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By D. Denton, L. Buckingham

The dry grinding and leaching circuits of the Barrick Gold’s new Roasting Facility at Goldstrike Mine in Nevada, USA incorporate well proven technologies in a unique combination. During the design of the plant, every effort was made to utilize the best available technologies from the perspective of capital, environment and operating costs. Crushing is a two stage process using gyratory and cone crusher. Ore is stockpiled and then reclaimed to two parallel dry grinding mills. The double rotator dry grinding mills include a drying chamber, coarse and fine compartments and utilize a gearless motor drive (GMD) or “wrap-around”. In-circuit product transfer is accomplished with air slides and bucket elevators. Finished product separation is performed by both static and dynamic classifiers with the final product captured in baghouses. Recycle of unfinished product utilizes cascade chutes. The final ground product reports to two 2000 ton roaster feed silos. The two-stage oxygen flu-solids roasters with their associated gas train are the subject of a separate paper. The cyanide leach circuit is a standard carbon in leach system with circular swept screens for interstage carbon retention. The loaded carbon is sent to the existing Goldstrike autoclave plant for stripping and regeneration. Tails, after cyanide destruction, are deposited in the existing tailings dam with tails from the autoclave facility. Throughout the circuit, Clean Plant Design criteria were used to assure environmental compliance, ambiental acceptability and ensure worker health and safety. The commissioning and operation of the double rotator grinding technology has been very successful at Barrick Goldstrike.

Jan 1, 2001

By AKIHIRO YOSHIMURA, HIDEKAZU KATO, KOTA TAKATORI, YASUNARI MATSUNO

Chalcopyrite (CuFeS2) is the most refractory copper mineral when treated in conventional sulfate media leaching systems. This is the first study to examine the use of a dimethyl sulfoxide (CH3SOCH3, DMSO) solution containing copper chloride (CuCl2) for the leaching of chalcopyrite. Leaching experiments for a copper concentrate composed mainly of chalcopyrite were conducted at ambient pressure at 313–413 K. The leaching fractions of Cu, Fe, S, Au, and As were investigated. It was found that 90% of the Cu was extracted in 2 h, and 94% was extracted in 4 h at 373 K, which is competitive with other conventional processes. A DMSO solution containing CuCl2 could selectively dissolve the valuable metals Cu and Au from chalcopyrite, but leave minerals with little economic value such as pyrite (FeS2) and As in the residue. Chalcopyrite is oxidized by cupric ion in proportion to the stoichiometric ratio of Cu in the concentrate to the initial cupric ion in the DMSO solution, which is enhanced by the presence of oxygen below 373 K.

Mar 12, 2021

By H. Sevim, M. K. Mohanty, Y. P. Chugh

The economics of “Conventional” and “Advanced Fine Coal Cleaning” (AFCC) circuits for refuse pond reclamation as well as active mine/preparation plant applications have been evaluated. The benefits of innovative tailings management schemes on the profitability of mining enterprises have also been evaluated as a part of this study. Analyses have been conducted for scenarios involving generation of two different product qualities of 5.81%, a quality that was obtained during AFCC circuit operation at SIU, and a more typical 8% product ash. The inability of the conventional circuits to achieve profitability while producing the lower ash content product is revealed from this approach. The spiral-only circuit is unable to produce a 5.81% ash product. A different version of the same circuit involving spirals and column flotation produced the desired product quality but could not maintain profitability. The AFCC circuits on the other hand, achieve net present values greater than $6 million, with return on investment in excess of 50%, in the water-only as well as dense medium mode, with and without tailings management. Addition of tailings management system to any of the circuits is found to enhance the project economics. The comparison of water-only and dense-medium applications of the AFCC circuits indicate a better suitability of the dense-medium circuit for producing premium quality products. Application of AFCC circuits in active mines offer better economics compared to applications in refuse pond recovery operations. The superior project economics are a result of reduced overhead cost and use of existing material handling facilities. Sensitivity analysis reveals the significance of capacity utilization on project economics.

Jan 1, 2002

By G. A. Grandy, P. F. Thomas, C. D. Danecki

When considering the mill drive system for a grinding application, a large number of questions must be answered. Depending on the mill size and type, the mill can be driven by several configurations of drive systems: a single low-speed motor connected to a pinion driving a ring gear, two low-speed motors connected to two pinions and driving a ring gear, or a gearless motor mounted directly. In addition, a gear drive system can have a reducer placed between a high-speed motor(s) and pinion(s) or a power path splitting pinion stand. In some designs the reducer is integral with the pinion stand driven by a high-speed motor. The technical and commercial implications of several mill drive options are presented. Initial cost, cost of installation, cost of commissioning, and cost of operation and maintenance are presented for each drive option considered. The impact of each drive system on the design, cost and operation of the overall plant electrical system is discussed. Also, consideration is given to mill drive availability, and the potential cost resulting from delays in plant production.

