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By Donald S. Skufca

This chapter focuses attention on major factors pertaining to plant design and general arrangement of equipment. Considered are efficiency of operations, coordination of maintenance and repairs, plant testing of reagents and possible future plant expansions. The design and general arrangement of equipment considers accessibility for maintenance and isolation for repairs, minimum personnel for operations and cleanup, safe working conditions with minimum interruptions to operations. The constant introduction of new reagents requires eventual plant testing and the manner of isolating a “line” or part of the facilities to allow comparisons in the testing of new reagents is discussed. As technology improves and process changes occur, additional equipment or plant expansions are inevitable. Space for these eventualities must be considered while the general arrangement drawings are in the development stages.

Jan 1, 1986

By Regina N. Tempel, Mae S. Gustin, Mark A. Engle

This study characterizes the hydrogeochemistry of groundwaters near opalite-hosted epithermal hot-spring type mercury deposits in the Ivanhoe mining district, Elko County, Nevada. Local groundwaters generally range from Ca-HCO3 to Ca-Mg-Na-SO4 type waters with background mercury concentrations ranging from 0.014 to 0.32 ug/l. Leaching experiments conducted on mineralized rocks, using typical water chemistries to represent local groundwaters, yield total mercury concentrations ranging from 6.3 ug/l to 27.4 ug/l after one year of reaction. Geochemical modeling indicates dissolved mercury is dominated by HgO(,) and that precipitation of quicksilver controls mercury concentrations to an upper limit of 63 ug/l.

Jan 1, 2000

By S. K. Kawatra, M. T. Rusesky, T. C. Eisele, D. X. Zhang

It has been observed in some mineral processing plants that grinding circuit efficiency varies seasonally, such as in some plants which are located in the northern US and Canada and undergo large seasonal temperature changes, with the grinding circuit efficiency different between summer and winter. This indicates that the temperature of grinding circuit slurry has a noticeable effect on grinding performance. The effect has rarely been studied. To this end, an investigation to examine the effect of changing temperature on efficiency and determination of the mechanism responsible has been carried out. Plant investigations and laboratory experiments have been conducted in order to study hydrocyclones. It was demonstrated that when the pressure drop is held constant, the d50(c) size decreased approximately linearly with increasing temperature, while the shape of the reduced efficiency curve remained nearly constant. This effect was determined to be due to changes in slurry viscosity with temperature.

Jan 1, 1990

By R. Houot, C. Leschevin, G. Gillet

In mineral processing, conventional magnetic separators are equipped with traditional magnetic circuits (magnetic iron yoke with copper coils or iron-clad solenoid) that develop magnetic fields of less than 2 T'. For minerals of low magnetic susceptibility, use of these circuits has many disadvantages. Only a separator with a superconducting magnet can contribute to solving the problems and produce a high magnetic field. This paper presents and describes a magnetic separator having a superconducting magnet with integrated closed circuit for helium liquefaction. The system generator and maintenance are simplified by extensive automation realized by a versatile program- mable autocontrol unit. A comparative study if the results on concentration and purification of different raw materials with the new and with conventional separators is described.

Jan 1, 1987

By J. Kemeny, B. Norton, T. W. BoBo

Digital image analysis systems to quantify particle size of crushed materials have successfully been applied in large-scale mining operations throughout the world. Particle size measurement at various crushing and sieving stages, especially in aggregate production, will facilitate the industry’s desire and need to achieve higher levels of process control and automation. This paper will 1) summarize applications of digital image analysis in the industrial minerals industries and introduce the Split-Online technology; 2) detail an actual recent test application of digital image analysis that ultimately lead to the installation of an automatic, non-invasive particle size distribution monitoring system; 3) document how this information is being applied: and 4) summarize the new Split-Online Aggregates Module now available.

Jan 1, 2004

By Roy Eric Lurie

Computer based signal processing techniques for obtaining empirical dynamic models from measured mill circuit data are discussed. This modelling is the first step towards designing a particle size control strategy. Experimental data from a computerized acquisition sys tern is examined and analysed, and a number of model identification procedures are applied. The resulting models are compared and a suitable model is selected, illustrating the benefits of computer tools for control system design.

Jan 1, 1992

By J. C. Stankus, S. Guo, S. S. Peng

In this paper, a model is developed for a resin anchor bolt system in which the smooth bar is modeled by using one-dimensional truss elements, and the resin annulus is modeled by using axisymmetric elements. These two submodels are combined and then incorporated into an existing computer code called Roofbolt. After this development, all of the components in the resin anchor bolt system, including smooth bar, bearing plate and resin annulus, can be correctly modeled.

