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By B. A. Wills

With the increasing need to mine lower grade ores, high energy-related costs in comminution are of major concern. Very fine grinding is needed to liberate the very fine mineral particles in these ores. Not only is this expensive but it leads to greater losses in 'slimes'. In the early 1970's, 50% of the tin mined in Bolivia, 30% of the phosphate mined in Florida and 20% of the world's tungsten were lost in this way (Somasundaran, 1979). Gravity concentration techniques become unacceptably inefficient for particle treatment below 25-50µm, and even flotation fails in the ultra-fine range. Two approaches can be adopted to try to overcome this problem. The first involves increasing the efficiency of existing equipment or developing new slimes treatment processes. Gravity devices such as the Bartles-Mozley concentrator have been developed for this purpose and good recovery has been reported from 100µm down to 5µm. Such machines, however, have relatively low throughputs, so that large areas of plant space are generally required. Flotation is rapidly growing in importance for the treatment of ultra-fine minerals traditionally treated by gravity concentration.

Jan 1, 1986

By N. Damiano, C. Zhou, B. Whisner, M. Reyes

"The Industrial Internet of Things (IIoT), a concept that combines sensor networks and control systems, has been employed in several industries to improve productivity and safety. U.S. National Institute for Occupational Safety and Health (NIOSH) researchers are investigating IIoT applications to identify the challenges of and potential solutions for transferring IIoT from other industries to the mining industry. Specifically, NIOSH has reviewed existing sensors and communications network systems used in U.S. underground coal mines to determine whether they are capable of supporting IIoT systems. The results show that about 40 percent of the installed post-accident communication systems as of 2014 require minimal or no modification to support IIoT applications. NIOSH researchers also developed an IIoT monitoring and control prototype system using low-cost microcontroller Wi-Fi boards to detect a door opening on a refuge alternative, activate fans located inside the Pittsburgh Experimental Mine and actuate an alarm beacon on the surface. The results of this feasibility study can be used to explore IIoT applications in underground coal mines based on existing communication and tracking infrastructure.IntroductionThe U.S. approach to health and safety in mining has historically been reactive in the sense that health and safety regulations and mandates have traditionally been passed as a result of tragic mining accidents. An example of this is the Mine Improvement and New Emergency Response Act (MINER Act) of 2006, which was passed as a result of several mining accidents where tracking of and communication with underground personnel were severely limited. While this reactive approach has led to the development and implementation of highly impactful safety interventions and safety practices, there exists a technological revolution that can shift the paradigm toward a proactive approach based on preventative methods: Internet of Things (IoT).IoT is the network of physical objects, or “things,” embedded with electronics, sensors and connectivity to enable that network to achieve greater value and service by exchanging data with the manufacturer, operator and/or other connected devices (Atzori, Iera and Morabito, 2010; Gubbi et al. 2013). It should be noted that IoT has been defined from various perspectives, and hence numerous definitions exist in the literature. The apparent ambiguity of the IoT definition might be due to the fact that IoT is syntactically composed of two terms: the Internet and things. The first word pushes toward a network-oriented vision, while the second tends to put the focus on generic objects. The traditional Internet can be viewed as an internet of computers, so things connected to the Internet are computers only. IoT extends the internet by allowing other generic things that are commonly found in daily life, such as refrigerators and cars, to be interconnected through the Internet, thus creating a bridge between the virtual world and the physical world"

Jan 12, 2017

By W. Missildine, J. K. Hrica, I. Benbourenane, T. J. Orr, J. L. Bellanca

Each year, haul truck accidents account for a large portion of mining injuries and fatalities. To better understand why these accidents continue to occur, researchers from the National Institute for Occupational Safety and Health (NIOSH) utilized a cognitive task analysis methodology to identify the user requirements of surface haul truck operators and assess differences in perceptions between operators, managers, health and safety professionals, trainers, and maintenance personnel. Additionally, researchers used the critical decision method to focus on better understanding the cognitive demands, decision-making, and problem solving during nonroutine incidents. The preliminary results of this study identify and explore themes within the broad categories of hazards, skills & expertise, and training and provide detailed accounts of nonroutine incidents such as near-misses, loss of control, and collisions. These accounts reveal insights into operator decision making and event progressions that can then be used to build more realistic training scenarios and address hidden hazards and root causes of these incidents. These results, along with potential solutions offered by study participants, can inform future research and help identify creative interventions that can be used by mine operators to address haul truck safety issues

