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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 T. E. Wilson

The length of Alaska’s coastline, combined with the presence of a significant number of fjords, encourages consideration of marine disposal of mine tailings. However, since various factors govern the viability of the submarine tailings disposal (STD) option, the decision making process is complex. An expert system, called Submarine Tailings Disposal Expert System (STADES) that will help mining project planners explore the feasibility of STD, was developed. Existing literature, supplemented by engineering recommendations, on the various aspects of marine disposal of tailings was reviewed and formed the knowledge base for the expert system. The shell used to develop the expert system was LEVEL5®.

Jan 1, 2001

By G. Blackwell, E. Bozorgebrahimi

The trend in open pit mining has been to maintain cost competitiveness through economies of scale, particularly by implementing larger trucks and shovels. This paper considers the potential adverse impact of such scale adjustment, however, on dilution, maintenance, flexibility, and other aspects of operations. It examines the mine production characteristics affected by increased equipment size and attempts to quantify the impact on the overall operation. Reference is made to data from operations that have experienced a variety of equipment size ranges changes over the last decade.

Jan 1, 2003

By J. Andrew Leach, Robert T. Tape, Thomas G. Harper

A practical approach to elope stability design of heap leaches up to 90 m (300 ft) high is presented based on recent experiences with heaps throughout the Western U.S. Shear strength parameters for foundations, ore and liner systems are considered, with particular attention given to frictional contacts between geomembranes and clay or geotextiles. Stability of both ore and containment dikes is discussed including the effects of seismicity, staged dike construction, progressive heap development and in-heap solution levels. Design criteria and methods of analyses are presented along with techniques for improving stability.

Jan 1, 1987

By Zhou Aimin, Xie Benxian, Song Chongkai, He Zhexiang, Zhang Changqing

Concrete pump is commonly used to transport paste and high-density backfill over relatively long horizontal distances. However, since the investment in concrete-pump and its operating cost are quite high, the application of paste backfill is limited in China. For seeking an alternative paste backfill technology, squeezed-transport technique and equipment has been developed. The new technology has been adopted at Tonglushan Copper Mine of Daye Nonferrous Metals Corp for overcoming a difficulty of long-distance transportation of high-density cemented tailings fill. It proved to be an alternative paste backfill method with simple backfill system, saving investment and low operating costs.

Jan 1, 2001

The importance of factoring mining dilution into the estimation of ore reserves in an open pit mine is discussed. An example that relates the issue of mining dilution to the size of the smallest volumes that can be mined selectively is given. The relationship between the size of the selective mining units (SMUs) and the variance of their average grade is presented. The concept of variance reduction and its use in factoring mining dilution into geostatistical ore reserve estimation is described. An approach to estimate a variance reduction factor by way of conditional simulation is introduced.

Jan 1, 1998

By R. L. Grayson, Y. J. Wang

An application of material requirements planning (MRP) to coal mine inventory control is presented. MRP is an efficient material control system that integrates the production planning and inventory management functions. Net material requirements are determined from the production forecast utilizing bill of material files, the inventory status file, and the purchase order status file. Net requirements are computed for each period in a specified planning horizon, and purchase orders, offset by lead time, are initiated routinely to ensure timely receipt of materials. The MRP system is especially useful in production-inventory systems in which con¬sumption of materials is directly production dependent.

Jan 1, 1987

By D. Greene

Close integration of mine planning and operation is a long-sought goal. Success is achieved in varying degrees depending upon mine complexity, size, and sophistication, but too often is more limited than desired. Despite tremendous strides in the development of computer-aided mine planning, digital plans usually must still be converted to error-prone paper maps and physical ground surveys for actual excavation and reclamation. However, advances in GPS, operator displays, and mobile computers now enable equipment operators to work directly from on-board digital plans. CAES offers reduced survey costs, faster field transition time and improved excavation accuracy coupled with faster, more informed decision making regarding key mining operations.

