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By Robert Hochscheid

When the original water-only cyclone patents were established in the 1950?s, the supplies of low cost oil and natural gas were abundant and low selling prices for metallurgical and steam coal provided little incentive for developing more sophisticated coal cleaning systems. Bituminous coal sold for less than $5.00 per ton, and in this period many domestic coal producers discarded to the slurry pond the coal finer than 0.5-mm. For many producers, the selling price would not permit the recovery of the capital and operating costs required for dewatering and drying the fine coal. Water-only Cyclones Clean Fine Metallurgical Coal The first broad interest in the water-only cyclone became evident in the mid- 19601s, and though some work was done on coarser coals, investigators were particularly interested in cleaning coal finer than 0.5-mm. Flotation was the only fine coal cleaning method that was broadly accepted, but short-comings were recognized and investigators were looking for an effective fine coal cleaning device or system. Because of the greater market value and the need for reducing pyritic sulfur in metallurgical coals, much of the development work of the 1960's was done on coking coals.

Jan 1, 1981

By Peng Gao

Coal-based reduction followed by magnetic separation is an innovative technology used in processing refractory iron ores. Given that size is essential to the separation of the metallic iron from the gangue, the morphology of metallic iron particles and their evolution during coal-based reduction are investigated in the present work. The size of the metallic iron particle increased from 128.76 µm to 565.70 µm when the reduction time increased from 20 min to 60 min at 1,225° C and C/O (i.e., the amount of coal addition in terms of the gram-atomic ratio of the fixed carbon in the coal added to the combined oxygen in iron oxides) of 2.5. Based on our microstructural and metallographic analysis, the iron ore reduction process can be divided into three stages: (1) metallic iron particle formation, (2) iron oxide reduction and metallic iron assembly and (3) metallic iron particle growth. Almost all iron oxides are reduced to metallic iron in the second stage. These newborn metallic iron particles are energetically active and able to assemble and grow, and are eventually separated from the gangue. The large metallic iron particles benefit the subsequent magnetic separation process.

By Donald P. Richards

Is a shaft the same as a tunnel and can it be approached in the same manner for design and construction? The most obvious difference between a shaft and a tunnel is that of orientation; whereas a tunnel is commonly near horizontal or slightly dipping, a shaft is commonly vertical or steeply inclined. As a result, design and construction methods employed for tunneling, in general, cannot be directly applied to shafts, although some of the basic concepts of behavior are quite similar. Many of the shafts that have been sunk in various parts of the world are owned by private mining companies. Each company has generally accumulated years of experience in shaft sinking and mining techniques pertinent to its particular geographic location. When a new shaft is to be sunk or an existing shaft deepened, the tendency often seems to be to continue to use the methods that have been used successfully in the past.

Jan 1, 1979

By d&apos, I. J. Agati

The stockpiling and reclaiming of bulk materials can be a challenging task for engineers seeking the optimum solution for plant needs, reliability, and at lowest unit cost. The objective of this paper will be to expose advantages, disadvantages and limitations of many storage and reclaiming systems to the responsible engineer and management. The paper will emphasize the practical aspect of stockpiling and reclaiming methods. Many valuable and interesting papers are available dealing with the theoretical viewpoint and application of a particular manufacturer's machine. Several of these are mentioned in the bibliography. As many practical parameters as possible will be given. After twenty years in the field of designing and selling bulk materials handling systems, the needs of the user and the plant are recognized and reasonably understood. This paper cannot give solutions to all problems In this vast field but will stress practical applications and examples of various installations. The evolution of advancements in materials handling is based upon not only technological innovations, but learning from many experiences of others and utilizing them as stepping stones to improved installations.

Jan 1, 1969

By Caibin Wu, Bin Xie, Jiaqi Tong, Ningning Liao, Chong Zeng

Understanding the energy-size reduction relationship is vital to grinding process; therefore, this paper aims to show the energy-size reduction of magnetite-calcite binary mixture in a laboratory wet conical ball mill. Single magnetite, single calcite, and blended magnetite-calcite mixture at three weight ratios in four particle sizes were ground in a laboratory wet conical ball mill at four grinding time periods. The results showed that the particle size distribution of both fine particles and coarse particles of single and mixture ground product fitted well with the PSD computed by Rosin–Rammler-Benne function. The larger mass percentage of calcite is, the higher t10 of binary mixture ground product is. On the contrary, t10 in the mixture decreases as the percentage of magnetite in the mixture increases. The different breakage behaviors in blended samples are due to the hardness and particle size. The results of calculated ratio of energy absorption factor showed that the calcite consumed more energy in the breakage process of binary mixture than ground alone. The JK size-dependent breakage model based on the t10 method fits all the experiment data, be it generated from pure minerals, mixtures at different weight ratios, or each component separated from the mixture.

