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By A. K. Fallaw, G. Wang, L. R. Moore, S. Dobson, Y. Xiong, J. Gu

"As ores degrade, mining techniques and chemistries change to meet market demand and maintain product quality. The balance of recovery and grade is a significant challenge in the Crago Process where an anionic collector is used to float phosphate, followed by acid scrubbing, then an amine float to improve product grade. As the grade is a requirement for DAP and MAP production, recovery is the criteria to suffer. Phosphate losses in the amine float can bring overall recovery down by as much as 18%, creating a growing need to think outside the box to improve recovery. This paper will focus on the theory of amine tail recycling and the best methods to optimize the overall phosphate recovery by recycling the tails from the cleaner flotation step. INTRODUCTION In 2014 the total US phosphate production was down 13% over the prior year, from 31.9 to 27.1 Mt, which accounts for 12.32% of the world’s phosphate rock production. Florida and North Carolina phosphate production accounted for 80% of total US phosphate production, which was down from 85% the previous year. This decline is due in part to the closing of the last phosphate mine in Polk County, FL - which had an operating phosphate mine for over 100 years (Gurr, 2015). Another factor contributing to the reduction in contribution from FL & NC is the increasing challenges in beneficiating the remaining ore deposits. The Central Florida mining district has historically been in the Bone Valley deposit, where raw apatite was abundant with P2O5 values as high as 15%. The Bone Valley ore also had characteristics favorable to beneficiation to 27.5-29.7 %P2O5 while achieving recoveries above 86%. The move southward into the Hawthorne Formation has seen the ore feed grade hit some historic lows, and the matrix characteristics pose more challenges to phosphate producers. The Hawthorne Formation experienced lateritic weathering after the Bone Valley formation which altered the apatite to aluminum phosphate minerals, and alteration of montmorillonite to kaolinite, releasing MgO that caused the dolomitization of the top of the Hawthorne limestone (Cathcart, 1966). Elevated levels of dolomite can yield an increase in slurry viscosities, reduce production rates, and increase energy costs in the wet-acid fertilizer process. The MgO will also act to dilute grade, making it more difficult to achieve a standard 18-46-0 product (McHardy, 1981)."

Jan 1, 2016

By M. Zaske, E. R. Mortensen

"As mine operators continuously look for ways to improve functionality and increase the capacity of their facilities, existing process equipment is often pushed to and past its designed limitations. As a result, equipment manufacturers are asked for economical solutions to meet redefined processing needs. Newmont Mining in Nevada was faced with such a need in its carbon-in-leach (CIL) train. In a collaborative effort between Newmont and Derrick Corp., tests were conceived to assess the viability of drop-in replacement screens using a three-dimensional screen panel. The synthetic pyramid screen panel was designed to increase flux while maintaining the existing equipment footprint. The test is the end result of an ongoing research and development project that Derrick undertook in an effort to refine and upgrade its urethane screening media. The application of this new screening media is presented for this CIL application along with future plans to implement the technology in trash, safety, carbon dewatering, carbon sizing and other scalping applications.In spring 2014, Process Machinery Associates (PMA), Derrick’s local area representative, met with Newmont to discuss the operation of the in tank screens in the CIL train at Twin Creeks, near Golconda, NV. The process was originally designed for about 12+ kt/d (13,000+ stpd) but the throughput has been steadily rising since the plant was commissioned. Newmont now requires 14.5 kt/d (16,000 stpd) to be processed. The original screens were running at their maximum capacity, and Newmont required additional screening capacity to continue the upward trend in production.Physical separation by use of screening is one of mineral processing’s oldest methods. Screening media can be prone to blinding and pegging, and the necessary support structures required for finer apertures result in smaller open areas. Therefore, more screening area generally requires larger panels and, thus, larger machines, screening media that does not blind or a combination of both.In an effort to avoid larger machines, Derrick had been working on a revolutionary threedimensional panel that would add nonblinding screen area in the same footprint of an existing machine. Alpha testing of the new screen panels began at Newmont Mill 2/5 in July of 2013. It was still occurring when PMA approached Twin Creeks about beta testing a refined machine and pyramid panel. After presenting the initial results, Twin Creeks determined that an upgraded machine and pyramid panels would be a possible solution to meet production needs. The testing of a machine eliminated the risk of capital costs to Newmont and provided Derrick the opportunity to obtain additional data."