Mar 2, 2022

By W. M. Luff

Introduction The Brunswick No. 12 mine is located about 27 km (17 miles) southwest of Bathurst, New Brunswick. The deposit is a stratiform massive sulfide deposit occurring in a series of sedimentary and volcanic rocks of the Tetagouche Group. These rocks are generally considered to be Ordovician in age. Ore reserves at Brunswick No. 12 are 104 Mt (115 million st) grading 3.72% lead (Pb), 9.01% zinc (Zn), 0.32% copper (Cu), and 97.9 g/t (2.8 oz per st) silver (Ag). Production in 1984 was 3.5 Mt (4 million st) at 3.57% Pb, 8.91% Zn, 0.32% Cu, and 100 g/t (2.9 oz per st) Ag. Total payable silver production that year was 211 t (6.8 million oz). This made Brunswick one of the largest silver producers in Canada. Bathurst-Newcastle area and Brunswick Mining Interest in the Bathurst area was aroused in 1897 when W. Hussey discovered an iron formation at Austin Brook, just south of Brunswick No. 6 deposit. This area, and the current No. 6 area, was explored from 1897 to 1907. Iron ore was mined at Austin Brook from 1907 to 1913 and from 1942 to 1943. Any occurrence of sulfides was overlooked until 1952. In 1952, M. J. Boylen Enterprises investigated the small sulfide body associated with the Austin Brook iron formation. Other electromagnetic anomalies associated with the iron formation were investigated. The No. 6 deposit was found late in 1952, when hole B12 intersected 97.5 m (320 ft) of massive sulfides. The No. 12 deposit, 10 km (6 miles) to the north, was found in 1953. More than 30 massive sulfide deposits have since been identified in the Bathrust area. In the 1950s, St. Joe Lead Co. did extensive test work on the No. 6 and No. 12 deposits, including shafts at No. 12, lateral development at No. 12, and testing at both deposits.

Jan 10, 1986

By John A. Riddle

Some of the pitfalls and problems in selecting and applying corrosion-resistant materials in uranium plants are discussed, together with some suggested solutions. Includes some cost data.

Jan 1, 1979

By J. A. Lepinski

The FASTMETSM Process is a coal-based process for converting iron oxide fines into metallic iron. The end product, direct reduced iron (DRI) is used as a low residual charge material in electric arc furnace steelmaking. This paper describes the FASTMET Process and its potential application in the United States. Operating results from a 175 kg/h process simulator are presented. Characteristics of the end product are discussed. Process economics are reviewed along with plans for scaling-up the process to full commercial size.

Jan 1, 1993

By D. Seneviratne

Iron transfer from the pregnant leach solution (PLS) to the electrolyte can have a major economic impact on solvent extraction (SX) operations. High iron transfer will lead to greater operational costs, due to increased reagent consumption through electrolyte bleed and make up, or increased power costs due to decreased electrowinning current efficiency. Bioleaching of low-grade copper sulfide ore from the Kennecott Utah Copper Mine was investigated in a large scale piloting program including SX and electrowinning. Plant data and lab test work conducted throughout the course of operation, show that the unique containing PLS high ferric iron with high pH can lead to lower Cu: Fe selectivity than is typically seen in traditional copper SX operations. The impact of high ferric iron on the plant operation, and methods to reduce iron transfer will be discussed. Special considerations need to be taken for plant operating conditions and selection of SX reagents (including both extractant and aromatic content of diluent) based on the feed PLS characteristics.

Feb 23, 2014

By R. E. Scheffel

In February, 1976, Ranchers Exploration and Development Corporation obtained an option from Foote Minerals, Inc., to evaluate reprocessing of two uranium tailing piles. Foote received ownership of the Naturita and Durango tailing piles in 1967 through the purchase of Vanadium Corporation of America. The option was exercised in November, 1976, after initial testwork proved that a viable extraction technique existed. Preparation for production at Naturita began immediately with engineering and en¬vironmental permitting proceeding simultaneously. Production began in December, 1977, just 22 months after acquisition of the property and-was completed 17 months later.

