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By C. G. Janes, N. Finkelstein, L. M. Jr. Johnson

In May, 1966, the General Services Administration (GSA) announced a program to encourage additional domestic production of copper in the interest of national security. Upon learning of the copper production expansion program, Duval Corporation entered into negotiations with GSA for development of the Sierrita copper-molybdenum property under the program. Agreements between the GSA and Duval Sierrita Corporation, a wholly owned subsidiary of Duval Corporation, were concluded in 1967, with the Sierrita Concentrator beginning operation in 1970 at a designed capacity of 72,000 STPD. Subsequent additions and modifications have expanded capacity to 90,000 STPD. This property, located approximately 20 miles south of Tucson, Arizona, represents an investment including working capital of about $200 million. These funds were provided from an $83 million loan from GSA, repayable in copper valued at 38 cents per pound, $48.75 million of bank loans subject to U. S. Government V- loan guarantees, and Company capital contributions. Current general operating statistics for the concentrator are listed below: Ore Grade 0.32% Cu., 0.030% Mo. Daily Tons Milled 90,000 STPD Annual Copper Production 94,600 Tons Annual Molybdenum Production 15,000,000 Lbs. Annual Silver Production 1,135,000 Ounces

Jan 1, 1976

By Edwin H. Bentzen, Immo H. Redeker

Important industrial minerals are separated and concentrated by froth flotation by industry today. The following descriptions are presented as an overview of the methods employed to separate and recover a few of these industrial minerals. The minerals described in this section of the book are not, by any means, the only important minerals treated by froth flotation. Other minerals, such as calcite, kaolin, wollastonite, rare earths and vermiculite were not included, primarily due to the confidential nature of the information held by the Minerals Research Laboratory and the Colorado School of Mines Research Institute. Flotation of nonmetallic minerals is sometimes viewed as alchemy. However, the art is, in reality, based on sound chemistry, experience and a little luck in the treatment of new ores. In the flotation of nonmetallic minerals, as opposed to base metal sulfides, highly specific treatment conditions are required to accomplish separations. The presentation of the treatment of each of the minerals described was outlined as follows: DEPOSITS PROCESSING SPECIFICATIONS FLOWSHEETS (in some cases) A presentation of the factors, often critical, which must be carefully investigated to accomplish successful flotation of nonmetallic minerals is presented in the section on Sulfonate Collectors, elsewhere in this volume.

Jan 1, 1986

By K. G. Colman

Introduction This text is intended to provide the operator and turnkey contractor with the basic data for sizing vibrating screens to be used in ore crushing plants. The basic capacities, modifying factors, etc.. used in the area requirement calculations were developed empirically and modified to their present values based upon years of practical applications. It must be pointed out that screening is much more of an art than an exact science; however. the information presented here should provide for reasonably accurate screen sizing when applied to many metallic ores. Types of Screens There are two types of screens which can be used for strictly sizing applications. These are two- and four-bearing screens; both are inclined circle-throw machines. Two-Bearing Screens The motion of a two-bearing screen is generated by unbalanced weights attached to the vibrator shaft. The body of the machine is usually supported by steel coil springs (see Fig. 8). The main advantage

Jan 1, 1985

By Hans von Michaelis

Gold metallurgy has advanced remarkably over the last decade. Even more significant progress will be made over the next five years, particularly in the application of advanced comminution techniques and control, preconcentration (flotation, ore sorting and coal gold agglomeration), enhancement of cyanide leaching technology, non- cyanide leaching, treatment of refractory ores and concentrates, and improved recovery systems. Carbon adsorption processes have become standard practice for ores with relatively high gold/silver ratios, but ion exchange potentially offers distinct advantages and has recently been demonstrated to perform better in at least one application. Even in the established zinc precipitation and CIP processes several important practical improvements are emerging as experience is gained at the ever increasing number of operating plants. Improved process control and reduction of reagent consumption costs are two important goals of industry at this time.

