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By B. Gigas, M. Preston, M. Giralico

Optimized mixer settler designs will now handle total flows of over 6,000 m3/hr.Computational Fluid Dynamics (CFD) is a timely and predictable tool for design development. Lightnin has the capability of using numerical analysis methodology to evaluate flow patterns and phase separation. CFD can show performance differences between changes, in mix tanks, in settler geometry, and in liquid depth, against variable flow rates. Understanding the differences allows the development of optimized designs. This paper focuses on the major design components of the mixer settler and how technological advances will lead to further improvements, when designing for today’s largest flow plants.

Jan 1, 2004

By Michele Ashby

The mining industry is facing new risks from peak commodities, the energy and economic crisis and stock market pressures. The Green Mining Industry Initiative is a risk management strategy for the future of the mining industry. Defining the Risks The bad news is peak commodities, energy and economic crisis and stock markets collapsing are the issues that are already hitting everyone?s bottom line and draining the treasuries of every mining company around the world. Higher energy costs are affecting the bottom line more than ever before, which is creating more risk for companies. Mining companies have major land positions around the world and they have major energy needs. Uncontrollable increases in energy costs, increased regulations for diesel fuel emissions and energy intermittencies are costing mining companies more time, money, and man-power, which are cutting into profits and hitting the balance sheet. The good news is, there are practical energy solutions which are off the grid, tried and true methods which can be implemented in a cost-effective manner and will increase profitability and save shareholder values as well as energy security for these companies and their projects. To date, most of the mining resource industry has not yet considered or used other forms of power like clean, sustainable, or alternative energy for their own energy needs. The reasons have primarily been pushback from the mining industry due to beliefs of older technologies in alternative energy, a lack of understanding of the cost advantages long term, and perceptions of environmental relativity.

Jan 1, 2008

By Reginald Dias

Mining operations take a tremendous toll on equipment, operating in difficult conditions day after day. Owners and operators cannot make the job any easier, but they can give their equipment an advantage. Equipment life may be extended through preventive maintenance and the proper application of quality lubricants. This means lubricants that are made to last longer and stand up better to the punishment mining equipment must endure. There are several practices to consider as part of a successful preventive maintenance program. A good place to start is to review original equipment manufacturer recommendations about servicing and maintenance intervals for each part of the equipment, especially the engine. If these recommendations have not been followed, owners and operators must begin periodic service work on equipment to help minimize equipment down-time and extend engine life.

Jan 1, 2003

By William H. Langer

Large amounts of limestone fines co-produced during the processing of crushed lime-stone may be useful in the sequestration of carbon dioxide (CO2). Accelerated weathering of limestone (AWL) is proposed as a low-tech method to capture and sequester CO2 from fossil fuel-fired power plants and other point sources such as cement manufacturing. AWL reactants are readily available, inexpensive and environmentally benign. Waste CO2 is hydrated with water to produce carbonic acid. This reacts with and is neutralized by limestone fines, thus converting CO2 gas to dissolved calcium bicarbonate. AWL waste products can be disposed of in the ocean. Feasibility requires access to an inexpensive source of limestone and to seawater, thus limiting AWL facilities to within about 10 km (6 miles) of the coastline. The majority of U.S. coastal power-generating facilities are within economical transport distance of limestone resources. AWL presents opportunities for collaborative efforts among the crushed stone industry, electrical utilities, cement manufacturers and research scientists. There is a concern that CO2 generated from human activities is contributing to climatic and environmental changes. Approximately one-third of anthropogenic CO2 emissions come from burning fossil fuels to generate electricity. Each power plant is capable of emitting several million tons of CO2 annually. A variety of other industrial processes, such as cement manufacture, oil refining, and iron and steel production, also emit large amounts of CO2. The level of atmospheric CO2 can be reduced by capturing CO2 from point-source emissions and storing or sequestering it in isolation from the atmosphere (U.S. Department of Energy, 2003). In 1999, G.H. Rau and K. Caldeira proposed a geochemistry-based method that is referred to as accelerated weathering of limestone (AWL) in a paper titled ?Accelerating carbonate dissolution to sequester carbon dioxide in the ocean ? geochemical implications.?

