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By C. A. Holley

The generation of coal fines is a growing problem which has serious environmental and resource recovery Impact. Several methods of agglomeration are studied including the production of briquettes for the consumer market. Simplified process flow diagrams, "order of magnitude" plant capital cost and operating costs are presented.

Jan 1, 1986

By Richard J. Fantel

This paper addresses the impact of declining world rutile resources upon the production of titanium products and their asso¬ciated costs. Titanium is used primarily for the production of pigments; in its metal form it is considered a strategic and critical material to the U.S. defense and aerospace industries. There are two major mineral sources for titanium: ilmenite and rutile. Both these mineral types can be used to produce titanium pigments. Only high grade titanium concentrates, such as rutile, high-grade ilmenite, and synthetic rutile (which is produced through further processing of ilmenite), can be used in the production of titanium metal. This paper draws upon the data and analyses of a recent Bureau of Mines Minerals Availability Program appraisal that evaluated the international availability of titanium from market economy countries. The paper will show that production from economic rutile mines will decline sometime after the turn of the century and that rutile shortages could be alleviated by production from other high-grade titanium resources such as higher cost rutile deposits and anatase deposits, or through an increase in world synthetic rutile capacity.

Jan 1, 1984

By H. A. Zollinger

The Hallmark Distribution Center is one of the most sophisticated material handling and order filling facilities in the world. The 53 million cubic foot facility houses an ultra-modern, computer- monitored distribution complex that handles as many as 1/4 million orders per day. The Distribution Center replaces 16 leased buildings scattered through- out metropolitan Kansas City and, in addition, re-leased 4 floors in mid-town Kansas City needed for creative and administrative expansion. This new facility is the nerve center for distribution of Hallmark products in United States and Latin America. The size and gross numbers of all parts of the system is a significant accomplishment, but the purpose of this paper is to explain the technical advancements in the state-of-the-art of material handling and controls. The system iteself is made up of seven sub-systems including receiving, warehousing, picking rack stocking, towline, order filling, order sorting, and shipping. Significant techniques were used in each of these areas as well as technical advancements in the state-of-the- art. The most significant points are in 4 of the areas and are discussed in this paper.

Jan 1, 1973

By B. C. Haydon

Manganese silver ores are well known to be refractory towards cyanidation. Various processes have been suggested for improving the amenability of these ores. A sulfurous acid pre-leach is one such process. This paper traces the development and implementation of the sulfurous acid pre-leach process for the retreatment of manganese silver tailings at Tonopah, Nevada. An account of the test work program is presented, followed by a description of the operating plant and specimen metallurgical performance. The paper also summarizes the history of the Tonopah tailings, their mineralogy and makes reference to previous application of the sulfurous acid pre-leach process.

Jan 1, 1984

By Alan English

This paper reviews the process control systems used in early commercial pelletizing plants, traces the development of these systems into present day practice, and briefly outlines advanced automation concepts being considered for future installations. It deals specifically with controls for the balling circuit, pelletizing machines, and related material handling and combustion equipment. The importance of instruments for visual observation and data logging is discussed, and the potential use of computer control is evaluated.

Jan 1, 1965

By K. Rajamani

The word adapt means "to change so that one's behavior will conform to new or changed circumstances." Applying this definition to process controllers suggests that an adaptive controller can change its behavior in response to changes in the dynamics and disturbances of the process. In the minerals industry there are many control cases where adaptive control will provide superior control as compared with more traditional PID (proportional, integral, derivative) control. A typical plant uses as many as 100 to 200 control loops for lprocess regulation. Therefore, the task of initially tuning and then periodically retuning these controllers is a formidable problem, During the time the controllers are "un-tuned", product quality may deteriorate and unstable operations may result. Adaptive controllers are capable of tuning themselves, thus avoiding this problem. The computers commonly used in distributed control systems are easily capable of implementing adaptive controllers. In addition to the possibility of using the control computer to implement adaptive controllers, many distributed control systems will offer adaptive control as a standard feature in the near future.

