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By E. R. Johnson

The copper concentrator of the Braden Copper Co. is at Sewell, Chile, on the westem flank of the main Cordillera of the Andes, at an air distance of approximately 50 miles southeast of Santiago, the capital of Chile. The region is mountainous and space is at a premium because of the rough terrain and the danger of snowslides. The ore, a porphyry copper, is mined by a block-caving method in the El Teniente mine. It is hauled to the crushing plant, a distance of 2.6 miles, through a tunnel because of the severe climatic conditions. The usual large, coarsely set, primary reduction machines found in many ore-treating plants are not required because of the mining method employed and the limiting 12-in. spacing of the grizzlies at the head of each ore pass in the mine. It is the purpose of this paper to describe the numerous improvements made in the crushing section of this large flotation concentrator during the past I5 years to increase the efficiency of the plant and to raise the daily output from around 20,000 to 30,000 tons. The reader should keep in mind that all changes were made within the existing building because of the limited space and the high cost of the heavy mill construction required to withstand the snow loads. The present plant, as well as the former, operates on a 24-hr, 7 days a week basis. The crushing plant commenced operations at its present site in 1921, the main equipment being No. 7½ gyratories, followed by 48-in. horizontal Symons disk crushers. Fines were removed by I-in. stationary grizzlies ahead of each unit. In 1924 a third stage of crushing was provided by the addition of 55½-in. rolls in open circuit. During 1925, the Symons disks were replaced by 73½-in. rolls. All the rolls were changed to closed circuit, with elevators and screens to give a final product of 9 pct plus 3-mesh. The flowsheet of a typical crushing section of this period is shown in Fig I. The ore was withdrawn from a common bill serving the five crushing sections in the plant by means of any number up to six 36-in. wide-apron feeders, which discharged onto a common conveyor belt. This conveyor was equipped with a magnetic head pulley and the crusher attendant was stationed near the discharge end to pick out pieces of mine timber that might be in the ore. The ore was discharged over a 13/4-in. spaced bar grizzly and the oversize of this grizzly was crushed by a No. 7½ McCully gyratory crusher set at 13/4-in. opening on the closed side. The grizzly undersize joined the gyratory discharge and was conveyed to a set of 73½ by 20-in. Garfield rolls set at I in. These rolls operated in closed circuit with a bucket elevator and two vibrating screens placed in parallel.

Jan 1, 1949

By Robert F. Randolph, Jeffery L. Kohler, David C. Byrne

Multiple versions of an educational message can reach a diverse population more effectively than a single version. For instance, some workers are trained in formal classrooms while others are self-taught. The National Institute for Occupational Safety and Health has developed multiple versions of a hearing loss simulator (an interactive software package, a Web-based module, and an electronic slide show) to show how a single set of information can be readily adapted to different delivery methods. The three versions of the simulator were developed with a minimum of effort and expense compared to a single, less-flexible version. The interactive software is best for training sessions led by a hearing conservation professional, the Web pages are best suited for an individual worker, and the slide show is best for a small, more-generalized, training class. This paper will describe additional advantages and disadvantages of different delivery systems and will show what considerations are helpful in designing content that can be readily adapted to alternate presentations.

Jan 1, 2002

By Daniel Hodouin, Claude Bazin

"A graphical method to assess the size reduction by grinding is presented and illustrated with data collected from laboratory grinding tests and industrial grinding circuits. The method lies between the graphical comparison of size distributions and the population balance model. The method is easy to apply and provides a quick way to compare grinding mill performances under various operating conditions and processed ores. The application of the method to industrial mills shows that a grinding mill operation could present an invariant behaviour that can be exploited for simulation purposes.INTRODUCTIONThe size reduction of particles by grinding has been studied for decades and several books were published on the subject. Most of the recent studies focus on the modelling of the ball, semiautogenous and autogenous grinding mills operation (Napier-Munn et al., 1996) because accurate simulators can be used for design, optimization and control. Although the development of realistic simulators is progressing, the trial and error method is still used by many operators to identify optimum operating conditions for a grinding machine.Laboratory tests allow the characterization of the material submitted to grinding and the analysis of various operating conditions, such as ball size or shape, mill speed and slurry concentration of solids, on particle size reduction. Similar tests can be conducted in a plant, but results are often difficult to analyze due to errors associated with sampling and sensor accuracy. This paper presents a graphical method to assess the degree of size reduction carried out by a grinding machine. The paper consists of three sections. The first section describes the method and the following sections illustrate the method with data taken from laboratory and industrial grinding machines."