Jan 1, 2015

By Larry Murphy, Mohammad R. Jafari, David M. Giel, Sharat K. Kalluri

"Built in 1940’s to provide a key roadway arterial between New York and Boston, the Heroes Tunnel is the only highway rock tunnel in the state of Connecticut and is part of the Wilbur Cross Parkway. This 365.0 m long tunnel consists of two barrels, each with two lanes of traffic, and carries over 71,000 vehicles per day. For nearly 70 years, the tunnel has seen millions of vehicles pass through but time has taken its toll and now the tunnel lining, ventilation system and radial section joints are significantly deteriorated and in need of rehabilitation. Owned and maintained by the Connecticut Department of Transportation (CTDOT), CTDOT initiated a unique managed approach to mitigate the risk, social impacts and financial implications associated with rehabilitation of this tunnel. This new approach consists of performing field inspection and conducting a comprehensive study to explore six rehabilitation options, including construction of new tunnels and enlarging the existing tunnels. The main criteria for this study are: Impact on traffic and the resulting delay cost; Construction cost; Construction duration; and Construction complexity. This paper will present the results of the alternative study. PROJECT BACKGROUND Location and Importance Heroes Tunnel is located in the State of Connecticut within the Town of Woodbridge and the City of New Haven near the Town of Hamden border. Heroes Tunnel is the only true highway tunnel in the State of Connecticut. The tunnel is part of the Wilbur Cross Parkway (Route 15), a scenic connection between Hartford and New York. Originally constructed and opened to traffic in 1949, the tunneled portion of the parkway passes through the West Rock Ridge. The tunnel was originally named West Rock Tunnel, but was re-designated as Heroes Tunnel in 2003. Route 15 is a vital roadway within the State transportation infrastructure. In the vicinity of Heroes Tunnel, Route 15 carries approximately 71,000 vehicles daily. Locally, Route 15 provides access to residences, shopping centers, and points of interest, as well as other state roadways. Regionally, Route 15 connects New York to the Hartford area and serves as an alternate expressway route to I-95 and I-91. The tunnel is approximately 365.0 m long and passes through the West Rock Ridge. West Rock Ridge is an 11.3 km long rock ridge located on the west side of New Haven. A network of suburban streets abuts the mountain on all sides and a seasonal paved park road climbs to the crest of the ridge. Figure 1 depicts the tunnel topography and location."

Jan 1, 2016

By H. Cho

A study was undertaken to investigate the liberation behavior of coal macerals through size reduction and density separation. It was seen that the liberation of coal organic components could be achieved by size reduction, allowing selective separation of coal organic components. However, the degree of liberation is dependent on the history of coal: the extent of liberation decreased when the size of the primogeniture coal decreased. The liberation of coal macerals was analyzed by examining the Liberation Index. It was seen that although comminution produced fine particles enriched in inertinite (primarily fusinite and semifusinitie), these particles were less liberated than the coarser particles. However, the liberation of macerals increased when all the feed was ground to a finer size.

Jan 1, 1996

By H. V. S. Tingley, D. Helfant Ghose

"Ten years ago," said a mining industry personnel manager, "we used to wine and dine new mining engineering graduates. Now I can pick and choose among men with 10 years of experience." Comments like that are common throughout the industry today. During the 1970s, the US and Canada did indeed suffer from a severe shortage of mining engineers, especially experienced ones. Moreover, it seemed likely this North American shortage would worsen. Increased production of minerals and coal was pushing demand for mining engineers upwards, and there appeared to be substantial new employment prospects for them in the nascent synfuels industry. The oil majors entering the mining industry were pushing for an increased professionalization of mining management, heralding a trend towards higher intensity in the use of mining engineers. In response to the shortage, mining schools expanded their programs dramatically. By 1982, American schools were churning out more than 600 new mining engineers per year, compared to barely 200 in 1970 (Table 1). The timing of the explosion in the number of mining engineers could not have been worse. The downturn in the economy and the resulting slump in the mining industry coincided almost exactly with peak output of mining engineers. The market for mining engineers shifted from shortage to surplus with startling rapidity. The new crop of engineers, no longer courted by the mining companies, struggled to find any mining jobs. At the same time, experienced mining engineers found themselves thrown into the job market, some for the first time in decades. The current oversupply of mining engineers is assumed to be a temporary phenomenon. As the economy recovers, the demand for mining engineers is expected to pick up at least enough to absorb today's surplus. Not so, according to a recent study by Fenvessy and Schwab, a general management consulting and executive recruiting firm. In 1979, Fenvessy and Schwab was commissioned by a group of major mining companies to conduct a worldwide study of supply and demand for mining engineers to the year 2000*. The study began at the height of the North American shortage. One major objective of the study was "to identify means by which business and educational institutions may cope with and alleviate a future shortage of mining engineering talent." The findings, however, ran directly counter to expectations. The current oversupply will not disappear with economic recovery, the study concluded. In fact, the US and Canada are facing a massive oversupply that will probably last until the end of the century, unless enrollments in schools are reduced. Study Method Fenvessy and Schwab's conclusions are based on supply and demand models for mining engineers that it developed in the course of the study. Specifically, predictions for the supply of mining engineers are based on a survey of the 54 mining schools that account for about 90% of the world's annual output of mining engineering graduates. This survey asked for data on historical and projected number of graduates, obstacles to further expansion, changing trends in the use of mining engineers, and graduate career patterns. Fenvessy and Schwab developed three mining engineering supply scenarios from the survey data. The high case, considered unlikely for most of the industrialized world, is based on a continuation of the 1970's soaring growth rates. The middle case was established from the mining schools' own estimates of future growth in the number of graduating mining engineers. Finally, a "low growth" case for the US and Canada assumed that the number of graduating engineers will remain at current levels. Mining engineering demand was forecast using a complex model based on the demand for 50 major minerals. Formulas were

