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By S. K. Kawatra, R. A. Seitz

There is considerable variation in the types of coal flotation circuits in use in various parts of the world. For example, Russian plants frequently use scavenger flotation, while this is almost unheard of in the United States. The numerous circuit designs are intended to address specific problems in coal flotation, or to take advantage of the peculiarities of certain coal deposits. As a result, it can be difficult to decide which circuit is best for a given application. For this paper, coal flotation circuits were collected worldwide from many operating plants. These circuits include varying degrees of conditioning, and complexity ranging from simple rougher flotation to multi-stage split- stream processing. The design goals of each circuit are described, and the advantages and disadvantages of each are discussed. Extensive sampling campaigns were carried out in two plants with the most common types of coal flotation circuit (simple rougher, and rougher with deslimed feed). The performance of each plant was evaluated, and the benefits of more sophisticated processing in each case are described.

Jan 1, 1993

By J. A. Herbst, S. L. Blust

Optimization of blasting, crushing, and grinding operations is filled with challenges. One of the more difficult tasks is accurately sampling and determining the size distributions of blasted and crushed materials at a reasonable cost. The task is difficult because of the large size of fragments and the tonnage involved. However, the size distribution measurements are necessary for models that predict the performance of mine-through-mill operations. This paper is concerned with the use of video sampling for this task at National Steel Pellet Company's operation in Keewatin, Minnesota Data gathering, data analysis, model building, and mine-to-mill simulation are all described.

Jan 1, 2000

By John S. F. Dunlop

One of the more difficult problems frequently facing geologists and mining engineers is that of estimating the ore reserves of mineral deposits. Cost conscious mining operations invariably require an accurate knowledge of tonnage and grade for both short and long term planning. A case study is presented, showing how a classical frequency distribution was fitted to a population of drillhole assays. Using these results, a grade- tonnage curve is derived using the Lasky expressions, and the results discussed. A geostatistical analysis is then presented. First, variograms are drawn, models fitted to them and analyses made of drift and anisotropy. Second, simple block kriging is carried out and the results plotted on large 1000 scale plans, suitable for overlay with routine .mine plans. Kriging results are verified using two independent techniques: random kriging on a regular grid and inverse distance weighting. Finally an attempt is made to optimize the drilling grid, and to fully tabulate the total computer running costs for the work described.

Jan 1, 1979

By R. L. Wiegel

Several mineral process modeling and simulation packages are currently available for use in evaluating the performance of alternative process flow schemes. A critical link that has been missing from these packages is the ability to quantitatively model the effect of size reduction on the liberation of the valuable and waste minerals in the ore being processed. Although there have been several approaches taken to this problem over the past 25 years, none of them has led to a satisfactory conclusion. A technique was developed for measuring the effective liberation characteristics of magnetic taconite ores, and a program was constructed that makes use of these liberation characteristics in simultaneously simulating both size reduction and mineral liberation as it occurs in tumbling mills. This is an especially important step in the modeling of magnetic taconite processes, where magnetic rejection of low-grade wastes between grinding stages mandates that a predictive capability be available. The current application is specific to magnetic taconite, but it is possible that a similar approach could be used for other types of mineral systems. Key words: Modeling and simulation, Size reduction, Mineral liberation, Taconite, Magnetic concentrator

Jan 1, 2003

By K. Biswas, H. C. Lee, S. J. Jung

Ore passes are circular openings excavated in rock for in-mine gravity-transportation of ore. It is a very important component of the overall load-haul system of an underground mine. The function of an ore pass is two-fold: first, gravity-transportation of ore from the extraction level to the haulage level and second, the loading operation at the haulage level utilizing the gate assembly. In reality, like any other system component, an ore pass breaks down either due to a hang-up within the ore pass or due to a failure in the gate structure. The failure of the gate assembly may be attributed to a greater extent to the impact load as experienced by the components of a gate structure as a result of the direct impacts of the rock fragments and to a lesser extent to the static or 'dead weight' loads of the accumulated materials in the ore pass. This paper uses simulations in Working Model® as an aid to investigate the effect of both the impact and static loading on the gate assembly and on the inner-walls of the ore pass. The paper also investigates the impact of ore pass inclination and the presence or absence of dogleg on the static and impact loading of the same.

