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By William E. Horst

Ore grindability data based on various techniques to measure comminution characteristics are used to evaluate the crushing and grinding efficiency in mineral processing operations. The importance of achieving improved comminution efficiency, in terms of energy consumption, has been emphasized by recent increases in the cost of electricity. From a theoretical standpoint, the objective of a grinding operation might be expressed as maximizing the production rate at a given grind size while minimizing the energy consumption per ton of material ground. To achieve this objective in an industrial operation presents a challenge especially in view of changes in the raw material which are normally encountered. Various procedures1-5 used to determine energy-size parameters and grindability measurements have been reported. The proposed relationships between particle size and energy consumed have much in common between many of the techniques for measuring grindability. Probably the most widely used parameter to measure ore grindability in recent years is the Bond work index6, Wi, which is defined as the kw-hr per ton required to break from infinite size to a product size of 80 percent passing 100 microns. If the breakage characteristics of a material remain constant over all size ranges, then the calculated work index would be expected to remain-constant since it expresses the resistance of material to breakage. However for most naturally occurring raw materials differences exist in the breakage characteristics depending on particle size, which can result in variations in the work index depending on grind size. Consequently work index values are generally obtained for some specified grind size which typifies the comminution operation being designed or evaluated.

Jan 1, 1975

By Terence G. McCusker, E. Roy Anderson

A four-mile length of interceptor sewer tunnel in Manhattan has finished sizes ranging from 10'6" to 14'6" horseshoe. Mixed face conditions were anticipated in three areas and encountered in five. All were short but since the tunnel lies well below the water table and failures would involve important utilities, major structures and human lives, great care had to be exercized in choosing a construc¬tion method. Chemical consolidation was selected as the best approach with compressed air working as a backup system. Initially grouting was accomplished from within the tunnel, but treatment from the surface was more successful and was later adopted. The soils consisted largely of impermeable weak silts and it was found possible to inhibit access of water to this material so that it could be controlled by breasting within the tunnel without loss of stability. It is concluded that in the interlayered permeable and impermeable soils encountered, chemical grouting would successfully stabilize the working face. INTRODUCTION An interceptor sewer is currently under construction along the entire length of the west side of Manhattan. When complete, the tunnel will intercept and divert to a treatment plant (also under construction) a daily flow in excess of 200 million gallons per day. About 9 miles of the interceptor sewer is in tunnel and the remain¬der is cut-and-cover construction. The tunnel is almost entirely in Manhattan schist but where its alignment crosses major faults at comparatively shallow depths, mixed face and earth conditions are

Jan 1, 1997

By E. J. Ostrowski

The history of ironmaking dates back to 4000 BC when an open forge was used to produce a sponge iron from a heap of ore and charcoal. Even at this early date, man recognized the need for a fuel and a reducing agent. As time passed, man developed new methods of producing iron; however, these developments were centered on the mechanical aspects, and as a result, a furnace evolved which is now known as a blast furnace. During this period of evolution,' man struggled with the only fuel he knew - charcoal. Some 5600 years passed before any attempt was made to use coal as a fuel for the blast furnace. The use of coal had its beginning in 1619 when Dud Dudley of England first attempted its use in the blast furnace; as a-fuel and as a reducing agent. Coal charged to the top of the blast furnace was not satisfactory. The volatile matter of the coal choked the flues, and also the poor, strength qualities would not support the weight of the ore. Breaking up of the coal compacted the stock column to an impervious mass. One hundred and sixteen. years later in 1735, Abraham Darby of England introduced coke as the fuel and reducing agent in the blast furnace. The acceptance of coke as a fuel for the blast furnace was not spontaneous. As late as 1870, one-half of the pig iron product of the United States was made with anthracite coal, 30 per cent with raw bituminous coal and coke, and 20 per cent with charcoal. However, by 1910, 96.2 per cent of the blast furnace product was made with coke, 2.4 per cent with anthracite and coke admixture, and 1.4 per cent with charcoal. Coke became the standard fuel in the blast furnace. As the art of ironmaking progressed, more pig iron was produced and more coke was consumed. Coke oven capacity was progressively increased. In 1910, there existed approximately 4,000 coke ovens; in 1960 there was approximately 15,000 ovens. This increase in coke oven capacity was necessary to feed the mammoth appetite of modern blast furnaces.

Jan 1, 1962

The height of permanent slopes at the Panguna mine of Bougainville Copper Limited will vary from 350 to 950 metres. A few degrees difference in slope angle has a large effect on the ore/waste stripping ratio. Optimum slopes can be achieved if longer batter slopes (exceeding 45m height) are excavated using bulldozers to trim parallel to controlling fracture surfaces. Unnecessary slope flattening by incorporating benches can cost millions of dollars in lost ore. Faults and other major weaknesses, which can result in wedge failure or erodible zones have been treated successfully with shotcrete, rockbolts and cable dowels. To minimize support effort and interference with mine production, early identification and treatment of unstable areas is important.

