used by Finch and Ramirez, 1981). Others in industry, Hinde and Kalala (2009), for example, have noted the same. Lacking the complexity needed to maintain their interest, most researchers have ignored this model, broadly opting instead for Epstein’s (1948) characterization of grinding as a chemical reaction, combining selection rate and breakage size distribution functions. The much simpler ball mill model has previously been incorporated into a proprietary circuit modeling program (McIvor, 2005) and used for plant improvement work (for example, see McIvor and Finch, 2007, and McIvor, 2014). Now, by combining this business-friendly ball mill model with optimization criteria from functional performance analysis, a circuit modeling system (including the needed supplementary steps to assure successful plant implementation of circuit design changes) is at the disposal of every plant metallurgist, grinding equipment/ material provider and circuit designer.

Jan 11, 2017

By Chris Twigge-Molecey, John Peacey

To meet the business objectives of a metallurgical project, there is often a need for new and untried technology or equipment, whose very novelty can present serious risks to meeting those objectives. The key risk management approach is a rigorous stepwise progression from theoretical evaluations and laboratory tests to pilot plant trials. These must be followed by demonstration-scale trials before final construction of a commercial scale plant, paying particular attention to the magnitude of the scale-up between phases. Success depends on following a well-defined program, not eliminating any steps, and ensuring adequate resources are available to the development team. Chapter 6 discusses the nature of technology risks to metallurgical plant projects, and the rigorous management practices needed to identify, analyze, evaluate, and avoid or mitigate them.

Jan 1, 2015

By J. Roger Loebenstein

This report presents a U.S. Bureau of Mines study of the flow of arsenic-containing materials in the United States, based on the best data available in 1991, includes a consideration of arsenic as a byproduct of the processing of nonferrous metals, the fate of arsenic in manufacturing wastes, the quantity of arsenic used in products, tile fate of arsenic in dissipative uses, and the useful life of discarded products. Where possible, estimates are given of the amounts of arsenic lost from the materials flow. Arsenic byproduct of mining nonferrous metals. Historically, most U.S. production has been from the states of Montana, Washington, and Utah. The smelters in these states are believed to be the areas of the country where arsenic is most concentrated in the soil, tailings ponds, and waste dumps. Since the closure of the last domestic producer of arsenic in 1985, all arsenic has been derived from imported sources. Historically, arsenic was important in agricultural applications as an insecticide, herbicide, and cotton desiccant. As the environmental movement gained momentum and the toxicity of arsenic became better understood, most of the agricultural uses for arsenic were banned. Beginning about 1975, the use of arsenic as a wood preservative began to grow. After 1980, wood preservative uses became more important than agricultural applications. By 1990, 70% of the arsenic consumed in the United States was used by the wood preservative industry and 20% by the agricultural industry. The major source of domestic arsenic emissions in 1989 was from the U.S. copper processing indus¬try. About 7,800 mt/yr of arsenic was discarded in leach dumps, tailings, and slag. Another 800 mt/yr was liberated to the atmosphere and 1/100 mt/yr was exported in copper concentrates. On the consumption side, 9,200 mt/yr was lost, mostly from dissipative agricultural uses and the disposal of obsolete arsenical products.

Jan 1, 1994

By Brandon T. Buschmeier, Sonia S. Swift, Michael P. Walker, Frederic Masse

"Ground improvement has undoubtedly become a cost-efficient and effective solution to support the development of poor soil sites. Ground improvement elements, such as Controlled Modulus Columns (CMCs), replace piles by improving the subsurface soils and reducing settlement. As ground improvement becomes more popular, the applications become more creative and ground improvement is being used to control settlements under large structures with tight settlement tolerances.In this paper, we will discuss the use of CMCs to support two (2) large industrial warehouses where soil conditions would normally lead to the use of deep foundations and a structural slab, grade beams, and hung utilities to prevent excess settlement. Each of the sites we will discuss had poor soil conditions in the form of very soft or compressible soil, heterogeneous fill of varying thickness, and environmental contamination. At each site, we developed a design that would allow for the use of Controlled Modulus Columns (CMCs) with a Load Transfer Platform (LTP) in place of the previously-proposed deep foundations. The use of the CMCs also allowed for the use of spread footings and slab on grade construction. The benefits of this value-engineering approach include economy in the foundation system, risk mitigation by not disturbing contaminated soils requiring expensive removal, and ease of access for future sub-slab upgrades with new tenants. Additionally, the use of recycled concrete aggregate as an LTP is more environmentally friendly than placing structural slabs with heavy steel reinforcement.Designing for the settlement of large warehouses is challenging because it requires changing how we typically perform our designs. For most structures, the slab loads are relatively light when compared to the footing loads, whereas for warehouses, the slab is heavily loaded compared to the relatively light footing loads. Thus, it becomes essential to perform three-dimensional analyses to confirm that the proposed CMC layout will provide uniform support of the slab and footing across a variety of loading scenarios (loaded bays vs unloaded or travel bays). The complexity of the designs for these warehouses generated interest in conducting large area load tests over a grid of multiple columns. The performance of the area load tests provided invaluable information on the effectiveness of the LTP and CMC spacing. In this paper, we present a general description of CMC ground improvement, the differences between ground improvement and traditional pile foundations, our typical design methodology for CMC design, and the modifications to that methodology for warehouses."