Jan 1, 2002

By D. Corrigan, A. Ahmad, R. Sood, J. Bratt, R. Holt

Zinc oxide based electronic ceramics are being used increasingly to protect electric and electronic circuits against transient voltage surges. Varistors are produced by sintering and annealing ZnO based powder compacts through long sintering and annealing cycles. Because of the length of these cycles, a manufacturing plant is saddled with expensive high temperature equipment with low throughput. Ceramics Kingston Inc. has developed a new technology that uses 2.45 GHz microwave energy for sintering and annealing. The new technology has the potential for increasing equipment and labour productivity very considerably. Additionally, the new technology will result in appreciable energy savings and add flexibility to the manufacturing process. Microstructural examination of varistors sintered conventionally and by microwave technology showed considerably smaller grain size in the microwave sintered materials. The electrical properties of the microwave sintered ceramics compare very favorably with those of the ones sintered conventionally.

Jan 1, 1990

By Y. Zimmels, C. Feldman

Closed-circuit grinding processes are considered in the context of a reactor-separator circuit that involves multifraction streams and products. Because grinding circuits are low-efficiency, capital-intensive operations, modeling to maximize their economic return is appropriate. An attempt to develop and test such a model is presented in this work. The model relies on process simulation for both the mill and the separator, in conjunction with constraints imposed by product specifications. The grinding process was simulated using breakage functions, which provided complete data on the feed and product of the mill. A cyclone bank used as the separator was also simulated using known models. The overall process model provided a complete simulation of the multistream grinding and separation process. The process model was then incorporated into an economic model that predicts grinding cost, subject to process constraints, for a given set of operating variables. The model facilitates economic optimization of the grinding process as it relates to process variables and process hardware.

Jan 1, 1993

By Robert A. Jankowski, Charles Babbit, Natesa I. Jayaraman

The Bureau of Mines, together with Foster Miller Inc., has developed a compact, high pressure scrubber system for continuous miners. Powered by water energy alone, it can move up to 1.4 m3/s (3,000 cfm) of air and scrub a significant amount of the dust in the air. Full- scale model and underground trials showed excellent performance. Operated at 8.3 x 10[3] kPa (1,200 psi) and 38 L/m (10 gpm), the scrubber has reduced operator and return dust concentrations by more than 50 pct. This paper describes the full-scale model development, system fabrication and underground evaluations of this novel and inexpensive scrubber.

Jan 1, 1989

By Steven A. Tesdahl

Maintenance means keeping equipment running or restoring it to operating condition. However, the 21st century will usher in a broader need for equipment management, a cradle-to-grave strategy to preserve equipment functions, avoid the consequences of failure and ensure the productive capacity of equipment. Profitable future mining operations will have reduced the 35% of operating costs typically spent on maintenance and the unfavorable impact of downtime that often multiplied these costs by 300%. They will survive those operations that tried to carry outdated "maintenance" thinking beyond the year 2000. These surviving operations will have applied modern management techniques, technology and information to align the efforts of people with the needs of equipment. Future managers will use equipment management as an integral part of an overall production strategy. They will see it as a means of raising productivity, improving performance and minimizing downtime to maximize profitability. This global thinking will characterize all operations planning to survive in the competitive world of mining of the next century.

Jan 1, 1998

By Leonid P. Ni, Askar M. Kunayev

It is well known that processing of the high-silicon bauxites for obtaining alumina by the hydrochemical Bayer process is irrational due to the significant losses of alumina and alkali with red mud. The main source of losses of the mentioned compounds under the conditions of leaching by the Bayer process is the formation of difficultly soluble sodium alumosilicate of the composition Na20 .Al203, 2Si02 . n H20. A conventional method of an extra recovery of alumina as well as of regeneration of alkali out of red mud is the high-temperature sintering of the latter with soda and limestone with the subsequent leaching of sodium aluminate from the sinter by water or soda solution. A sequential version of the Bayer-sintering flow chart recommended for the prosessing of bauxites with an increased content of silica is based on this method. However, the sintering method is not the only alkaline method allowing to make an extra recovery of alumina likewise of alkali from red mud. Our investigations showed/I/, that the components mentioned can be recovered by a pure hydrochemical method of treating red mud with concentrated alkaline solutions, with lime (Ca0) being present, that was earlier succesfully used in the development of the hydrochemical method of processing nepheline rocks/2/. The possibility of extracting alumina and alkali from red mud is based on the reactions which can be schematically represented in the following way:

Jan 1, 1984

By Kim Lapakko

As part of a project funded by the US EPA, through the Western Governors' Association, the recent literature on the prediction of acid drainage from metal mine wastes was reviewed. Static tests such as Acid Base Accounting, Modified Acid Base Accounting, B. C. Research Initial Test, and APP:S Test attempt to quantify the total capacities for a mine waste to produce and consume acid. In kinetic tests (e.g. humidity cells, soxhlet extraction, elevated temperature oxidation, column tests, batch reactor tests, B. C. Research Confirmation Test) mine waste samples are subjected to oxidation and the resultant drainage pH is assumed to reflect that of mine wastes dissolving in the field. This paper summarizes information presented in the recent literature on static tests.

