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By C. Guria

A modeling, simulation and optimization study of a complex industrial fluorspar beneficiation plant (Kadipani, Gujarat, India) with fourteen/ten flotation banks is carried out to find an optimum/near-optimum circuit for the given quality of feed ore. The phenomenological flotation model developed by Mehrotra and Kapur (1974) is used for circuit optimization. Two different optimization problems are formulated and solved. The first optimization problem involves a single objective function, which uses available plant data to estimate the feed-characterizing parameters, i.e., the flotation rate constants, by minimizing the weighted sum-of-square errors between the computed and plant values. The second optimization problem involves two objective functions to obtain several simplified circuits. The number of non-linking streams and the overall recovery of the concentrate, i.e., the acid-grade product, are maximized simultaneously in this problem. The single-objective variant (SGA-II-mJG) of the binary-coded elitist non-dominated sorting genetic algorithm with the jumping gene adaptation, NSGA-II-mJG, is used for the first problem, while NAGA-II-mJG (Guria et al., 2005 a) is used for the second problem. Simplified circuits with a few split streams are proposed on the basis of the present optimization study, which enhance the recovery of the acid-grade product without affecting its quality, for a given total volume of the flotation cell-bank. Even though the optimal solutions have certain drawbacks, they suggest a meaningful direction in using an iterative fitting of parameters to such optimal circuits, followed by re-optimization. Key words: Froth flotation, Mineral processing, Industrial fluorspar beneficiation, Feed identification, Circuit/network optimization, Global optimal, Jumping gene, Genetic algorithm, Multi-objective optimization

Jan 1, 2009

By Paul E. Rosten

This paper describes some of the latest improvements that have been incorporated or planned by the Cleveland-Cliffs Iron Company to reduce operating costs and improve pellet quality. The Cleveland-Cliffs Iron Company operates and manages mining, beneficiation, and pelletizing operations in Michigan, Canada, and Western Australia. This paper deals with the grate-kiln pelletizing operations at Republic, Humboldt, Tilden, Empire, and Pioneer in Michigan, and the Adams and Sherman in Ontario, Canada. Table I characterizes .each operation in regard to location, ore type, pellet capacity and date that pellets were first produced. All of the operations with the exception of Pioneer and Tilden, utilize downdraft-two-pass grate cycles of drying followed by preheating. Pioneer utilizes an all-downdraft, three-pass grate cycle which consists of three drying zones followed by the preheat zone. The Pioneer and Tilden cycles have been described previously. (1) (2)(3) Tilden utilizes a three-pass grate cycle with a stage of updraft drying, followed by two downdraft drying stages. Recuperation systems which supply hot gases to a drying zone from second stage cooling were designed and furnished for Tilden I. Tilden II will be identical. Empire IV will also be furnished with a recuperation system. The Adams grate-kiln system was retrofitted with a recuperation system. This paper will summarize some of the efforts that are in effect or planned for grate-kiln pelletizing systems to (1) reduce operating and maintenance costs, (2) reduce energy requirements, (3) improve product quality, and (4) meet environmental standards.

Jan 1, 1977

By S. R. Dismuke

Ore at the Magmont Mine in southeast Missouri is extracted by the room and pillar method on two and sometimes three horizons. In 1991, an innovative plan was formulated for recovery of high grade ore in pillars using cable bolts to accommodate spans of more than 27 m (90 ft). A test area was subsequently selected and a recovery plan developed. A cooperative rock mechanics study effort by COMINCO METALS, the U.S. Bureau of Mines and the University of Utah was later established. When initially opened in 1968, the planned production rate was about 1,000,000 tons per year. Due to declining reserves, the production rate was decreased to 630,000 tons per year in November 1992. Pillar recovery now accounts for approximately 40%-50% of the mined tonnage and plays a vital role in allowing Magmont to continue to operate.

