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By V. Svalbonas

In the establishment of a useful failure criteria for complicated, fabricated structures, two basic areas of knowledge must be evaluated: 1. The accuracy of the applied stress analysis must be known in comparison with actual stresses encountered during mill operation. 2. The metallurgical fracture properties of the basic materials must be established with reference to non-destructive examination (NDE) methods to be used during fabrication. Both of the above can only be evaluated by use of full scale tests on the structures, and/or components, of interest. This paper describes such tests and comparisons as applied to several large mill installations. In addition, weldment component fatigue tests arid flawed casting strain gauge tests are also discussed. The combination of such test results allows for the formulation of failure criteria directly applicable to the fabrication and examination procedures followed in grinding mill structure manufacture.

Jan 1, 1982

By Dan Nilsson

Open pit mining is the strong sector of the American mining industry. In the middle of the 60's. 17-18% of the ore in metal mines was mined with underground methods. From the middle of the 60's to 1980 the production in open pit metallic mines increased from about 400 to close to 600 million short tons while at the same time the underground mine production decreased a little, from about 90 to about 80 million tons. Less than 15% of the ore prodction now come from underground mines. Large amounts of waste rock were also handled in the open pits. In the middle of the 60's about 600 milion tons were handled, in 1980 1,200 million tons were moved. This means that the average stripping ratio increased from about 1.5 to over 2.0 tons of waste rock per ton of ore, figure 1.

Jan 1, 1983

By R. Cooper, K. De Wet, A. Janwong

"Horsehead Metal Products is a zinc refinery in Mooresboro NC treating crude Waelz Oxide (WOX) to produce Special High Grade Zinc by a hydrometallurgical process, comprising leaching, zinc solvent extraction/electrowinning (SX/EW), melting and casting and bleed treatment. Cadmium removal by zinc dust cementation plays an essential role in the bleed treatment circuit to prevent a build-up of cadmium in the circuit. Silica, although not present at significant levels in the WOX feed material (approximately 0.3%), had a significant impact on the efficiency of cadmium cementation with zinc dust, most likely due to the passivation of zinc dust particles with silica gel. Solid/liquid separation efficiency by filter press was also impacted. The silica levels were mapped throughout the circuit in an attempt to identify the source of the silica issues. Adjustments including using PLS as feed to cementation, pH control in WOX leaching and neutralization have been introduced to mitigate the issues created by silica gel in the circuit. INTRODUCTION Located in North Carolina, Horsehead Metal Products Inc. is a hydrometallurgical zinc refinery processing Waelz Oxide (WOX) to produce Special High Grade (SHG) zinc. The flowsheet, known as the Modified Zincex® process, consists of leaching, solvent extraction, electrowinning, melting and casting and bleed treatment as illustrated in Figure 1. Cadmium cementation, part of the bleed treatment process, provides an essential bleed of cadmium from the circuit, as metallic cement. The Cadmium cementation circuit consists of agitated cementation reactors, a zinc dust addition system, filter presses, agitated purification (releach) reactors and a cadmium concentrate filter press Silica can be found in several forms in acid leaching. The first form is fine silicate particles. The size of the particles can vary from one to twenty microns (1). Fine silicate particles can lead to the formation of crud in solvent extraction circuits (2, 3). At Mooresboro, crud has been observed in Depletion, which is part of the solvent extraction circuit. Silica content in the solution in this section is high. The second form of silica is monosilicic acid Si(OH)4, which begins to polymerize almost immediately upon being leached into solution. Monosilicic acid polymerizes to silica gel or a silica precipitate dependent primarily on supersaturation (5). Factors that influence the rate of polymerization include temperature, sulfuric acid concentration / pH, hydrofluoric acid concentration, seeding, and dissolved salts concentration such as zinc and aluminum in the solution (4, 5, 6). In sulfate systems, silica solubility is reported in the range of 150 to 450 ppm of SiO2 (3, 5, 7)."

Jan 1, 2016

By Mike L. Aziz, Keith D. Ferguson, Glenda Ferris

The Equity Silver mine has been a severe producer of Acid Rock Drainage (ARD) since 1982. The mine was closed in 1994 and a compacted clay cover installed, but ARD continues to be produced. Three permanent employees manage the collection and treatment system at the site. The site still poses a significant environmental risk to the environment and downstream users and requires a high level of diligence. Various stakeholders' perspectives of the risk posed by Equity, and what constitutes acceptable risk, will be examined in this paper from a company operation staff, corporate environmental manager and downstream environmentalist perspective.

