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By Henrique D. G Turrer, Desmond Edifor, Marcello R. Cruz, Josue M. de S Junior, Darius Wonyen

A geometallurgical testing program was developed to anticipate ore behavior in the beneficiation plant and support production planning. Over 100 drill core samples from a major iron ore deposit were tested using bench-scale gravity and magnetic separation methods to assess variability in process responses. Results showed significant differences in key attributes such as iron grade, gangue content, slimes generation, and specific gravity, directly impacting concentrate grade, recoveries, and tailings quality. Correlation analysis and regression models were used to link feed properties to process outcomes, and a mass recovery estimation equation (Wrec) was developed for predictive use. The study proposes the integration of geometallurgical parameters—such as Fe, SiO2, Al2O3, LOI, ore type, size fractions, and slimes content—into the block model to support blending decisions and minimize operational risks. This work establishes a solid foundation for long-term mine-to-plant integration, with future phases aiming to expand testing and build a calibrated geometallurgical model.

Feb 22, 2026

By M. S. Safarzadeh

Cu-As feedstocks are among the most problematic copper sources that have been avoided over the past years. The high arsenic content of such ores/concentrates combined with their refractory nature have directed the metallurgical industry towards developing efficient technologies for the treatment of high-arsenic copper ores/concentrates. As the most important member of Cu-As-S mineral system, enargite (Cu3AsS4) is frequently encountered in some of the important copper deposits. Several hydrometallurgical and pyrometallurgical processes have been examined for the treatment of enargite concentrates, but currently, no commercial operation exists. In an effort to develop an original processing option, an acid bake-leach process has been identified and applied to an enargite concentrate containing ~67% enargite, ~27% pyrite (FeS2), ~3% chalcopyrite (CuFeS2), ~6% sphalerite (ZnS) and <1% galena (PbS). Sulfuric acid baking of this concentrate resulted in the transformation of the concentrate to S8, As2O3, HFe(SO4)2?4H2O, PbSO4 and Cu0.47Fe0.53SO4?H2O, all of which (except elemental sulfur and PbSO4) dissolved during the water leaching step. More than 87% Cu and 64% As were leached when the concentrate was baked at 200°C over 7 h with a sulfuric acid to concentrate weight ratio of 1.6. Less than 1% As was lost to the gas phase. Upon water leaching, copper and arsenic were released to the solution at a concentration ratio of about 3:1. While enargite is very reactive during the sulfuric acid baking reaction, other minerals present in the concentrate such as pyrite, galena, and sphalerite may compete to consume sulfuric acid and be converted into their corresponding sulfates at different levels. The purpose of this paper is to evaluate phase transformations during the acid bake-leach process for the treatment of an enargite concentrate, and to study the effect of sulfuric acid dosage on the extraction of Cu, Fe, and As. In this regard, the concentrate, baked concentrate, and the leach residues are characterized and a conceptual process flowsheet is described for the acid bake-leach process for the treatment of enargite concentrates.

Feb 23, 2014

By S. R. Brown

A number of relatively recent factors associated with the design of new metallurgical processing plants have made the effective training of operators a requirement for a successful start-up. Some of these factors include large capital investment in a minimum of processing lines, highly complex process control systems, and stringent regulations on plant effluent, to name a few. More than ever, operating mistakes during the start-up phase can lead to substantial delays in achieving design production, as well as problems with government authorities if permit limits are exceeded. The only way to assure your return on plant investment is to ensure new plant operators have the knowledge to properly run the plant from the outset. A comprehensive set of operating manuals specifically targeted for plant operators and foreman, written by experienced operating personnel, is the only effective way to provide the necessary information for start-up-related training.