Jan 1, 2017

By ROY BERENTZ

MANUFACTURE is the transformation of material by the application of energy and power. The energy of a man exerted throughout a day is equivalent to about one horsepower-hour of mechanical work an amount which can be purchased for less than 2c. It is evident that manual labor is uneconomical if mechanical energy can be applied effectively, or without disproportionate expense. Since manual energy is relatively so costly, economy demands that mechanical power be employed so as to reduce the human effort connected with mining operations to a minimum. Power, like other commodities, is most efficiently produced in large quantities. Mechanical transmission, once prevailing, is being rapidly superseded by electric drive. There are many reasons for this change; such as increased production, ease and accuracy of control, convenient application, ease of moving, etc.

Jan 1, 1930

By S. E. Phillipson

Four massive pillar collapses in limestone mines, and one in a marble mine, occurred between 2011 and 2021 in benched areas at the Appalachian physiographic province. We characterized the rock mass at 43 limestone mines using the Geological Strength Index and, by plotting the results on a physiographic relief map, determined that GSI values between 55 and 70 preferentially occur in the Appalachian and Ouachita Mountains, which were subject to deformation during the Ouachita and Alleghanian Orogenies. Limestone mines located in formations of similar age in the Interior Plains, where deformation was less developed, are characterized by Geological Strength Index values over 80. We present the results of pillar strength calculations that incorporate the Geological Strength Index from mines that experienced massive collapse, as well as from mines with benched areas that did not collapse, to demonstrate the negative effect that a jointed rock mass has on pillar stability. We suggest that pillar designs, particularly those in which benching will be incorporated, should include allowance for rock mass quality. Because of the preferential dominance of lower GSI values in the Appalachians, we further suggest that pillar designs in this environment may require additional engineering assessment, especially where benching is intended. Lower GSI values may often translate into greater overbreak, which results in loss of pillar volume, corresponding wider back spans, and a decreased width-to-height ratio.

Jun 25, 2024

By V. E. Housman

EPA's Mining Waste Section within the Office of Solid Waste is continuing to collect and analyze information on mining waste management practices. Starting in 1991, the Mining Waste Section has continued to conduct site visits and prepare case study reports on the waste generation and management practices of operating mines. In choosing sites to study, a reasonable attempt was made to provide diversity in mining commodity types, geographic regions, geology, climate, and environment. To date, EPA has visited the following mines: Asarco Troy (copper) in Montana, Newmont Rain in Nevada (gold), Cyprus Thompson Creek (molybdenum) in Idaho, LTV Steel (iron) in Minnesota, Phelps Dodge Morenci (copper) in Arizona, Doe Run Fletcher (lead) in Missouri, Brewer (gold) in South Carolina, IMC Four Corners (phosphate) .in Florida, Pennzoil Culberson (sulfur) in Texas, Nerco Cripple Creek (gold) in Colorado, Copper Range White Pine (copper) in Michigan, Magma San Manuel (copper) in Arizona, Colosseum (gold) in California, and several gold placer mines in Alaska, including the Valdez Creek Mine. EPA has prepared a case study report on each facility. The mine operators were provided an opportunity to comment on their respective site visit report and their comments have been included in' each respective report. These site visit reports have in turn been incorporated into technical resource documents which provide a detailed description of each mining sector. EPA is currently reviewing the technical resource documents and plans to release the documents in the Spring of 1994.

Jan 1, 1994

By Corale L. Brierley

Bacteria, algae and fungi react to heavy metals in their environment by immobilizing, mobilizing and/or transforming metals. Microorganisms carry out these changes by (1) precipitating metals outside of the microbial cell, (2) binding and complexing metals to the outside of the microbial cell's protective coating, (3) accumulating metals inside of the microbial cell, or (4) transforming metals by oxidation, reduction, methylation or demethylation. Most of these mechanisms are operative in constructed aerobic and anaerobic wetlands for metal's remediation. Several more advanced biotechnologies for metal's removal from aqueous streams have been introduced, but have not been widely accepted commercially.