Jan 1, 2000

By R. J. Roman

During the refining of primary magnesium metal: a spent flux (sludge) is produced which is considered a dangerous waste by the Washington State Department of Ecology. Four years of research, testing and marketing has identified two beneficial markets for the spent flux: 1) as a fertilizer and soil admendment as a result of the material's high potash and nitrogen content and its high lime equivalence and 2), as a roadway deicing agent to clear roads of ice and snow as a result of both the salt content and the flux containing chemical compounds which exothermically react with water.

Jan 1, 1988

The impact of smoothing on the definition of ore and waste boundaries using linear estimation and conditional simulation methods is discussed. The nature of transfer functions is examined including their ability to incorporate categorical data (e.g. a dominant lithology code). An Ore Block Optimization (OBO) transfer function is presented that provides a clear guide for the mining geologist. Advantages are seen in defining stockpile cut-off grades and meeting production targets such as maximizing head grade, maximizing ore tonnes or minimizing ore loss or dilution. Each of these scenarios impacts on mine profitability and grade control.

Jan 1, 1999

By James R. Jones

The tempo of air pollution control regulations has increased dramatically in the past few years. Because coal mining operations are frequently located in remote areas away from urban developments, specific regulations applying to coal mines have received lower priority and are thus only now being promulgated and/or enforced. Therefore, many mine operators are not yet familiar with the regulations and the impact upon their method of operations. Few have been faced with an inspector on the property sighting them for specific violations. Several of the Mid-western states are just now requiring permit applications to be submitted.

Jan 1, 1973

By Robert H. Marshall

The application of simulation to production planning at a large, complex open-pit mining operation proved to be challenging and enlightening. The mine is divided into two separate pits and several dump areas which are served by the same truck fleet. The operating system consisted of shovels of two different sizes, wheel loaders, and a fleet of three different truck types moving material from seven source locations to ten dumping sites. The interconnecting haulroad network included many common segments. There were operating constraints unique to the system, such as: traffic rules; manpower limitations; shovel, material-type, and destination priorities and production limitations; and a unique, non-centralized dispatching method for truck distribution. The truck distribution was further constrained by the matching of trucks to shovels, loaders, and destinations by truck type. The gathering and transformation of input data as well as the evaluation of results and validation of the model were also challenging. Despite a high level of sophistication in production reporting, some input data were neither readily available nor backed by field observation. As a result, many innovative techniques had to be used to develop realistic input data and to validate the simulation results. Nevertheless, this case study definitely proved the feasibility of applying computer simulation techniques to short and long range mine planning and budgeting at a large, complex mining operation.