Apr 13, 2011

By Peter V. Avotins

During last year's AIME meeting in New Orleans, Deepak Malhotra and I were discussing some of the topics that would be presented in this Symposium. It seemed appropriate that along with papers on specific reagent and flocculant types, we should address research management aspects of new product development. This development is a long, arduous task that requires a significant technical and fiscal commitment by the chemical company and potential users. A flow chart depicting the research process is shown in Figure 1. The sequence of events are plotted on an undefined time line. Our experience has shown that it takes 3-5 years to complete a typical reagent development project. A new project starts with an idea of how to do something better. The ideas range from relatively simple product modifications to opportunities created by technological change. An example of this is the use of flocculants in tailings operations to close the water recycle loop. The change was brought about by the need to conserve water and comply with environmental statutes. The result was the development and wide-spread use of synthetic polymers to help in solid-liquid separation. More recently the ups and downs of oil prices have led to development of coal water slurries as an alternative to fuel oil. The slurries contain high levels of chemicals (up to 3%) to insure proper stability and burn characteristics. There are technical changes under way right now that may lead to ideas for other new products. One exciting source of new technology is the ability to manipulate genetic material of microbes to select for specific capabilities. This has evolved by leaps and bounds over the past 5 years. Biologically assisted leaching and removal of wastewater impurities are two possible end uses. I'm sure that there are many others. The ideas can originate anywhere and are often half-baked at first, but to lead to new products they must be refined to provide project definition and eventually a research plan. A chemical ,development project cannot be started without approval to commit the company's resources. The internal selling job is often very difficult. The company must see clear financial benefits in order to launch efforts that may not pay off for many years. It is critical to project the total market, profitability, eventual market share, and timing of introduction of the new product. There is much uncertainty in this and the research manager is often skating on thin ice to retain his credibility. Once we obtain support from upper management, the research team is assembled to start the project. The teams generally consist of organic chemists, research metallurgists, and technicians. They have access to analytical scientists and technicians for surface and analytical chemistry. The projects are often augmented by help from university staff and consultants. This is particularly true where there is a need to develop fundamental understanding of the technology in addition to synthesis of chemicals. The project now proceeds along two lines. First, there is an emphasis on understanding the prior art. Extensive literature and patent searches are undertaken to provide research leads and to keep from "reinventing the wheel" and infringing on someone else's patent. The scientists and technologists are qualified to conduct computer-assisted library searches. This process usually uncovers 80-90% of the relevant information. The remainder is very much harder to get and requires the help of professional library search staff with scientific backgrounds. Along with literature searching, the team begins synthesis of new compounds. These are screened by use of techniques such as microflotation or filtration in a Buchner funnel. The scientists are looking for the direction of response as they modify structural features . Inevitably, a large number of candidates reach the next stage, a laboratory bench test. At this point it is possible to set up a research plan and use project management techniques to monitor progress. The bench tests are conducted in larger equipment, usually requiring 100-1000 grams of test substrate. Typical laboratory flotation tests are run in Denver or Wemco cells.

Jan 1, 1986

By Michael Karmis

The International Conference on Sustainable Development Indicators in the Mineral Industries(SDIMI 2003) was held May 21-23, 2003 on the island of Milos, Greece. The objective of this international conference was to assist the mining and minerals industries in their global transition to sustainable development. The main theme of the conference was the development, monitoring and assessment of sustainable development criteria for mineral operations. Emerging technologies were also presented that can assist in the development of criteria and performance indicators.

Jan 1, 2003

By David D. DiPonio, John DiPonio, Roger Van Omen

The greatest opportunity to attain the most favorable prices for underground construction projects occurs during the competitive bidding period. The Owner, Engineer, and Contractor need to have a thorough understanding of the project’s design concept, how it is going to be built, and what it is going to cost. This paper presents the opinions of three engineering professionals who are well established in their sectors of heavy civil underground public works construction. This paper will outline and summarize the considerations that the three principal contracting parties of Owner, Engineer, and Contractor need to make to obtain good price quotes at the time of bids.

Jan 1, 2005

By B. J. Arnold, F. F. Aplan

A model incorporating rate and residence time to describe the froth flotation process was used to provide data for the evaluation of various kinetic flotation models and to provide scale-up information from laboratory to industrial scale coal froth flotation. Rate constants were determined in laboratory and plant froth flotation tests and the residence time distribution was measured for a bank of four 21 ft 3 (0.6 m3 ) WEMCO cells treating Upper Freeport seam coal and a bank of four 300 ft 3 (8.5 m3 ) cells treating Lower Kittanning seam coal. It was found that a lag time for continuous flotation should be incorporated into scale up models and that a kinetic froth factor ratio of between about 2.0 and 2.8 should also be used to scale up data from laboratory to plant scale.

Jan 1, 1989

By U. Thorley

Management of mine and tailings reclamation activities by surface mining oil sands operations in Alberta, Canada is experiencing increased national and international attention. Of particular concern is the ability of existing mines to execute and fund reclamation activities. Concern stems from a lack of demonstrated tailings reclamation technologies, perceptions of a poor track-record of reclamation activity by industry, and a lack of transparency with respect to the potential cost of reclamation activities relative to the monies secured in Alberta?s Environmental Protection Security Fund (EPSF). Limited information is publicly available regarding reclamation costs and technologies. Available data typically comes from disparate sources. This paper examines the expected costs of oil sands reclamation activities through a study of corporate Asset Retirement Obligation (ARO) liabilities, the Province of Alberta?sEPSF, and published data relating to reclamation costs.Issues relating to current liability funding are introduced.