Jan 1, 1992

By R. C. Bryan, D. B. Jamison

This paper describes a procedure for minimizing the operational costs associated with blending sodium in coal at a surface mine in the Powder River Basin. Mine site blending is performed by adjusting daily production rates for high- and low-sodium pits. These adjustments are designed to produce a consistent sodium value called the blending target. The mine's contractual limit for sodium is sufficiently close to the field average value that any decrease in the sodium blending target may result in an opportunity cost, if the number of potentially minable tons is reduced. Conversely, any increase in the blending target may result in a higher sampling cost if more information is required to keep the blend within contractual limits. Blending parameters were defined using a geostatistical block model of sodium content that was based on analyses of hundreds of in-pit sample holes. Variograms for these data were used to compute the marginal costs of opportunity and sampling for a series of hypothetical in-pit drilling patterns. These marginal costs provided a basis for selecting optimum values for key parameters such as the blending target, production variance and in-pit sampling density. The benefit of implementing these optimized parameter values is that operational costs of sodium blending will be minimized over the long-term. At the mine where this procedure was developed, each dollar spent to increase the sampling density to the optimum value was shown to generate a $10 savings in opportunity cost.

Jan 1, 1991

By A. Unal, H. Sevim

The utilization of high-sulfur Illinois coal by utility plants has been decreasing since the enactment of the 1990 Clean Coal Air Act Amendment. Illinois coal producers can make their coal more attractive by offering the choice of taking the coal combustion and flue-gas desu furization products from the utility plants and placing them in the abandoned sections of their mines To be competitive, however, coal producers need to select an environmentally acceptable transportation-handling-placement system through which the cost-per-ton of product disposed of can be minimized In this paper, several such systems are presented The favorable operating conditions of each system are determined in terms of distance and tonnage ranges. For a 90 kt/year (100 thousand stpy) operation, it is found that, up to a distance of 150 km (93 miles), transporting products by truck would be less expensive than using rail cars and intermodal containers. Also, a case study is given in which a cost analysis is conducted for an underground coal mine receiving products from two Illinois utility plants. At 90 kt/year (100 thousand stpy) and a distance of 40 km (25 miles) between the power plant and the mine, it is found that truck transportation and under ground placement would cost $0.090/tkm ($0.131/st-mile) and $2.98/t ($2.70/ st), respectively.

Jan 1, 1999

By D. L. Jones, S. Knoerr, J. Mansanti

The Buckhorn Mine in Nevada currently treats oxide ore using heap leach methods, but exploration has identified sulphide reserves which are refractory in nature. Preliminary testwork was conducted on the sulphide material to screen potential pre-cyanidation treatment methods. Processes evaluated included pressure oxidation, biological oxidation, nitric acid oxidation and roasting. An initial economic and process analysis of the results concluded that roasting was the only viable process, and only if the roaster off-gases were converted to soleable sulphuric acid. Further economic analysis indicated that roasting of the whole ore was more attractive than pre-concentrating by flotation, followed by roasting of the concentrate. These results were generalized to show that for high sulphur ore a roaster/acid plant combination is more attractive that either of the other options, ie. pressure leaching or bioleaching, provided the by-product acid is soleable.

Jan 1, 1990

By Rob McIvor, Joe Keating, Gary Simmons

As more complex ores are processed, finer grinding becomes more necessary. A cross section of several industries will be presented with discussions not only of find grinding issues but also the classification of fine particles. JOHN MANSANTI: Our next topic will be fine grinding. Again, the intent is to present a topic that is generic enough to apply to multiple industries. Our first speaker is Gary Simmons. Gary is filling in for Phil Walker from Twin Creeks. Phil was not able to join us this week, because of some issues they're having with the autoclave. Gary, being involved in the development phase, is very familiar with the topic. Gary spent about three years with American Cyanamid and another four years with Noranda. He also spent some time with Meridian Gold, then became the director of metallurgy with Santa Fe Pacific Gold. He spent seven years there and is presently the director of process technology with Newmont Gold.