Jan 1, 1987

By B. W. Cavender

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

Jan 1, 1992

By Elwyn H. King, Thomas R. Kuesel

I. CONCEPT MARTA's Peachtree Center Station is being mined out of hard rock, directly beneath Atlanta's central business district, with minimal surface disruption during construction. Its cost is competitive with that of a conventional cut-and-cover alternative owing to its design concept, which utilizes the rock as a primary structural and architectural material. II. PLANNING The station was originally planned for cut-and-cover construction. However, Peachtree Street is unusually narrow for a main business street (generally 78 feet (24 m) between building lines) and cut-and-cover construction would therefore be very disruptive to surface traffic and severely restrict access to adjacent buildings, including Peachtree Center, Atlanta's showcase business/commercial complex. (See Fig. 1.) Tunneling had been considered, but was initially thought [ ]

Jan 1, 1979

By D. R. Taylor

Treatment of bentonite clay with mineral acids yields a modified clay product of high surface area and acidity which exhibits enhanced adsorptive and catalytic properties. A highly specialized segment of the clay industry based on this process has evolved into worldwide business with a capacity of about one-half million tons/yr. This paper will present data on the chemistry, mining, manufacturing and applications for acid- activated clays.

Jan 1, 1986

By C. Hosten

This paper presents the results from an extensive research program on the vacuum filtration of iron ore slurries. Experiments were conducted with the addition of several types of flocculants and surfactants. The filtration response of the slurries was studied in terms of the cake formation rate and the residual cake moisture. An analysis of the results is presented in ascertaining the role of flocculants and surfactants during filtration

Jan 1, 1983

By Leons Kovisars

Two-thirds of the world copper produced in 1979 incurred cash costs between $0.35 and $0.89 per lb, averaging $0.62 per lb. North American costs are higher at $0.48, $0.88, and $0.68 per lb, respectively. Variable cash costs are $0.20, $0.58, and $0.39 per lb for the world; $0.29, $0.63, and $0.46 per lb for North America. Cash costs are relevant for comparing existing operations and evaluating market pricing during periods of excess supply. Analysis of full costs of production (cash costs plus income taxes, profit, and non-cash items) becomes relevant in evaluating the incentive price required to develop new production plants. In mid-1979 this cost (incentive price) was about $1.10 per lb; it is expected to approach $2.00 per lb by 1985.

Jan 1, 1979

It was shown previously that chalcopyrite could be floated without using a collector when the ore samples were treated with small amounts of sodium sulfide (Na2S). The role of this reducing agent was considered to be one of a cleaning agent to remove the hydrophilic surface oxidation products. It was later found, however, that the collectorless flotation could be obtained only under slightly oxidizing conditions. This might suggest that collectorless flotation is not due to the clean surface but to the elemental sulfur which may be present as an incipient oxidation product. Therefore, a search for the presence of elemental sulfur has been made by means of ESCA, mass spectrometry, and solvent extraction followed by W spectrophotometric analysis. On the basis of these results, the mechanisms of collectorless flotation are discussed.

Jan 1, 1983

By R. D. Lopez

The concept of "heat recuperation" for the grate-kiln pelletizing system was first implemented at the Sydvaranger plant in Norway in 1974. Essentially, heat recuperation involves bringing hot air from the second stage of the pellet cooler to the drying zone to increase drying-air temperature to the maximum limit. 'Burner-fuel savings result from a lower kiln secondary-air mass flow at a higher temperature. Because of the fuel benefits achieved at Sydvaranger, heat recuperation has been included innumerous new grate-kiln plants built since then, and some older plants have been retrofitted for heat recuperation. In recent years there has been much confusion about the fuel benefits of heat recuperation. To answer some of the questions, a mathematical model was developed and plant tests were conducted at Minntac Phase 111. Minntac is a magnetite taconite concentrating and pelletizing plant, and Phase III has two indurating lines. This paper presents the results of the studies and plant tests.

Jan 1, 1980

By B. C. Haydon

Manganese silver ores are well known to be refractory towards cyanidation. Various processes have been suggested for improving the amenability of these ores. A sulfurous acid pre-leach is one such process. This paper traces the development and implementation of the sulfurous acid pre-leach process for the retreatment of manganese silver tailings at Tonopah, Nevada. An account of the test work program is presented, followed by a description of the operating plant and specimen metallurgical performance. The paper also summarizes the history of the Tonopah tailings, their mineralogy and makes reference to previous application of the sulfurous acid pre-leach process.

Jan 1, 1984

By David A. Lee

It was estimated in Chemical Week1 that the uranium fuel requirements for the U.S. Electric Utility Industry by the mid 1980's would be about four times that-of what it is today. This corresponds to approximately 45,000 tons per year of 'yellow cake' - of which a good portion is represented by ammonium diuranate - vs. the 11,700 ton total estimated for 1975. Perhaps just as significant is the 40-fold increase in thirty years projected for the entire world since 1970. Thus by the year 2000. 'yellow cake' production could be in the order of [3]50.000 short tons annually.2 'Yellow cake', so named because of its inherently bright yellow color, is a finely divided precipitate that can be formed after the leaching step when refining uranium ores. Feed solids enhancement then occurs to at least 50% by weight using filters or centrifuges This is followed normally by drying and then calcining with the conversion of ammonium diuranate to triuranium octoxide represented by the following equation: [9 (NH4)2 U2 07 heat 14 NH3 7 + 15 H2O7 + 2N2/ + 6 U308 4] Theoretically, assuming 100% conversion every 100 kgs. or 100 lbs. of ammonium diuranate will result in 90 kgs. or 90 lbs. of triuranium octoxide.