Jan 1, 2011

By Alan A. Campoli

The US Bureau of Mines (USBM) conducted research to develop improved guidelines for selecting the type and pattern of roof support in different geologic environments. The goal is to minimize the over and under design of mine roof support, resulting in more productive and safer mines. To obtain the necessary data on roof behavior and support performance, USBM conducted several field studies. Each study covers roof geology, stress regime, ground reaction, support interaction and mining environment. A consistent experimental design is being used. This includes measurements of roof bolt loads and roof movements. So far, 10 studies have been conducted in several geologic settings.

Jan 1, 1996

By Reed Thorne

To many people, rescue from elevated, sometimes vertical, locations brings about thoughts of heroism mixed with brawn and self-sacrifice. Images are conjured of cliff rescues where the technical effort is hanging from a few seemingly small nylon ropes hundreds of feet above the ground. Such is the vertical realm of technical rope rescue. This is a technical field in which the author serves professionally as battalion chief of (rope) operations for a northern Arizona fire district, and as a private sector instructor to mines in the United States and Canada.

Jan 1, 1996

By M. M. Fine

Development of a process for winning copper from pelletized chalcocite concentrate without matte smelting and converting is underway at the Twin Cities Metallurgy Research Center, Bureau of Mines. The new route from concentrate to metal includes 2-stage fluid-bed treatment; pelletized concentrate (33 percent Cu, 7 percent S) is first desulfurized (to about 0.5 percent S) in an oxidizing atmosphere, and in the second stage the calcine is metallized by reduction with hydrogen. Thereafter, the reduced product plus 10 percent CaO is routed to a smelting furnace to separate metallic copper from the gangue. Recovery and the Cu content of the product at this point are in the 97-98 percent range. The metal must be refined to remove sulfur and iron to make wirebar copper. An important feature of the process is the pelletizing of the fine concentrate into mini-pellets prior to fluid-bed treatment, which has permitted shorter reaction time, decreased dusting, and facilitated subsequent processing.

Jan 1, 1970

By Carl-Henrik Knudsen, Rolf Tore Arnesen, Eigil R. Iversen

Recovery of iron and copper from acid mine drainage was studied in pilot scale at a continuous treatment plant at the mine site of the King's mine in Roeros, Norway. The average load on the plant was 1 m3/h. The process tested in this project is a three-step process consisting of: 1) Fe(OH)3 precipitation at pH 3.5, dewatering of iron sludge and transport to ferric chloride plant; 2) after filtration precipitation of residual metals at pH 9, concentration of metal sludge by flotation; 3) extraction of metals from the sludge with sulphuric acid followed by recovery of copper by electrolysis. The copper could be used for local production of different crafts, but this condition needs a further evaluation. The process economy at a full scale plant is evaluated.

Jan 1, 2000

By B. P. Spigarelli

To meet the growing need for CO2 capture and storage technology, Michigan Technological University is researching CO2 capture and storage using carbonate solutions. The objective of the present study was to increase the absorption rate of CO2 into the carbonate solution without reducing the absorption capacity of the solution. This approach used a polypropylene glycol methyl ether (PPGME) as a surfactant to chemically alter the gas bubble size. Experiments were conducted to study the absorption rate of CO2 at varying surfactant concentrations of 0, 0.12, 0.24, 0.36 and 0.48 g/L. Results showed that as the concentration of surfactant increased in solution, the absorption rate also increased. The CO2 absorption rate increased from 3.45 mmol/min CO2 at 0 g/L PPGME to 3.92 mmol/min CO2 at 0.48 g/L PPGME. This amounted to a 14% increase in the CO2 absorption rate with no decrease in absorption capacity of the solution.