Jan 1, 2009

Because of its small interburden thickness, concentrated stress distributions, high coal seam metamorphism, and complex geological conditions, mining the five coal seams (Nos. 5, 7, 8, 9 and 12) of Kaiping coalfield is difficult. Kaiping coalfield is located within 80 m in the Kailuan Group. The overburden caving caused by mining the five coals seams was measured using ZTR12 geological penetration radar (GPR) survey combined with borehole observations. The development characteristics of full-cover rock fractures after mining were obtained from the GPR scan, which provides a measurement basis for the control of rock strata in close multiple-seam coal mining. For the first time, it was found that the overburden caving pattern shows a periodic triangular caved characteristic. Furthermore, it is proposed that an upright triangular collapsed rock pile and an inverted triangular area with larger fragments piled up alternately appear in the lower gob. The research results show that the roof structure formed in the gob area can support the key overlying strata, which is beneficial to ensure the integrity and stability of the upper coal seams in multiple-seam mining of close-coal seams.

Jan 7, 2020

By M. Wickham

Design of an open pit backfill requires an understanding of highly varied processes including slope stability, hydrogeology, pit lake chemistry, climate, runoff, and mine waste behavior. Dynamic systems modeling (DSM) provides flexibility to the designers of open pit backfill, allowing them to directly integrate many different physical processes and varying levels of complexity. DSM also provides for the efficient application of uncertainty analysis to define a range of possible results, the sensitivity of the results to uncertainties in model inputs, and the value of additional data. This paper presents the results of an analysis using DSM to evaluate a pit backfill design at an Arizona mine. The objective of the partial backfill was to stabilize an active slope that threatened facilities adjacent to the pit. DSM was used, in part, to develop a pit lake water balance model for evaluating the influence of the backfill on the ability of the pit to maintain passive hydraulic containment of groundwater and surface water inflows and for evaluating costs for various backfill scenarios.

Jan 1, 2001

By W. Petruk

Imaging is a fundamental requirement when characterizing minerals, ores and related products. Images are used for presentation, texture analysis, characterization, image analysis, identification, etc. The image mode that is utilized is dependent upon the application, mineral properties and available instruments. Different instruments produce images that display different features; in order of increasing complexity they are: hand specimens, a non-polarizing microscope, polarizing optical microscope, scanning electron microscope (SEM), low vacuum SEM, microprobe, secondary ion mass spectrometer, staining, cathodoluminescence, tomography and others. Image analysis uses images produced with either an optical microscope or a SEM, but the SEM images are superior in this application.

Jan 1, 2001

By J. T. Hollow

The Fort Knox Mine is located in Alaska?s interior, where the average ambient air temperatures range from -24°C (-11°F) in January to 16°C (61°F) in July. The mill processes a free-milling gold ore utilizing both a gravity recovery circuit and conventional cyanide leach/carbon-in-pulp circuits. Mathematical models have been developed to accurately predict the impact of leach circuit slurry temperature on gold leaching, carbon adsorption and cyanide destruction kinetics. Additionally, an energy-balance approach has been used to model the seasonal variations in slurry temperatures throughout the Fort Knox mill. The energy-balance model, combined with the kinetics models previously developed to predict plant performance, was used to justify a tailing thickener installation at the Fort Knox Mine. This paper describes the development of the energy-balance model and its prediction of plant performance assuming a tailings wash thickener to reduce heat loss from the mill. Also presented is an analysis of the post-project plant performance that validates the model and shows that the mine produced an additional 596 kg (19,155 oz) of gold while reducing mill reagent costs by $6,302,000 during the first 38 months of operation.