Jan 1, 1995

By Joseph H. Herz

Recently, the President of the Portland Cement Association, Robert D. Maclean, gave the keynote address at the Rock Products Eighth International Cement Industry Seminar. He said, after listing the seven plagues our industry is suffering, "none of these items I have listed is a sales or marketing problem. Further, none is a problem that can be relegated to long-term study by public or private research agencies. They are here-and-now problems to be faced daily by producers, researchers, equipment manufacturers and consultants. THE DAY OF THE PRODUCTION MAN IS HERE." (1)

Jan 1, 1973

By H. Ankara

Determining the identicalness levels of the same model trucks working in open pit mine transportation system by means of statistical analysis methods is very significant in terms of availability analysis. In this study, the identicalness levels of two trucks picked randomly from the 170-short-tonne truck fleet working in open pit coal mine over one-year period were examined through a non-parametric test, Mann-Whitney U test for two samples. Time to failures (TTFs) and Time to Repairs (TTRs) of the trucks were analyzed with this test technique and then whether they were identical or not was determined. In order to determine whether the trucks identified to be identical at the end of this test displayed the same mining performances within the same open pit transportation system, the availability analysis of the identical trucks was carried out. As a result of the availability analysis, it was observed that the trucks had availability values that were very close to each other. It was also determined that Mann-Whitney U test could be employed together with availability analysis. Finally, it was observed that Mann-Whitney U test for two samples could yield rapid results in the performance analysis of complex systems like open pit mines.

Jan 1, 2010

By William H. Mount

Since the late 19405, St. Joe has operated rubber-tired, trackless mining equipment underground in its Southeast Missouri Lead Belt operations. At first, the trackless equipment was operated in conjunction with rail haulage equipment in the room-and-pillar operations, but was to later replace rail haulage completely. The first pieces of equipment to travel on pneumatic rubber tires were short-haul shuttle cars of 12-ton capacity hauling rock from the heading to the mainline railroad. Early-model drill jumbos were the next pieces of production equipment to be carried on rubber, along with mobile slusher ramps. Mobile diesel equipment, in the form of conventional rear-dump trucks, made its appearance underground in the early 1950s, introducing the era of relatively high-speed mobile equipment as compared to the electrically powered shuttle cars. Haulage distances for rubber-tired vehicles were no longer dictated by trolley lines and trailing cables and tires were subjected to increasingly severe applications. St. Joe&apos;s first completely trackless mine, the Hayden Creek Mine, was opened in 1952, employing rubber-tired drill jumbos, electric shuttle cars, and for the first time, an articulated diesel truck consisting of the tractor unit of a conventional earthmoving scraper and a rear-dump rock wagon. Those machines rolled on the first true earthmover tires to be used underground by St. Joe. The articulated truck concept proved to be very successful, and constitutes an In- creasing portion of the underground haulage today.

Jan 1, 1975

By G. A. Irdi

An automated method of microscopy for determining the pyrite size distribution on two base coals that were crushed to 28 mesh x 0 has been developed. Polished epoxy-bound coal pellets were prepared and examined by a Zeiss IBAS image analyzer utilizing a program developed from provided software. Pyrite size distribution determination is considered a necessary first step in pyrite characterization that could lead to successful predictions, by microscopy, of a coal&apos;s theoretical pyritic sulfur removal. Our research efforts to date have indicated that the IBP-S can be a reliable instrument for determining pyrite size distribution in crushed coal. A program was also developed to convert pyrite size data to a weight basis for comparisons to the results from chemical analyses. The problems encountered in our research and their solutions will be presented in the discussion.

Jan 1, 1986

By Robert H. Merrill

In 1960, the Kennecott Copper Corp. and the U.S. Bureau of Mines entered into a joint research program to determine the changes in stress, strain, and displacement created by changes in slope angles. The field site was the Kimbley Pit, located near Ely, Nevada; the supporting laboratory investigations were made at the Bureau&apos;s Denver Mining Research Center. Following a study to determine the rock stresses in the mining district, the strike and dip of geologic defects (fractures) in the rock, and the laboratory-determined strength of the rock, a new slope angle and pit configuration was selected, and instruments were installed to measure changes in stress, strain, displacement, microseismic noise rate, and sonic velocities at several points in the west wall of the pit. Between February and November 1966, the west slope was changed from an average angle of 45° to a new slope angle that started at 45° on the south wall, gradually increased to 57 ½ at the center of the west wall, and to 61° on the north wall. The pit was deepened from about 500 feet to about 550 feet. About 2.55 million tons of waste and ore were removed by stripping and mining.