Jan 9, 1983

By L. Mao

A first-order flotation rate equation was derived by incorporating both hydrodynamic and surface forces involved in bubble-particle interactions. The hydrodynamic forces were calculated using an appropriate stream function, while the surface forces calculated using the extended DL VO theory. The equation was used to predict flotation results as functions of several important parameters such as contact angle, Zeta potentials of air bubbles and particles, and bubble size. The predictions are consistent with experience, and can be explained in view of the various sub-processes considered in the model.

Jan 1, 1997

By Steve Skelhorn, Dan Ifrim

"A tunnel project poses many challenges; the operation of the Tunnel Boring Machine (TBM) being one of them. Mechanized tunneling is known as a safe and effective alternative to other methods in terms of schedule and cost; however, efficiency can be severely affected by a bad TBM selection and qualification and employment of inexperienced operators. The success of a mechanized tunneling project involves a comprehensive and interdisciplinary consideration of all contributing factors such as TBM technical specification and selection, TBM design and procurement including ancillary equipment and tunnel linings. The tunnel equipment selection along with the operation can make or break the project. The objective of this paper is to address the importance of the skills and qualifications of the TBM crew with particularity to the TBM Operator. The study includes the Owner and Consultant involvement in the selection and pre-qualification of the TBM crew and specifically the TBM operator as well as the role of Contractor and TBM manufacturer in TBM operator training. This paper also analyzes the possibility of issuing a TBM operator certification, and discusses the benefits and significance of periodic training and certification programs. INTRODUCTION Training in the tunneling industry is not a new topic. The industry continues to evolve and become more complex with technology advances and expansion of mechanical tunnelling to mechanized shaft construction, large diameter drilling and mining industry applications. The need for professionals trained to operate mechanized tunnelling equipment is ever increasing, while there is a significant number of veterans who will be ageing out in the next 5 years. Consequently attracting young professional is a very important aspect of sustaining a qualified pool of professionals. For any given tunnel project, the owner and the engineer spend up to several years, studying the ground conditions during preliminary and final design. Post contract award the contractor spend additional months studying the ground again to develop the optimum means and methods for construction. All this time and money spent at the beginning of the project has the purpose of developing the optimum tunnel design, assessing the risk associated and implementing mitigation measures to reduce risks to acceptable levels. Following the tunnel design process, sophisticated TBMs are being specified and sourced to ensure the best tool for the job. The question raises here: Are there available experienced/trained professionals capable of operating these sophisticated machines?"

Jan 1, 2016

By M. A. Mahtab

This paper presents the results of a parametric study of the influence of natural features (stress field, rock strength, and strength and orientation of fractures) as well as the influence of induced features (undercut span, boundary slot, and other boundary-weakening measures) on the cavability of an undercut block of ore in mining by the block-caving method. The two-dimensional finite element analysis technique was used for this study. A coarse "mesh," along with linear homogeneous assumptions for rock properties, was used to model the problem of initiation of caving in a block of ore. Interpretation of the test results suggests that weakening the "abutments" of the block as well as certain orientations of natural fractures exercise significant influence on cavability. These findings hold promise for immediate application to known situations in block-caving mines.