Jan 1, 1995

By Yakup Cebeci, Leyla Kalender, Ceylan Yarluğkal Altınışık, Hikmet Sis

The abstract highlights the challenges in concentrating complex and non-sulfide lead-zinc ores and emphasizes the importance of froth flotation for their beneficiation. The study focuses on using process mineralogy to understand the flotation behavior of these ores from the Görgü region. The ore samples were characterized using various techniques, revealing oxidation and carbonation of primary minerals. The flotation results were interpreted in light of the mineralogical data, explaining the poor outcomes due to the complex nature of the ore, poor liberation, and lack of hydrophobicity.

Mar 22, 2022

By R. D. Bartlett

Large open pit mines in desert climates, such as the Phelps Dodge Morenci copper mine in Arizona, can create groundwater cones-of-depression of considerable size and :ability. The hydraulic containment provided by the groundwater depression prevents migration of process solutions into the surrounding regional aquifer. Copper leach operations that fall within the groundwater depression may not require costly lining if passive containment can be demonstrated. An approach is presented in this paper that was successfully used to demonstrate passive containment. The approach includes a combination of groundwater modeling and a water balance analysis of leaching operations failing within or immediately near the open pit.

Jan 1, 1999

By A. Lashgari, V. Kecojevic

This paper presents research on the environmental impact of digging and loading equipment used in surface coal mining. Environmental impact was assessed through the measurement of equipment exhaust and dust emissions, and sound level. In this study, exhaust emission refers to carbon dioxide (CO2), carbon monoxide (CO), nitrogen oxides (NOx), sulfur oxides (SOx) and volatile organic compounds (VOCs). Dust generation refers to fine particles (PM2.5), inhalable particles (PM10) and total suspended particulate matter (TSP). Sound level refers to the sound pressure level at different distances from the equipment. Modeling of the environmental impact of digging and loading equipment was conducted using the Microsoft Visual Studio.NET software package. This research was a part of a broader project involving the development of a software system for the selection of productive, cost-efficient and ecofriendly mining systems, sponsored by the Appalachian Research Initiatives for Environmental Sciences (ARIES). This research may assist mining professionals in quantifying the environmental impact of digging and loading equipment, and developing strategies for reducing the overall impact of such equipment in surface mining.

Jan 1, 2013

By Bernard Lewis

This report summarizes fundamental research and technical studies conducted by the Explosives and Physical Sciences Division of the Bureau of Mines from July 1, 1949, to June 30, 1950. It is the fourteenth of a series of annual reports whose aim has been to bring to the reader a résumé of the research results that have appeared in published form during each fiscal year under the authorship of members of the staff. These are referred to throughout the report.

Jan 1, 1951

By Jie Li, Longxiang Li, Wenbing Guo, Gaobo Zhao, Yuhang Hu

Surface subsidence caused by underground longwall mining is a very complicated process in time and space, influencing building and structures on the surface of the mining area, including houses, pipelines, and highway. The field monitoring data of surface subsidence are essential for protecting them. This study investigated the dynamic and residual subsidence characteristics of both the surface and the highway over a 730-day monitoring period on a longwall panel. Three monitoring lines (Lines 1–3) were established to monitor the subsidence process, and three stages were identified: initial stage of surface subsidence, active period of surface subsidence, and residual subsidence deformation stage. The maximum subsidence value on the highway (1,786 mm) was smaller than that on the surface (2,094 mm), and the maximum subsidence velocity on the highway (41.7–50.8 mm/day) was also lower than that on the surface (66.7 mm/day). During the residual subsidence deformation stage, both the surface and highway subsidence velocities decreased to below 0.6 mm/day. Furthermore, differences in subsidence characteristics between the surface and the highway were analyzed, with the subsidence value on the highway always being less than that on the surface, while the subsidence velocity during the residual deformation stage was not always lower. This could be attributed to the influence of dynamic loads from vehicles, which could induce additional residual subsidence on the highway. Further investigation into this phenomenon will be conducted in future research.