Jan 1, 2007

By J. A. Halt, E. Larsen

"The Sydvaranger magnetite mine closed in 1996 due to low iron ore prices and was reopened in 2009. The flowsheet has remained more or less as in the old plant, based upon two grinding steps followed by magnetic separation. The magnetite is free of harmful elements and should be attractive on the high quality market. This requires a concentrate containing less than 2% SiO2, which previously was achieved by amine flotation. Amine was preferred because it could be used with sea water. The use of amine is now restricted by the Norwegian Climate and Pollution Agency. Therefore, testwork to replace cationic with anionic flotation was done. Activation of quartz with Ca or Mg ions prior to anionic flotation was shown by research from 1960 to 1980 to be effective under laboratory conditions. The old research results have been followed up in order to make a commercial process for Sydvaranger. Calcium activation works excellently with all Sydvaranger ores, including the ones containing amphibole minerals, but Ca activation requires the high and not environmentally friendly pH of 12.4. Magnesium activation at pH 10.5 is a little more challenging, because the maximum concentration of MgOH+ is about 100 times lower than that of CaOH+. Fortunately, the major impurity in the main Bjornevatn orebody is quartz, which responds well to Mg activation. The process does not appear to depend much upon water quality, as the silicates may already be activated during grinding and magnetic separation in recycled water. The new process is environmentally friendly, as only well-known household reagents are used; oleic acid or tall oil, dextrin, sodium hydroxide and magnesium chloride at pH 10.5.IntroductionThe processing plant of Sydvaranger Gruve AS (SVG) is located in the port town of Kirkenes in the northernmost part of Norway, 10 km by rail from the high-grade deposit of Bjornevatn. This plant has been able to beneficiate magnetite ore to up to 99.5% purity, as described by Sandvik and Malvik (2001). Using the magnetic properties of the ore and making the most out of its enviable liberation characteristics, the original plant consisted of ball mills and 600-mm magnetic separators. The plant was shut down due to market conditions in 1996 but reopened in 2009."

Jan 1, 2015

By D. H. Horswill

The Red Dog Mine is the world’s largest zinc mine. It is located 145 km (90 miles) north of the Arctic Circle in northwest Alaska on lands owned by the Inupiat Eskimo organization called the Northwest Alaskan Native Association (NANA) Development Corp. NANA acquired surface and subsurface title to this resource as part of its settlement lands under the Alaska Native Claims Settlement Act. In 1982, NANA entered into a lease agreement with Cominco. Cominco is an international mining company focused on zinc. It built and operates the Red Dog Mine. NANA’s principle objective in the development of the mine was to have it contribute to the development of sustainable communities within their traditional region. This meant creating job opportunities in a modern economy while preserving the traditional subsistence lifestyles. Preservation of their culture, language and traditions are as important to the NANA people today as they were in the past.

Jan 1, 2000

By A. A. El-Midany

Traditionally, the choice amongst different upgrading techniques or in finding the optimum operating conditions for a given upgrading technology depends on whether one is looking at the grade or the recovery of the valuable mineral in the concentrate. In fact, the conclusions are not usually the same. This is because the best technique or optimum operating conditions for the highest grade are not the same as the conditions to achieve the maxi-mum recovery. Therefore, a unique measure that takes into consideration both grade and recovery is urgently needed. Finding such a measure is the objective of this paper. A proposed measure provides a selectivity index in the range of 0 to 1, where 0 is no selectivity and 1 is ideal selectivity. The index can be obtained by plotting the so-called Fuerstenau upgrading curve, which relates the recoveries of the components in products of separation and a running regression applying a one-parameter equation. The measure was applied to assess the selectivity of selective flocculation under different operating conditions when used as a sensitive upgrading technique for ultrafine ground ores. After applying the proposed selectivity measure in the case of the selective flocculation of ultrafine Egyptian iron ore without the addition of cations, it was found that the optimum conditions are pH 11, 1 kg/t sodium silicate and 0.4 kg/t potato starch with a selectivity index of 0.55. With the addition of cations, the optimum conditions were found to be pH 11, 1 kg/t sodium silicate and 2 kg/t potato starch with a selectivity index of 0.65. It should be noted that determining these optimum conditions using the traditional grade or recovery measures was highly ambiguous.