Jan 1, 1981

By D. Govender

In recent years, economies of scale have continued to drive copper projects to larger throughputs to offset depleting lower grade resources. A decade ago, there were only a small number of projects that stretched beyond 100 kt/d (110,000 stpd) throughput rates. Today, and moving forward, virtually all the major copper projects are sized beyond this, with throughput rates up to 250 kt/d (275,000 stpd) now under evaluation for a number of key projects in Chile and Peru. This paper explores the development from the 160 m3 (5,650 cu ft) flotation cells, through to the 257 m3 (9,076 cu ft) cells and to the current 660 m3 (23,380 cu ft) machines. The contributions of specific copper concentrators to this growth phase are reviewed in this article. The historical basis of flotation machine scale-up is also briefly discussed. Metallurgical results as well as layout, maintenance and operational aspects are highlighted.

Feb 1, 2014

By MARK J. VANARELLI

Estimating groundwater inflows in rock deep tunnels is critical to the safety of personnel constructing the tunnel and the cost of construction. This paper presents two case studies for estimating steady-state groundwater inflows into deep rock tunnels. The case studies included the Chattahoochee and Nancy Creek tunnels. In this paper, statistical methods were applied to packer test data obtained from exploratory borings during geotechnical site investigations. A semi-empirical procedure was utilized for estimating groundwater inflows into these deep rock tunnels. It is the most widely used method/procedure in the tunnel industry. The Chattahoochee and Nancy Creek tunnels are deep rock tunnels which exhibit radial flow conditions. For the radial flow condition, a statistical analysis presented in this paper indicates that the semi-empirical procedure works well; however, variations in the procedure and/or an insufficient amount of testing could lead to underestimations of the inflow quantities. Packer test data plotted in histograms were observed in all cases to be log-normally distributed for the radial flow condition. Modeling using Monte Carlo simulations was observed to be an effective tool for removing irregularities in the distribution of the data and incorporating high-end permeability data to derive reasonable groundwater inflow estimates. This paper is based on the PhD thesis entitled “Improvements to the Current State of the Practice in Steady-State, Groundwater Inflow Estimates into Rock Tunnels based on the Application of Statistical Analysis Methods of Packer Test Data obtained from Exploratory Borings During Geotechnical Site Investigations.”

Oct 9, 2020

By Paul Soros

There has been a steady increase in shiploading capacities in the last 20 years. One of the reasons has been the general increase in ship sizes, with the largest vessels currently around 280,000 DWT in the bulk trades. Obviously, the large vessels can accept loads faster and their economic utilization justifies higher loading rates, up to a point. The high capacity facilities have loading rates far beyond this point. The economic logic of these facilities is based on the fact that for a given annual throughput the capital and operating cost of a single high capacity system is less than that of two smaller systems. Thus, where the projected throughputs are large, there is a great incentive to reduce capital costs by maximizing capacity. Tubarao, in Brazil, designed for a 100 million ton per year throughput with one finger pier and one high capacity berth is a successful demonstration of this approach. In the current state of the art, the high capacity systems have shiploading capacities in the range of 10,000 - 16,000 TPH, for annual throughputs of 20 million tons and larger per loading berth.

Jan 1, 1982

By YONGQIONG YANG, Ning Wang, CHONGGUANG LUO, LI ZHU, Hanjie Wen, SHENGJIANG DU, Hannian Gu

Niobium in kaolin clay from the Late Permian sequences was reported in the range of several hundreds of micrograms per gram and was considered as a potential resource for its high concentrations and large areal distribution. Ti-bearing minerals associated with kaolin clay were identified as the main host phase for niobium in some case studies. However, the correlation between the concentration of niobium and titanium is poor, and the types of Ti-bearing minerals and modes of occurrence of niobium are not clear. Typical kaolin clay samples from the Late Permian sequences from southwest China were characterized, and the final products derived from kaolin clay sample were investigated using XRF, ICP-MS, XRD, SEM, and TEM (EDS). The results reveal that there were three types of TiO2 mineral phases in the clay samples: (a) massive TiO2 minerals and (b) aggregates of nano TiO2 minerals did not contain niobium while (c) granular TiO2 minerals were the source of niobium from the EDS analysis. The granular TiO2 minerals included anatase and rutile, both of which were the sources of niobium in kaolin clay in the current study. The findings are of great theoretical implication for source and origin study of Ti-bearing minerals and guidance for separation and recovery of niobium from kaolin clay.

