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By Aldo F. Barsotti

The production and consumption of industrial minerals in the United States traditionally have played important roles in mining and in the supply of the bulk of basic raw materials to the economy. This diverse group of minerals extracted and consumed by a variety of industries accounts, on a weight and volume basis, for most mineral-based products consumed in our economy. Industrial minerals form the bulk of the basic raw-materials feedstock for most of the construction, agricultural, and inorganic-chemical-manufacturing sectors, and a good portion of the transportation, manufacturing, organic chemical, and service sectors of the U.S. economy. In this presentation, I discuss current estimates of the amount and value of industrial minerals mined compared with all mining in 1997. I then present a summary of 1997 production of industrial minerals by several end-use industries. This is followed by a historical perspective of the consumption of industrial minerals as a subset of all basic materials, with special emphasis on the aggregates industry. The presentation concludes with a look at the geographic distribution of industrial mineral operations in the United States and some thoughts about the future.

Jan 1, 1999

The design of solvent extraction plants has been generally based on the assumption of steady operating conditions in both the settler and the mixer units. However, recent experience in both large and small plants has shown this not to be the case. Mixer transients include start up aqueous locking and partial phase separation in secondary mixers, which both lead to reduced plant capacity or overflow of upstream mixers. Analysis of the hydraulic pressure profiles has generated new design methods to eliminate the effects of the partial or complete phase separation. Changes to the method of specification and selection of primary and secondary mixers have been made to eliminate the onset of partial separation during operation. The observation of settler operation has shown that it is also a dynamic process, even under "steady-state" conditions. Four transient phenomena have been identified that lead to internal circulating flows, poor disengagement of fine secondary haze and erratic and high entrainment levels in the discharges. A, first approximation analysis has shown that there are significant pressure differentials within settlers, and these change along the length and with the phase separation rates. A technique to control the effects of these transients was developed that allows plant performance to be improved beyond "standard" expectations. The design and selection of the settler internals is described. Key words: Solvent extraction, Mixer-settlers, Phase separation, Entrainment, Mixer transients

Jan 1, 2003

By Alain Broussaud, Guy Fourniguet, Jacques Franck, Pierre Conil

Steady-state simulation is now in current use to assist mineral processing plant design and optimization. However, the reliability of results generated by simulators has not until now been seriously investigated. A simulator supervision algorithm was designed and programmed to study both the influence of the reliability of experimental data on the accuracy of unit operation model calibration, and the influence of unit operation model accuracy on the results of direct plant simulations. An application to a grinding flotation plant is described and discussed. The approach may open the way to the quantitative analysis of the risks taken in mineral processing projects, which would be similar to the application of geostatistics to mining projects.

Jan 1, 1990

By K. Fotoohi

This paper presents a basic, and yet practical, three-dimensional finite element model that was developed by the authors for stress/stability analysis of mine structures. While the code is linear elastic at this stage, it has some practical features that make it an attractive tool for mine design. Such features include: simulation of mine backfill support, mining induced strain energy calculation, powerful out-of-core frontal solver and failure analysis by Mohr-Coulomb or Hoek-Brown failure criteria. Model development criteria are discussed, and the potential application of the model to mining is demonstrated by design examples.

Jan 1, 1998

By K. V. K. Prasad

Stochastic simulation has been routinely used for performing risk and sensitivity analyses in a variety of fields. The commonly used means of generating the simulations has been the Monte Carlo approach, which usually employs a Simple Random Sampling (SRS) scheme of the variable distributions. This method is prone to sample clustering and requires a large number of samples to represent the distribution faithfully. This can become problematic for simulating complex processes where it is impossible to run an arbitrarily large number of replicate simulations. The Latin Hypercube Sampling (LHS) method uses a stratified sampling approach that assures representation of the input distributions for any given number of samples. In this paper the LHS and SRS approaches are compared, using a petroleum resource estimation example.