Jan 1, 1975

By E. Topuz, J. Mastoris

The problem of defining the optimum final limits of an open-pit mine has challenged the mining industry for the last three decades. The difficulty results mainly from the great number of variables involved and from the sheer computational effort required in real-life applications. An actual lignite deposit is used in this study to introduce and apply a new methodology that can be used as a basis for surface-mine design optimization. A geologic-reserves model of the deposit is first developed with the use of an integrated geostatistical-modeling package. The model is transformed into an economic one through the use of flexible objective function formulation(s). The final open-pit limits are then optimized using a competent commercial optimizer, and comparative-sensitivity analyses are performed to study the effect of some basic mining and economic parameters on the optimal pit design. The conclusions drawn can develop useful guidelines for decision making by the mine operator.

Jan 1, 1996

By Lawrence Lien

The reduced need for traditionally trained and educated personnel in the mining industry is systemic to the changing mining industry. Universities and other training institutions are meeting the traditional skill needs required by the industry, but are the skill needs going to be the same in the near future? The answer may be no. Mining is changing because of increased liabilities and costs of environmental and safety is-sues; lower grades of minerals in traditional mining activities and the advent of new bio-chemical processes and robotic equipment. More productive and economic alternatives, and larger, more sophisticated and automatic equipment, are also changing the industry. Engineering is more specific, accurate, precise and expensive. Measurement is more thorough and timely of progress, production, costs and productivity. And, the industry will likely be engaging in more undersea mining, possibly space-based processing, less human interaction and more remote control of events than was previously thought possible.

Jan 1, 2011

By T. Tomioka

1. An Overall View of the Japanese Ferroalloys Industry 1) Depressed Demand for Ferroalloys: In Japan consumption of ferroalloys in the last ten years has decreased, although there has been some fluctuation from year to year. During this term production figures of the steel industry, which are closely related to consumption of ferroalloys, are as follows: Shipment of steel products for the domestic market has declined gradually from 69 million tons in 1979, which was the peak year for steel production, to 60.3 million tons in 1982 and 60.4 million tons in 1983, the level of 1978. In addition, exports also have been a downward trend since 1976, which was the peak year with tonnage of 34 million tons, to 28 million tons in 1982 and 31 million tons in 1983.

Jan 1, 1984

By R. L. Grayson

Compliance standards for respirable dust, which are reduced because of high quartz concentrations, have become an industry-wide problem. Research on the physical and chemical character of quartz-classified particles in respirable coalmine dusts indicates that they mine exist in intermixed layers or may be coated by clay or coal material. The relative amount of intermixing varies with the coal seam being mined. If most of the quartz particles of a mine dust are "pure," then the dust may have a high fibrogenic risk potential because of truly free silica and the compliance standard should be lowered. If, however, the quartz is locked inside another material matrix or coated, a reduced compliance standard may not be appropriate.

Jan 1, 1992

By Hassan El-Shall, M. N. Ahmad, Ponisseril Somasundaran, C. R. Holland, G. M. Walker, N. Iles, R. D. Chandler, Regis Stana, B. Duddy, Patrick Zhang

Phosphoric acid is a major raw material for the production of ammonium phosphate (AP) that is used as an intermediate in fertilizer production. Impurities within commercial grade wet process phosphoric acid are important in producing a fertilizer granule with good handling properties. The impurities identified as being important are; iron (III), aluminium and fluorine-containing compounds. Results show that the viscosity of the AP slurry produced increases by increasing the amount of impurity in the acid. Bench scale tests have been successfully replicated on a plant scale leading to a better understanding of the composition of impurity levels within phosphoric acid required to produce a high quality, free flowing, hard, spherical and non-caking granular fertilizer.

Jan 1, 2002

By R. L. Grayson

Compliance standards for respirable dust, which are reduced because of high quartz concentrations, have become an industry-wide problem. Research on the physical and chemical character of quartz-classified particles in respirable coal mine dusts indicates that they may exist in intermixed layers or may he coated by clay or coal material. The relative amount of intermixing varies with the coal seam being mined. If most of the quartz particles of a mine dust are "pure," then the dust may have a high fibrogenic risk potential because of truly free silica and the compliance standard should he lowered. If, however, the quartz is locked inside another material matrix, or coated, a reduced compliance standard may not he appropriate.

Jan 1, 1991

By A. Bruynesteyn

Procedures are discussed to determine if a waste material can become acid producing when left exposed to the environment. When wastes proves to be acid producing, methods are described that can be used to determine the characteristics of the effluents produced from a commercial size waste dump, taking into consideration that large quantities of pollutants can accumulate inside a waste dump during dry periods. The length of such dry periods and the quantity of rainfall greatly affect effluent characteristics.