Jan 1, 2001

By J. Marts

Underground longwall coal mining sections are operated as sealed gobs if the coal is prone to spontaneous combustion. Sealing along the gate roads during longwall face retreat limits the flow of fresh air (oxygen) into the gob and, thus, deprives the spontaneous combustion reaction of oxygen. In a project sponsored by the National Institute for Occupational Safety and Health (NIOSH), researchers at the Colorado School of Mines have used computational fluid dynamics modeling to simulate the flow of gases in sealed longwall gobs. The models were validated using measurements and observations from the field and demonstrate that targeted injection of nitrogen along the gate roads inby the face can be used to control the size and location of explosive methane clouds within the gob and to minimize or eliminate the explosion hazard resulting from the formation of flammable methane-air mixtures.

Sep 1, 2013

By E. Giama, A. Macridis, A. M. Papadopoulos

ISO 14031 is an international standard that describes a process for measuring environmental performance evaluation by setting quantitative indicators and providing a structured approach for organizations to follow, independent of location, size, complexity and type of activity. It is not a standard for certification as ISO 14001 is, but it fits into the ISO 14000 series of standards and is intended to assist organizations to apply environmental management systems and obtain environmental evaluation. This case study’s main objective is to identify the interaction between ISO 14031 and ISO 14040-42. ISO 14040-42 is referring to Life Cycle Analysis (LCA) methodology. More specific, LCA is applied (based on the ISO 14040-42 standard) to stone wool’s production, the market dominating thermal insulation material, produced by bauxite and amphibolite. LCA is used as a decision making tool for the development of environmental indicators (based on ISO 14031 guidelines) and for environmental performance evaluation.

Jan 1, 2005

By Paul D. Tomlingson

There are huge benefits for mining operations that have a well-defined maintenance program that is understood and followed across the total operation. But for operations lacking a quality maintenance program, there is equal assurance that nearly every major maintenance problem can be traced to this omission. Few problems will be permanently corrected until such a program is implemented. Definition The maintenance program re-quires the interaction of all mine departments. Initially, the production department will request work and the maintenance department will identify work, principally through preventive maintenance inspection and testing efforts. Maintenance will then classify the new work to determine the best way to respond. Maintenance will plan selected major jobs to enable its crews to carry them out more effectively. Maintenance will schedule the planned work with operations. Supervisors will assign all types of work to their crews then, control the work through effective supervision. As work is completed, maintenance will measure the work using an accurate information system. Next, it will assess overall accomplishments against goals such as performance standards or budgets. In addition, the pro-gram would prescribe a means to evaluate every aspect of the operation as it affects maintenance so that necessary improvements or changes can be identified, prioritized and acted on. Such evaluations should be part of a mine-wide continuous improvement effort. A well-defined maintenance program is one of the best investments a mining operation can make to assure its profitability. Educating the total operation on the pro-gram assures long-term dividends from the investment.

Jan 1, 2008

By W. H. Pomroy

In its 2001 diesel particulate matter (DPM) rule for metal and nonmetal underground mines, MSHA established an interim concentration limit of 400 micrograms of total carbon (TC) per cubic meter of air (400TCµg/m3), and a final concentration limit of 160TCµg/m3, to be phased in over five years. Following a court challenge to the 2001 rule, MSHA, industry and organized labor reached a partial settlement of the litigation under which the agency agreed to issue a proposal to amend the 2001 rule by, among other things, changing the surrogate from TC to elemental carbon (EC), applying MSHA's traditional hierarchy of controls, and revising requirements for one-year special extensions for complying with the final DPM exposure limit. MSHA issued a final rule in 2005 converting the interim concentration limit from 400TCµg/m3 to 308 micrograms of EC per cubic meter of air (308ECµg/m3) based on a miner?s personal exposure. Pending further rulemaking, MSHA retained the final concentration limit of 160TCµg/m3. In May 2006, MSHA issued a final rule that clarified that the final limit of 160TCµg/m3 would be based on a miner?s personal exposure rather than as a concentration limit. The 2006 rule also phased in the final DPM limit in three steps over two years, beginning in May 2006 at 308ECµg/m3, followed eight months later in January 2007 with a limit of 350TCµg/m3, and finally reaching 160TCµg/m3 in May 2008. Also in the 2006 rule, MSHA committed to converting the 160TCµg/m3 limit to an EC limit in future rulemaking. This paper reviews the DPM exposure limits in the context of the MSHA rulemakings and discusses the DPM engineering controls that were utilized by mine operators to attain compliance with each progressively lower limit.