Jan 1, 1994

By Waldo Valderrama, Luis Magne, Paola Grandela

The effect of liner shape on power consumption was studied in a small laboratory mill under various operating conditions. It was found that the angle subtended between the lifter front face and the face in contact with the mill case has the most significant influence. The increasing height of lifter reduced power consumption, whereas the lifter spacing did not show any influence. The effect of height is less relevant at lower front angles. Highest power consumption is achieved with a 45" front angle. A comparison of cylinders and balls under identical conditions gives higher power consumption for ball charges. The data does suggest that, for maximum power draw, slip in the outer layers of the charge and the early recirculation of energy to the mill case should be avoided. Both factors prevent an efficient energy transfer to the mill charge.

Jan 1, 1995

By John O. Marsden

Technology development has played a crucial role in the minerals industry throughout history. The development of new technology allows mankind to produce metals and minerals at progressively lower cost of production in real terms, and therefore at progressively lower prices, improving their availability, accessibility and utilization worldwide. However, the developers of such technology are not guaranteed to reap the benefits from this effort: There is an expectation that technology developers will gain an advantage over their competitors. Is this a short-term benefit that results from a temporary cost or efficiency improvement, or is it a sustainable longer term "edge" that prevails even after metal or mineral price has been eroded by the implementation of a major step change technology? This issue is examined by reference to several case study examples in the copper industry. BACKGROUND The development and adoption of new technology has played a crucial role in the commodity minerals industry throughout history. As new, cost-efficient technologies are commercialized, the cost of production decreases, and this enables lower grade ore to be processed profitably. This in turn increases the availability and supply of the metal or mineral of interest, and ultimately (in a free market environment where the supply- demand balance determines price) inevitably decreases the metal or mineral price. This leads to the question: Why should mining companies invest in (new) technology development if the result is a decrease in the product price? The answer is to achieve competitive advantage, where the application of new technology enables one or more

Jan 1, 2004

By H. Walqui, A. Buendía

The Toquepala concentrator expansion project incremented the capacity of the existing concentrator by 15,000 Metric tons per day (t/d), from 45,000 to 60,000 t/d. The plant is located in southern Peru,1,200 km southeast of Lima. The implementation plan for the expansion project was based upon an engineering and procurement contract, and a construction contract. The overall Project Management was by Southern Peru Copper Corporation (SPCC). The expansion followed a very aggressive schedule that considered a construction period of only ten months, with minimum interference to the existing facilities. Major equipment was purchased during basic engineering. This paper details the design, construction, and commissioning of the 6.4 m diameter by 10.2 m long ball mill, and the performance of the milling circuit during the first two months of operation.

Jan 1, 2003

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 D. M. Smith, M. J. Meulendyke, P. J. Moroz

An extensive program of marked ball wear testing (MBWT), laboratory corrosion studies, and worn ball surface analyses has been used to gain insight about the role of corrosion in the overall wear process. In some environments, localized corrosion is observed; the actual wear mechanisms in such cases are pitting/spalling and abrasion. Factors affecting the occurrence of pitting include the abrasiveness of the ore, corrosivity of the slurry, corrosion resistance of the media, and galvanic coupling effects. Elimination of pitting substantially improves overall wear resistance. When pitting is not observed, the contributions of general corrosion are significantly less.

Jan 1, 1988

By Alan A. Campoli, Michael D. Zuber, Frank E. McCall, Gerald L. Finfinger

Injecting water under pressure to wet the coalbed in advance of mining reduces mining-generated respirable dust. Owing to economic and geological barriers, water infusion for longwall dust control in the United States is currently limited to the Pocahontas No. 3 Coalbed in Virginia. Water is pumped into the coalbed through underground boreholes drilled horizontally from the headgate toward the tailgate side of retreat longwall panels. This paper theorizes that the barriers to widespread utilization of water infusion for longwall dust control could be overcome by long-duration, low-pressure water infusion through vertical gob gas boreholes. Currently, 43% of the 72 longwall mines in the United States employ vertical gob gas boreholes. Computer coalbed reservoir simulation suggests that one vertical surface borehole could infuse the same longwall panel area as four horizontal boreholes in the current water infusion system for longwall dust control in the Pocahontas No. 3 Coalbed.