Jan 1, 1968

By Bruce D. Hebb, Shahin Shadlou

Fiber Reinforced Polymer (FRP) is an excellent material choice for a broad spectrum of corrosive fluids and, in many cases, offers the best value per dollar. FRP Flanges present the greatest design challenge of all standard piping components. The theory underlying the design of flanges is very complex. In addition, due to the nature of FRP material, proper fabrication of the flanges is as critical as the design. In this review, the challenges of making FRP flanges along with the design techniques and best practices of fabrication that will lead to a high-quality flange will be discussed.

Feb 1, 2024

By Terry Owen

Business development process. Throughout Cyprus Amax&apos;s early months in Russia, the company stayed focused on what was needed from a deposit for economic success. Cyprus Amax&apos;s reason for success in Russia is that all involved - its Russian partners, the workforce and expatriates - provided a focused effort that served the project as it worked through the tender process and the Russian regulations. The company developed an understanding of the regulatory process by working with solid, ethical partners. Infused into the Kubaka management structure were Russians with the knowledge to facilitate the process and a professional group of expatriates. Developing credibility and a solid rapport with the Russian mining authority was critical to the success of this venture. Identifying and gaining the trust of key Russian individuals was also critical during the early stages. Gaining their trust and building credibility was part of the process. These key Russians were brought to the United States to visit existing Cyprus Amax mines. These efforts proved valuable in building an understanding with the Russians about the kind of company Cyprus Amax is and the kind of efficient operations that it can run. This was a learning process for all parties. Fortunately, the company was dealing with intelligent and educated people.

Jan 1, 1997

By W. H. Schiffbauer

The U. S. Bureau of Mines has been investigating methods and technology that, when applied to existing continuous coal mining machines, may improve production and safety. Toward those goals, a microcomputer network has been designed that provides automated control and monitoring of all mining machine systems using a single twisted pair cable (two conductor stranded wire twisted together to provide a level of noise rejection). The network also provides -connections for intelligent sensors and systems for navigation and diagnostics. The flexibility of the network is demonstrated in that features can be added and removed without redesigning the whole system. A general description of the network&apos;s integration to a Joy&apos; 16CM, Joy 14CM, Jeffrey 102, and a custom built auger machine is provided. The microcomputer networks for the Joy 16CM and the Jeffrey 102 have been installed onboard the mining machines and have been extensively tested at the Bureau of Mines test facility. The Jeffrey 102 system has also been tested in an actual highwall coal seam. Both systems have performed satisfactorily. The microcomputer networks for the Joy 14CM and the Auger Miner have been tested and await installation on the respective machines.