Jan 1, 2009

By R. W. Fedors, S. T. Green, G. R. Adams, C. Manepally, L. B. Browning

This paper provides estimates of large-scale temperature gradients that can be used to support modeling of natural convection and cold-trap processes in thermally perturbed drifts. Temperature influences estimates of the quantity and chemistry of water contacting engineered components (e.g., drip shields and waste packages) in a potential high-level waste repository at Yucca Mountain, Nevada. Temperature gradients drive natural convection and cold-trap processes, which could affect the distribution, quantity, and chemistry of liquid-phase water contacting drip shields (waste packages).The confluence of high temperatures, liquid-phase water, and high chloride may lead to corrosion of drip shields and waste packages. An overview of the evolution of environmental conditions in thermally perturbed drifts is presented to provide a context for the estimates of temperature gradients. A mountain-scale conduction-only model is used to estimate temperature gradients and temperature differences for a drift located at the center of a potential repository. Thermohydrologic models and heat transfer algorithms are used to evaluate the reasonableness of the conduction-only results. Estimates of temperature using an in-drift heat transfer algorithm account for the possibility of drift degradation and formation of a rubble pile on the drip shield. Temperature differences between the center and ends of the drift are estimated to rapidly increase to 80 °C soon after repository closure. That temperature difference decreases over time to 15 °C after 10,000 years. Local temperature gradients are generally estimated to be less than 0.2°C/m, though the gradients can be much larger near changes in lithology and near the end of the drift. The estimates of temperature gradients do not account for intermediate- and small-scale variations, such as those influenced by differences in heat loads between waste packages, intra-layer variations in thermal properties of the surrounding fractured rock, or localized drift degradation.

Jan 1, 2004

By Don F. Macfarlane

This paper describes the field application of the NTH fracture classification to rock encountered in the construction of the 9.6 km long, 10m diameter, Second Manapouri Tailrace Tunnel. Excavation of the tunnel was undertaken by TBM between 1997 and 2002, in gneisses, granitic and diorite rocks. The paper outlines an adaptation of the NTH fracture classification used during the geological logging of this tunnel. The NTH fracture classification was primarily applied to assess discontinuity spacing for tunnel support requirement decision-making. The paper includes some general comparison of NTH classes with overall penetration rate.

Jan 1, 2008

By W. D. Bachman

A study has been made of wet, autogenous grinding of disseminated copper ores, including testing of a large number of samples from Kennecott Copper Corporation's Chino mine. The efficiency with which the various samples could be ground was found to vary over an extremely wide range, even among samples taken from different locations within the same ore body. These variations in grindability can be qualitatively correlated with the composition of the rock and the fracturing and alteration that had occurred. Because of the large-scale non-homogeneity of disseminated copper ore bodies, extensive and careful testing of autogenous grinding is needed. An accurate correlation of the grinding data from various samples with the geology of the ore body and with mining plans will indicate if variations in grinding mill throughput can be avoided in practice by mixing or blending of mill feed and if, therefore, autogenous grinding can be applied successfully.

Jan 1, 1970

By W. F. McDermott

The transportation of solids by pipeline is not new. In 1891 a United States patent broadly covering a method of pumping coal with water was granted to W. C. Andrews. His pilot plant was constructed on what is now the site of the New York Public Library in Manhattan. His process was applied to pumping coal mine waste back into the worked out portion of coal mines. On October 26, 1967, the world's first long distance iron ore slurry line was put into service by Savage River Mines. The commissioning of this 5.0 million dollar installation climaxed three years of development, testing, and construction and proved the Company's faith in pioneering this unique transportation method for iron ore. This paper will discuss some of the more pertinent items in connection with that three- year period. Also to be discussed will be the operation of this line during the past eleven months.

Jan 1, 1968

By D. Keech

The Conveyor Equipment Manufacturers Association (CEMA) specification B105.1 “Welded Steel Conveyor Pulleys” adequately defines standard pulleys for most aggregate material handling applications. However, many aggregate applications demand pulleys of higher capacity and reliability than that offered by CEMA pulleys. This paper examines the CEMA Pulley Standard and pulley specifications for aggregate applications requiring greater capacity and reliability than the CEMA Pulley Standard. Higher reliability increases the uptime and has a lower total cost of ownership.