Jan 1, 1980

By R. W. Smith, J. Dubel, M. Misra

The bacterium Mycobacterium phlei is highly hydrophobic and negatively charged. It has specificity for selective adhesion to fine coal particles, mainly due to hydrophobic interaction. However, it does not attach to pyrite and ash forming minerals present in the coal matrix. Results have shown that this bacterium is an excellent flocculant for fine coal. Not only, are the coal particles visibly aggregated, but the optical micrograph has shown that the coal particles are held in the aggregate by adhesion and bacterial bridging. With Mycobacterium phlei, the flocculation characteristic of coal is markedly different from that usually observed with synthetic polymeric flocculants. In particular, the entwining characteristics of the long chain molecules of synthetic flocculants are absent in the case of Mycobacterium phlei. Since the hydrophobic interactions between the adhering particles are of greater importance in the formation of particle aggregation, the flocculation process is very selective.

Jan 1, 1994

By Bernd Hagenah, Hans-Peter Vetsch, Eric Jones, Sean Cassady, Danielle Johnson, Petr Pospisil

There are a number of issues associated with freight trains in non-electrified tunnels that are fundamental during the planning and operation of a rail tunnel. During uphill operation, increased air temperatures at the air intake locations of diesel trains can reduce diesel motor efficiency (stalling/choking) and affect HVAC systems. Strong airflows can aggravate fire scenarios due to fanning or water-reactive cargo materials. This paper focuses on the impact of freight trains on tunnel safety concepts, strategies to overcome heat issues at locomotive air inlets and air quality in tunnels operating diesel trains.

Dec 1, 2022

By Huijun Shao, Qiang Liu, Zhengming Yi

The increase of the proportion of high Al2O3 content iron ore fine in iron and steel enterprises has brought about a series of problems such as the increase of the viscosity of blast furnace slag and the difficulty of the separation of slag and iron. In order to solve this problem, the effect of increasing MgO content on the technical and economic index, the cold strength, and metallurgical properties of high basicity and high-alumina sinter was studied through sinter pot test. Nova400NanoSEM field emission scanning electron microscope was used to analyze sinter microstructure. The experimental results show that when the MgO content fraction in the sinter with high basicity and high aluminum increases from 1.72 to 2.49%, the vertical sintering speed decreases by 4.38mm/min, the utilization coefficient decreases by 0.51t/(m2 h), and the low-temperature reduction degradation index increases by 6.7%. When MgO content in sinter is 2.11%, drum index and reducibility index are the highest, reaching 61.93% and 86.39% respectively. Mg2+ is mainly solid dissolved in the magnetite lattice and replaces Fe2+, up to 3.64%. The generated magnesie-containing magnetite inhibits the phase transition from Fe3O4 to Fe2O3 oxidation process in the sinter cooling process, which reduces the generation of secondary hematite and is conducive to improving the low-temperature reduction degradation performance of sinter.

Jul 4, 2021

By J. Jeremy Burden, Bruce S. Brown

A major question in the design and permitting of a tailings storage facility is the quality and quantity of seepage which will occur from the base of the tailings facility into the underlying foundation and groundwater regime. A corollary to this is what liner system, if any, is necessary to protect the groundwater regime from unacceptable contamination. Modern tailings storage facilities are generally designed as drained tailings deposits whereby all free water is removed from the facility by decant, drainage and evaporation. This removes the source of on­going seepage and allows for efficient and timely reclamation of the facilities. Quantifying the residual seepage from the base of the tailings deposit is complicated due to the following factors:

Jan 1, 1992

By A. English, Edward Martinez, L. A. Haas, N. W. Johnson, Harrison Copper, M. E. Tawil, C. C. Harris, G. V. Jergensen, D. Halbe, M. P. Amsden

Declining US ore grades along with skyrocketing energy, materials, labor, and regulatory costs underscored the urgency for technological innovation in the mineral processing area. Re¬liance on the scale-up and automation of unit operations was the sector's primary battle plan. Debate continues on the upper size limit of concentrating plants and whether process controls should be centralized or distributed in the mill. In the materials handling area, the economics of large-scale and mobile systems, particularly conveyors, were well documented in the literature. Comminution, the most costly and energy consuming area of the processing flowsheet, saw improvements in process controls and liner designs. The trend toward larger grinding units stalled somewhat during the year owing to some operational problems at commercial plants. Research and development of apparently less expensive physical separation processes-that also boast recovery of cleaner and more environmentally acceptable products -gained momentum during the year. Because of escalating capital cost requirements for new plant capacity, the year saw a greater interest by mill designers to re-examine existing capacity. The focus here is clearly to modify or retrofit unit operations with more efficient components as an alternative to installing more costly new equipment. The problems facing the processing sector during the 1970s can be expected to continue in the decade ahead. Technological gains from scale-up and process controls appear

Jan 5, 1980