Jan 1, 1997

By H. Lyn Bourne

This is the 10th annual tabulation of US mineral royalties published in MINING ENGINEERING. The first year, 1982, the author solicited information about royalties and the cost of reserves. That column contained only a few royalties - not enough to tabulate. Since then, the response has been sporadic but the entries have grown to more than 300. Some have been deleted. Some of the older information has been deleted to make room for new entries. All indications suggest that the readers enjoy and use the information. But more information is needed. Russian practice In 1989, this column gave a brief history of mineral leasing and royalty payments as the concept applies to mining in the United States. This year's narrative deals with information about the mineral ownership in Russia. That country is in political and economic turmoil, including administrative systems and methods. And many laws are likely to change. What follows describes the Russian system of mineral ownership as of early 1992, according to Kirill Kavun. He begins "All the subsurface space of the Russian Federation with minerals contained belongs exclusively to the state. This forms the Common State Mineral Fund. Land parcels may be state, municipal, public or private property. They may be let to be owned and used by individuals, juridical persons, national/territorial or administrative/ territorial formations." This seems to apply to surface rights, as known in the US.

Jan 1, 1992

By R. D. Hansen, R. R. Klimpel

This paper discusses the influence of frother type and dosage on recovery/selectivity in coal/sulfide mineral flotation as a function of particle size. It is shown that different frother structures exhibit quite different but consistent performance characteristics depending on the underlying particle size ranges involved as well as the dosage levels of both the frother and collector. The data presented on existing commercial frothers and some new special purpose experimental frothers is used to illustrate some general operator guidelines on proper frother selection and use.

Jan 1, 1987

By D. G. Bosse

Equipment choices for ultrafine grinding encompass several different types of dry and wet size-reduction devices These need to be put into functional perspective for systematic analysis of capabilities and limitations versus processing requirements of the materials to be satisfactorily ground Particle strengths plus maximum and average sizes are the primary variables controlling grinding action requirements and equipment options for efficient processing These are fairly well understood and provide the starting point for decisions Particle space requirements under dynamic processing conditions vary with particle shapes and size-distributions by as much as 30X This additional major variable IS not widely appreciated and does need adequate description to provide a firm basis for selecting processing compositions and procedures

Jan 1, 1983

By Mary-Lee Athorn, David A. Barratt

An opportunity to compare the performance of different tunnel boring machines (TBMs) operating in similar rock conditions occurred during the construction of a major water scheme in the UK. The principal objectives of this study were: (i) To collate, analyse and present the data available for the four TBM drives of the Kielder Aquaduct Scheme in terms of the tunnelling system performance and the downtime experienced, particularly where these were influenced or controlled by geotechnical parameters. (ii) To isolate the major sources of machine downtime and highlight those aspects of the tunnelling system that critically affect tunnelling progress rates (iii) To determine, by statistical techniques, relations between TBM performance and rock properties.

Jan 1, 1986

By G. H. Schnakenberg

In 1986, the US Bureau of Mines (USBM) embarked on a major research effort to develop technology that could substantially reduce worker exposure to face hazards by simply relocating the equipment operators to an area of relative safety. This reduced-exposure mining system (REMS) research effort enhances the USBM's ongoing health and safety efforts aimed at reducing and controlling dust and noise and reducing accidents through training and better mining practices. This paper reports on the progress made on the developing research and demonstrates the technologies required for the computer-assisted teleremote operation of continuous mining machines, haulage systems and roof bolting machines.

Jan 1, 1998

By B. Govindarajan, L. S. Rao, T. C. Rao, B. R. Rao

Laboratory leaching experiments were conducted to extract potassium from glauconitic sandstone, and the effects of important variables were studied. The reduced time plot (RTP) for all of the variables obtained from the experimental data has been quantified by this simple equation: R = 100 (1 - exp (-0.693 *(T/T50)0.605) The time required for 50% extraction (T50) has been correlated by a regression equation to variables such as acid strength, temperature, fluorite: glauconite ratio and % solids. Both of these equations were used to predict the extraction percentage at different process-variable levels. In addition, several other experiments were conducted at arbitrary levels of the variables to verify the equations developed.