Jan 1, 1982

By Mark E. Smith, Gerald J. Gierszewski

Introduction The purpose of this paper is to present a procedure used by the authors for evaluating and designing soil liner systems. This method is particularly valuable in evaluating various treatment schemes for chemically amended soil liners. A tabulation of laboratory test results on various soil types are presented to quantify the effectiveness of certain treatments. A typical liner design program includes developing and proving soil borrow sources, designing the cross-section of the liner system, developing construction specifications, and providing construction services to ensure the intended product is achieved. Material Source Development The first step in designing a soil liner is to identify and evaluate suitable borrow sources within an economical haulage range. This is best done in a two step approach: a reconnaissance level investigation to identify target areas and a detailed evaluation of those targets. Reconnaissance: The goal of the preliminary investigation is to locate potential borrow sources for liner quality soils. This includes all natural materials which can be compacted, chemically treated, or otherwise amended to yield an installed permeability at or below some target value. This requires utilization of all available data sources: Soil Conservation Service, BLM, aerial photos, USGS geologic maps, and project geologist records. The goal at this stage is to locate shallow deposits of favorable soil types. The Unified Soil Classification System provides an excellent first pass grouping. Clays, clayey sands and silts are the most favorable soil types, although silty sands and occasionally clayey gravels can make excellent liners, and are often amenable to chemical modification. The lowest permeabilities are generally achieved with CH, CL and MH soils. Once preliminary targets have been identified using visual examination, laboratory classification tests should be performed to further refine the selection. Testing at this stage should include gradation, plasticity and hydrometer analyses. Additionally, "preg-rob" testing should be done as early as practical. Preg-rob is a phenomenon where gold or silver ions in solution associate with the clay, or other, minerals. When this occurs, a portion of the gold or silver leached from the ore is actually tied-up by the clay and thus a reduces recovery. Testing for this consists of agitating a small sample of the soil in a solution containing dissolved gold or silver, preferably of similar chemical make-up as the solution which will contact the actual liner. The solution and soil are assayed before and after agitation to determine loss to the clay. A reliable estimate of the hydraulic conductivity, commonly referred to as permeability, can be developed from the D10 value by the use of Hezen's formula: K = 100 (D1012 This relationship is limited to soils where the finer particles do not move due to the force of flowing water (i.e.: "hydrodynamic stabilitym)(1). Additionally, the effect of platty particles on permeability is not as predictable as the effect of equidimensional particles. D10 is the sieve opening size at which 10% of the material is finer. Plasticity is also important from several standpoints. Constructability is directly related to plasticity. Very plastic clays and non-plastic silts both tend to be difficult soils, while medium plastic clays and clayey sands are generally very desirable. Post construction performance is also related to plasticity (e.g. swelling, shrinkage cracking, frost heave, etc.). Additionally, low plasticity silts and silty sands generally do not respond well to chemical amendment. Source Development: The result of the reconnaissance evaluation should be an estimate of the relative probability of developing a suitable borrow source within an economical haul distance. Of course, "economical distance" depends on the degree of handling and treatment the borrow material requires, as well as the cost of synthetic alternatives. The purpose of the detailed investigation is to prove out quantity and quality of material sources, and determine design parameters such as degree of compaction, mixing, treatment and thickness of liner. The emphasis of the testing program should be permeability and strength. Strength becomes increasingly important as the slope of the liner and the height of the heap increase. Permeability testing should evaluate the effects of compaction, water content, mixing and chemical treatment where appropriate. The effects compaction and water content during compaction have on

Jan 1, 1987

By Roland W. Rammler

In recent years, the crude oil reserves of the world have increased at the same rate as the consumption. A Consideration of the global figures suggests that adequate supplies of petroleum will be available during the next decades. On the other hand, it in a fast of economic and political significance that the reserves in the industrialized countries increase much more slowly than in the developing countries. In Western Europe the reserves have even decreased. At the present time, about 70 % of the petroleum reserves of the world are in the Middle East and in Africa in regions in which political arises are prevalent or impending. For the industrialized countries, the discrepancies between the consumption and reserves in various regions of the world are a strong urge to investigate whether oil can be recovered from other sources. The situation will probably not be changed to a large extent by the discovery of oil in the north of Alaska. The main starting materials for the production of synthetic crude oil are coal, oil shale and tar sand. In North America, where the consumption of petroleum increases more rapidly than the reserves, there are enormous deposits of each of the three materials. This fact is another incentive toward the utilization of these unconventional oil reserves, which provide a reliable basis for a supple of energy for a long time to come.

Jan 1, 1970

By Bert Allard, Åsa Sjöblom

The River Vormbäcken is the recipient of treated AMD from the Kristineberg mine site, northern Sweden, where mining of a complex sulfidic ore has taken place since 1940. Parts of the river flow through different kinds of wetlands. The changes in metal concentrations and water chemistry that occur upon passing these wetlands have been studied by analysis of water chemistry data from a number of stations along the river collected during 11 years of monthly sampling. It is concluded that the impact and functioning of wetlands cannot be elucidated from chemistry data alone. Future studies including e.g. reconstructed water flow are needed.

Jan 1, 2000

By D. R. Buist

The Taharoa plant of New Zealand Steel Mining Limited extracts a 57% Fe titano-magnetite concentrate from a large mineral sand deposit 90 miles south of Auckland on the west coast of New Zealand's North Island. The plant consists of an 18-inch suction cutter dredge which feeds a 750 TPH floating separation plant. An initial gravity/ size separation is obtained using cone concentrators. Finished concentrate is produced by a combination of conventional drum magnetic separators and top fed wet Mortsell magnetic separators. Concentrate is stockpiled by cyclone, and reclaimed by a bull- dozer and tunnel system. Repulped concentrate is pumped by sub- marine pipeline to slurry tankers anchored at a single buoy one mile offshore. Current concentrate production rate is in excess of one million metric tons per year.