Jan 1, 1984

By Warren C. Gerler

An overland belt conveyor system is installed for only one reason to save money. It must pay its way on a ton-mile basis over a stated period of time, and do so in competition with other forms of transportation. Such a system with its economies has recently been installed at Simco-Peabody's mine near Coshocton, Ohio by Link-Belt Company. Three miles in length, this system carries coal from open pit and underground mining facilities to the Conesville Power Plant of Columbus & Southern Ohio Electric Company. The coal was formerly trucked from the mine direct to the power plant; but over the years the mining operations have moved progressively farther and farther from the plant, making the over-the-road hauling distance correspondingly greater. Simco-Peabody has mining operations over a considerable area just east of the Conesville Station. The majority of the coal is recovered by conventional strip mining. Some underground mining` is performed by the high wall method.

Jan 1, 1963

By John L. Shafer

Often an in situ leach is the only practical economic method for copper recovery from small low grade oxide deposits. The decision to develop a copper property by an in-situ blast and leach is strongly dependent on ore grade, tonnage, hydrology, and the copper extraction and acid consumption rates. The inherent "leachability" of the ore will in part determine the desired amount of fracturing of the ore deposit by the blast in order to obtain a copper extraction rate that is economical. For the last several years Occidental Research Corporation (ORC), the corporate R&D for Occidental Petroleum has under-taken a modest effort to address the question of "how to best identify and determine the information necessary to predict and control the operation of an in-situ leach for the economic recovery of copper."

Jan 1, 1977

By George H. K. Schenck

It seems appropriate to review the history of mechanization of our underground coal mines at this time when many favorable flags are flying for this industry. It is a reasonable hope that such a review may stimulate thinking as to the directions that new technological developments are apt to take and in which members of the Society of Mining Engineers are destined to play important roles. Discussion of the relative importance of the various changes that have taken place since the advent of electric power provides the starting point. It is in the economic factors utilized that we find conditions which permit more efficient utilization of the capital committed to the industry. Concepts rather than specific items are emphasized in the following discussion because once the value of a concept, such as mechanical conveyors, is established, it then spawns many variations which are not significantly different. The shift from animate to inanimate energy has been the most important change in the modern industrial scene, including coal mining. Although introduced into coal mines for some purposes early in the period of general electrification, the coal industry adopted mechanical power relatively slowly, and 1944 was the first year in which a majority of deep-mined coal was mechanically loaded.

Jan 1, 1968

By L. J. Vincze

The program of study of pellet binder materials was begun by the ORF in 1963 to examine various Canadian materials as substitutes for bentonite which is imported in large tonnages (199,270 tons in 1969) from the U.S.A. for Canadian pellet plant operations. Most of the raw bentonite used in Canada originates in Wyoming, North Dakota and more recently Greece, resulting in relatively high transportation costs to pellet producers. Some Canadian bentonites available in Western Canada (Alberta) can be beneficiated for uses as pellet binders but could not compete in cost with U.S. sources due to the cost of beneficiation and the higher rail transport charges to Eastern Canada. It is difficult to find a substitute for bentonite, and many materials have been investigated by research groups but, so far, no economic substitute is in use. However, some success is apparent in studies of low cost materials such as clays, sea weed, peat moss and low grade coal, The work done by the ORF over several years has covered systematic test¬ing of Ontario clays, lignite, some types of tree bark, waste sulphite liquors of various kinds, and peat moss as binders for iron ore pellets. The major effort has been concentrated on peat moss and has included a study of the influence of different additives. Since analysis of peat moss for humic acid is difficult and time consuming, a certain amount of time was devoted to development of improved methods, the most useful of which was a spectrophotometric method based on extraction of peat by sodium pyrophosphate for determination of humic substances. In the present paper, only the most recent work concerning the use of peat moss with suitable additives is discussed in detail, since it is the most conclusive and best documented portion of the program.

Jan 1, 1971

Explosives are used to mine coal. Any blast results in three size categories of products, namely over-, middle-, and under-size. Boulders can still be broken smaller in further operations after blasting. The under-size, for instance coal fines, negatively affects the mining efficiency. Their reduction ensures better returns. The paper concerns investigations aimed at reducing coal fines' generation. Inherent fractures are identified as one of source of fines. The discussion is therefore centered on establishing a relationship between the fracture occurrence, the explosive properties and the blast outputs evaluated in terms of the fines generated.