Jan 1, 1989

By Douglas J. Uhren, Gary W. Gilbert

This paper describes the risk elements associated with difficult glacial geology, including boulders, heavy groundwater inflow, and potential running soils all coupled with a potentially corrosive service environment. The matrix workshop for the 168-inchfinished diameter sanitary sewer interceptor tunnel in Columbus, Ohio is assembled with the Design Team and the Owner’s design, operations, and fiscal staff. Corrosion protection alternatives are compared against cost and non-cost parameters with relative risk and weighting factors assigned. The Owner working in cooperation with the Design Team uses the matrix workshop to se

Jan 1, 2001

By John B. Ackerman, John G. Mansanti

INTRODUCTION Placer Dome's Turquoise Ridge Joint Venture operation is located some 75 km northeast of Winnemucca, a community in north central Nevada. Formerly known as the Getchell Gold Corporation and First Miss Gold, the operation mines refractory ore from the Getchell and Turquoise Ridge gold deposits located on the east flank of the Osgood Mountain Range above the Kelly Creek Basin in the Potosi Mining District. Mining has been ongoing at Getchell since shortly after its discovery in 1934, and was the nation's second leading producer of gold after Homestake in the early 1940s. Over its history the Getchell property has been mined for gold, tungsten, molybdenum and arsenic; mining methods varied from open pit mining to underground mining; processing options included conventional milling, flotation, roasting, heap leaching, and most recently pressure oxidation followed by CIL (carbon-in-leach). As an historical note, the US Bureau of Mines developed the use of carbon for gold recovery at Getchell during the 1940s (Horton 1999). Placer Dome acquired the property in May 1999. The pressure oxidation plant was mothballed in July 1999 and the property was placed on care and maintenance in February 2002 pending further exploration results. The property is currently ramping up to full production status. A joint venture agreement (75% Placer Dome, 25% Newmont) was established with Newmont Mining in 2003 and ore is processed at their nearby Twin Creeks autoclave plant. Mine dewatering is a key element to success. Arsenic is a ubiquitous mineral in many of the mineralized areas of northern Nevada, necessitating treatment of water prior to re-infiltration.

Jan 1, 2005

By H. Wu, V. Izaxon

Intensive ventilation is required during the excavation of a mine opening and the subsequent exploitation of the mineral resources. The exchange of heat between the ventilation air and the rock mass has a major influence on the thermal regime of a mine, especially in the initial segment of the airway. In frozen ground, heat flow into the rock mass from the ventilation air can result in the eventual thawing of the permafrost, which can result in roof-rock instability. This paper presents a mathematical analysis of the dispersion process of ventilation-induced heat by thermosyphons placed on the surface of the mine. The principal uses of thermosyphons in the Arctic are to reduce the ground temperature to prevent potentially unstable permafrost from thawing and to increase the bearing strength of the material. The mathematical model of the physical problem, generally known as "the Stephan problem," takes into account the varying thermo-physical properties of air and the frozen and thawed rock mass, the thermal properties of the freeing fluid in the thermosyphons and the phase change of water. Finite-difference techniques were employed to determine the temperature isotherms around the thermosyphons. It was found that two rows of thermosyphons on a 10- x 10-m grid provide an acceptable design spacing for reducing the ground temperature around the mine airway.

Jan 1, 1997

By D. A. Norrgran, J. N. Orlich

Described is the application of high- intensity magnetic separation throughout the spectrum of industrial minerals. Performed either wet or dry, the separation has application in both the recovery and concentration of value minerals and in removing deleterious mineral constituents. The various types of magnetic separators along with the design and operating parameters relative to separation response are characterized. The characteristics of specific minerals to magnetic collection and the production of high-grade concentrates are described. Laboratory, pilot-scale, and plant studies carried out on a variety of industrial minerals have demonstrated the effectiveness of magnetic separation as either a primary or a secondary unit operation to achieve product quality.