By George S. Austin

Perlite is rhyolitic glass with 2 to 5 percent by weight (wt.%) bound water held within the silicic-glass structure. It is often distinguished by vitreous, pearly luster and concentric perlitic fractures ("onionskin"). Occurrences worldwide are associated with Tertiary to middle Quaternary volcanic rocks. Perlite is in silicic domes, plugs, laccoliths, flows, vitric tephra, chill margins of dikes and sills, and welded ash-flow tuffs. It is a hydrated volcanic glass formed through secondary alteration of obsidian by the incorporation of water into the glass/silica structure. Post-emplacement hydration (weathering) of cooled glasses by meteoric water is the principal alteration process, but some hydration by magmatic or meteoric water during or shortly after emplacement, or hydration by water exsolved during cooling may occur. Commercial "perlite" is any volcanic glass that expands or "pops" when heated quickly to plasticity while evolving steam and thus forming a lightweight, frothy material. The expansion temperature typically ranges from 1,100 to 1,500°F. An expanded volume increase of 10 to 40 times the original volume yields expanded densities of 1.5 to 11 pounds per cubic foot (lbs/ft3). Perlite is mined by eight companies at 10 operations in six western states. New Mexico accounts for more than 80% of the total tonnage mined. The rest comes from Arizona, California, Colorado, Idaho, and Nevada. In 1992, domestic production was 571,000 short tons (st), domestic apparent consumption was 591,000 st, and the value of crude perlite was $15.3 million. In 1991, with about the same production and price of crude perlite, the gross value for expanded perlite was $101.7 million. Perlite exports in 1992, primarily to Canada, are estimated an 30,000 st; and imports, from Greece, are an estimated 50,000 st. In 1992, 70 plants in 33 states expanded crude perlite. Construction uses of expanded perlite accounted for 66% of total domestic sales. Expanded perlite used as filter aid accounted for 15%. All other markets, including use as a filler and in agriculture, accounted for 19%. Leading states for expanding perlite, ranked by order of sales, were Mississippi, Pennsylvania, California, Illinois, and Georgia. Domestic perlite encounters transportation disadvantages in some areas of the eastern United States compared to perlite imported from Greece. However, western U.S. perlite exports to Canada offset this in large part, and net import reliance for perlite is about 3% of domestic consumption. Perlite grab samples were tested at the New Mexico Bureau of Mines and Minerals Resources (NMBMMR) for their basic suitability in horticulture, construction, filter aids, and fillers/extenders using Perlite Institute techniques modified by the NMBMMR. Most commercial perlite ranged from 2.5 to 3.0 wt.% bound water for all major types (classical, granular, and pumiceous). Expanded density varied widely, but the lowest density of 1.9 lbs/ft3 was for granular. Average brightness of expanded perlite was 47.6 to 69.3%. Nonexpansibles, commonly obsidian or "dead" perlite, ranged from 18 wt.% to less than 1 wt.%, with granular perlte generally the lowest. Compacted density was not related to either perlite type or nonexpansibles present. Sieve analyses of the -50+100 mesh product showed that, in general, pumiceous perlite produces more fines and classical and granular perlite average 60 to 80% -30+100 mesh after expansion. Samples were tested for crystalline silica that ranged from below the detection limit of 0.5 wt.% to nearly 0.2 wt.%, but most tested below 0.5 wt.%. Although quartz content can be lowered in the expanded product by the expansion process, producers can further lower crystalline silica in the product by mixing low-quartz crude with high-quartz perlite before expansion. Chemical analysis by x-ray fluorescence confirms the rhyolitic composition of perlite, but indicates that surface weathering may increase the concentration of some elements, such as potassium and calcium, by infilling cracks or fissures developed during or after perlite emplacement.

Jan 1, 1995

By R. J. Cornelius

Gold with minor associated copper mineralization in the area of what is now the Bougainville porphyry copper deposit has been known since the 1920s and was probably known in German colonial times, pre- 19 14, although no records persist other than a reference by Stanley (1922) to copper specimens from Kieta that he saw in Rabaul. Stanley did not at the time believe that they came from Kieta. Gold was first discovered at Kupei by Jack Comb in 1929 and the Kieta Goldfield was proclaimed in May 1930. In December 1932, the Tapu Reward Claim at Moroni - the site of the Bougainville Copper concentrator, was pegged by C.W.M. Evans who prospected up river from the West Coast. The Pumkuna (Panguna) Reward Claim on the site of the subsequent porphyry copper deposit was granted in February 1934 to G.A. Myers. n May 193 1, the Kupei Reward Claim was transferred to Bou- gainville Gold Options NL and later reverted to Jack Comb and then the Bougainville Syndicate, as did the Pumkuna and Moroni claims. Most of the interested parties had come from the Edie Creek rush on the New Guinea mainland. In 1935, N.H. Fisher, the geologist in Rabaul for the New Guinea administration who later became director of the Australian Bureau of Mineral Resources in Canberra, reported on the three gold areas. Norm Fisher described the gold and copper mineralization and its habit in great detail and this report had a major influence on the events leading to the discovery in the 1960s. Gold production up to the Japanese invasion probably did not exceed $50,000 in value. Half a ton of copper-gold ore from Kupei was sent to O.T. Lempriere's in Sydney for assay in the early 1930s.