Jan 1, 1990

By John A. Cherry

Groundwater monitoring conducted at an acidic uranium-tailings impoundment in Wyoming and at one in Ontario indicate that at these unlined impoundments situated on unconfined sand aquifers, there exist well-developed plumes of contaminated groundwater. In the literature similar results are reported for three other unconfined aquifers at mill sites in Wyoming. The plumes extend for distances of several hundred to a few thousand metres from the impoundments. They have a zone of low pH beneath and adjacent to the impoundments and a larger zone of near-neutral pH that extends to the outer limits of the plume. The low-pH zones are generally small compared to the neutral-pH zones because the advance rate of the fronts of acidic tailings-derived water is slower than the average velocity of groundwater which controls the advance of the high pH zone. The retardation of the acid fronts is a result of geochemical reactions that cause hydrogen-ion consumption in a slowly-advancing neutralization zone. Within each of the plumes, the low-pH zone has high concentrations of transition metals, heavy metals and radionuclides. In the neutral-pH zones all of the metals and radionuclides occur at significantly lower concentrations and are generally at levels much below those specified in national drinking water standards. An exception at two of the Wyoming sites is uranium, which exists at levels close to the drinking water limit. A second exception is ferrous iron at the Ontario site, which occurs at high concentrations throughout most of the plume. The carbonate alkalinity at this site is much lower than at the Wyoming sites. The field data indicate that even in very permeable aquifers with a low content of silt and clay, there is normally a considerable capacity for acid-front retardation. To take advantage of this capacity to control contaminant movement in the design, operation and decommissioning of tailings impoundments, it is necessary to be able to predict the rate of acid-front movement. This predictive task has two primary components. The first is to identify the important flow paths from the tailings through the groundwater system and the second is to determine the degree of acid-front retardation that will occur as the tailings-derived water moves along these flow paths. Relative to these two tasks determination of the effects of hydrodynamic dispersion is generally of lesser importance and simple approximations that do not involve field or laboratory tests are probably adequate. In order to effectively apply the acid neutralization concept to the prediction of subsurface contaminant migration at uranium-mill tailings, improved representations of hydrogeochemical behavior of iron and aluminum in the neutralization zone and of the consumption of hydrogen ions through reactions with carbonate and aluminum-silicate minerals are required. Along with the hydrogen ions contained in the tailings water the ferrous iron represents a large potential source of acid but the extent to which ferrous iron converts to ferric iron to produce acid is problematic. Detailed hydrogeochemical evaluation of existing contaminant plumes and the performance of laboratory experiments under appropriate redox conditions ore prerequisites for the improvement of predictive models. However, the existing field and laboratory data provide a basis for preliminary predictions of contaminant migration from acidic uranium tailings impoundments.

Jan 1, 1982

By G. T. Lineberry

The Work Crew Performance Model (WCPM) is a method for designing, implementing, and evaluating? performance improvement strategies for machine operators and other mining personnel. The WCPM offers a practical approach for measuring job proficiency and identifying costly behaviors. It enables interventions aimed at performance improvement, especially training, to be assessed monetarily. Two interrelated elements of the WCPM are emphasized: observational techniques for establishing performance baselines and measuring performance outcomes and cost linkages between job competencies and measures related to profitability. Inter-and intra-subject differences in performance-related behaviors of regular and incidental shuttle car operators were detected during field validation of the WCPM. Downtime data were used as outcome measures to test linkages between performance error rates and cost consequences. Use of a simulation program for analyzing continuous mining face operations showed how common shuttle car operating parameters (e.g., payload, tram rate) can be used as cost-conscious indicators of performance variability and therefore as targets for performance improvement.

Jan 1, 1994

By William G. Pariseau, Mark K. Larson, Heather E. Lawson

Rational design based on engineering fundamentals is essential for the layout of safe, stable shafts and tunnels. Shafts and tunnels including winzes, raises, adits, and crosscuts are lifelines to the underground and must be secure. The contribution of this paper describes a significant extension in existing software previously developed for five important design problems in strata-bound mines such as coal, trona, salt, potash, and some large, lead-zinc mines. This extension in software allows analysis to proceed in three easy steps: (1) preparation of a strata properties file, (2) generation of the finite element model, a mesh, and (3) finite element program execution. Circular, elliptical, and rectangular shaft sections are available for a single shaft, twin shafts, and shafts in a row. Spacing of twin shafts and shafts in a row is a free parameter (pillar width). Tunnel shapes are the same as shafts but include the conventional arched back section. Dipping strata of variable thickness, depth and orientation relative to the excavation of choice are allowed. The analyses are three-dimensional. An elastic-plastic material model based on associated rules of flow and an N-type yield condition for isotropic, transversely isotropic, or orthotropic rock are used for all strata. Example analyses from several hardrock mines are provided to illustrate the three-step process including mesh plotting and plotting of selected results. The goal of this software is to advance mine design technology for improved miner health and safety.