Jan 1, 1995

By Katsunori Okaya, Toshio Inoue

Application of the discrete element method incorporating the simple kinetic model of the ball-to-ball and ball-to-wall interactions enables us to visualize the details of the grinding actions prevailing in the ball mills. We have developed a computer program to represent a generic mill model with which we can simulate tumbling mills, vibration mills, centrifugal mills and planetary mills. While the program can be used for various purposes including design of new equipment, one obvious application of it is the analysis of the conventional tumbling ball mills for better understanding and improvement. The purpose of this paper is to present a model and to observe its behavior in particular attention to the spatial distribution of the energy dissipation as well as the energy spectrum and their dependence on the major parameters such as mill speed, ball filling, liner configuration, slurry viscosity and the hardness of the ore.

Jan 1, 1995

By Mark G. Aylmore, Eric J. Grimsey

Anenopyrite, both pure and in some cases associated with pyrite, was laboratory roasted either isothermally or at a constant heating rate, at temperatures mainly between 723 and 923 K and under environments of air, sulfur dioxide, oxygen and argon, as well as S02/02/H20/N2 mixtures. The mineralogy, arsenic contents and in some cases surface areas of the calcines were evaluated so as to provide an enhanced understanding particularly of the conditions under which the important transformations to pyrrhotite and magnetite occur. A thermodynamic analysis is also undertaken to rationalize the observations and provide some guidance for the operation of commercial roasters.

Jan 1, 1990

By G. L. Finfinger, F. E. McCall, A. A. Campoli, M. D. Zuber

Injecting pressurized water into a coalbed prior to mining reduces mining-generated respirable dust. Because of economic and geological barriers, water infusion for longwall dust control in the United States is now limited to the Pocahontas No. 3 Coalbed in Virginia. Water is pumped into the coalbed through underground boreholes that are drilled horizontally from the headgate toward the tailgate side of retreat longwall panels. This paper theorizes that the barriers to widespread utilization of water infusion for longwall dust control could be overcome by long-duration, low-pressure water infusion through vertical gob-gas boreholes. Currently, 43% of the 72 longwall mines in the United States employ vertical gob-gas boreholes. Computer coalbed-reservoir simulation suggests that one vertical surface borehole could infuse the same longwall panel area as four horizontal boreholes in the current water-infusion system for longwall dust control in the Pocahontas No. 3 Coalbed.

Jan 1, 1997

By Paul J. A. Lever

The mine environment is dynamic and operating conditions change continually and are difficult to predict. New equipment, variable geological conditions, modified layouts, and different equipment operators make monitoring and control system difficult to apply without continual software maintenance. The paper reports on algorithms that were developed, encoded with Knowledge Craft Tools, and tested on underground coal mine data to adapt to the dynamic environment. The system receives data from sensors in near real time and then identifies patterns in the data. Using a set of mode features the data is automatically checked to determine the present operating mode. When the operating mode changes from the previous shifts, the system automatically learns the new mode characteristics and uses that mode context for further data analysis. The concepts presented in this paper are applicable to a wide variety of mining scenarios, not just underground coal mining.