Jan 1, 1987

By Dennis C. Drehmel

Because of their relatively low cost, carbonate rocks are desirable in abatement of air pollution by acid gases. Although many processes and types of equipment have been proposed to control or prevent the emission of acid gases, this paper considers only three: dry-limestone injection, wet-limestone scrubbing, and chemically active fluid beds. For the dry-limestone-injection process, surface area-especially from pores in the 0. 2- to 0.3-micron range-is one of the important parameters which will discriminate between less and more reactive carbonate rocks. Marls, chalks, oolitic calcites, and other fine- grained limestones show larger-than-average surface areas and better- than-average removal efficiencies. Inert chemical impurities such as silica detract from reactivity. A dolomite is not necessarily less re- active than a calcite. For the wet-limestone-scrubbing process, dissolution rate of the carbonate rock controls the differences in stone reactivity. In this process the dolomites are less reactive than the calcites. In addition, more than 90 percent of the dolomitic impurity in Fredonia white lime- stone is inert during limestone scrubbing. Dissolution rate is also a function of particle size for large-grained carbonate rocks. Fine grinding of such rocks will increase the dissolution rate to that of a fine-grained rock. Hence the requirement of high dissolution rates may be met by some grinding of fine-grained material (e. g., marl, chalk, or other limestone) or by fine grinding of coarser grained material. For chemically active fluid beds, chalks have the best capacity to absorb both SO2 and H2S. However, most chalks are probably unsuitable for fluid beds because of high attrition rates. Because dolomites are generally more reactive than calcites with both SO2 and H2S, a dolomite would be the feed material of choice for a chemically active fluid bed.

Jan 1, 1974

By A. Pinches, R. Winby, P. J. van Staden, M. K. Rhodes, P. C. Miller

This paper is a progress report on the commercialization of using bioleaching for base-metal concentrates. The paper focuses on bioleach processes for recovering copper from chalcopyrite and nickel/cobalt from pentlandite/pyrrhotite. Data is discussed from pilot-plant trials in which an overall recovery >95% was obtained for the bioleaching of copper from chalcopyrite. The pilot plant was operated in closed circuit with solvent extraction and electrowinning circuits for final metal recovery. For the bioleaching of nickel and cobalt from pentlandite/pyrrhotite, an overall recovery of 97% was achieved. Precipitation routines were used to produce a final nickel/cobalt product. The pilot plants were capable of treating a few kilograms of concentrate per day. Prominent features in the design of a 1-t/day (1.1-stpd) copper-bioleach demonstration plant for the treatment of chalcopyrite concentrate are discussed. The plant, which is now under design, will be constructed and operated based on the results obtained from the laboratory pilot-plant campaigns. Issues of scale-up for the demonstration plant, together with integration into upstream and downstream processing, are also addressed. Independently derived capital and operating costs are presented for a possible commercial plant. These cost studies indicate the principle economic issues in considering the application of bioleaching to the extraction of base metals. The benefits of bioleaching complex concentrates that are not amenable to physical beneficiation and economic treatment by conventional smelting are highlighted. Issues, such as the environmental aspects, that illustrate the benefits of bioleach technology are given.

Jan 1, 2000

A Mineração da Trindade (Samitri) is a major Brazilian iron ore producer. Founded in 1939, privately owned Samitri operates six mines with a total production capacity of 14.5 Mt/a (16 million stpy). The mines are located in southeastern Brazil in the state of Minas Gerais. They are operating in the iron ore quadrangle, Brazil's primary iron ore-producing region. In addition to iron ore production, Samitri has the capability to produce 350 kt/a (386,000 stpy) of ferruginous manganese ore from two mines, also located in the iron ore quadrangle. Historically, about 70% of Samitri's production of lump ore, sinter feed and pellet feed is exported. Destinations include Belgium, Luxembourg, France, Germany, Trinidad and Tobago, China, Turkey and the United States. Alegria Mine In September 1989, Samitri started a new processing plant to treat itabirite, a low-grade iron ore. The goal of the plant was to produce sinter feed (coarse fraction) and pellet feed (fine fraction). Primary separation of sinter feed from pellet feed was accomplished with conventional vibrating screens making a 0.4-mm (40-mesh) cut. The screen oversize was stockpiled as sinter feed. The undersize was deslimed with hydrocyclones and upgraded by conventional froth flotation. Resulting pellet feed grades ranged from 3% to 3.5% Si02. A change in pellet feed requirements by Samarco Mineração SA, a Samitri subsidiary, called for Si02 levels below 1 % and increased production levels. Moreover, market demands called for a change in sinter feed size distributions. Unfortunately, lower pellet feed Si02 levels could not be achieved with the existing process. This was because of the presence of 35% +0.15 mm (+100 mesh) in flotation feed. Flowsheet development. Laboratory and pilot-plant studies conducted at Samitri's research facility found that to achieve lower Si02 levels, the +0.15 mm (+100 mesh) in flotation feed must be kept below 5% to 10%.