Jan 1, 2004

By D Johnston

Within the first full year of BarrickÆs Cowal Gold Mine operation, the Lake Cowal Foundation Limited (LCF) has already been delivering results consistent with its goal to protect and enhance the natural environment of Lake Cowal and its catchment area. The LCF is a non-profit Environmental Trust established in June 2000 in conjunction with the development consent process for the construction of BarrickÆs Cowal Gold Mine. Its primary goal is to protect and enhance Lake Cowal, a nationally significant ephemeral wetland located 350 km west of Sydney, New South Wales, Australia. Significant concentrations of water birds visit the lake and the Australian Heritage Commission listed Lake Cowal on the Register of the National Estate in 1992. The LCF is managed by a Board of Directors from representative member organisations including the Total Environment Centre, National Parks Association, Nature Conservation Council and Barrick Australia Limited. Although largely funded by Barrick, the Foundation also attracts external funding and works in partnership with a diverse range of other groups and organisations, beyond the mine fence. The total value of currently approved projects is estimated to be in excess of $7.1 million, which includes æin-kindÆ contributions made by the local community and in particular the Lachlan Catchment Management Authority (LCMA) and local farmers. To date, LCF has been involved with the development and implementation of 30 projects with a total of 34 project partners. LCF has worked with over 60 landholders to improve Lake Cowal and its catchment, with 6180 ha of land now being managed for conservation or sustainable farming in the local area. Many landholders have been, or are involved in property planning or participating in other training opportunities. Sustainability of LCF programs and outcomes will be assured by commitments to projects within four key themes: conservation, research and research support, sustainable farming and community education and training. The LCF works independently from the mining company and has no responsibility for the environmental management within the mining lease. It is about capitalising resources generated by the mine to enhance environmental outcomes in the wider Lake Cowal catchment area by working collaboratively with the local community, industry and government authorities to ensure the long-term protection of a unique wetland ecosystem affected by landscape scale degradation.

Jan 1, 2007

By K. C. Mills, P. N. Quested, A. P. Day, R. F. Brooks

"Methods have been developed to measure the physical properties of molten materials relevant to the fluid flow in high temperature processes. Data for the densities, viscosities and surface tensions of Al-, Ni- and Fe-based alloys are compared with (i) values for the pure metals and (ii) estimated values obtained from models making use of chemical composition of the alloy. Experimental values for metallurgical slags are also given and compared with estimated values.1 IntroductionPhysical property data has proved very useful in improving process control and product quality. For instance, in the continuous casting of steel the viscosity (TJ) of the mould flux is important since it determines (i) the optimum casting conditions, nVc = 2.5±1 dPas (m min-1) where V c is the casting speed and (ii) the level of slag entrapment (which leads to inclusions) in the metal. Thus data for properties like viscosity are exceedingly useful in understanding the process and the problems encountered and the causes of defects and problems.Another interesting development which has helped to increase our knowledge of processes and improve process control and product quality is the development of mathematical models of the fluid and heat flow in the process. These models have been developed to the stage where one of the prime requirements is for good physical property data for the industrial materials involved. Recently, Oxley [1] has shown that the use of reliable, experimental, property values for the commercial alloy in a commercial software package produced a significant improvement in the prediction of casting defects. Thus reliable property data are required for liquid metals but also for (i) liquid slags since many processes involve the use of a slag to refine and protect the metal or to lubricate the mould and (ii) refractories, sand and investment moulds."

Jan 1, 1999

By Caio Henrique Vidigal

No processo siderúrgico de uma usina integrada são gerados diversos combustíveis como subprodutos, os quais são reutilizados internamente ou mesmo, comercializados. Na ArcelorMittal Tubarão, isso ocorre com o Alcatrão, um subproduto do processo de coqueificação do carvão. No Presente trabalho são descritas melhorias implantadas no Sistema de Carregamento de carretas para comercialização do produto na empresa. Essas melhorias visaram eliminar duas fragilidades do sistema original: o risco de transbordo devido dificuldade de visualização do nível da carreta e o risco de exposição do motorista/operador aos hidrocarbonetos presentes no alcatrão, em caso de deficiência do sistema de exaustão dos vapores gerados e da não utilização correta dos EPIs definidos para a atividade. Para tal, foram realizadas algumas adequações ao processo, com a instalação de uma cabine para operação remota do carregamento e para monitoração do nível das carretas, utilizando um sistema de visão termográfica.