Jan 1, 1996

By James E. Myers

This study is a survey of the current "state-of-the-art" of commercially-available sonar tools to monitor the true shape of man-made cavities within the Hutchinson Salt of south-central Kansas. The work entailed ferreting out the available information, most of which is proprietary in nature; then examining actual existing conditions and arriving at a reasonable scientific evaluation of the method. Our studies were confined to one LPG field and two brine well operations in south-central Kansas. No field testing of any devices was performed, only questioning user firms, and studying cores, logs, and sonar surveys graciously made available by the companies we have contacted. Since these data are still somewhat proprietary, the company participants have asked that their company names be omitted from this presentation.

Jan 1, 1973

By E. O. Strahl

In the search for economic mineral deposits, the need for efficient mineral or chemical assays is of prime importance. Costly analytical methods and long delays in obtaining assay results severely limit the effectiveness of an exploration program. The assay problem becomes acute once a potential ore body is located and large numbers of samples are generated in close interval drilling programs. In order to avoid the delays and high costs of extensive assays, the exploration geologist or mining engineer is likely to be required to curtail his drilling program, composite samples, or restrict the required analyses to a limited number of critical elements. As a result, the definition of the potential ore body may be less than needed for final economic evaluation. The assay requirements for bauxite exploration usually involve a considerable number of total elemental and empirical analysis. Since the Bayer process for extracting alumina from bauxite involves the selective dissolution and reaction of specific minerals from the bauxite, a direct chemical analysis for elemental composition yields only a portion of the data required to effectively describe the potential economic value of ore body or deposit. To fully characterize the economic value of a bauxite requires digestion, mud separation and mud settling tests under conditions approximating a commercial Bayer plant. A close approximation of the process behavior of a bauxite also can be calculated from a combination of the chemical and mineralogical analyses. By determining the elemental chemistry, mineralogy, and Bayer plant processing characteristics of a few samples of a given bauxite, correlations can be derived that permit defining a bauxite in terms of a given set of process conditions.

Jan 1, 1977

By Bruce R. Sutherland, Jim B. Ramsden, Gerry L. Bolton

Conductive metal powders are important building blocks for today's micro-electronic circuitry. Formulated into inks, they provide the interconnects needed to complete a complex integrated circuit and the means to enter the world of miniaturization. Traditionally, the inks have been based upon expensive metals such as silver, palladium, platinum and gold because of their excellent electrical conductivity and resistance to corrosion and oxidation. The use of a copper based ink, as an alternative to precious metal inks, recently has received considerable attention. Instability in the prices and limited supply of certain precious metal systems have driven up production costs, making the development of a lower cost copper system more attractive to manufacturers. However, lower production costs are on1 y real ized if performance and reliability can be maintained. While the development has been driven by cost, copper does offer some significant performance advantages over noble metal systems: conductivity as good as silver and 4W better than gold; leach resistance better than silver and equal to gold; stability at high frequencies better than gold or silver; strong film bonding characteristics; and compatibility with most solders. These benefits, however, do not come without cost. The inherently reactive nature of pure copper, while providing unique performance properties, makes it difficult to process. Unl i ke precious metals which can be fired in air, copper would oxidize and so requires special furnaces and atmospheres. Despite these difficulties, the transition from precious metal thick film systems to copper is gaining momentum. Manufacturers of high density, high performance circuitry are exploring the performance advantages of copper over gold and silver and the manufacturers of consumer products are considering the potential cost savings of copper over silver-palladium. Sherritt has developed a fine copper powder for this industry. Through association with the ink manufacturers, it has been found that performance properties of the ink vary with the physical and chemical characteristics of the powder. Production Process The production of very fine copper powders at Sherritt is based upon the disproportionation of cuprous ions as outlined in Equation [1] (1).

Jan 1, 1990

By Roberto Zaragoza

Historically, the control of flotation operations has been viewed by many as an art. Only recently has process measurement and control come to be viewed not as an ?art? but as a very complex and productive science. In recent years, process control applications to flotation plants have been established and already some gains have been reported for several industrial operations using individual stabilizing control loops including level, pulp flow, pulp density, reagent addition rate and pH (Paakinen, 1979; Hales, 1985). The use of process control computers combined with on-line x-ray florescence (XRF) in industrial flotation circuits has made the application of more sophisticated control techniques feasible in the mineral recovery process. In spite of the availability of reliable instrumentation in modern flotation plants, satisfactory control strategies are difficult to develop and implement. Extremely important factors such as changes in ore type, liberation characteristics, flotability, degree of oxidation on particle surfaces, and specific gravity constitute unmeasured disturbances to the process. Most current control systems cannot adapt specifically to such disturbances.