Jan 1, 1997

By Kaye P. Strong, Desmond M. Levins, Anthony G. Fane

1. INTRODUCTION The safe disposal of tailings is the most important environmental question facing the uranium mining industry today. This is because tailings present a major long term radiological hazard as they contain about 71% of the radioactivity originally in the ore. The magnitude of the problem can be appreciated by considering the quantity of tailings involved. For example, projections of milling programs in Australia indicate that there will be 100 million tonnes of tailings produced by the year 2000 (Levins 1980). The United States currently has in excess of 100 million tonnes and by the year 2000 will have between 900 and 1700 million tonnes (Landa 1980). Present options for tailings rehabilitation include leaving them above ground, returning them to the mine or placing them in specially excavated pits. In any event, the tailings will be covered with earth and revegetation attempted. This will remove the problems of airborne radioactive dust and water erosion of the tailings, at least in the short term, but diffusion of radon-222* from the tailings may still occur. The Atomic Energy Control Board of Canada (1981) has proposed a maximum allowable radon flux from rehabilitated tailings of 0.074-0.37 Bq m -2s-1(2-10 pCi M-2 s-1); the exact level is to be determined "after discussion with other regulatory agencies and the industry". The United States Nuclear Regulatory Commission (USNRC 1980) has been more restrictive in recommending a maximum flux of 0.074 Bq m -2s-1 (2 pCi m-2s-1). As a guideline they also suggested a minimum depth of covering material of 3 m to achieve this surface flux for tailings typically found in the western milling regions of the United States. The design of rehabilitation schemes is aided by a knowledge of radon transport through tailings piles. In this paper we present the results of a theoretical analysis and experimental study of radon diffusion through selected Australian tailings and cover material. The minimum cover criteria of 3 m is reexamined in the light of these findings. [ ]

Jan 1, 1981

By R. H. T. Garnett

Recovery performance may be measured in absolute terms or in relative ones that relate the actual mining outcome to what was expected. Consideration is possible in terms of the control exercised by the operator. The eventual mineral output is the only figure known with complete certainty. The paradox is that, while performance is judged against the sampling, the reverse also applies. The R/Efactor and its four component factors are the best overall measures of performance. The choice of equipment for sampling and mining is very important. The sampling process may introduce errors and the sample density may lead to poor mining block selection. The resulting recovery performance is most visible on a regression curve. Changes in the cutoff grade must also be taken into account to avoid unrealistic production targets. Estimation methods incorporating different mathematical assumptions and techniques may cause over-or underestimation of the grade and volume. If the selective ability of the mining equipment does not match the size of the reserve blocks, the performance will be compromised. The treatment plant efficiency, the throughput rate and the degree of bedrock clean-up also affect performance. The maximization of throughput does not yield the optimum results. Marine conditions, which are outside the operator's control, affect not only operational availability but also performance. Examples are provided from actual operations for various commodities, showing the relative magnitude of the different effects upon performance.