Jan 1, 1997

By G. Karahalios

Industrial minerals always play an important part in the technological growth of a country. The extraction and trading of industrial minerals continues to expand, but the industry is now subject to stricter environmental guidelines. This paper presents the current status and growth potential of industrial mineral exploitation in the southeastern European region, i.e. Albania, Bosnia-Herzegovina, Bulgaria, Croatia, the Former Yugoslav Republic of Macedonia, Greece, Italy, Serbia and Montenegro, Slovenia and Turkey. Annual production figures per country are presented for 1992-1998. These figures are compared to each other, and, where applicable, they are compared to world production figures. The marketing of industrial minerals to Europe and other regions of the world and the effects of such trade on the local economies are also evaluated when such data are available.

Jan 1, 2000

By A. S. Dremukha

The problems of geological exploration are discussed on the basis of computerized modeling of, complex orebodies, as well as the task of data authenticity evaluation. The theoretical baseof modeling is solving the problem of determining the parametres of orebodies sizes distribution along random intersections by exploratory workings. The relationship is established between univariate distribution moments in the intersections and the moments of the orebodies sizes distribution in three dimentions. It is suggested to use the obtained results for compyter modeling of the orebodies accumulations and for imitation modeling of their exploration. The computer experiments with the models make it possible to establish the optimum parametres of exploration networls.

Jan 1, 1989

By S. Saklar, i. Bayraktar

The effect of the feed size distribution on the kinetic parameters in pyrite flotation was studied. The kinetic parameters of the particular sizes were determined as a function of whether other particle sizes were present. From the data, a relation between the pyrite flotation rate and the particle size distributions was obtained. It was shown that the flotation rate constant (k) is a function of the size modulus (dt) of the Gates-Gaudin-Schuhmann distribution, and its variation may be expressed as k = a • exp(b . d,) for either individual size fractions or composite feed. Parameters a and b are dependent on the particle size distribution of the feed. Specifically, parameter a increases linearly as the distribution becomes coarser. The above relationship was also tested under conditions in which the collector (KAX) dosage was varied from 130 to 278 g/t. It was shown that the established relation was not dependent on the collector dosage.

Jan 1, 2002

By Z. T. Bieniawski, D. A. Newman

The Geomechanics Classijication (RMR System) (Bieniawski, 1979) was modified for entry and roof support design in underground coal mines. Adjustment multipliers were introduced to incorporate the influence of high horizontal stresses and the roof support reinforcement into the existing classification system. Sixty- two case histories of standing and fallen mine roof were collected from two mines in the northern Appalachian coalfield. Twenty-seven engineering and geologic parameters were recorded for each case. A partial correlation analysis was carried out on the cases to establish which parameters have a significant im- pact on the stand-up time of supported coal mine roof. Survival analysis, a statistical technique used in medical research to assess the effect of a drug or treatment on a patient's life expectancy, was conducted together with stepwise multiple regression to derive values for the adjustment multipliers. A practical example is included to illustrate the application of the modified Geomechanics Classification to underground coal mine design.

Jan 1, 1987

By D. C. Wilder

Deformations during heating and cooling of three drifts in granitic rock were influenced by the presence of faults and shear zones. Thermal deformations were significantly larger in sheared and faulted zones than where the rock was jointed. but neither sheared nor faulted. Furthermore. thermal deformations in faulted or sheared rock were not significantly recovered during subsequent cooling thus a permament deformation remained. This inelastic response is in contrast with elastic behavior identified in unfaulted and unsheared rock segments. A companion paper (Butkovich and Patrick, 1986a) indicates that deformations in un- sheared or unfaulted rock were effectively modeled as an elastic response. We conclude that permanent deformations occurred in fractures with crushed minerals and fracture filling or gouge materials. Potential mechanisms for this permanent deformation are asperity re-adjustments during thermal deformations. micro-shearing, asperity crushing and crushing of the secondary fracture filling minerals. Additionally, modulus differences in sheared or faulted rock as compared to more intact rock would result in greater deformations in response to the same thermal loads.

Jan 1, 1986

By B. Cavender

The operating lifetime, or production rate, selected for a mining project is among the most important factors influencing the project's design and ultimate economic success. Incorrectly-determined lifetimes can lead to the erroneous rejection of projects as uneconomic as well as the suboptimal exploitation of producing properties. This paper examines the optimal lifetime calculation using traditional discounted cash flow and recently-proposed option pricing techniques. Using each method, the production rate is determined as that rate at which the project's net present value is maximized.