Oct 30, 2017

By Z. Jin, D. DePaoli, P. Zhang

"Phosphorite, or phosphate rock, is the most significant secondary rare-earth resource. It contains high amounts of phosphate-bearing minerals along with low contents of rare earth elements (REEs). In Florida, about 19 Mt of phosphate rock are mined annually and most are used to manufacture fertilizers using a wet process, in which sulfuric acid reacts with phosphates to produce phosphoric acid and phosphogypsum. In the wet process, REEs are also leached out into solution and eventually get lost in the leaching residue and phosphate fertilizer. Recovering REEs from Florida phosphate rock in the wet process will be beneficial to broadening rare-earth availability, improving the quality of phosphoric acid product and protecting the environment.This study focuses on the influences of wet-process operating conditions on REE leaching efficiency. The results indicate that REE leaching efficiency increases with phosphoric acid addition in the initial pulp. At a temperature of 75 °C, a stoichiometric ratio of sulfuric acid (H2 SO4 ) to calcium oxide (CaO) of 1.05 and a weight ratio of liquid to solid of 3.5, REE leaching efficiency reached a relatively high value of 52.82 percent. The trends of REE leaching efficiency were similar to those for phosphoric acid (P2O5 ). Extensive tests on the leaching residue showed that during leaching, about 90 percent of the REEs were released from the phosphate rock but only 52.82 percent ended up in the leaching solution. This phenomenon can be attributed to two factors: (1) the effect of phosphate ions (PO4 3-) in the solution, which caused REE ions to form REE phosphates and be precipitated into the leaching residue, and (2) the influence of large amounts of anions such as sulfate (SO4 2-), dihydrogen phosphate (H2 PO4 -) and hydrogen phosphate (HPO4 2-) anions as well as the polar molecule H3 PO4 , which surrounded the REE cations and formed an ion atmosphere that prevented the PO4 3- from contacting and combining with REE cations. Interaction of these two opposite effects determined the REE distribution between leaching solution and residue."

Jan 1, 2017

Your assessment of the minerals business. I would first like to express our profound sadness and sincere condolences to the families of the miners who lost their lives in recent mine mishaps particularly in West Virginia, and other locations. Any loss is unacceptable. It is time to review and, if required, re-establish a rigorous health and safety agenda in the mines. It must involve a review of health and safety regulations. And innovative training methods for sensing, awareness and mitigation of health and safety hazards must be developed. As far as the minerals business is concerned, I am excited about the outlook for mining. Over the last 20 years, global demand for minerals has closely mirrored the growth of the gross domestic product. Minerals re-main a major part of the world’s economic foundation. And that will continue to be the case. It is no surprise that the fortunes of the mining industry rise and fall with general economic trends. Globally, mining has been strong — thanks to the explosive economic growth in Asia. The U.S. mining industry has performed reasonably well, with notable strength in the metals, coal and construction and aggregate areas and with some softness in the industrial minerals sector.

Jan 1, 2006

By John R. Hawley

"This paper is intended as a review of the progress that has been made in the Province of Ontario in the field of acid drainage waste treatment technology.Three years ago, at the Third Annual Meeting of the Canadian Mineral Processors, we presented a paper entitled ""The Problem of Acid Mine Drainage in Ontario"". At that time I was working for the Ontario Water Resources Commission. The paper turned out to be the very beginning of the Commission's acid mine drainage control program. In the intervening three years, the Ontario Water Resources Commission has been amalgamated with other government groups and has evolved into the present Ontario Ministry of the Environment. Today the Ministry is involved in running one of the most advanced acid mine waste control programs in the world.As a part of its mining program, the Ontario Ministry of the Environment has published three major reports which deal directly and specifically with the industrial waste disposal problems that may arise at a mining operation. In order of publication, these reports are as follows:(1) ""The Problem of Acid Mine Drainage in the Province of Ontario"".This 338-page report covers all aspects of the problem of acid mine drainage and includes detailed sections on acid flow detection, acid flow chemistry and acid flow treatment.(2) ""The Use, Characteristics and Toxicity of Mine-Mill Reagents in the Province of Ontario"".This report, 244 pages in length, gives the chemistry and toxicity of nearly all of the chemicals that find common use in the Canadian mining industry. Most of the toxicity figures quoted are the result of a comprehensive bioassay program that was initiated by the Ministry."