Jun 4, 2022

By Roe-Hoan Yoon, Kaiwu Huang

Derjaguin and Dukhin (1961) were the first to develop a model for bubble-particle interaction in flotation from first principles by considering the surface forces in wetting (or flotation) films. The model predicted that the energy barriers to bubble-particle attachment arise from the ζ-potentials of fine particles, which corroborates well with an earlier work of Fuerstenau (1957) reported for the flotation of quartz using dodecyl ammonium acetate (DAA) as collector. In the present work, a series of surface force measurements have been conducted by accurately monitoring the changes in bubble curvature during bubble-silica surface interactions. The curvature changes are then used to determine the capillary force, which is the sum of the hydrodynamic and surface forces. By subtracting the former that can also be determined from the curvature changes, one obtains the surface forces (or disjoining pressure). The results obtained as functions of pH and collector concentrations show that control of the ζ-potentials of bubbles relative to those of the silica surfaces is critical for maximizing the negative disjoining pressure, which is conducive to promoting bubble-particle attachment in flotation.

By D. R. McConnell

The seafloor in the US Pacific OCS and EEZ is enriched to varying degrees in critical and economically important minerals such as nickel, manganese, cobalt, copper, zinc, REY (rare earth elements plus yttrium), titanium, vanadium, antimony, gold, and silver. These mineral deposits take the form of polymetallic nodules on the seabed, cobalt rich ferromanganese crusts on seamounts and ridges swept clean of sediment accumulation, and seafloor massive sulfides formed by hydrothermal systems at geologic plate spreading centers and volcanic margins. Each of these mineral deposits form on or near the deep ocean seafloor where water depths are typically 4000 m to 5500 m and on the seamounts and volcanic arcs that rise from these depths. Commercial interest in deep sea mineral deposits and the potential for collecting or mining them began in earnest in the 1970s but has been heightened in the last 20 years as the international framework for developing these minerals in International Waters has matured that has coincided with forecasted rapid rising demand for minerals to supply energy and manufacturing needs for the green economy. Compilation reports published by academia, government, and private companies are reviewed to assemble data and assess the prospects for deep sea marine minerals in the US Pacific OCS and EEZ. Key compilations were made by the Circum-Pacific Council and USGS in the 1980s and 1990s. These, together with recent (2023) efforts by USGS to compile geochemical data from USGS affiliated marine research sampling cruises from the 1980s and 1990s, historical data maintained by NOAA National Centers for Environmental Information (NCEI), and recent publicly disclosed results from ISA contractors are used to inform the known occurrence and prospectivity for polymetallic nodules, cobalt-rich ferromanganese crusts, and seafloor massive sulfides in the US Pacific OCS and EEZ.

Feb 22, 2026

By J. E. Golsan

Barrick Gold Corporation installed an expert style control system on the grinding circuit at its Mercur mine. Barrick's main objective was to increase mill throughput by a minimum of 3%. The expert system team collected operating data and then created a knowledge base using Comdale/X expert system development software. The expert system moved from on-line "advisory" mode, testing of expert rules, to full process control in four weeks. Expert system control benefits include a 9-15% increase in mill throughput, consistent mill loading leading to less wear on SAG mill parts, and improved downstream process control.

Jan 1, 1998

By A. D. Kalogeropoulos, T. N. Michalakopoulos

This paper deals with the numerical simulation of rock cutting laboratory tests using the discrete element method. The main objective is to provide a method for calibrating numerical DEM models of rock cutting in a systematic way so that realistic results are yielded. The numerical models are developed with the discrete element code Yade, which models rocks as a collection of bonded spheres. The models are calibrated in a four-step process based on the design of experiments method and optimization. The calibrated models are evaluated both quantitatively and qualitatively against actual laboratory cutting tests, in terms of the ratio of the simulated mean cutting force to the actual one and the cutting force time series, respectively. The fully calibrated models showed that the simulated cutting process matched qualitatively the actual cutting force recordings and underestimated the mean cutting force by approximately 3%. It is concluded that well-calibrated numerical simulations of the rock cutting process can provide not only a better understanding of the process itself but also quantitative data regarding the cutting force and energy requirements.