Jan 1, 1994

By P. L. Webster, S. D. Thompson

The Coal Mine Belt Capacity Simulator (CMBCS) was originally developed to provide an improved belt capacity simulation through more detailed, flexible and realistic modeling of belt loading. While this model offered improved capacity design for conveyor belts and surge bins, it lacked the capability to simulate some key protection and segregation applications for bunkers. Recently, CMBCS was extended so that these latter bunker applications could be considered. In addition, a fear minor extensions were made to improve the model's flexibility and of efficiency. These various extensions and the steps taken to verify and validate them are described. The associated modifications in the model's input and output as well as the model's current requirements and availability are also discussed.

Jan 1, 1992

By Bart Lorang

Mining and mineral processing companies have historically leveraged technology and science to the fullest to reduce costs and improve product. Information technology is arguably one of the fastest moving technologies used by the mining industry. However, the business model for managing that technology and IT professionals often is fundamentally the same model that evolved from 1960's mainframe era. This paper will present a perspective of today's technology; review emergent computing technologies and attempt to id- advancements in computing anticipated in this decade. It will then discuss how the traditional IT model fits the technologies of today and the next decade. It will suggest roles IT professionals may play in the future to best leverage these technologies.

Jan 1, 2002

By R. Cook

Knowledge based applications are becoming important to Associated Manganese for efficiently dispatching ore of appropriate grades to customers on time. The G2 expert system shell has been used to develop blending and scheduling applications using a combination of object-oriented rule based, procedural, and heuristic approaches. The blending application, for example uses a heuristic approach for creating blends from thousands of small stacks of manganese ore of various grades and sizes, to meet customer specifications while fully exploiting the available inventory. Data capture and data warehousing have become important issues, and the Internet shows strong potential for distribution of pre-processed information.

Jan 1, 1997

By Christophe Bragard, Jason Choi, William H. Hansmire

This case history provides a physical benchmark of tunneling technology progress comparing an old hand-mined tunnel to a modern 20-ft-diameter EPB TBM that mined in the same ground. This rare opportunity to see how tunnels were constructed many years ago occurred when an old 10-ft-diameter storm drain tunnel in the way of os Angeles subway construction was demolished and replaced with obas berglass pipe. Steel rib and lagging initial support was exposed showing solid-sawn 2" × 12" × 48" redwood lagging. This paper documents the as-built old tunnel, how it was successfully replaced, and some lessons learned.

Jun 23, 2024

By W. M. Schafer

The risk that water quality will be degraded by mining activity can be evaluated using risk analysis techniques. Water quality impacts can occur where water-rock interactions with tailings, waste rock, or leached ore lead to increased loading of constituents into surface or groundwater. Constituent loads contributed by mining facilities are determined by the migration route and chemical evolution of mine water. Mass load contributions from mines can be determined by estimating the prototype pore water in contact with mining waste, predicting the rate and timing of flow, assessing the degree of geochemical attenuation, and modeling chemical mixing with natural surface or groundwater. Mining facility siting and design measures can alter the chemical evolution of mine water by varying the quantity or quality of flow. Stochastic risk management techniques provide a powerful tool for quantitatively identifying the environmental consequences of various siting and design alternatives.

Jan 1, 1998

By Angelus S. C. Owili-Eger

The past decade has witnessed an unprecendented proliferation of groundwater computer models. Some of these numerical models were developed for the purpose of simulating groundwater movement in mining environments and predicting inflow rates into active mines. However, a general acceptance of these models as routine planning tools by the mining industry has been slow. Until recently, the major use of these models in the industry is by consultants. There are several reasons that have contributed to this situation. Some of these factors - include scarcity or non-existence of an appropriate data base information required for executing these models, the difficulty and costs involved in acquiring data, and the fact that the instructions for using these models are often too involved and time consuming. Today, however, the state-of-the-art technology has been advanced to a level where numerical models can be routinely used to simulate and predict inflow rates into active mining environments. Such environments include highly fractured (longwall) and deforming flow media. Features integrated into these comprehensive and yet easy to use models are double-porosity-pressure, multiphase, and non-darcian flow conditions. This paper reviews the role that computer modeling has played in mining-related operations by presenting several case studies and the state-of-the-art tools currently in use. Included will be some of the practical field applications that have been compiled during the past decade.

Jan 1, 1986