Jan 1, 1973

By Eugene F. Casey

An immersed tube tunnel is one which is composed of elements that are prefabricated in a dry dock or on shipways, usually away from the actual tunnel site, floated into position and then lowered into a preexcavated and graded trench below a body of water. The elements or segments are then connected to each other under water, and the entire immersed tube tunnel covered with a protective blanket. Because water is essential, this method of construction offers advantages in a relatively limited field. By the very nature of the method, lowering elements to the bottom of an underwater trench, immersed tube tunnels are primarily used for crossing bodies of water, such as rivers, bays, straits, canals, etc. Although this method of construction was first used for a subaqueous railway crossing under the Detroit River in 1906-1910 and again in 1912-1915, for a four track subway tunnel under the Harlem River in New York, the reason immersed tube tunnels construction has not been used more extensively is simply a matter of economics. Bridges, compressed air tunnels and similar structures could be constructed at a lower cost.

Jan 1, 1970

By P. Bevilacqua, M. C. Williams, T. P. Meloy

We will bet you that, without prior programming within 10 minutes, we can design and simulate a 10,000 unit operation separation circuit. We will even do it at your place. We do it all the time. [ ] There are no tricks; we do it in a spreadsheet. We do it in those user friendly spreadsheet such as Quattro Pro. Spreadsheets must be user friendly. Accountants use them as do managers, business men, lawyers, doctors and salesmen. What these users seldom realize, is how powerful a mathematical tool a spreadsheet is. Among their other capabilities, spreadsheets can do a finite element analysis. That is why they are useful for accounting. That is also why they are more useful to engineers in the mineral industry. Spreadsheets are ideally suited for the engineering problems in the mineral industry. We have used then for solving problems in: a) mine ventilation; b) circuit design and optimization of dense media, flotation and sizing; c) comminution circuit design; d) shaking tables; e) Humphrey spirals; f) sluice ways and channel flow; g) lock particle and liberation problems; h) tunnel and shaft stress problems; i) cascadograph simulation; j) complex heat transfer problems; k) flow in porous media; and sheet flotation (Figure 1). Mineral industry problems presented on or with a spreadsheet are an excellent teaching instrument, problem statement and solution tools and sales devices. Spreadsheets answer easily, quickly and reliably many mineral industry engineering problems. What makes spreadsheets so useful to the mineral industry. The short answer is: they are easy to use; mineral industry problems fit the spreadsheet format. Those reasons are part of the answer. The real answer lies with the structure of the spreadsheet itself. Essentially, a spreadsheet is a "finite element analysis" form of computer software. Many mineral industry problems are readily solved by finite element analysis techniques. While some in the mineral industry may think they have never heard of finite element analysis, most use it weekly if not daily. Any profit and loss statement is essentially a finite element instrument. In fact, any array of numbers where one number is related to another may be construed as a finite element analysis product. Finite element analysis is a common daily activity. To get an appreciation of a finite element analysis, think of a monthly sales forecast for the next year. For each product and for each month, there exists a dollar figure for the forecasted amount of sales. In the forecast statement, for a given product in a given month, there is a "box" where the forecasted figure is presented. The forecast figure in that box was arrived at through some type of formula. The formula probably required some information from other neighboring boxes in the master forecast statement. Voila, one has a finite element analysis. Today the analysis would be done in a spreadsheet. A typical mineral industry problem is ventilation in an underground mine. Think of a rectangular room and pillar mining operation. Each room has air entering at a given pressure and velocity and air leaving at another pressure and velocity. During steady state, the air entering and leaving the room is determined by conditions in the adjacent rooms. One can readily model the room and pillar mine layout in a spreadsheet, and then find the flow in and out of each room at steady state. Change the flow by moving a brattice cloth or blocking off a path way and one gets a new air flow profile. Change the numbers on the spreadsheet that reflect

