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By Eric Ohl

Due to the world's ever increasing minerals and energy demands, process plants have to cope economically with ever growing throughput rates. This trend has accelerated the development of high capacity vibrating screens. Screens with screening areas of 30 to 50 square meter (322 to 540 square feet) and width of 5.5 meter (18') are technically possible and are being used presently with great success. This paper will concern itself with the general aspects of large screen design, by using modern technology and the latest findings with regards to fatigue strengths relative to the laws of vibration. It also will investigate the technical and economical limits of such designs.

Jan 1, 1983

By A. Pinches, R. Winby, P. J. van Staden, M. K. Rhodes, P. C. Miller

This paper is a progress report on the commercialization of using bioleaching for base-metal concentrates. The paper focuses on bioleach processes for recovering copper from chalcopyrite and nickel/cobalt from pentlandite/pyrrhotite. Data is discussed from pilot-plant trials in which an overall recovery >95% was obtained for the bioleaching of copper from chalcopyrite. The pilot plant was operated in closed circuit with solvent extraction and electrowinning circuits for final metal recovery. For the bioleaching of nickel and cobalt from pentlandite/pyrrhotite, an overall recovery of 97% was achieved. Precipitation routines were used to produce a final nickel/cobalt product. The pilot plants were capable of treating a few kilograms of concentrate per day. Prominent features in the design of a 1-t/day (1.1-stpd) copper-bioleach demonstration plant for the treatment of chalcopyrite concentrate are discussed. The plant, which is now under design, will be constructed and operated based on the results obtained from the laboratory pilot-plant campaigns. Issues of scale-up for the demonstration plant, together with integration into upstream and downstream processing, are also addressed. Independently derived capital and operating costs are presented for a possible commercial plant. These cost studies indicate the principle economic issues in considering the application of bioleaching to the extraction of base metals. The benefits of bioleaching complex concentrates that are not amenable to physical beneficiation and economic treatment by conventional smelting are highlighted. Issues, such as the environmental aspects, that illustrate the benefits of bioleach technology are given.

Jan 1, 2000

By J. Michael Howard

Holes cored through the Prairie Creek lamproite volcanic complex at the Crater of Diamonds State Park by companies interested in the site's commercial diamond potential give an opportunity to redefine the size and shape of the Prairie Creek pipe. Relationships of cored rock sequences and the discovery of a previously unrecognized major rock type allow a reinterpretation of the sequence and type of intrusive activity. Trench sampling of diamondiferous rock units yielded a diamond content far below what was anticipated based on an estimate from historical records. Inadequacies of shallow bulk-testing methods for a diamondiferous pipe are examined.

Jan 1, 1999

By E. W. Geist, W. J. Bronkala

PRINCIPLES OF MAGNETIC SEPARATION The application of magnetic separators relies on the different behavior of individual mineral particles under the influence of magnetic forces. When exposed to a magnetic field, all materials are affected in some way. According to whether materials are attracted or repelled by the magnetic field, they are designated paramagnetic or diamagnetic, respectively. Paramagnetic materials are attracted along lines of magnetic force from points of lower magnetic field intensity to points of higher magnetic field intensity. The very strong response of some materials to a magnetic field is sometimes designated ferromagnetic and the particles attracted frequently retain magnetic properties after the applied magnetic field is removed. Diamagnetic materials are repelled along the lines of magnetic force from points of high magnetic intensity to points of lower field intensity. Only limited commercial use of diamagnetic effects has been made. For practical applications, the paramagnetic groupings are: 1. Strongly magnetic (ferromagnetic) 2. Magnetic 3. Weakly Magnetic 4. Non-magnetic The limits of these groupings are not well defined and will vary in some mineral species. Only a few minerals are ferromagnetic (magnetite is an example) and arbitrarily some investigators have selected 10,000 gauss, or 1 Telsa, as the dividing line between low and high intensity magnetic fields. I. S. Wells has developed a table indicating the magnetic intensity required to separate a selected grouping of minerals which is shown in Table 1 on page 2. A similar table has been developed by Carpco Inc. of Jacksonville, Florida in conjunction with the use of its high tension separators. This table, Table 2 on page 3 shows other minerals grouped in the broader categories cited above. Magnetic separation methods are used either to separate valuable minerals from nonmagnetic waste or magnetic impurities or other valuable magnetic minerals from bulk nonmagnetic values. Magnetically susceptible mineral particles occur as either individually discrete particles,