Nov 30, 2020

By LINDSAY BOTTOMER, Tassos Grammatikopoulos, Massoud Aghamirian, MARK FEDIKOW

A master composite (Master Comp) sample was prepared from three pegmatite zones from the Zoro Dyke D1 for mineralogical analysis and heavy liquid separation (HLS). The mineralogical examination was conducted on a subsample that was crushed to approximately P80 = 600 μm. The sample consists of spodumene (10.5 percent), quartz (29.3 percent), plagioclase (29.0 percent), K-feldspars (21.3 percent), micas (5.1 percent), tourmaline (2.9 percent) and Fe-Mn-phosphates (0.1 percent). Liberation of spodumene (88 percent) and gangue minerals, including quartz (89 percent), feldspars (94 percent) and micas (83 percent), is very good at this P80 . The average lithium (Li) concentration is 3.7 percent in spodumene, 2,196 ppm in micas, 1,001 ppm in tourmaline and 115 ppm in K-feldspars. Spodumene accounts for 96 percent of the total Li in the sample. The mineralogical data indicate the potential to recover spodumene by flotation with minimal Li losses due to other Li carriers. The HLS was conducted on a subsample that was crushed to smaller than 6.4 mm, with the smaller than 600 µm fraction removed from this test. The HLS results indicate it is possible to produce a high-grade lithium concentrate, with close to 6 percent Li2O, after the rejection of iron silicates with magnetic separation.

By J. Herbst, J. Groppo, A. Noble, R. Q. Honaker

"Coal and coal byproducts produced annually contain a sufficient amount of rare earth elements (REEs) to meet current U.S. demand. The REEs exist in the form of minerals, ion-adsorbed elements associated with clays, and chemically bonded elements within the organic coal matrix or host mineral. Researchers at three universities collaborated to evaluate the effectiveness of existing physical and chemical concentration processes for the recovery of the REEs. The efforts found that physical separation processes can increase the total REE content in the thickener underflow material collected from a Central Appalachian coal cleaning facility from around 300 ppm to values greater than 17,500 ppm on an ash basis. Leaching followed by solvent extraction was found to be the most effective to recover the REEs from coarse middlings materials collected from multiple coal basins, as indicated by recovery values exceeding 80 percent. Based on material characterization data and process evaluations conducted for several potential feed coal sources, economic recovery of the REEs will require byproduct production of both clean coal and REE concentrate using a process flowsheet that is unique for each source. IntroductionRecent studies initiated by the National Energy Technology Laboratory showed that U.S. coals contain significant amounts of rare earth elements (REEs), suggesting that rare earth minerals (REMs) and/or REEs can be produced as byproducts (Ekmann, 2012). According to the report, the richest source of REEs is the Central Appalachian coal. At present, there are 208 coal preparation plants located in the region consisting of areas within the states of West Virginia, Kentucky, Pennsylvania, Virginia, Alabama and Tennessee, with a total capacity of 166,495 t/h, or more than 1 Gt/y (Fiscor, 2014). If only a portion of these plants are retrofitted with advanced separation processes, the U.S. coal industry would become a significant producer of REE concentrates as byproducts. An inherent advantage of becoming a byproduct producer of REEs is that no mining cost needs to be part of the production cost."

Jan 1, 2017

By Jerry R. Riding

Metallurgical process methods have seen dramatic improvement over the past fifty years. As these improvements have come about, more and more emphasis has been placed on obtaining accurate and rapid analysis of the metallurgical processes. Well-defined conventional laboratory analysis procedures which have proven to be reliable were developed early in the mineral industry's history; however, these conventional procedures, which have not changed appreciably in fifty years, have the serious drawback that they are too slow to be of appreciable value in automatic control of the processes. For example, the assay results normally become available to a mill operator from eight to twenty-four hours after a sample is taken. Since the desired mineral separation can only be made while the minerals are in the flotation circuit, conventional assay results provide information similar to postmortem reports. Consequently, using conventional procedures, the mill is operated with information from an earlier period of time, which may not reflect current conditions. In recent years there has been a steady increase in the volume of required samples. At the same time, labor, material, and overhead costs have continued to rise causing the cost per assay to reach an alarming level. This rising cost per assay, plus the increasing demand for rapid analysis necessary for control, has caused the mining and metal processing industries to look toward other techniques to solve these problems As a result, X-ray fluorescence which can provide on-stream analysis necessary for control, as well as perform numerous laboratory assays at lower cost and at a much greater speed than conventional methods, has gained wide-spread attention. In addition, multichannel X-ray fluorescent instruments are now available which have been perfected to the point where the analysis of the most important chemical constituents is available within one minute after a sample is presented to the X-ray analyzer. Because of these obvious advantages, extensive use is being made today of X-ray analysis in the mining industry to analyze slags, ores, and mineral content of rocks. The results are used to make quick decisions for both mining and beneficiation of metals. For example, X-ray systems which provide rapid on-stream analysis of the slurries at desired points Fn metallurgical processes have recently been developed. The successful application of these systems has moved the milling process a step closer to fully automatic control.