Jan 1, 2008

By Jamal Rostami, Richard Kastner, Ahmad Ramezanzadeh

Improving the accuracy of the performance prediction models for hard rock Tunnel Boring Machines (TBMs) is important in estimation of the schedule and cost of tunnelling in related projects. The effects of rock mass on performance of TBMs has been studied extensively, yet due to the complex nature of the process, impact of many parameters influencing machine advance rate are not very clear and there is still room for improvements. More accurate estimates can be obtained by better understanding of operating parameters in various geological conditions and can lead to matching machine specifications with job conditions, optimizing machine performance, and avoiding long delays and downtime for increased productivity. This paper will offer review of two case histories including Queens Water tunnel in New York and KCRC project in Hong Kong. The analysis of the available field data, including the geological back mapping and results of laboratory testing of rock mechanical properties, machine operational parameters and achieved rate of penetration will be presented. This includes statistical analysis of available field data to provide a better understanding of the influence of rock mass properties on performance of hard rock TBMs as well as related formulas to improve performance estimates.

Jan 1, 2005

By T. Tafi

The Ute-Ulay project area is located approximately five miles west of Lake City, in Hinsdale County, Colorado. The Ute-Ulay Mine site is approximately one mile east of the project area. The elevation of the site is 9,200 feet and is adjacent to Henson Creek (Figure 1) [ ] The Ute-Ulay Mining complex is an inactive gold, silver, and zinc mining/milling operation, that operated from the 1880?s until the 1970?s, and sporadically into the late 1990?s. The mining complex comprises several levels of underground mines, a flotation mill, and an abandoned town site. Due to the narrow, steep sided canyon, milled tailings were pumped upstream one mile in a sluice box to a wider section of the canyon, and deposited into five tailings impoundments and one berm located between the impoundments. An estimated 9,000 cubic yards (yd3) of fine grained tailings were located in the impoundments adjacent to the creek. The Ute-Ulay project area consisted of the mill tailings impoundments located upstream from the historic mine.

Jan 1, 2011

By Narendra N. Khatri, Michael Deutscher, Jozef F. Zurawski

Five sewer connections were required to divert Combined Sewer Overflow (CSO)from existing outfalls to an old underutilized large diameter brick sewer (the Easterly Interceptor). The connections were part of an on-going CSO control program by the Northeast Ohio Regional Sewer District (NEORSD) in the City of Cleveland, Ohio. Each connection was made by pipejacking and hand-mining a fiberglass-reinforced polymer (FRP) pipe through soft glaciolacustrine clays and silts. Jet grouting was utilized to stabilize the soils and fill the voids surrounding the interceptor prior to making the underground connection. Reinforced concrete liners were constructed inside the aging brick sewer to provide structural stability during ground improvements and connection work. The project also involved micro tunneling two approximately400 foot lengths of FRP pipe through soft ground using a slurry pressure balanced machine.

Jan 1, 2005

By Dr. Peter J. Conroy

The current study is part of the U.S. Department of Energy's (DOE) on-going subsidence research program. The long-term objective of the DOE program is to develop analytical methods of subsidence prediction applicable over a broad range of geologic and mining conditions encountered in the United States. The DOE currently has several contracts in progress to develop a sound data base that can be used in the development of predictive models. Dames & Moore is currently under contract to the DOE to collect and analyze detailed subsidence and hydrologic data from a coal mine employing longwall mining methods in the Eastern Coal Province. Work under Contract No. DE-AC22-80PC 30335 began in October of 1980 and will continue through September of 1984. This paper summarizes the work that has been completed through September of 1981 and presents the results that have been achieved during this period. Technical difficulties encountered during both the installation and monitoring phases are discussed, and recommendations for future work are presented.