By Ossi V. I. Hintikka

There are several limestone deposits around the Lohja area in southern Finland. Raw material for cement rock is mined from some of them. The formations are geologically complicated, and therefore selective mining is used whenever possible. One of these mines is the Tytyri underground limestone mine, which is divided into two parts; Törmä and Solhem. In addition to the selective mining system hand sorting or picking must be used at the Tytyri mine to improve the overall grade of the blended limestone. Some means were needed in order to improve the quality and to increase the feed rate by the elimination of hand sorting. Sorting machines were considered and eventually a Sortex 811MW was pilot plant tested at the Ojamo mine near Tytyri. This machine now continues to be used on production.

Jan 1, 1971

By L. J. Vincze

The program of study of pellet binder materials was begun by the ORF in 1963 to examine various Canadian materials as substitutes for bentonite which is imported in large tonnages (199,270 tons in 1969) from the U.S.A. for Canadian pellet plant operations. Most of the raw bentonite used in Canada originates in Wyoming, North Dakota and more recently Greece, resulting in relatively high transportation costs to pellet producers. Some Canadian bentonites available in Western Canada (Alberta) can be beneficiated for uses as pellet binders but could not compete in cost with U.S. sources due to the cost of beneficiation and the higher rail transport charges to Eastern Canada. It is difficult to find a substitute for bentonite, and many materials have been investigated by research groups but, so far, no economic substitute is in use. However, some success is apparent in studies of low cost materials such as clays, sea weed, peat moss and low grade coal, The work done by the ORF over several years has covered systematic test¬ing of Ontario clays, lignite, some types of tree bark, waste sulphite liquors of various kinds, and peat moss as binders for iron ore pellets. The major effort has been concentrated on peat moss and has included a study of the influence of different additives. Since analysis of peat moss for humic acid is difficult and time consuming, a certain amount of time was devoted to development of improved methods, the most useful of which was a spectrophotometric method based on extraction of peat by sodium pyrophosphate for determination of humic substances. In the present paper, only the most recent work concerning the use of peat moss with suitable additives is discussed in detail, since it is the most conclusive and best documented portion of the program.

Jan 1, 1971

By L. Sandbak

The Turquoise Ridge Joint Venture (TRJV) is located in northern central Nevada, and is situated within the Basin and Range province, near the northeast end of the Osgood Mountains (see Figure 1). The TRJV mine consists of typical Carlin type- gold mineralization characterized by low strength rock of altered limestones, siltstones, and mudstones. The weak nature of the ground facilitates the underhand cut and fill mining methods. TRJV has been working to optimize ground support and mechanize top cut drift sizes and eliminate operating hazards associated with jackleg drilling. Safety Factor analysis based on bolt strengths has allowed us to pursue larger sized top cut drifts and to evaluate bolt length sizes and spacing. Switching from jackleg sized drifts of 10?W x 10?H to a mechanized 12?H x12?W top cut drift design has the potential to decrease overbreak, provide more uniform drift design sizes and bolt patterns, and increase ore production by at least 38%.

Feb 23, 2014

By Donald M. Benjamin

Florida&apos;s electrical needs are served by 58 utilities of practically every type: six investor-owned, 34 municipal, 17 cooperative, and one federally-owned. They range in size from a small municipal system with a, 2 MW annual peak demand CD a large investor-owned utility serving about one-half of the state with an annual peak demand of 8,600 MW. (1),(2) These utilities are interconnected at several voltage levels with 230kV serving as the pre-dominant voltage for the bulk power transmission system. About 275 miles of 500kV circuits are found within two systems, but no tie-lines yet exist at this voltage. Due to Peninsular Florida&apos;s (that portion of the state east of the Apalachacola River) geographic location and shape, it cannot, at present, depend upon its interties with the remainder of the nation to completely support the sudden loss of the state&apos;s largest generator. Therefore, the utilities maintain a total amount of spinning reserve to cover for this single contingency outage at all times. Most of the state&apos;s electric utilities belong to the Florida Electric Power Coordinating Group (FCG) which, through its standing committees, coordinates the planning and operation of the member systems. Though a formal, centrally dispatched pool does not exist in the state, generating utilities which belong to the FCG&apos;s Operating Committee subscribe to an energy broker operation to maximize the savings that can accrue from economy interchange. Studies are underway, with participation from the staff of the Florida Public Service Commission, that are investigating both central planning and dispatch of the peninsula&apos;s electric utilities. Florida&apos;s electric load is mainly residential. During: 1976, 48.8% of all electrical energy use was by residential customers; 31.8%, commercial; 16.2%, industrial; and 3.2% for all other. By comparison, 32.7% of the United States&apos; load was residential, followed by 40.5% industrial, 23.0% commercial, and 3.8% other.