Jan 1, 1993

By Q. Feng

Study has been carried out to apply fly ash as a high strength, water-resistant precast construction material through geopolymerization. Experiment results show that the working conditions such as water content, the concentration of NaOH, curing temperature and curing time, significantly affect the mechanical property of geopolymer matrix. Through optimization, an above 100 MPa compressive strength has been achieved with the geopolymerization products. Water soaking tests show that the geopolymerization product has a very high water resistance without losing noticeable compressive strength even after a one month soaking time. To elucidate the geopolymerization mechanism, microscopic techniques such as SEM/EDS and XRD are also applied to investigate the microstructure, the elemental and phase composition of geopolymerization products. The findings of the present work provide a novel method to apply fly ash as a high strength water-resistant precast construction material. INTRODUCTION Geopolymerization is a process of obtaining a polymeric structure from aluminosilicate by dissolving aluminosilicate sources in a strong alkali (NaOH) solution and condensation of free [SiO4] and [AlO4] tetrahedral units (Davidovits, 1985 and 1988; Duxson et al, 2005; Xu et al, 2000, 2002). After being cured at an elevated temperature for a specific time, the geopolymerization product shows a greatly increased compressive strength. Therefore, the product can be used as construction material such as bricks and road pavement. It provides a very promising method to apply aluminosilicate sources such as fly ash as a construction material for a sustainable development. Fly ash is a main industrial waste which needs to be carefully impounded because of its potential impact on environment. Many efforts have been tried to utilize fly ash as construction materials substituting Portland cement because of the following reasons. First, fly ash is a silica/alumina rich aluminosilicate source, which makes the specific material an ideal source for the geopolymerization process. Secondly, the particle size of fly ash is usually very small (< 50 microns) and it saves a lot of energy consumed during the production process of cement for grinding. Thirdly, fly ash is an ideal source for geopolymerization because it is reactive to alkali even at a mild temperature. In the past twenty years, many studies have been carried out on the geopolymerization of fly ash to a make construction material. However, there are some disadvantages associated with the conventional methods of treating fly ash (Palomo et al, 1999; Perera et al, 2007; Temuujin, et al, 2009; Hanjitsuwan et al, 2014). First, in most of the proposed geopolymerization methods, a salient amount of sodium silicate has to be added. It therefore makes it complex whether the achieved mechanical strength of geopolymerization products is due to a real geopolymerization process between fly ash and alkali or just largely the solidification of metal silicate in air at an elevated temperature. Secondly, the authors have noticed that when the geopolymerization product is soaked in water, the solution pH increases sharply and the products will lose its compressive strength gradually in water. Thirdly, the compressive strength of the geopolymerization product as reported is usually less than 50 MPa.

Jan 1, 2019

By Josef J. Schwegel

The first vertical shaft lime kiln operating according to the parallel-flow regenerative principle was developed and built in the nineteen-fifties by Schmid-Hofer in Austria. Upon proving this concept of calcining or "burning" limestone to be very energy efficient for the production of good quality lime, Maerz Ofenbau AG of Zurich, Switzerland was in 1965 licensed for the design detailing and construction of these kilns. The first regenerative shaft type lime kiln outside of Austria was built in 1966 and through close co-operation with customers and their operating personnel, the advanced technical developments of today&apos;s kiln designs were accomplished. At present approximately 190 kilns of this type in capacities ranging from 60 to 700 short tons per day have been built or are under construction throughout the world in highly industrialized as well as less developed countries.

Jan 1, 1981

By Kadri Dagdelen

The definition and shortcomings of traditional cutoff grades are discussed. . The concept of optimum cutoff grade policy which maximizes the Net Present Value (NPV) of annual cash flows coming from a mining project is introduced within the basic framework outlined by K. F. Lane. Several examples are used to demonstrate the shortfalls of cutoff grade policies obtained by various heuristic optimization techniques. An algorithm to obtain an optimum cutoff grade policy which maximizes the NPV of a project is given and described in detail.