Jan 1, 1976

By Brig M. Moudgil

It was reported earlier that francolite and dolomite from the South Florida deposits cannot be selectively floated using conventional conditioning with sodium oleate as the collector. However, dolomite could be separated from francolite if the minerals were first conditioned at pH 10 followed by reconditioning at a lower pH. An optimum separation was achieved at a reconditioning pH below 4.5. Reconditioning pH and collector concentration were determined to exert a major influence on the selectivity. Flotation, adsorption and transmission infrared spectroscopic results are presented to elucidate the mechanisms underlying the observed selectivity.

Jan 1, 1984

By J. H. Elledge

Hydraulic Transportation of Phosphate Ore from, a 40,000 Cubic Yard per Day Strip Mine IMC is transporting 1500 yards per hour of phosphate ore in a water slurry a distance of approximately five miles from a strip mine to a flotation beneficiation plant at their Noralyn Operation. in Barrow, Florida. This ore, which consists of approximately 1/4 phosphate, 1/2 silica sand, and 1/4 clay slimes, is being pumped through a 20 inch O. D. pipeline using seven 20 and 18 inch GIW metal pumps direct connected to electric, motors. This paper details some of the problems involved and the specific methods used to accomplish this bulk material handling requirement.

Jan 1, 1966

By Sean Harvey

One of the manifestations of the dynamically induced failures in deep coal mines is the violent ejection of coal from the ribs. A possible protection against such failures is the use of a specifically designed dynamic support system with reinforcement units having the sufficient capacity to absorb the kinetic energy of the dynamic failure and a skin support that can adequately contain the disintegrated coal. With this method of mitigation in mind, a recently introduced yielding rock bolt, trade name Roofex, has been identified (Harvey and Ozbay, 2009) as a possible energy absorbing component of a dynamic support system. According to the manufacturer?s specification, the Roofex bolts can yield 300 mm (or more) displacement while holding 80 kN pull load. In order to assess the performance of this support unit in coal ribs, a series of in situ pull tests performed in two coal mines in Colorado. The results show that, under conventional pull test loading conditions, Roofex yielding bolts perform very close to their claimed specifications, thus showing a potential for their use as the main energy absorbing component of a dynamic support system. Further studies are required to confirm the in situ performance of these bolts under dynamic loading conditions and also to develop a containment component for a dynamic support system for the mitigation of dynamic coal rib failures.

Jan 1, 2009

By J. H. Bassarear

Conventional crushing and grinding circuits are compared to semiautogenous circuits. Recent installations of each circuit are reviewed and seven methods of using autogenous or semi- autogenous techniques are described. Steel and power consmption data are reported and benefits of a dedicated digital computer are discussed.

Jan 1, 1981

By J. J. Pavlica

Grinding in steel mills adversely affects the flotation removal of pyrrhotite from magnetite ores. To elucidate the effect of grinding media on the floatability of pyrrhotite, rest potential and short-circuit current measurements were made on electrode combinations of pyrrhotite-mild steel and pyrrhotite-stainless steel. Galvanic contact of pyrrhotite with mild steel increased the rate of surface reactions on pyrrhotite in air-exposed and oxygenated solutions. It was postulated that the formation of ' an iron hydroxide coating on the pyrrhotite adversely affected its floatability. Its formation was minimal when pyrrhotite was contacted with stainless steel. Fine magnetite particles caused slime coating on pyrrhotite surfaces by magnetic interaction and impaired the flotation of pyrrhotite.

Jan 1, 1982

By R. L. Grayson

For the years 1990 and 1991, West Virginia's underground coal small-mine fatality rate « 20 employees) was approximately ten times higher than the national coal industry rate. Although the total number of fatalities decreased to 17 in 1992 (from 22 in 1991), West Virginia still led ,the nation in coal mining fatals. A team of mining and safety professionals from West Virginia University studied the problem over the past year, interfacing with the Mine Safety and Health Administration and the West Virginia Office of Miners' Health, Safety and Training. A clear path for 'formal intervention was determined and is presented here.

Jan 1, 1994

By Kourosh Shahriar

The occurrence of rock falls in underground coal mines entails detrimental effects as fatal or non-fatal injuries on workers, stoppages in mining operations and breakdown of equipment. In this paper, a risk assessment approach on the basis of a decision analysis trend is employed in order to assess the possibility of and manage roof falls. Risk is then assessed by determination of likelihood of occurrence and the cost of consequences (outcomes). In this regard, collected real roof fall data from Tabas and Kerman coal regions comprising of several underground coal mines are used. It is concluded that the annual accidents due to the roof falls occurrence in the all investigated mines are so high that it is economically feasible to improve the support systems and to implement a suitable educational program as well as an accurate supervision and other elements of safety management.

Jan 1, 2009