Jul 1, 2023

By Robert D. Thomson

The plastics industry runs into the billions, both in the dollar value of its finished, products and in the pounds of plastic raw material produced. It is, too, one of the fastest growing industries with a 300 percent increase in production in the past ten years. Informed estimates set 5.9 billions pounds as the plastic volume for 1959. Statistically, this is equivalent to a per capita consumption of 25 pounds in the United States. Plastics are man-made materials in contrast to natural materials like wood and are a family of materials -- not a single material - each member having special advantages. A generally accepted definition; for plastics is; a large and varied group of materials which consist, wholly or in part, of combinations of carbon with oxygen, hydrogen, nitrogen, and other organic and inorganic elements. This, while solid in the finished state, at some stage in its manufacture is soft enough to be formed into various shapes, most usually through the application either singly or together of heat and pressure. Many combinations and many different materials are thus possible. Therefore, for purposes of simplification, most plastics can be classified under one of 14 recognized basic family groups. These groups in turn generally can be further classified into one of two major subdivisions - thermosetting or thermoplastics. A few plastics are in between and they can be formulated to be either thermosetting or thermoplastic.

Jan 1, 1960

By Marc Boyer

Modern civilization, modern industry, and modern standards of living, bring into, sharp relief the present-day essentiality of metals .and minerals, and the wide and diversified use which is made of them. Any attempt, therefore, to appraise the international situation today must take into consideration the metal and mineral resources of the world. If, as some believe, the world is divided into two distinct ideologies of political belief, one unalterably opposed to the other, so that armed conflict is unavoidable, then the question of national strength in mineral resources becomes of paramount importance. If, however, it is possible to avoid war by raising the standard of living in the underdeveloped ?areas of the world, thus ensuring all peoples everywhere against the dread spectres of starvation and disease, then the development of the world's mineral resources assumes even greater importance. Today it is difficult to realize that, prior to the industrial revolution in Great Britain, only a few of the metals and minerals now in common use entered into the everyday life of the people. !iron and steel, copper, lead, tin, and zinc, usually in .their unalloyed forms, along with the more common industrial minerals, were those most widely used, and then only in limited amount. With the advance of technology in metallurgy and in fabricating skills, the list of commercial metals and minerals has expanded until today they number more than eighty.

Jan 1, 1951

By Pier Francesco Paglini, Gian Luca Menchini, Pier Francesco Boschi

"PROJECTThe “Caltanissetta” Tunnel is part of the ANAS S.p.A (National Autonomous Roads Corporation) $ 1.3 Billion Highway 640 Caltanissetta-Agrigento (Sicily, Italy) Rehabilitation Project, consisting in upgrading of 62 km (40 miles) of highway. The Italian multinational construction company Cooperativa Muratori & Cementisti di Ravenna, is the General Contractor for the design and build contract. The highway S.S. 640 starts from Porto Empedocle, to the intersection with the Motorway A 19 Catania-Palermo.The entire project, double carriageway designed for speed 70-120 km/h and maximum longitudinal slope of 4.2%, is divided into two sections. First Section: just finished and opened to traffic. Second Section: mainly involving the province of Caltanissetta, length about 28 km (18 miles), works started in 2013. This second section includes the most challenging work of all the project, the “Caltanissetta” tunnel consisting of two separate tubes, each with 3.9 km length and inside diameter of 13.50 m, in order to host 2 traffic lines and an emergency line. HORIZONTAL AND VERTICAL ALIGNMENT - GEOLOGY AND HYDROGEOLOGYThe plan alignment of “Caltanissetta” tunnel is formed by two tubes which are located at a minimum mutual distance of 22 m to a maximum of 63 m, with n. 9 pedestrian and n. 4 road cross passages; ventilation shafts are not provided. Overburden over portals area is about 5 m till a maximum of 120 m. Tunnel sections have variable longitudinal slope from 2.6% to 0.5%, transversal slope of about 3.5%. Right tube length is 3,992 m, left tube length is 3,877 m."