Dec 28, 2022

By Yongjun Xian

The release of fluid inclusions has a strong potential for the unintentional activation of pyrite during flotation. The present study aims to characterize fluid inclusions in a natural pure pyrite. The results indicate that a certain amount of fluid inclusions exist in the pyrite. The fluid inclusions assume a variety of shapes, including long strips, oval shapes and irregular shapes, with sizes that range from a few microns to dozens of microns. From the EDS results of hollow positions that resulted from the fracture of the fluid inclusions on the pyrite surface, certain amounts of Al, Cr, C, O, Ag and Cu were clearly detected; these elements were not detected in FeS2 pyrite itself. The contents of the inclusions were released into solution when the sample was subjected to a grinding process. Under experimental conditions of 2 g of pyrite cleaned in 40 mL of pure deionized water under an inert atmosphere, the concentrations of Cu, Fe, Cl- and SO4 2- released from the inclusions reached concentrations of 3.29 × 10-6, 32.52 × 10-6, 51.57 × 10-6 and 75.90 × 10-6 mol/L, respectively. These values are significantly greater than those from the experimental nonoxidative and oxidative dissolution of the pyrite. The fluid inclusions of pyrite were, therefore, concluded to represent the dominant sources of Cu, Fe, Cl- and SO4 2- in the aqueous solution. The present investigation provides a new understanding of the source of the unavoidable metal ions in the pulp and may benefit understanding of the flotation theory and environmental geochemistry.

By H. Sevim

The utilization of high sulfur Illinois coal by utility plants has been decreasing since the enactment of 1990 Clean Coal Air Act Amendment. Illinois coal producers can make their coal saleable by offering the choice of taking the combustion by-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 by-product disposed can be minimized. In this paper, a few such systems are presented. The favorable operating range of each system is determined in terms of distance and tonnage. A case study is given whereby cost analysis is conducted for an underground coal mine receiving by-products from two Illinois utility plants.

Jan 1, 1997

By Tyler Luxner

Stillwater Mining Co. (SMC) is the largest primary producer of platinum and palladium in North America. SMC operates two underground mines in south central Montana, along the 45-km (28-mile) platinum/palladium J-M Reef in the Stillwater Complex. The Stillwater Mine exploits 9.6 km (6 miles) of deposit strike length and East Boulder Mine exploits 4 km (2.5 miles) of deposit length. The two mines are 20.4 km (12.7 miles) apart with SMC controlling a considerable length along the entire J-M Reef trace. Production at the Stillwater Mine began in 1986 and in 1988 the first tunnel boring machine (TBM) was commissioned, becoming an integral part of mine development at SMC. TBMs have been used for developing production footwall laterals (FWL) to access new mining blocks at the Stillwater Mine, as well as boring twin crosscut ac-cess tunnels at the East Boulder. Two TBM development expansion projects are currently in progress: the Graham Creek project at the East Boulder Mine, which will extend footwall lateral development 2,591 m (8,500 ft) to the west, and the Blitz project, where a TBM will be commissioned to extend east out of the Stillwater Mine to 3,658 m (12,000 ft) beyond the current production mining front. General strike and dip of the Reef is west to east and to the north, respectively.

Jan 1, 2012

By Sahin Furkan Sahiner, Onur Golbasi

Effective maintenance planning is vital for coal mining operations, where haul truck fleets directly determine production continuity. This study presents a discrete event simulation (DES) model for evaluating maintenance strategies under multiple failure modes and their interdependencies. The model integrates corrective, periodic preventive, and opportunistic maintenance, dynamically updating equipment lifetimes through probabilistic time-betweenfailure and time-to-repair distributions. Applied to a fivetruck coal haulage fleet over a one-year horizon, results show that periodic preventive maintenance delivers the highest availability (76%) under unconstrained conditions, slightly outperforming corrective-only maintenance (75%). Opportunistic and integrated approaches performed worse (68% and 69%), reflecting redundancy from overlapping interventions. These findings suggest that structured preventive programs provide the most reliable outcomes when costs and resources are not limiting. The DES framework serves as a baseline for future models incorporating cost, spare parts logistics, and workforce availability, supporting robust maintenance planning in coal mining operations.

Feb 22, 2026

In early 1970, General Mills Chemicals, Inc. announced the availability of en improved liquid ion exchange reagent, LIX® 64N, for the recovery of copper from various solutions, such as dump leach liquors. LIX 64N has been shown to be a considerable advance over LIX 64, and is presently in use in three commercial plants. Results have been very gratifying. For example, one of the plants was designed for operational production of 40,000 pounds copper per day, and in fact reached this output within the third week following startup of the plant. In addition to the operating plants, another is scheduled to come on stream this month with L D( 64N being used to extract and recover both copper and nickel. The chemical properties and operating characteristics of this reagent have been fully described in a previous paper. 1 LIX 64N is quite an effective and selective extractint for copper, even with copper contents as high as 15 g/l, but the reagent is somewhat limited in pH range, and loses some of its extraction efficiency as the pH drops below 0.8. Liquors derived from vat leaching, electrolytic tankhouae bleed streams, or some of the new leach schemes derived to solubilize copper from sulfide concentrates are examples of the liquors that present major problems when treated via liquid ion exchange. LIX 64N could extract some of the copper from such streams, but recovery was limited to about 75 percent. Also, in some parts of the world there are streams which are relatively low in copper (-5 g/l) but which are very high in acid (25-50 g/1 H2SO4). Again, LIX 64N can attain only about 75 percent recovery from such streams. For effective treatment, these streams require a reagent which will maintain the excellent selectivity of LIX 64N, and will