Jan 1, 1999

By R. Fedel-Moen, R. W. L. Kimber, B. D. Williams, S. R. Ragusa

The use o f cyanide to extract gold from ores is widespread. In the process of extracting gold, cyanide may form metal cyanide complexes with a variety of other metals present in the ore. This study was carried out to investigate the biodegradation of the Cu(I)-cyanide complex and tetracyanonickelate under varying pH and nutrient additions. Detailed studies using shake flask cultures and bioreactors showed that naturally occurring bacteria residing on gold-leach-pad ore uti¬lized the Cu(I)-cyanide complex (CuCN) and tetracyano-nickelate, Na2(NiCN4), as carbon and/or nitrogen sources. Ammonium-nitrogen (NH4+-N) and/or cyanate (CNO-) accumulated in solution as the metal cyanide complexes were degraded. The accumulation of cyanate as a product is a concern due to its toxicity. Degradation rates were increased if a growth substrate (peptone, 0.1%) was added to the medium or if bioreactors were primed with peptone before addition of the metal-cyanide complex. Tetracyanonickelate was degraded at pH 8 without added peptone, but it was not degraded at pH 10. The addition of peptone was required for degradation of the Cu(I)-cyanide complex at pH 8 and pH 10. At pH 8, the addition of peptone resulted in the accumulation of cyanate, whereas, at pH 10, cyanate was not detected in the cultures. Biodegradation of metal-cyanide complexes was faster (approximately 1.5 to ten times faster) in bioreactors than in shake flask cultures. The addition of peptone was not required for degradation of metal-cyanide complexes in bioreactors. However, priming the bioreaetor with peptone resulted in higher metal-cyanide degradation rates over multiple cycles.

Jan 1, 2000

By Y. Topkaya, R. E. Johnson, D. Buttinelli, B. R. Palmer, A. Geveci, L. Stoppa, C. Lupi, F. Pochetti

Representative samples of a composite mixture of three typical Cu/Zn complex sulphide ores, namely Black-, Yellow- and Altered-ore, from the Cayeli deposit in Turkey, were used for leaching tests in 2.2 M FeCl3, or 1 M CuC12-2 M NaCl solution in the temperature range from 313 K to 363 K (40O to 90O C), with and without the presence of an organic solvent for elemental sulphur, such as CCl4. The leaching rates of copper and zinc were quite high, as expected, in FeCl3 solution and complete recovery of both metals was obtained at the highest temperature when the solvent was present. However in CuC1, solution, extraction yields of the order of 95% only for Cu and Zn were achieved and the positive effect of the solvent was not clearly shown. The kinetics curves of Cu leaching by FeCl3 indicated a model of reaction rate depending on the particle surface, as in a chemically controlled reaction, in tests with the presence of CCl4. Without the solvent, or in CuCl2 media, the model of the diffusion controlled reaction seemed to prevail. Values of apparent activation energy, in both of the leaching processes, were determined and compared with those reported in literature.

Jan 1, 1993

By Kenneth J. Miller

Froth flotation is one of the most actively pursued research and development areas in the coal preparation industry today. Many new types of flotation machines and processes are being developed and compared in an effort to handle the increased quantity of coal fines produced by finer grinding for greater liberation of ash- forming and sulfur-bearing mineral matter. Of the many new machines and processes under development for deep cleaning ultrafine coals, it is quite likely that many will not reach industrial use in the near future; in fact, it is quite likely that some never will. Therefore, it is the objective of this paper to select and describe a few of the new flotation machines and processes that appear to have reached a level of development that would suggest their eventual use on an industrial scale. It is probable, and doubtless will be argued, that some of the selections given in this paper should not have been included, while others should have, but the reader must understand that the author is restricted by the information available. And because most of the information available comes from those who are developing the equipment and/ or processes, it is often confusing and conflicting. Thus with a somewhat moderated plan, the author proposes to point out some in- congruities in the literature in the hope that such information might promote more independent study and perhaps explain the abundant promise versus the scant use of the new equipment and processes described.