Jan 1, 1986

By C. W. Matthews

Introduction Screening is an art, one of the oldest in the process field today, and one of the most widely used in our present age. Screening is being applied to an ever-increasing number of assignments, in an ever-expanding circle of industries. Screening is defined precisely as a mechanical process which accomplishes a separation of particles on the basis of size and their acceptance or rejection by a screening surface. Particles are presented to apertures in a screening surface and rejected if larger than the opening, or accepted and passed through if smaller. Screens are machines with screening surfaces used to classify materials by size. The screening surface is the medium containing the apertures for the passage of the undersize material. Screens are put to many uses - size separation, dewatering, desliming, media recovery, scalping, trash removal, washing, dedusting, conveying, concentration, and many combinations of these functions. It is interesting to note that screens are used for handling commodities

Jan 1, 1985

By J. Hazen, R. Jenner

This project was developed at the PCS Phosphate Mine in Aurora, NC. This site includes a surface mining operation, beneficiation plant and chemical processing facility located in the coastal plain of eastern North Carolina. The phosphate ore being mined at this operation is a 10 to 12 meter (35 to 40 foot) thick colloidal deposit located approximately 30 meters (100 feet) below the ground surface. The ore is pumped to the beneficiation facility where it is separated into clay, sand and concentrate streams. The concentrate product is utilized at the chemical plants to produce a wide range of products including fertilizer, industrial phosphates and animal feed products. The Cyclone Dike Builder (CDB) project developed a technique for dewatering the beneficiation tailing sand stream and providing innovative placement for dike construction. Future material balance requirements at the PCS Phosphate mine required an improvement in tailing sand placement technique to accomplish strategic objectives. The water volume of the sand slurry forces significant quantities of sand out of the dike profile during deposition. PCS Phosphate and MetPro Supply of Florida developed a mobile high-density hydro-cyclone station to remove most of the water and significantly increase the density of the sand being placed for dike construction. This high-density sand slurry is then effectively controlled using minimal heavy equipment operation.

Jan 1, 2004

By A. T. Iannacchione

Recent fatal injuries occurring during pillar retreat coal mining call for better identification of the hazards and recognition of risks. Ground control hazards associated with room-and-pillar retreat mining tend to intensify with depth, requiring extra precautions in the form of additional controls. In many locations these activities are further complicated by local complexities often associated with unique or novel circumstances, such as over-mining or under-mining. One technique recently studied by NIOSH, Major Hazard Risk Assessment (MHRA), may help mine operators to mitigate the risks associated with pillar recovery operations. The approach was trialed at two underground coal mines in southern West Virginia that are currently practicing pillar recovery. The first step in the MHRA process involved reviewing the segments or parts of the pillar extraction mining system and identifying associated hazards and threats to the operation. Some of the high risk hazards at these two sites included: ? Rock fall during pillar extraction covers equipment and injury occurs during recovery operations, ? Rock fall above the roof bolt horizon, potentially injuring ? workers and/or requiring recovery action, ? Rib fall under deep cover, potentially injuring workers, and; ? Strata instabilities associated with subsidence of the interburden due to simultaneously mining two seams in close vertical proximity to one another. The mines? risk assessment teams then considered each threat individually in order to systematically identify potential unwanted events. The top unwanted events were examined individually using structured risk analysis tools. The output from the process includes a list of priority existing controls for monitoring and auditing, and a second list of potential new controls. These controls consisted of: Examples of best practices, ? Enhanced communication, ? Implementing standard operating procedures (SOP), ? Protocols for emergency response actions, ? Effective layouts, ? Efficient monitoring, and; ? Successful audits. This paper documents the process as it unfolded at the two mines, and analyzes the strengths and weaknesses of the MHRA technique as it applies to pillar recovery operations. This work was part of a larger NIOSH research project. NIOSH was responsible for: 1) facilitating the risk assessment process known as Major Hazard Risk Assessment (MHRA), 2) documenting the risk assessment process, and 3) providing mine management with a written draft summary of the risk assessment process. The results of the risk assessment represent the thoughts and opinions of the individual risk assessment teams and should in no way be construed as an endorsement of the risk assessment output by NIOSH or the University of Pittsburgh.