Jan 1, 1978

By Brad Simser

Several case histories from Glencore’s Sudbury Operations show how passive seismic monitoring data is used for geotechnical decision making. The data comes from three different seismic arrays monitoring two open stoping deposits, and a narrow vein cut and fill/blasthole operation. Mining depths range between 1000 to 1680m below surface. The deposits are hosted in hard igneous rocks typical of the Sudbury basin, with characteristically high horizontal stress (approximately 1.8 times the depth of overburden). Rockbursting is the main geotechnical risk, due to the strong brittle nature of the rock and local high mining extraction. Fault related seismicity includes both fault slip events, and the stress channelling effect as the mining front approaches a major fault structure. Planar data trends generally line up with known faults and often indicate early stage fault activation. The structures are risk ranked based on their seismic response. This has been particularly useful at the Nickel Rim South Mine (NRS) where the structural fabric (jointing and small-scale faulting) is generally parallel to the more through going faults. The persistence of structures is difficult to measure, and the NRS faults generally have low offsets and thin gouge. The visual difference between the more persistent structures that occasionally generate large seismic events (up Mw 2.9 to date) and localised joints/slips is often minor. The seismic monitoring data clearly shows the more active structures. This information is highlighted on mine plans to help guide enhanced ground support and seismic re-entry protocol barricade locations. Pillar loading/yielding is a key element to the blasthole operations where a primary/secondary mining sequence is used. The secondary pillars are mined in a yielded state with just-in-time development. An example of the seismic signature of a secondary stope is shown with emphasis on the need for high location accuracy given the stope widths of 12.5 to 15m. The ratio of the shear wave energy to primary wave energy (Es/Ep) has long been used as a method to estimate source mechanisms; the higher the ratio, the more likely the event is fault slip versus rock fracturing. Data sets are filtered on Es/Ep ratios to highlight both fault slip populations and stress fracturing mechanisms. Examples of seismic data quality checks, high stress development, and re-entry protocols are also shown in the case histories.

Apr 26, 2022

By T. A. de Almeida, M. de Paiva Bueno, M. Powell

The mining industry is one of the foundations of modern society, providing not only the raw materials needed to maintain a contemporary lifestyle, but also serving as a basis for the development of future technologies. From the most basic components of an appliance to the materials needed to design an electric car or a space rocket, each raw material has gone through a painstaking procedure of extraction and processing, and ways to make this process more efficient will be of great help to meet an ever-increasing demand for minerals. One of the biggest challenges when extracting mineral resources is to measure the variability of the mineral body prior to processing. Comminution is the most power-demanding stage, and the lack of geometallurgical testing, often for financial reasons, may result in an inefficient operation. The Geopyörä Rock Breakage test was developed with the objective of making mineral variability data more accessible by providing both standard comminution parameters and rock mechanical properties at low cost, and with a modest sample size, allowing a larger number of samples to be tested to reduce uncertainties and assure productivity. The objective of this paper is to present the results of an extensive validation of this new rock breakage method against two of the main tests currently in use, namely the SMC® and Bond ball mill work index tests. More than 100 samples have been tested and the results compared, showing that the new method can accurately estimate the parameters of the traditional tests. This confirms that the new test is a reliable tool for comminution and geometallurgical tests.

Feb 1, 2023