Jan 1, 1982

By Earl Rau

Introduction Will cogeneration be a major power source in the future? The location of electric power generating plants has changed. In 1900, more than 50% of electricity was generated by industrial plants. Since then, industrial plant generation of electricity greatly decreased to 17% in 1950 and to only 3% in 1980. Changing economics in electric power generating costs, though, may allow cogeneration to reverse this trend. Cogeneration has been defined as the simultaneous production of electric (mechanical) and thermal energy from a single energy source. Some applications are considered to be byproduct generation of electricity from industrial, thermal operations. Cogeneration is not new to the mining and minerals industry. Smelters and steel mills have used waste heat to generate electricity. Public Utilities Regulatory Policies Act of 1978 The potential for increased industrial cogeneration of electricity is related to the March 9, 1978 enactment of the Public Utility Regulatory Policies Act (PURPA). The US Supreme Court ruled that PURPA is constitutional. The court upheld requirements that utilities interconnect to cogenerators. It also ruled that 100% of avoided costs be used as the guideline for electricity sales by a qualifying facility (QF) to a utility. The state of New York established a floor price $0.06/kWh for electricity sales from a QF to a utility. It is obvious, then, that a cogenerator must first establish price and then become a qualifying facility in order to sell electricity to a utility. Proposed cogeneration plants The estimated industrial cogeneration potential for the years 1986 to 2000 is 9500 to 25,000 MW. Industries represented in this cogeneration estimate are pulp and paper, petroleum, chemicals, food, textiles, rubber, plastics, steel, lumber and wood, cement, glass, metal fabrication, and industrial parks. A cogeneration plant has been proposed for the Union Carbide chemical plant in Institute, WV. A steam turbine/generator would be installed to replace the pressure-reducing valve in the 2.7 MPa (400 psig) header. Scott Paper Co., Mobile, AL, proposed a cogeneration plant using a coal- and wood-fired boiler and a turbine/generator to produce process steam and electric power. A cogeneration system has been proposed for a large oil refining plant. A pulverized coal boiler would produce high-pressure steam to operate a turbine, generator. The exhaust steam from the turbine will go to the process and an existing turbine. Kansas City, MO's Armour meat-processing plant has proposed a cogeneration plant. This proposal is to use a natural gas or oil-fired, gas-driven turbine and a generator. The waste heat from the gas turbine would go to a heat recovery boiler for use as process heat. Dade County, FL is implementing a central energy system to supply electricity, air conditioning, and domestic hot water for five buildings in downtown Miami. The cogeneration system is to provide flexibility, to optimize fuel use efficiency while serving the variable thermal demands. Generation of electricity from municipal waste is not considered to be a cogeneration process but is covered by PURPA. Special considerations are provided for waste/electric power generation to encourage the development of these systems. ?