Jan 1, 2016

By J. W. Griffith, J. L. Stauffer, L. M. Demers, D. C. Kuhn, S. Riliog

"The relative activation of eicosanoid production which results from the exposure of the alveolar macrophage (AM) to mineral dusts is thought to be a key factor in the pathophysiology of occupational lung disease. We compared in vitro basal and silicastimulated production of prostaglandin E2 (PGE2) and thromboxane A2 (TXA2) by AM from normal humans and non-human primates (Macaca nemistrina). In addition, we instilled mineral dusts directly into one lung of the non-human primate and evaluated AM eicosanoid production at two week intervals following dust instillation. Unstimulated AM from humans produce more PGE2 and TXA2 than do AM from M. nemistrina. However, in vitro exposure of AM from both species to silica dust produced a qualitatively similar increase in TXA2 production accompanied by no change in PGE2 production. Sequential analysis of AM eicosanoid production following a single bolus exposure to bituminous or anthracite coal dusts, titanium dioxide (Ti()i) dust or crystalline silica showed marked variability among individual non-human primates in qualitative and quantitative aspects of dust-induced eicosanoid production. However, the rank order of potency of the different dusts (silica> anthracite> bituminous) correlated with epidemiological evidence relating the type of dust mined to the incidence of pneumoconiosis. These studies suggest that the non-human primate may serve as a model for the study of both the role of eicosanoids in the etiology of dust-induced occupational lung disease and the biochemical basis for individual variability in the response of lung cells to mineral dust exposure. IntroductionOccupational inhalation of mineral dust can lead to chronic debilitating lung disease ( 1,2). One of the key components of the disease process is thought to be the interaction of mineral dust with the alveolar macrophage (AM) and the subsequent release by the AM of inflammatory and fibrotic substances (3,4). Chronic inhalation of mineral dust, depending on the type and amount of dust, may then produce a situation in which ongoing inflammation, accompanied by the destruction of functional lung tissue by products of activated AM and polymorphonuclear neutrophils, stimulates the production of nonfunctional matrix by lung fibroblasts.The AM produces several oxygenated derivatives of arachidonic acid (AA) which may play important roles in dust-induced lung pathophysiology (5,6). In previous studies in the rat, we found that prostaglandin E2 (PGE2). thromboxane A2 (TXA2) and leukotriene 84 (L TB4) were the major AA metabolites produced by AM (7). PGE2 is associated with pro-inflammatory activity (8) as well as anti-fibrotic activity since it downregulates interleukin -1 (IL-1) and tumor necrosis factor (TNF) release by AM (9-11). TXA2 is known to stimulate platelet activity, cause bronchial and vascular smooth muscle contraction (12) and to possess chemotactic activity (13). LTB4 is chemotactic for neutrophils and monocytes (14) and has been suggested as an additional regulatory factor in the release of TNF by AM exposed to silica dust ( 15)."

Nov 1, 1995

By Paul D. Merica

This year of 1926 marks the 40th. anniversary of nickel mining in Canada. Although the first nickel mine of the Sudbury basin was discovered in 1883, it was not until 1886 that the Canadian Copper Company was organized and actually began to mine copper-nickel ore from the Lady McDonald, Stobie and Evans mines. The intervening years have witnessed some exceedingly interesting nickel history, particularly interesting and gratifying as well to Canadians. Forty years ago, at the inception of Canadian nickel mining, the world's consumption of that metal was about 1000 tons per annum and this was supplied largely from New Caledonia ores refined in France. This nickel was used principally for the production of nickel-silver, coinage alloys, and for nickel-plating. No processes were then known for refining the Sudbury ores nor for the separation of copper from nickel. Consequently, the pioneers in Canadian nickel mining faced the double problem of finding a method of treating their ores, and of finding a market for the nickel when and if they could extract it.

Jan 1, 1926

By R. F. Stewart

A key step in changing coals to fluid fuels and chemicals is the conversion of coal to synthesis gas by gasification with steam and oxygen. As oxygen represents one of the largest single expenses in gasification, its cost is a vital factor in the economy of the process. At present, the most economical method for producing tonnage oxygen is by the conventional rectification of liquefied air. Several alternate methods have been proposed for producing oxygen from air: (1) methods based on physical or chemical sorption of oxygen from air by liquids or solids or (2) the oxidation of certain inorganic com-pounds to higher oxides unstable at higher temperature levels. Economic limitations are discussed by which these methods may be evaluated. Chelated metals of the salcomine type are promising chemical sorbents of oxygen from air. This report covers a study of the reversible sorption of oxygen by salcomine and other chelates. The presence of water in the salcomine structure was verified; it is the loss of this water that causes slow deterioration of salcomine during cycling.

Jan 1, 1959

By Gustav Jahner, Michael Baltrusch, Norbert Hoffmann

Near the port city of Whitby in the north-east of England, Anglo American (AA) is setting up the deepest mine in the UK, which will have a depth of 1,500m. The purpose of the project is to extract and transport polyhalite, both underground, and to market it globally. As part of the construction works, BAUER Technologies Ltd, the UK subsidiary of BAUER Spezialtiefbau GmbH, constructed three different shafts using the diaphragm wall technique, with depths of up to 120m. In order to ensure the specified vertical tolerance of maximum 200mm, several measurement methods were applied, and the results were documented in a 3D model. Complex de-sanding plant technology and specially developed polymer products were adopted to regenerate the trench supporting bentonite-slurry.

Sep 1, 2022