Jan 1, 2003

By R. L. Virta

Editor?s note: Each year, the June issue of Mining Engineering features an industrial minerals review. Several people put in a fair amount of time in developing the material for this issue. Thank you to the industrial minerals annual review editor, to the technical committees chair and vice-chair, and to the authors of the individual commodity profiles. Jim Norman, member SME, of GeoTrans Inc., is the industrial minerals annual review editor. Abani Samal, member SME, of Pincock Allen & Holt, is chair of the industrial minerals technical committees. Technical committee vice chairs include: ? Abani Samal, member SME, of Pincock Allen & Holt, agricultural minerals. ? Aaron McMahon member SME, of Pincock Allen & Holt, ceramics and refractories ? Bradley S. Van Gosen, member SME, of the U.S. Geological Survey, chemical raw materials. ? Mark Zdunczyk, member SME, of Continental Placer Inc., construction materials. ? Jerry Gauntt, member SME, of Marston, fillers and pigments. ? Michael Cheshire, member SME, of Indiana University, sorbents, filters and process aids. ? Candace Trimble, Oil-Dri Corp. of America, specialty minerals. Their help makes possible this June industrial miner-als issue. On behalf of ME readers, the editors thank them. Ball Clay Four companies ? H.C. Spinks Clay (owned by Lhoist Group), Kentucky-Tennessee Clay (owned by Imerys Group), Old Hickory Clay, and Unimin Corp. ? mined ball clay in four states in 2008. Production, on the basis of preliminary data, was 964 kt (1.1 millon st) with an estimated value of $45.3 million. That was a 10- percent decrease in tonnage from 1.07 Mt (1.2 mil-lion st) with a value of $49.2 million that was produced in 2007. Tennessee was the leading producer state with 63 percent of domestic production, followed by Texas, Mississippi and Kentucky. About 73 percent of production was airfloat, 16 percent was crude and 11 percent was water-slurried.

Jan 1, 2009

By Edward Hall Smith

The E1 Indio Mine is located in the Andes mountains about 180 kilometers East of La Serena, capital of the Fourth Region of Chile. It is reached by an international highway running up the Elqui Valley as far as Juntas from where the last 42 kilometers is on a road constructed by the Company. The plant is located at 3.900 meters above sea level among extremely rugged terrain with nearby mountains rising about 5.500 meters. Climatic conditions at these altitudes are severe with winter temperatures down to -20°C. Snow storms lasting several days and leaving up to two meters of snow have been experienced, while fierce winds are corm=.

Jan 1, 1984

By G. H. Lewis, C. L. Krcil, N. S. Harding, D. E. Havekotte

Introduction Limestone injection work was completed in a 440-kW (1.5-million Btu per hour) pilot-scale combustor in preparation for a 50,000-kg/h (110,000-lb per hour) industrial steam boiler limestone injection test program. The main objectives were to: (1) identify the important variables that affect sulfur capture, (2) determine the maximum SO2 removal, and (3) determine the effect of limestone addition on furnace operability and heat transfer. A more detailed report is given by Lewis et al. (1985). The test program was divided into two phases. The objectives of Phase I were to determine the important variables that affect SO2 reduction and to investigate the effect of limestone addition on combustor operation and heat transfer surfaces. The objective of Phase II was to determine, using only the important variables identified during Phase I, the conditions that resulted in the greatest sulfur dioxide reduction. Phase I Test program Using one limestone, five variables were identified as having an effect on SO2 reduction. These are noted with their respective ranges: heat release rate [103 to 166 kW/m3 (10,000 to 16,000 Btu per hour-cu ft)], Ca/S molar ratio (0 to 3), flue gas oxygen concentration (3% to 5%), additive particle size [90% -150 µm (-100 mesh) and 90% -45 µm (-325 mesh)], and burner stoichiometry (SR = 0.75 and >1.15). A 2.3% sulfur northern West Virginia coal, pulverized to a nominal grind of 70% -75 µm (-200 mesh), was burned for the tests. The limestone used was obtained from a Maysville, KY, quarry and contained 51.75% (wt) CaO. An 11-run statistically designed program (plus three duplicates) was used to screen the five variables. The effect of limestone injection on the combustor heat transfer surfaces was determined by comparing the heat transfer rates through a slag panel and fouling probes during periods with and without limestone injection. Combustor operation was determined by noting any operating problems that occurred during the tests. Test procedure After furnace wall temperatures had stabilized at operating conditions, heat transfer surfaces (slag panel and fouling probes) and the convection section were blown clean, and a four-hour test was begun. The

Jan 12, 1986

The technical parametrization of reserves is a technique which has made an important contribution to the definition and the calculation of optimal mining projects. Its applications to a new open-pit optimization program have already been presented in various papers (François-Bongarçon and Maréchal (1976); François-Bongarçon and Guibal (1981)). The present paper gives a brief description of the general problem of parametrizing reserves before going into the details of the practical algorithms used in two typical cases, i.e. open-pit mining and mining between hanging wall and foot wall.