Jan 1, 1991

By C. Ptacek, D. Hiller, J. L. Janbor, H. Mccreadie

Between 1991 and 1994, metallurgical residues from a pressure-oxidation autoclave at the Campbell Au-quartz mine at Red Lake, northern Ontario, were neutralized with dolomite-rich flotation tailings and were deposited in a polyethylene-lined disposal area. Mineralogical analysis indicates that most of the As occurs as a crystalline ferric sulfarsenate, and some is associated with Fe oxides and with K-H3O jarosite. Field pore-water geochemical data from 1994 and 1995 showed increases in Fe(II) and As(III) concentrations, suggesting that the sulfarsenate and jarosite are dissolving; none of the discrete As phases included in a thermodynamic database limit dissolved-As concentrations, and these concentrations may continue to increase. These results demonstrate the potential for Fe and As loading through groundwater systems.

Jan 1, 1998

By Randy Fulton, Ignacy Puszkiewicz, George H. K. Schenck

Stuart Olson Construction, Inc. excavated 385m (1263 ft.) long twin tunnels with 6.25m (20.5 ft.) O.D., a portal and a cross-over for the Edmonton, "Metro". The work for Contract No. 76458, SLRT South Tunnel and Portal, in Edmonton, Alberta, Canada was performed in 1989 and 1990. NATM was specified because of the instability of glacial deposits. The contractor decided to use "two firsts" on this project: Fully mechanized NATM and a novel excavator¬mounted tunneling machine. An excavator was equipped with a cutter boom, and a loading and conveying system. This novel machine cost only about one-third of the price of a special NATM roadheader. This new combination of NATM and an excavator-mounted cutter boom offered a cost-effective alternative to shields, slurry TBMs and roadheaders for short tunnels in unstable ground. For NATM tunneling in hard rock or in mixed faces, the roadheader-type cutter boom can be replaced with an impact hammer (hydraulic breaker).

Jan 1, 1993

By Larry A. Enloe

The 16-to-1 milling operation is Sunshine Mining Company's first new silver and gold producing facility. The 16-to-1 underground mine and mill are located approximately 64 km (40 miles) southwest of Tonopah, Nevada. Ore re- serves in the epithermal vein deposit are estimated at 0.91 Mt (one million st) of ore, at an average silver grade of 206 to 240 g/t (6 to 7 oz/st) and an average gold grade of 1.2 g/t (0.035 oz/st). The underground mine uses a large diameter blasthole stoping system of mining using highly mechanized rubber-tired equipment. The mill uses conventional cyanide leaching with countercurrent decantation and Merrill-Crowe precipitation. The mill start-up was in February 1982 resulting in the first pour of dore' in March 1982. The mill's present annual production is approximately 31.1 t (1.0 million oz) of silver and 264 kg (8500 oz) of gold.

Jan 1, 1984

By Robert Giglio

Looking back over the last 150 years or so, it is not hard to see that electricity has been a primary force in shaping human development. It has been a basic ingredient in our industrial revolutions that simultaneously improved the productivity, working and living conditions within our farms, factories, hospitals, offices and homes. Today, it has become an essential part of our daily life and our future. Amazingly, we keep finding new ways to use electricity to make our lives more safe, comfortable and productive. It is a great success story of human ingenuity, achievement and development. Demand for electricity The convenience and value of electricity has not gone unnoticed by consumers. According to the U.S. Department of Energy (DOE) (Energy Information Administration, 2009), electricity is the fastest growing form of energy in the world and during the next 20 years the world will likely consume twice as much of it as it does today. In 2008, almost 20,000 terawatt hours of electricity globally were consumed (Energy Information Administration, 2009). That is enough electricity to light up more than two million baseball stadiums or power more than 11 billion computers continuously for an entire year. The United States has the dubious distinction of be-ing the largest consumer of electricity in the world with enough power to provide each American with more than 3 kW of electricity ? that is about twice the power currently available to Europeans, eight times the power available to the Chinese and more than 25 times the power available to the citizens of India (American Coal Foundation, 2009).

Jan 1, 2009

By G. France

The Blair Athol Coal Mine (BAC) is a large open cut operation in the Bowen Basin of Queensland, Australia. Current mine capacity is about 11 million tonnes per annum(Mtpa) of export coal. On-line analysis at BAC consists of two Coalscan 9500s installed directly on the output of the crusher plant and immediately before the product stockpiles, while a third Coalscan 9500 is installed on the transfer conveyor feeding the train loading bin. The two product Coalscans have a dual purpose. The first is to provide real time coal quality data directly back to the mining operations. The second is that of modeling the product stockpile with accurate on-line information. This modeling enables both production and coal quality personnel to accurately examine the coal quality of each stockpile with a degree of resolution which previously had never been achieved.

Jan 1, 1999