Jan 1, 1993

By William Petruk

Performance assessments are carried out to monitor operations, to evaluate performance and to identify processing problems. The assessment involves collecting and analyzing representative samples from critical points in a flowsheet and interpreting the data. Sample analysis techniques include chemical analyses, mineralogical investigations, mineralogical analyses, and materials balancing. Chemical analyses provide the lowest cost assessment and should be used liberally, particularly in monitoring a process. Materials balances performed on chemical assays for a suite of samples are used as a first step in evaluating a process. Mineralogical investigations are more expensive than chemical analyses but need to be used only at the beginning of mining and metallurgical operations and as a second step in assessing processing problems. Quantitative mineralogical analyses combined with materials balancing provide the most complete performance assessment, but the procedure is expensive. On the other hand, the assessment has the potential of a large payback when carried out where warranted.

Jan 1, 1991

By M. Scherbakov, W. Shi

Abrasion is an important mode of performance for any element of an engineered product that involves material contact for example, a conveyor belt cover. Abrasion resistance is considered to be one of the leading factors in belt cover design and improvement. Various types of abrasion testing are reviewed by and compared to actual belt applications. A new quantitative screening torsional abrasion test is developed by Goodyear to mimic a dynamic contact between belt cover and differently shaped stones of various weights dropped onto belt at any angle, velocity and height.

Jan 1, 2004

By J. T. Ryan, Griffin. Wayne H.

This paper shows that if a drift has a brattice which is sufficiently leaky, changes in the operating point of the fan depend solely on the volumetric efficiency within the drift. Under this high leakage condition, an increase in the length of the drift causes very little shift in the fan operating point. For less leaky brattices, the operating point depends on both the fan characteristic curve and the volumetric efficiency. It is shown that for the fan curve and drift parameters used in this paper the fan operating point in a drift with a volumetric efficiency of 50% is essentially the same as a drift which has a zero efficiency. In this region of efficiency, an increase of 300% in the length of the drift causes only a 3% increase in fan operating pressure.

Jan 1, 1993

By W. J. Pennstrom, J. R. Arnold

This paper focuses on solution-balance management around heap-leach operations. Experience has shown that increased leach recoveries can be achieved by utilizing various leach-solution recirculation techniques. The most prominent solution-recirculation technique is intermediate leaching. The net effect of intermediate leaching is to increase recovery plant performance by increasing solution concentration tenors, to increase metal recovery by increasing the total leach time and to decrease the overall capital expenditures required for metal-recovery facilities. The adverse effect on the flow of cash from increased metal inventories in the recirculating solutions is offset by increased metal recovery and lower operating costs per unit produced.

Jan 1, 2000

By L. B. Hales

The advent of the process control computer with its capabilities of monitoring, storage, and real-time control has revolutionized control technology in the mineral industry. Initial efforts to introduce the computer into process control began in the early 1960's. However, it wasn't until the last decade with the introduction of integrated circuits and minicomputers that truly successful applications became visible. Computer hardware and real-time operating software have improved to the point that they rarely provide major problems in the implementation of successful control systems. At this time the most prevalent problems and obstacles affecting the successful implementation of a control system are as follows: (1) reliable and representative sampling systems; (2) rugged and reliable process sensors; (3) the availability of well-defined control strategies; (4) the willingness of plant management to provide the continuous support necessary to acquire and/or train appropriate personnel in the operation and maintenance of advanced control systems. Discussion of these problems and of the instrumentation required for the successful application of computers in minerals processing plants follows. In order to enhance this discussion the remainder of this subsection is broken up into individual mineral processing categories.

Jan 1, 1979

By John A. Herbst

At the last Comminution Symposium a challenge (Meloy and Williams, 1992) was issued to "predict the typical straight-line, self similar" tumbling mill product size distributions using a population balance model (PBM). Implicit in this challenge is the assumption that the PBM is inadequate for predicting real world grinding performance. This response is presented in three parts: I. Theoretical analysis of the general PBM and its appropriateness for comminution system modeling. II. Examination of the accuracy of prediction of real world milling behavior using linear and nonlinear PBMs. III. Evidence from recent microscale comminution research. This paper concludes with recommendations concerning future research which will: 1. further elucidate mechanisms of particle destruction and creation as well as attrition and 2. increase the accuracy of model predictions in highly nonlinear situations

Jan 1, 1997

The objective of the fines flotation step in a coal preparation plant is to maximize coal recovery subject to a constraint on the allowable ash in the concentrate. The objective is achieved when the incremental ash is driven to a target value determined by an economic constraint. In this paper, a phenomenological flotation model and ash analyzer combination are identified that allow the development of a soft sensor for incremental ash and subsequently a model-based strategy which manipulates key flotation variables to achieve the control objective. A combination of plant tests and computer simulations are presented to evaluate control-system performance in one operation.

Jan 1, 1999