Jan 1, 1992

By R. N. Chakravorty

It is well established that coal can react with oxygen in air at ambient temperature and as a result heat is produced. If the heat is not fully dissipated the temperature of the coal mass will increase, thereby enhancing the rate of oxidation with a greater production of heat. If this phenomena continues, the coal mass can ignite under favourable heat accumulation conditions. A number of mine fires are caused each year due to this phenomena, commonly known as spontaneous combustion. The early detection of spontaneous combustion is of prime importance to mining engineers since any fire which could be detected at an early stage may save the mine from considerable damage and subsequent loss of production. Obviously, there is no single general criteria by which one can assess whether the under- ground mining of a coal seam will result in liability to spontaneous combustion. This has made it imperative to develop systems for the early detection of heating and to follow its development. In recent years considerable advances have been made in the design and development of methods for the early detection of spontaneous combustion. The Mining Research Laboratories (CANMET) is presently investigating the problem of spontaneous combustion in coal mines with Kaiser Resources Ltd. at their hydraulic mine at Sparwood, B.C. on a co-operative basis, and some of the work was described earlier in the Canadian Institute of Mining & Metallurgy Bulletin (1,Z). This paper summarizes and updates the work done by CANMET on the detection of spontaneous combustion in coal mines.

Jan 1, 1980

By Rudolf E. Greuer, Xintan Chang

Mine fires have always been of great concern to mining engineers and their behavior has been studied for a long time. Although an abundance of observations exist, no satisfactory mathematical model for their interpretation and extrapolation has become known. The paper presented here tries to close this gap, making use of the laws of chemical kinetics, energy and momentum conservation. To overcome the mathematical difficulties, the fire zone is axially divided into segments and radially into sections, each one with an extension of only a few inches. Conditions in segments and sections are updated in time intervals of one second or less. To solve the large number of resulting equations, a numerical solution is performed. The model has so far been tried on timber fires. It confirms experimental observations on the ignition phases and equilibria of these fires.

Jan 1, 1987

By A. Bayer, T. Klopfer

"As a leading global strategy consultancy, Roland Berger Strategy Consultants firmly believe that the issue of sustainability is at the core of every business activity. Thus, strategies to enhance corporate sustainability (CS) are an essential cornerstone in the consultancy's approach to develop and implement new strategic concepts for the clients. In this paper, the authors conclude that innovation is the only solution possible to guarantee growth and welfare gains while achieving sustainable development. More efficient and effective ways are necessary to enable technical and social breakthroughs. To illustrate Roland Berger Strategy Consultants's vision on CS, four selected cases from the basic resources, energy and utilities sectors are presented. They demonstrate that the implementation of a CS strategy does not only refer to CEO spheres and are by no means just a moral justification for current business practices. Rather they show that the decision to opt for these new ways also opens up multiple opportunities."

Jan 1, 2005

By G. R. Rao, K. A. Natarajan, P. Devasia

The role of growth conditions and adhesion of Thiobacillus ferrooxidans on the leaching of chalcopyrite was investigated. Thiobacillus ferrooxidans grown on sulfur, thiosulfate and ferrous ion substrates was used in this comparative study. Growth on sulfur, a solid substrate, requires bacterial adhesion unlike that required in the presence of soluble thiosulfate and ferrous ion in a mineral-salts medium. Solid substrate-grown cells showed higher rates of leaching than those grown in liquid media. An initial lag period noticed during leaching by solution-grown cells was absent when solid substrate-grown cells were used. Such a behavior is attributed to the presence of an inducible proteinaceous cell-surface appendage on the sulfur-grown cells. This appendage aids in bacterial adhesion onto the mineral surfaces. Such an appendage is absent in solution-grown cells, as substantiated by electrophoretic measurements. The importance of bacterial adhesion and the direct mechanism in leaching by Thiobacillus ferrooxidans are demonstrated.

Jan 1, 1997

By W. K. Tolley, D. G. Kotlyar

Silver is an economically important component of many complex, massive sulfide ores. The beneficiation of this type of ore is now almost entirely accomplished by flotation. Silver recovery is often low, and little is known about the flotation behavior of the silver-bearing minerals. Floatability studies were conducted using silver-bearing tetrahedrite and lead-zinc ore. The effects of xanthate-collector concentration, conditioning time, potentiostatic control of the mineral potential and control of the pH on mineral floatability were evaluated. The floatability of the silver-bearing minerals was shown to depend on collector concentration and mineral potential. The effect of controlling the mineral potential during the flotation process is discussed.

Jan 1, 1996