Jan 1, 1988

By Bruno C. Boik

INTRODUCTION Cost Management is the evaluation and control of project scope, budgets, and costs with the objective to minimize costs and maximize the benefits to be derived from the use of project resources in conformance with Criteria stipulated or approved by the Owner. In order of importance, Cost Management is one of the most prominent Project Management functions because of its impact on the financial success of the venture. Cost Control and Cost Accounting are essential parts of Cost Management. The principal objectives of Cost Control are to monitor project commitments and expenditures, and measure performance for the detection of variances from acceptable standards and from control budgets so that timely action can be initiated to minimize costs. Cost Control is evaluation of current costs and projection of future costs, rather than the reporting of actual costs. Cost Control is not Cost Accounting. The primary objectives of Cost Accounting are the determination, classification, analysis and reporting in useful detail of actual costs. Following are some considerations on Cost Management and Cost Control as practiced by Owners and Contractors of industrial projects, Mining and Metallurgical projects in particular. COST MANAGEMENT Functions Conforming with the requirements of Owner's Criteria, the principal Cost Management functions are to • evaluate estimates of project costs and establish budgets for a scope of work and schedule; conversely, evaluate the scope of work that can be executed most effectively within a budget and schedule. • promote investigations and comparative evaluations of alternate designs and plans to find the most cost effective way to execute a project and minimize its operating costs. • based on Cost Control and Cost Accounting input, evaluate and initiate appropriate actions to correct deviations from approved budgets. assess project economics, the effect of changes on project economics and, if necessary, revise Project Criteria to modify their impact on costs.

Jan 1, 1986

By M. J. Virnig, Marc Le Vier, Rong Yu Wan, Jan D. Miller

Although most gold production from primary resources is achieved by cyanidation, many research activities have focused on alternative processes using noncyanide lixiviants. Such research has been prompted by environmental concerns and problems associated with the processing of refractory gold ores. Numerous research projects have been conducted to search for a noncyanide hydrometallurgical process for gold extraction. In this paper, a technical review of gold recovery from noncyanide solutions is presented, and new results are reported. Gold recovery techniques that are considered include activated carbon adsorption, cementation, solvent extraction, ion exchange, and reduction-precipitation.

Jan 1, 1993

By Kathleen Y. Knoebel

This paper describes a graphical mini computer system called MPASS 2 (Mine Performance Analysis/Simulation) which has been designed to conduct analysis of underground room-and-pillar mining operations using both conventional and continuous mining methods. Dynamic, graphic displays of mine face machine activities are presented on the CRT screen to provide extensive visibility into underground mining activities. MPASS 2 consists of: an interactive inputting system that graphically creates a room-and-pillar mine and describes the mine when production is initiated; a time-step simulator that produces statistical summaries of shift activities and uses CRT screen graphics for accelerated-time display of machine activities and delays; a statistical analysis subsystem for analyzing mine performance data; an industrial engineering system that permits users to enter actual machine activity statistics and replay mine operations on the CRT screen; and a data management system to store historical performance information on mine characteristics and operations. MPASS 2 operates on a Hewlett-Packard 9845B mini computer with 450 K bytes of extended memory, and is written in H-P BASIC. It has been installed at Freeman-United Coal Mining Company in West Frankfort, Illinois and at the U. S. Department of Energy Pittsburgh Mining Technology Center. Applications include production system simulation, industrial engineering analysis, production scheduling, new equipment evaluations, and training.

Jan 1, 1982

By J de Cuyper, V. M. Lovell, W. Freyberger

The recovery of apatite from the phoscorite ores occurring in the Transvaal, Republic of South Africa, involves a flotation process that is particularly difficult to characterize from a fundamental point of view. However, the reagents used, (tall oil fatty acid, nonylphenyltetraglycol ether, sodium silicate, and sodium hydroxide) can successfully bring about a separation of apatite from dolomitic calcite, which is the most troublesome gangue component. Recently, it has been demonstrated with some flotation feeds that the addition of certain polysaccharides can improve the flotation significantly. It has been shown that the metallurgy obtained is closely linked to the nature of the froth, and this, in turn, is influenced, often dramatically, by the presence or absence of certain of the reagents. The character of the froth depends less on the inherent frothing ability of these reagents than on the presence or absence of fine mineral particles in the froth, and on their surface characteristics and state of aggregation. The polyglycol ether and the polysacchar- ides have been shown to affect these properties, and it is suggested that a major function of these reagents is to modulate the properties of the fine particles in the pulp, thereby changing the character of the froth and giving rise to improved results.

Jan 1, 1976