Jan 1, 1971

By J. B. Malcolm

The discovery of tungsten-bearing quartz outcroppings in Vance County, N. C., by the Hamme brothers in 1942, made international news in the mining industry and was, in fact, one of the major ore discoveries made in the U.S. during the last 25 years. Operations began at the Hamme mine in 1942, but after 16 years of successful operation, the mine was closed down in 1958 under adverse market conditions. By that time, it had produced nearly 20 million lbs of metallic tungsten. Because of the square-set timber mining method then in use, mine operating expenses were high, actually representing 78% of the total operating expenses at the property. In timber work alone, 160 men were employed. Approximately 500,000 bd ft of timber were placed monthly at a direct supply cost of $1.00 per ton of ore mined. Late in 1959, following a slightly improved position in the tungsten market, company management decided that, by changing the mining method, the operation could be economically feasible. The major premise in this decision was that a reduction of from 25 to 30% of the mining costs could be achieved by the conversion of the mining method from square-sets to horizontal cut and fill. Reopening of the mine began in February 1960, Full production has now been reached and overall mine productivity has been doubled.

Jan 1, 1962

By Setareh Afrouz, Emily Sarver, Cigdem Keles

The resurgence of severe lung disease among US coal miners since the mid-1990s has led to efforts to better characterize and monitor respirable dust exposures, particularly focusing on mineral constituents from rock strata surrounding the coal. A rapid analysis method for silica (quartz) mass using direct-on-filter Fourier transform infrared (FTIR) spectroscopy has been developed, which can also estimate kaolinite, a primary silicate mineral in many coal mines.

Feb 24, 2022

By T. M. Yegulalp

A new explanation of the scale dependency of the strength properties of rock is presented based on the theory of extremes. A review of past work on specimen size strength relationship is followed by an introduction to the fundamentals of the underlying theory of extremes and its relationship to the scale effect on the statistical properties of the strength distribution. It is shown that the weakest link theory is directly related to extremal statistics and properties of strength distributions of rock can be derived as a function of the specimen size. Three sets of Brazilian test data are used to demonstrate the use of this approach.

Jan 1, 1992

By N. Arbiter

Fracture under low velocity free-fall and double impact, and under slow compression have been-investigated. The pattern of breakage and the size distribution of resulting fragments for sand-cement and glass spheres have been determined. Photoelasticity methods were used to simulate the stress distributions in free-fall impact in order to explain the observed patterns of breakage. Oblique fracture planes, occurring only in free-fall impact, develop along lines which coincide with the trajectories of principal compression as determined by mathematical analysis Breakage efficiencies for different modes of fracture were compared for both types of spheres. For the same specimen and loading system, static loading and low velocity dynamic loading induce geometrically similar stress fields resulting in reasonably similar fracture patterns and shapes of fragments.

Jan 1, 1968

By B. R. Benner

Progressive improvements in crusher design, screening efficiency, and operating experience along with the downsizing of many taconite operations has resulted in the abilitv of some crushing plants to produce a substantially finer product. This finer product opens the possibility of replacing the rods in the rod mill with balls as is the current practice at Sydvaranger, Norway. If this replacement could be accomplished substantial savings associated with metal wear and the elimination of rod charging may be realized. The purpose of this study was to compare the performance of a mill charged with rods with the performance of the same mill charged with balls at the pilot scale. The first objective was to establish whether we could achieve the same throughput rate at the same mesh-of-grind in a mill in which the rod media has been replaced by balls. The second point was to determine whether the ball media would create a significant tramp oversize problem.

Jan 1, 1990

By J. O. Marsden

This paper presents an overview of the innovative methods for gold and silver extraction that have been put into actual practice in North America since 1987. It is an update of a paper of the same title which was presented by Sass and Mansanti at the AMC conference in San Francisco in 1987. New practices, new equipment and variations of older practices that have been introduced in the last five years are discussed in each of the following categories: process selection trends, comminution, gravity concentration, flotation, oxidation, agitated and vat leaching, heap leaching, solution concentration and purification, zinc precipitation, electrowinning, tailings disposal detoxification, and reclamation.

Jan 1, 1993