Jan 1, 1982

By Hiroshi Soda, Atsumi Ohno, Hiroyuki Yamazaki, Alexander McLean

INTRODUCTION The method of heat removal during a casting process strongly influences the crystal morphology of the cast product and hence the metallurgical and mechanical properties of the solidified materials. In this paper, the Ohno Continuous Casting Process (OCC) is described in terms of the casting conditions and the type of structure observed in the cast product. Significant improvements are observed in workability, fatigue strength and corrosion resistance of castings produced by the OCC method, Ohno (1988). Applications of this technique to low melting point nonferrous metals and alloys are discussed. The feasibility of the application of this technology to high melting point materials is outlined. THE OCC PROCESS The OCC process involves delivering liquid metal into a heated mold, the temperature of which is held just above the solidification temperature of the metal to be cast. This is the key point which differentiates the OCC process from the conventional continuous casting method. A schematic illustration of the OCC process is shown in Figure 1. The Formation of a Single Crystal When the mold is heated above the solidification temperature of the metal to be cast, nucleation on the mold surface is prevented and solidification takes place only at the mold exit. The heat is extracted through the product being cast by a cooling device located near the mold outlet. Crystals are formed only at the tip of the dummy bar at the start of casting, and as the dummy bar travels away with a progressively increasing speed from the mold, the position of the solid liquid interface will align with the mold exit, producing a unidirectionally

Jan 1, 1990

By A. W. Popp

After forty years of exploration and development, the heavy mineral sand deposits of the Murray Basin are on the eve of substantial exploitation by Iluka Resources Limited, Southern Titanium NL and RZM/Cable/Bemax, whom plan to initiate mining and processing operations in 2005. A trial mining and processing operation was undertaken on the Wemen North strandline deposit in 2001-2003 by Murray Basin Titanium, a joint venture of Sons of Gwalia and RZM/Cable, which brought to light a number of mining and processing problems which have since been the subject of extensive studies and process development work. The mineralogy of these weathered strandline deposits is complex by industry standards due to the variety of the heavy minerals present, coatings on the mineral grains and the extensive weathering and alteration which has taken place during the past 50 million years. This paper provides an overview of the complex mineralogy that, in turn, dictates the processes that can be used to recover the valuable heavy minerals. The Murray Basin encompasses some 300,000 km2 and has been a depositional basin, often land locked, since the start of the Cenezoic Era. The economic heavy minerals include ilmenite, altered ilmenite, leucoxene of highly variable composition, rutile, and zircon. There are also other heavy minerals present such as cassiterite, chromite, and monazite in quantities that pose both problems and opportunities. The clay content and overburden thickness also play a major role in the selection of the deposits to be mined. Project Services Consultants (PSC) has undertaken the preparation of this paper as part of its ongoing participation in the mineral sands industry and in particular the project development activities in the Murray Basin region currently being undertaken by Iluka Resources. PSC has been involved with the mineral sands business for several years with senior staff having in excess of 30 years global industry experience. The company is well placed to provide a range of services to clients like Iluka Resources in the areas of project development, execution and strategic development and industry advice.

Jan 1, 2005

By D. Bedell, J. Robitalle, D. Macgilliveray

Agnico Eagle (Cadillac Quebec, Canada) selected the new Eimco PEC E – CAT™ clarifier thickeners for their counter-current decantation circuit, which handles approximately 200tph leached gold/silver ore. The E-CAT is based on rakeless ultra-high rate thickening technology that originated in South Africa. Four 9m diameter and two 10m EIMCO E – CAT ultra high rate, rakeless thickeners were installed in the fall of 2000. Thickening and clarification performance has been excellent. Problems with level control have been resolved and the plant personnel continue to improve the operating control techniques. The CCD circuit is critical to the success of the operation and good recovery. Data will be presented showing the wash ratios and recovery achieved. A brief history of the operation and the decision to utilize the CCD system will be presented.

Jan 1, 2002