Jan 1, 2009

By M. Fornaro

A small size quarrying activity (3 different quarries with an overall production in blocks less than 10.000 m3/year) has been exploiting for a long time the ?Tonalite? deposit of Adamello-Presanella. In 1967, given the outstanding natural beauty of the area, a natural park has been established with the aim of preserving environmental quality and, at the same time, of providing a sustainable development to the area. Because of the potential impacts of a mining activity in such a context, a specific study has been recently carried out in order to define if and how the quarries could co-exist with the park, beyond the ?administrative results? of a classic environmental impact assessment. The paper deals with the process that drove to the conclusion that the activities are not ?a priori? incompatible with the aims of the park. In the opinion of the authors, a responsible quarry management, which must take inspiration from the care given to environment by traditional alpine productive activities (e.g. the use of water, of wood, and of the stone itself), and take advantage of modern technologies in terms of emissions and safety, can be considered not only compatible with the protected area, but even able to positively contribute to the protection of the land and environment (Barisone et al., 2001). A series of specific prescriptions, which have been adopted by the Park Authorities after this study, are also discussed in the paper: only the definition of suitable spatial and temporal limits, the adoption of effective technical practices and a strict control are considered to be able to drive this ?exceptional? activity towards the final goal of real sustainability.

Jan 1, 2007

By Eric R. Braun

Ore reserves in the Republic mining district were nearly exhausted in 1984 when hole D-54 intersected a vein twenty- eight feet in drill width averaging 1.57 opt gold and 11.95 opt silver below post-mineral lake beds. The discovery area, termed "Golden Promise", has announced proven and probable ore reserves of approximately 372,000 tons averaging 1.0 opt gold and 4.5 opt silver, and drilling indicates another 756,000 tons of mineralized material containing 0.37 opt gold and 1.4 opt silver (Hecla fourth quarter 1986 report). This paper describes new geological interpretations made as part of a district research study sponsored by Hecla Mining Co., which led to the D-54 discovery. Important new geological concepts include: 1) re-interpretation of the volcanic stratigraphy of the district and recognition of a suite of pyroclastic rocks that are unique to the Republic graben, 2) identification of disseminated subaerial mineralization at a paleosurface that corresponds to the newly described upper contact of the Sanpoil Volcanics, 3) recognition that epithermal veins have a maximum productive vertical range of 0-500 meters, measured from the paleosurface, and 4) veins exhibit visual and geochemical vertical zoning within the productive zone with highest gold occurring at an optimal depth, which is interpreted as the average depth of hydrothermal boiling.

Jan 1, 1987

By Peter Zhang

The immediate roof at the test site consisted of laminated clay shale that is likely to be susceptible to weathering. With seasonal dry-wet cycles in the mine ventilation air, the roof in the intake air would deteriorate and lose integrity over time. In many instances, the weathering-prone roof would gradually scale off piece by piece between bolts and over the entry corners. In some long-term entries, roof weathering could develop up to 2-3 ft deep with columns of bolted roof hanging under the upper intact roof. If wire mesh is used, the roof bags down and reduces the entry height, and the weight of the bagged roof tends to pull the bolts out and poses a safety hazard. An effective measure is always sought to support this type of weak roof that is sensitive to moisture degradation. One solution is to seal the roof shortly after entry development to prevent moisture penetration so that roof integrity can be maintained for the long term. In this application, a polymer-based sealing material was tested in the Rockspring mine for weathering protection and reinforcement. The material is a one-component polymer powder for spray application onto the roof and rib. The sealant material is mixed with water in the spraying nozzle to apply to the roof and rib as a paste. The product sets within 5-10 minutes and forms a membrane as thin as about 1/8-in. The membrane will quickly develop tensile and bonding strength within minutes and completely cure within a few days. Through sealing, bonding and lateral reinforcement, the integrity of the weak roof can be maintained. The material has been tried in a long-term evaluation over several months in a set of main entries in the Rockspring mine owned and operated by Rockspring Development, Inc., affiliate of Foundation Coal. Preliminary evaluation has shown that the material is an effective and economical solution to ensuring the long-term stability of weathering-prone roof.

Jan 1, 2009

By Roy L. Klein

The production of synthetic fuels from coal has been pioneered by South Africa. South Africa made a decision in 1975, due to the threat of an oil embargo, to proceed with the construction of Sasol Two, then followed by Sasol Three. South Africa has large coal but little indigenous petroleum reserves. The indirect coal liquefaction process used by Sasol since 1955 is the only commercially demonstrated method available for producing transport fuels from coal. The new plants consume 27 million tons per year of coal from a single mine that now produces transport fuels in sufficient quantities for energy independence.