Jan 1, 1974

By D. F. Lascelles

D. F. Lascelles (School of Earth Sciences, MacQuarie University, North Ryde, N. S. W., Australia)- The paper contains many misconceptions commonly held by both geologists and soil scientists with regard to soil processes. The analogy between supergene copper enrichment and "nickel laterite" deposits is quite apt and the use of nomenclature from the former in describing supergene nickel deposits is justified. However, care must be exercised with regard to the notable differences in

Jan 1, 1974

By Douglas Milne

Most empirical and numerical approaches to design in rock mechanics incorporate rock mass classification. Numerical design methods generally use classification values to calculate input parameters for stress-based failure criteria. Empirical methods use classification to allow comparisons between similar rock mass conditions, generally based on a graphical design technique that differentiates stable and failed opening geometries. Classification systems are the best tool available for assessing rock mass properties; however, there are problems with classification systems that should be high-lighted. Rock mass performance can only be realistically estimated by coupling a unique description of the rock mass with known loading conditions. Current classification systems cannot provide a unique classification value. The weightings applied to quantify rock mass properties for classification can result in significantly different rock masses having the same classification values. These weightings have been proven effective for tunnel design and support, but classification systems are now used for many more applications. Rock classification systems evolved from a quick and easy field tool for estimating tunnel stability and support requirements. The need for a rapid field tool means that rock mass classification is relatively insensitive to improved methods of measuring rock mass properties. Problems with classification systems and their application are highlighted in this paper. These problems must be recognized and documented before improvements can be made. An understanding of the evolution of classification systems and their application for both numerical and empirical design approaches is invaluable in highlighting current shortcomings.

Jan 5, 2007

By Joner O. Alves

The disposal of scrap tires has been a serious environmental problem. The treatment of this waste by pyrolysis and combustion has advantages since the landfill space is dwindling and the production of fuel becomes of technological interest. However, that processes needs a rigid control of emissions. This work presents a study of the light hydrocarbon gases (HC) generated during the burn of waste tire chips in a two-stage laminar-flow horizontal furnace. Different temperatures in the primary and secondary stage of the furnace were tested, and the oxygen/nitrogen percentage was also varied during the combustion process. A gas chromatograph was used to identify and quantify the components of the gaseous products of combustion and pyrolysis. The results showed the behavior of the gases during the burn of tires, providing valuable information to the control of hydrocarbon emissions.

Jan 1, 2010

By R. Bauer

Adaptations and redesign of the existing already very successful and proven road milling machine concept and technical innovations such as an optimized, specifically for mining application developed cutting drum, cutting housing design and cutting tools, high manoeuvrability achieved via a tight turning radius, a three disk clutch system and a cutting drum drive that allows for the acceptance of higher loads, a complete reinforcement of the chassis to withstand higher vibrations and torque, the installation of increased engine power via a modern drive unit, a specifically for mining/construction applications developed operator’s platform and finally a redesigned air intake system and the adaptation of the levelling system resulted in far more cost effective and advantageous capabilities of Wirtgen Surface Miner in soft to medium hard mining and construction applications. As the achieved results show for the first time in modern surface mining history mechanized cutting is capable to compete successfully against traditional drill, blast/ripping and other conventional mining methods.

Jan 1, 2007

By Jon Sinnreich

Ensuring the accuracy of collected data during deep foundation static load tests is of paramount importance. Typically, pile head displacements are measured relative to a purpose-built reference system, which is assumed to be fixed. This study presents a simplified error analysis of this assumption, illustrates the potential magnitude of these errors, and proposes an improved method of pile head displacement monitoring.

Jan 1, 2009

By H Hutchinson

Froth flotation is applied to mineral sand concentrates in order to produce commercially viable xenotime concentrates. Experiments indicate that a xenotime product containing 38% Y2O3 at 47% recovery or 34% Y2O3 at 83% recovery can be obtained from a 27% Y2O3 feed. The process involves a primary stage of reverse flotation at which oxide and silicate gangue is floated, and secondary stage of direct flotation at which xenotime is floated. Of the various collectors screened an amphoteric compound was found to be effective at both stages. This was made possible by the addition of sodium silicate at the second stage, which acted as depressant for the remainder of the gangue. Similar studies on a low grade feed material were somewhat unsatisfactory as the grade achieved fell short of what was targeted.

Jan 1, 1990

By A. Vien, B. C. Flintoff, R. P. Edwards

"A major thrust in industrial automation over the past few years has been the exploration and incorporation of higher level (supervisory and optimizing) control strategies aimed at more fully exploiting the existing control system infrastructure. There is little doubt that this is worthwhile pursuit, however, one must not lose sight of the maintenance and development requirements of the basic control system. Statistics on loop performance indicate that this too is an area of considerable potential. In this paper the authors look at some of the less elegant, but arguably equally important issues in mineral processing plant control. The focus is on controller structures, loop tuning, sampling, filtering, and some of the other principal components of the regulatory control foundations. In many cases significant improvements in control performance can be achieved by getting back to the basics.IntroductionEvery modem concentrator has a state-of-the-art computer control system in place. Several of these are contemplating installing, or have installed, advanced control systems, such as expert systems, but the foundation of their control system remains the PI controller. Although the authors are not aware of any survey or published information for the mineral processing industry, it is reasonable to assume that it would be similar to the pulp and paper industry. ""The average [pulp] mill has some 2000 control loops of which 97% use PI control. This means that PID, dead time compensation, adaptive controllers, specialized algorithms, ... , constitute only 3% of the installed base."" (Bialkowski [1992]).Bialkowski [1992] also stated that ""If you have been keeping score, only 20% of the loops surveyed actually decrease variability in automatic over manual mode of operation, in the short term."" He attributed the problems to: poor tuning (30% of all loops), control valve problems (30% of all loops) and process problems (20% of all loops). There appear to be a serious need to go back to basics and review the existing control system."