Jan 7, 1987

By Wojciech Klecan

Cobb County, located on the northwest side of Atlanta, GA, is continually growing and, like many other metropolitan areas, it needs to increase the capacity of its waste water system to meet future demand. The Cobb County Water System (CCWS) is the responsible agency for water distribution, waste water collection and treatment in most areas of the county. CCWS, one of the most progressive agencies in the metro-Atlanta area, is addressing its future waste water capacity needs in the southern part of the county with the construction of the South Cobb Tunnel and Pump Station. This project consists of an 8.8-km- (5.5-mile-) long, 8.2-m- (27-ft-) diameter, tunnel boring machine (TBM) excavated waste water storage and conveyance tunnel; six tangential vortex-flow intakes ranging from 1,533 to 5,700 L/s (35 to 130 mgd) peak flow capacity, two construction shafts, six 1.8-m (6-ft) finished diameter connecting tunnels ranging in length from 6 to 975 m (20 to 3,200 ft) and a 5,700-L/s (130-mgd) wet/dry pit pump station. The pump station will have a semi-circular wet well with a dividing wall that extends almost to the top of the shaft and a spilt dry well for reliable operation. Roller gates will control the flow to the wet well from the tunnel. The pump station will have six 1,420 L/s (32.5 mgd) pumps and two sets of stair wells and elevators. With a finished diameter of 32 m (104 ft) and a depth of 62 m (204 ft), this is the largest pump station shaft constructed so far in Georgia for the dewatering of a waste water tunnel. The pump station shaft was also the highlight of the well attended and successful 2009 Shaft Design and Construction Short Course held in Atlanta, Sept. 10-11. The two-day course was sponsored by the Underground Construction Association of SME and Pennsylvania State University and concluded with a field trip to the pump station shaft. The tunnel starts south of the city of Austell and finishes at the South Cobb Water Reclamation Facility (WRF), located on the banks of the [ ] Chattahoochee River just north of Interstate 20 (Fig. 1). The South Cobb Tunnel will run 30 to 137 m (100 to 450 ft) below the surface, with an average depth of about 91 m (300 ft), through metamorphic rocks (Fig 2). The construction contract was awarded to Shea-Traylor JV with the lowest bid price of $305 million and notice-to-proceed was given on July 14, 2008. Jordan Jones & Goulding, Inc. (JJG) is the project designer and performed the geotechnical investigations. Parsons/Jacobs Associates is the construction manager. The South Cobb Tunnel is CCWS?s second deep hard rock tunnel. The 15.3-km- (9.5-mile-) long, 5.5-m- (18-ft-) diameter TBM excavated the Chattahoochee Tunnel was the first deep tunnel to be construced in Cobb County. Construction began in 2000 and the project was completed four years later. It is located about 16 km (10 miles) northeast of the South Cobb Tunnel in similar geology. It was designed by JJG to meet east Cobb?s long-term waste water capacity needs and provide flow equalization to the R.L. Sutton WRF. The Chattahoochee Tunnel was named ?Outstanding Civil Engineering Project of the Year? by the Georgia Sec-tion of the American Society of Civil Engineers in 2006.

Jan 1, 2009

By S. H. Jason Choi

The Systems Conveyance and Operations Program (SCOP) is being implemented to convey tertiary-treated effluent to Lake Mead near Las Vegas, Nevada. The Reach 3 Tunnel Project is part of SCOP. The tunnel?s planned location along and across the Las Vegas Wash creates challenging tunneling conditions. A number of feasible excavation and initial support methods are being considered during the final design stage. This paper describes how the tunnel construction options were refined based on anticipated tunneling conditions and compatibility between tunnel excavation and initial support methods. A brief description of the most significant characteristics of the anticipated ground conditions is included for the purpose of discussion.

Caterpillar’s 797 327-t (360-st) mining truck is currently being tested at the company’s proving facilities. Mine evaluations began in the second quarter. The unit will be commerically available in North America in 2000 and worldwide in 2001. The new model is the largest of Caterpillar’s off high-way truck line. In addition, the company has replaced its 966F series II and 970 F wheel loaders with the966G and 972G models. 797 mining haul truck Caterpillar developed the 797 mining haul truck in response to mining companies seeking to reduce cost per ton in large-scale operations. The 797 is sized to work with loading shovels used in large mining operations. And Caterpillar will match the body design to the material being hauled, to optimize pay-loads.

Jan 1, 1999

By C. H. Bucknam

Classical acid-base accounting using modified Sobek titration methods has resulted in interpretation of results for materials with neutralization potential (NP) less than 20 tons of CaCO3/1000 tons of material (2% CaCO3) as "uncertain" due to lack of sensitivity within that content range. Standardization of a "fizzless" acid neutralization potential (ANP) method was undertaken in the American Society for Testing and Materials (ASTM) International using two ranges of sulfuric acid additions based on reaction pH and carbonate carbon estimates rather than subjective fizz testing as well as hydrogen peroxide additions to correct for mineral acidity. The method is identified as the acid neutralization potential acidity (ANPA) titration method. During interlaboratory testing a positive bias was discovered within the "uncertain" range which was further investigated and resolved by increasing the test sample weight from one to five grams for samples needing improved accuracy in materials with ANP <2% CaCO3. Test results from the interlaboratory testing of the low range method is presented and compared with the results from the original ANPA method in the paper.

Feb 27, 2013