Jan 1, 1998

By Y. Topkaya, Lloyd Petrie, Dianne Marozas, R. E. Johnson, Steven Paulson, J. H. Canterford, B. R. Palmer, R. B. Bhappu, Lorin Redden

This paper describes a fundamental approach to in situ leach mining (ISLM) lixiviant development which emphasizes leaching selectivity through detailed characterization of mineral-solution interfacial chemistry and post-leach geochemistry. This experimentation and modeling approach consists of: (1) petrographic identification of reactive ore and gangue minerals; (2) determination of leaching kinetics of individual minerals through batch leaching tests; (3) evaluation of bulk solution geochemistry through column leaching tests; and (4) ISLM simulation of element species transport and geochemistry through core leaching tests. Recent results confirm good leaching selectivity for manganese, but reveal post- leach precipitation and permeability loss during core leaching experiments.

Jan 1, 1993

By I. Ehie, Y. P. Chugh

Physical mine modeling and computer simulation techniques were used to conduct technical feasibility and economic analyses of selected pit configurations for surface mining a single coal seam dipping at about 15% to a maximum depth of 46 m (150 ft). Pit orientations along the true dip (dipline), along the strike (strikeline), and along an apparent dip were studied. Physical models of each pit configuration were prepared first to delineate potential operational problem areas and also to furnish data for the computer simulation models. A dragline microsimulation, a shovel/truck simulation, and a surface mine cost analysis models were used to conduct the study. Sensitivity analyses were conducted on variables such as the pit width, block length, and seam pitch. The productivity (m3/h) of the mining equipment (dragline or stripping shovel) under each set of conditions was used to optimize the pit configuration. Both block length and panel width were found to significantly affect the dragline productivity. Larger size trucks were preferable to smaller size trucks in the pit con¬figuration along an apparent dip. The cost analysis results showed that the pit configuration along the seam dip was more economical than the pit along the strike or along an apparent dip for the mining condition studied.

Jan 1, 1987

By D. S. Holmes

Biological processes for metal solubilization and ore beneficiation are in widespread use today. There are also some promising new applications of biotechnology in the areas of metal concentration and toxic metal cleanup. Recent progress in genetic engineering promises both to revolutionize the existing biological process and to expedite the adoption of the new biological applications. But before it can do so effectively, progress must be made in many areas of fundamental research and in biochemical engineering. These issues are addressed with special reference to the biotechnology of semi-enclosed containers (bioreactors), dumps, heaps, in situ and under- ground leaching, and with respect to the biotechnology of metal concentration. Finally, certain biological considerations for bacterial strain improvement are discussed.

Jan 1, 1987

By Mark A. Alspaugh, E. A. “Bud” Viren

The driving force behind most advances in technology is need. In the early 1980s, underground coal miners in the USA wanted to build longer conveyors to handle larger capacities but continue to use fabric reinforced belting with mechanical fasteners. Conveyors with intermediate drives were certainly the answer but achieving reliable designs required a significant learning curve. Basic design methodologies had to evolve including advanced simulation of starting and stopping along with complex control techniques and logic. Some components also evolved as specific performance requirements changed Today, in addition to underground mining, the technology has been used extensively in the tunneling industry where the need is for control of belt tensions to negotiate tight horizontal curves. Even though intermediate drives are not used extensively on the surface yet, the lessons learned will find their way to long overland surface conveyance where smaller components are more available and reliable, and often with less capital cost. This paper will document the evolution of intermediate drive technology over the last 30 years and will show examples of its current use.

Jan 1, 2004

By V. T. McLemore

The Steeple Rock district in New Mexico is a major epithermal gold-silver district that exhibits district zoning. Five types of ore deposits occur within the district: •base-metal veins (with gold and silver) form the center of the district and occur along the Carlisle fault, •gold-silver veins along northwest-trending faults and outward from the base-metal veins, •copper-silver veins along the margins of the district, •fluorite veins along the margins of the district, and •manganese veins along the margins of the district. Areas of older acid-sulfate alteration occur throughout the district and also exhibit the following zoning: massive silica/chert zone (inner), silicified zone and clay zone (outer). This alteration overlies regional alkali-chloride (propylitic to argillic to sericitic) alteration. Synthesis of available data suggests the acid-sulfate alteration is related to a shallow, but older, epithermal hot-springs system. Subsequently, younger epithermal veins formed along faults.

Jan 1, 1996