Jan 1, 1983

By R. W. Smith

Though generally rather non-selective in nature long chain collectors nevertheless function in different ways in accordance with their own particular physical characteristics. Altering various parts of their structures such as chain length, type of chain, etc. can therefore substantially alter the adsorptive behavior of the collectors in a set environment. The effect of such structural differences of the collectors on physical parameters such as solubility, critical micelle concentration, acid or base strength, tendency to be expelled from the aqueous phase is discussed, as is also the effect of these parameters on flotation behavior.

Jan 1, 1989

By A. M. Alfantazi, R. R. Moskalyk

Over the years, improvements have been made in the recovery of nonferrous metals, including improvements in the areas of mineral processing, pyrometallurgy and hydrometallurgy to extract cobalt as a byproduct from host minerals containing mainly nickel, copper and associated precious metals. At present, the technological emphasis is on solvent extraction coupled with electrowinning (SX-EW) for lateritic sources of supply within the Southern Hemisphere, such as in Australia and New Caledonia. Although sulfide-bearing ores, such as those found in Canada and Russia, will serve as a viable long-term source for cobalt, a ubiquitous metal, the future trend is anticipated to be in the implementation of compact and efficient SX-EW facilities that apply state-of-the -art innovation with environmental compliance This paper serves to collate the known practices for the recovery of market-grade cobalt by means of electrowinning from either an aqueous sulfate medium or chloride medium after upstream leaching, solvent-extraction and solution-purification procedures. For completeness, other commercial production techniques for the recovery of cobalt as a sulfide or oxide product are included in the summary of current cobalt processing practices.

Jan 1, 2000

By David Sainsbury, Bevan Thompson, Yuejun Cai

The practice of placing loose rockfill as passive support in open stoping voids, of narrow vein mineral deposits, lends itself to the sterilisation of substantial mining reserves in the requirement for regional crown/sill pillars. Significant benefits are to be gained by the Australian mining industry via the development of improved guidelines for the extraction of such sterilised mine pillars. The application of selectively injecting specifically developed ettringite (calcium sulphoaluminate hydrate) type cement grout into loose rockfill, enables an artificial pillar to stabilise the surrounding rockmass and prevent the caving of loose rockfill from the previously backfilled void during extraction of remnant crowdsill pillars. This paper presents the results of laboratory testing used to reduce the technical risks associated with the design of cemented rockfill pillars. A laboratory testing program was devised to investigate the critical parameters influencing the performance of a stabilised rockfill matrix, along with the critical parameters influencing the interpretation of laboratory test samples. The factors investigated include; sample size and shape, particle size distribution, curing time, water quality, cement : water ratio and the confinement effect.

Jan 1, 2001

After the war that was nearing an end In early 1945, regular consulting work for Bralorne, the Bradleys, Pennsalt Chemical Co., and a directorship and occasional consulting for Homestake Mining Co. made it almost certain that in spite of my 61 years I would have enough work to feed my family. But this routine work would not provide enough income to lay up funds for the inevitable future when I could no longer do arduous work. And it would not give me the adventure that had first lured me into mining. Therefore I was greatly relieved as well as pleased when, in the 18 months from April 1945 to November 1946, I was asked to make three of the most adventurous as well as profitable examinations that ever came my way. Pati[n]o Mines, Bolivia The first of the exciting jobs was an examination of the Pati[n]o tin mines in Bolivia. After I had unsuccessfully tried to induce Anaconda to purchase these mines In 1915, the World War I crisis that had forced the half-Indian accountant to try to sell the mines had come to an end. The European market for tin improved dramatically, and "Don Simon" was able to borrow money for expenses while the concentrates were still In Bolivia. He took advantage of the favorable conditions by buying adjacent properties and increasing development work until his Bolivian tin mines were the greatest in the world. And his daughter had marled the French Count de Boisrouvain and was cutting a swath In high International society. Pati[n]o wanted to get rid of the drudgery of running a complicated mining Industry in a remote area In Bolivia when the fleshpots of Paris were much more seductive. An added incentive was the fact that his miners had become unruly and had even threatened his 11fe.