Jan 1, 1969

By R. V. Ramani, K. V. Raj, S. Bandopadhyay

The air flow problems in openpit mines are complex. Computational fluid dynamics (CFD) models can provide detailed information regarding air flow pattern, velocity distribution, temperature, and pollutant concentration in an enclosed domain of an openpit mine. A range of turbulent models can be selected with varying complexity and accuracy. Pollutant transport models, however, differ in their assumptions and structure as well as in the algorithms they use. As a result, predictions vary from model to model. This paper presents a study of pollutant transport in an actual openpit mine under a stable boundary layer. The objective was to test two turbulence models using similar geometry and the same input conditions and model constants. Measured data were used to compare the results of the two CFD models, namely, the kappa-epsilon (к-є) model and the Large Eddy Simulation model. Despite the complex synoptic situations, different meteorological input data and fast-changing conditions, the simulation results from both the models were in good agreement regarding the dispersion of pollutants.

Jan 1, 2015

By Jon A. Hummer, Aleksandar D. Bugarski, Shawn Vanderslice, Teresa Barone

Reducing the contribution of heavy- and light-duty diesel-powered equipment to concentrations of aerosols and gases is essential to industry’s efforts to improve air quality in underground mining operations. The results of this study demonstrated a potential of control strategies based on retrofitting existing power packages with diesel oxidation catalyst (DOC) and diesel particulate filter (DPF) systems and repowering existing systems with advanced power packages to reduce contributions of diesel-powered vehicles to concentrations of diesel aerosols and criteria gases in underground mines. The implementation of viable exhaust aftertreatment systems and advanced diesel power packages could be instrumental in the underground mining industry securing a clean, economical and dependable source of power for mobile equipment.

By T. Cienski

The paper presents and discusses the results of a detailed study conducted on the subject of energy consumption in the comminution of industrial minerals. The study was based on pilot circuit testing, plant operating data collection, detailed equipment data and literature research. The areas covered by investigations include: high efficiency classification; air classifiers for cement grinding circuits; grinding aids in dry grinding: dry grinding circuit, control based on particle size measurement. Results obtained indicate a large potential for the reduction of energy consumption, in particular in the traditionally high cement clinker grinding circuits. Better classification techniques and correct application of grinding additives can significantly reduce power used per ton of product and also substantially increase grinding circuit output.

Jan 1, 1990

By Robert S. Foote

The U.S. Energy Research and Development Administration (ERDA) is currently conducting a national program to survey for uranium the conterminous United States and Alaska by 1980 using airborne and surface techniques. This paper discusses the techniques used and some of the results of airborne surveys conducted to date by Geodata International, Inc. Airborne gamma radiation and the earth's magnetic field data are measured to provide data leading to regions potentially more favorable for the exploration and discovery of uranium ore. High-sensitivity radiometric and magnetic field data have been gathered from an aircraft with an average surface altitude of 400 feet (Figure 1). Under most conditions, data are usable up to an aircraft surface elevation of about 1250 feet where limitations will be discussed. Results of data analysis under GJO-1632, GJ0-1644, GJO-1654 and GJO-1663 will be discussed.

Jan 1, 1976

By W. Collingwood

As openpit mines continue to grow deeper and productivity continues to increase, the management of respirable dust and noxious gases can become a challenge. The natural wind flow in openpit mines is often recirculatory. This recirculation traps dust and gases in deep openpit mines. This problem is particularly acute in high-latitude openpit mines, due to a phenomenon known as atmospheric inversion. In the winter, arctic and subarctic regions experience short days and long nights. This deficit of solar radiation creates a situation in which cold, still air accumulates near the bottom of the pit. In openpit mines, this can result in unhealthy accumulations of gases and other contaminants. In this study, the natural wind flow patterns in and around openpit mines were investigated using a computational fluid dynamics (CfD) program. Two-dimensional models were created for a variety of pit geometries. The effect of depth, slope angle and wind speed on the recirculation pattern in the pit was examined.

Jan 1, 2012