Jan 1, 1992

By B. R. Satio, P. G. West-Sells, D. B. Dreisinger, B. J. Y. Leong, G. A. Kordosky

Electrolytic techniques have historically been used to remove arsenic, antimony and bismuth from copper refining electrolytes. However, both solvent extraction and ion exchange techniques have been heavily researched and in a number of cases commercially introduced. In this study a large number of solvent extraction reagents and ion exchange resins were screened to determine the selectivity of the reagents for impurity removal. Solvating extractants were found to efficiently remove arsenic from electrolyte. The extent of arsenic extraction increased in the following order: TBP < DBBP < DPPP < Cyanex 925 < Cyanex 923. Antimony and bismuth extraction from electrolyte were demonstrated with the reagent 2EHAP04. The ion exchange resins UR-3300 and Duolite C-467 were found to strongly extract antimony and bismuth from electrolyte. C-467 appeared to be superior to UR-3300.

Jan 1, 1993

By C. D. Elifrits, N. B. Aughenbaugh

Laboratory tests of samples of fine- grained, argellaceous rocks, commonly referred to as shales, have shown that various changes in their moisture content can be correlated with loss of strength. This reaction to a change of in situ conditions at abandoned mine sites when combined with the field relationships at locations where the predominant overburden material is fine-grained, argellaceous, and fractured provides a predictive tool for engineers dealing with subsidence problems. Such a tool should enable engineers to recognize areas that are prone to be affected by surface disturbing subsidence features.

Jan 1, 1987

By A. F. Peterson

There is no single mining problem at Benson that does not exist at some other mine. There are four, however, that require special attention primarily because they occur together and have an influence on each other. These are the nature of the mineral occurrence, the shape of the ore body, the operating schedule, and the climate. It is the purpose of this paper to describe mining practices in relation to these four factors. Iron ore was first noticed in the Star Lake area early in the nineteenth century. Prior to Jones and Laughlin leasing the facilities built by the Defence Plant Corporation, several companies tried to mine the ore body but gave it up as uneconomical. While there is a little high grade (40%) magnetite, most of the ore contains 20 to 25% iron and not enough was known prior to World War II to design a profitable operation. By 1943, and certainly in the years that followed, technological developments in ore dressing and mining not only put the magnetite into the category of a commercial ore, but made possible the concentration of the non-magnetic iron mineral, martite. This last development nearly doubled the ore reserve. Jones and Laughlin bought the DPC holdings in 1946 and has since expanded the plant to its present capacity of 4,400 gross tons of concentrates daily or 1,600,000 gross tons per year. Magnetite makes up 62% of this production at the present time, but it will be necessary before long to bring martite production up to about 45% of the total because of the ratio of the two ores in the reserves. To keep the plant supplied, 14,000 to 15,000 tons must be mined and crushed daily, with a ratio of concentration that varies from 2.8 to 3.4. The ore body is 12,000 feet long and varies in width from 600 to 1,500 feet. The waste rock is, for the most part, a granite gneiss, and the overburden, of which little is left, is a glacial drift sand. For the entire reserve, there is a half ton of rock for every ton of concentrate, but the stripping ratio is more than one to one at present because of the existence of more rock in the upper mining levels in relation to the ore. The dirt stripping or development work that cannot be handled by company facilities is contracted to an outside firm. The need for this diminishes every year and will soon disappear. The deposit looks like a "J" in plan, with the long leg running approximately north and south and the short leg to the west. The primary crushing plant, consisting of a 54" gyratory followed by two 18" gyratories and a 1,500 foot conveyor belt to the fine crushers, is located on the third level where the long and short leg of the mine meet. The widest part of the pit lies just the north of the crusher. The mine is operated on a lease that expires in 199l0 There are two fee owners, the Benson Iron Company, which owns slightly overhlf of the reserves, and the Newton Falls Paper Company, which owns the balance. There is no appreciable difference in the mining on the two fees, so the ore is removed in strict proportion to calculated reserves during each year. Basic mining equipment consists of eight 45 yard electric shovels, a fleet of twenty-five 22 ton end dump trucks, eleven churn drills for nine inch blast holes, and two small percussion drills for four to five inch holes, There are the normal auxiliary items, such as dozers, graders, wagon drills, and two drop-ball cranes. Power is purchased and, where practical, is used at 4100 volts. Pit drainage pumps can handle a maximum of 11,500 GPM from the several sumps, but water is a problem only during the spring or when a sudden thaw follows a heavy snowfall.

Jan 1, 1958