Jan 1, 1987

By Richard Klimpel

A common problem in mineral processing and chemical engineering is the need to estimate flow rates and/or weight ratios involved with engineering operations for which it is inherently difficult to directly measure stream weights. Simple examples of this situation include stream separators (a classifier operating on a particle flow) and stream mixers (the mixing of new feed and circulating load in a ball mill circuit). Often in these types of operations, it is possible to sample the streams involved to get approximate component analyses (e.g. size distributions of solid streams, chemical composition of chemical streams). In this paper various formulae are developed which can be used to estimate stream flow rates or weight ratios given information on the stream components. The type and level of experimental error present in the stream component analyses does have an important bearing on the numerical values (and reliability) of the weight ratios calculated by the various formulae. A simple but theoretically sound method is shown for selecting appropriate estimation formulae for any given engineering operation. The derived formulae are applied to sets of experimental classification data for illustration purposes.

Jan 1, 1979

By L. W. Saperstein

One of the most critical skills developed by underground coal miners is the ability to interpret natural warning signals in terms of impending roof failure. A miner receives a variety of signals which can be called warning and which can be classed broadly by sense: aural, visual, and tactile. This paper concentrates on those signals which are airborne and audible. These signals are creaks, cracks, pops, groans, snaps, booms, tears, rips, and other assorted pulses which emanate from the roof strata, coal pillars, and artificial support in response to the stresses induced by the mine opening. These pulses are sometimes referred to as "talk". Although it is clear that miners rely on roof talk to assess the roof's stability, it is not clear of what roof talk is composed. It has been described in a variety of figurative ways, but has not been scientifically characterized. As will be shown shortly, the purpose of this research is very specific. The ramifications, however, are very broad, and are, indeed, still being followed.

Jan 1, 1974

By D. Malhotra

The number of variables which can effect flotation of molybdenite is very large. This paper discusses the effect of two operating variables, namely, the degree of aeration and agitation, on the grade and recovery of molybdenite. A series of factorially designed flotation tests were carried out in a "Leeds Automatic Laboratory Flotation Cell." The analysis of flotation results indicate that molybdenite can be characterized into fast-floating and slow-floating components. The rates of fast-floating components, which do not create a problem in flotation, could be varied by changing agitation of airflow rates. However, the rate of slow-floating components was stable and was only a function of residence time in the float machine. The degree of aeration has a significant effect on the grade of MoS2 with only a slight effect on the recovery of MoS2. The degree of agitation has a slight effect on the grade, but does not effect the recovery of molybdenite. The implications of the results on the design of flotation cells and control and optimization of the existing circuits is subsequently discussed.

Jan 1, 1977

By John A. Wolfe

Applications of mathematical statistics to the field of exploration are still relatively new. There are two primary reasons why little has been published in this field. First, if one discovers an effective technique for exploration, he does not like to disclose it. Second, the geologist needs to work closely with a mathematical statistician, and the communications barrier between the disciplines is formidable. The authors of this paper, one a geologist and the other a statistician, were interested in the economic benefit which appeared to be possible in the interdisciplinary area which they have called "geostatistics." An actual example has been selected to illustrate this benefit.

Jan 1, 1962

By R. D. Schmidt

An in situ leaching geochemical simulator consisting of flow, mass transport, and graphics support programs has been developed. Two dimensional flow in heterogeneous porous media is modeled using a semi-analytic boundary integral technique. This method involves mapping streamlines to straight line segments in the complex potential plane. Leachant concentration and mineral values are modeled in this plane using the (one dimensional) potential coordinates. A fully implicit finite difference scheme is used to solve the resulting coupled system of four concentration equations. Graphical representations of streamline patterns, concentration histories, profiles and recovery curves are generated. An application of the model to uranium leaching in a heterogeneous aquifer and ore zone setting is presented.

Jan 1, 1985