Jan 1, 1998

By Linda Gaines

Use of vehicles with electric drive, which could reduce our oil dependence, will depend on lithium-ion batteries. But is there enough lithium? Will we need to import it from a new cartel? Are there other materials with supply constraints? We project the maximum demand for lithium and other materials if electric-drive vehicles expanded their market share rapidly, estimating material demand per vehicle for four battery chemistries. Total demand for the United States is based on market shares from an Argonne scenario that reflects high demand for electric-drive vehicles, and total demand for the rest of the world is based on a similar International Energy Agency scenario. Total material demand is then compared to estimates of production and reserves, and the quantity that could be recovered by recycling, to evaluate the adequacy of supply. We also identify producing countries to examine potential dependencies on unstable regions or future cartels.

Jan 1, 2010

By Peter Moser, A. Gaich, E. Grasedieck Zechmann

In The SMX Blast Controller is a novel tool for precisely controlling the geometry of a blast based on the technology of 3D imaging. It enables to derive precise information about the geometry of the face of a bench in a quarry from a pair of stereoscopic images taken from the bottom level of a bench with a calibrated standard digital camera. Apart from staking out the blast position with delimiters that mark the area to blast and taking then two images (freely), no further actions are required which allows performing the data acquisition without requiring any surveying skills. The 3D image generation and blast planning does not require special computer. It is estimated, that every blast foremen is able to work with the system after a one-day training as the system includes a high grade on automatism. The software package allows the blast foreman to design and stake out a blast, based on provided geometric values, such as burden, side spacing, hole inclination, sub-drilling, row number & distance and drilling pattern. The software connects these values with the 3D information acquired by the digital images. All the drill & blast information can be used also for blast documentation. The SMX Blast Controller overcomes also the problem of doing the back transfer from maps derived by surveying into nature as the resulting 3D image and all the information associated to it (hole position, etc.) can be correlated with the nature by visual comparison and the help of a single reference line, defined by two points. The system is designed to be used also in small to medium quarries. It can help, that the control of the geometry of the bench face and the precise design of the charge of the blast on a borehole per borehole basis will become an accepted daily routine.

Jan 1, 2006

By Terry Keough

Contents for discussion ?Current liner technology ?Innovation of magnetic products ?Development of magnetic wear liners ?Installation and change out method ?Uses and capabilities ?Internal wear liners ?Summary Vulcanized rubber ?Many of you are familiar with using vulcanized rubber to provide wear protection on mining equipment. For years, this was the standard for most mining equipment, and mines spent a lot of money fabricating and lining steel equipment.

May 1, 2010

By G J. Corbett, T M. Leach

A continued exploration programme has further defined the geology of the Tolukuma vein system, verified the resource indicated by Newmont, and identified potential for additional mineralisation. The resource at Tolukuma Hill, designated as zone C, is a mine recoverable 432,000 t at 18.1 g/t Au & 46 g/t Ag. Mining will be by a combination of open pit and underground at a rate of 100,000 t per annum. Processing will be by SAG mill, gravity circuit and CIL plant. A diatreme breccia, localised at an intersection of structures and a relationship of gold to base metal sulphides, are indicative of a strong porphyry association. Typical epithermal features such as crustiform banded quartz and quartz pseudomorphing platy calcite are also present and locally contain lesser gold mineralisation. Pre-existing dilatant structures have acted as a host to the ore fluids, resulting in the formation of the semi-continuous Tolukuma-Gulbadi veins over a 1100 m strike. A fluid flow model suggests that mineralizing fluids were sourced from a diatreme margin and migrated laterally along dilatant structures. Bonanza gold grades are interpreted to be derived through fluid quenching in the flexure between a hanging wall split, which hosts much of the Tolukuma Hill resource, and the feeder graben structure. Thus, the relationship between the pre-mineral structural geometry and fluid upflow at the margins of a diatreme breccia, controls the ore setting.

Jan 1, 1995