Jan 1, 1976

By Peter T. Luckie, Felicia F. Peng

INTRODUCTION The maximum recovery of cleaned coal at the required quality is of major concern to plant operators. However, the quantity and quality of products of coal cleaning, predicted by theoretical calculation based on washability studies and determined in the operation of actual commercial cleaning plants, will be different for each coal. Therefore, during the last half century, coal preparation engineers have repeatedly sought methods for evaluating the technical and economical efficiency of separating coal in coal cleaning equipment and for predicting the quantity and quality of cleaned coal produced, as well as profit- ability for the entire plant. Many formulas have been proposed by investigators to evaluate the efficiency of various coal cleaning operations. Performance criteria in use today are capable of defining all of the important aspects of a given concentrating operation; however, each criterion has certain restrictions or limitations. It is important, therefore, to understand how such formulas can be used and the problems involved in their construction. Technical Measures of Equipment/Plant Performance Conventional measures for evaluating the performance of a preparation plant are generally the same as those used to evaluate equipment performance. Measures involving separation efficiencies are influenced by the following three broadly encompassing primary factors: (1) density composition of the feed coal, (2) design characteristics of the cleaning unit, and (3) relative density of the separation. Since separation efficiencies are dependent on factors involving the nature of the coal, they are termed dependent criteria and represent a very broad technical indicator of an individual process or plant performance. Performance measures known as independent criteria are influenced mainly by quantitative errors inherent in the design and operation of the processing equipment. Economic Measures of Plant Performance True assessment of coal cleaning methods require reference to economic measures such as profitability. During the years in which technical efficiency criteria for characterizing plant performance were being improved, coal preparation engineers were also seeking appropriate economic criteria to assess plant performance. Technical and economic effectiveness of plant performance are important parameters for coal preparation flowsheet design. The relationship of the technical and economic parameters can be formulated in an economic model and mathematical model with the aid of computers. The computerized models

Jan 1, 1991

By D. E. Munson, H. J. Sutherland

Empirical methods for describing the shape of the subsidence trough over coal mines in Europe are tested against field measurements of subsidence over longwall panels in the United States. The graphical methods developed by the National Coal Board in the United Kingdom do not correlate well with the U.S. measurements; however, the profile functions typically used on the Continent give quite acceptable fits to the data. In the case of two longwall panels mined at Old Ben No. 24 in Illinois, a trigonometric profile function appears the best choice; in the case of two longwall panels mined at York Canyon in New Mexico, an error integral function is somewhat superior. Analyses of subsidence development curves show that rate effects occur. A comparison of fitting parameters establish influence functions as an important methodology for future analysis. In conjunction with the evaluation of empirical methods, an analytic model based on material failure and bulking was developed. A key element of the model is the void-volume distribution function which establishes a mechanism for transfer of significant amounts of the mined volume to the surface. Preliminary calculations demonstrate the features of the model and illustrate close correlation to physical observations in the field. Moreover, centrifuge models simulating the subsidence process have been used successfully to demonstrate the dominant or key failure modes necessary to the analytic model. General features of the centrifuge simulations and model calculations correlate well.

Jan 1, 1982

Power consumption of stirred media mills has been studied by an approach developed from work on stirred reactors. Relationships between torque required to rotate both disc and pin impellers immersed in dense particulate media as a function of speed, impeller and tank dimensions, and other relevant variables are evaluated. Data collected during numerous different experimental conditions are analyzed. The results can be summarized and presented in the form of characteristic plots, general equations and dimensionless group correlations involving power and modified Reynolds numbers. Special attention is directed towards the rheological properties of the media, which is considered as non-Newtonian liquids and hence, the equation of power law liquids is employed. Procedure for estimating parameters of effective viscosity and scale-up guidelines with respect to power consumption are put forward.

Jan 1, 1994

By H. N. Frock

The use of low-angle forward light scattering for measurement of particle size distribution has been described previously.1 Laboratory instrumentation using this technology is used routinely in operating plants for quality control and production control.2,3 Extension of the technique to on-line process monitoring and control has also been undertaken in several important areas. This paper will discuss the application of MICROTRAC R systems to the monitoring of particle size in wet slurry processes and dry powder grinding circuits. Examples of existing installations will be given with emphasis on performance and on-line reliability.

Jan 1, 1979

By Fathi Habashi

IT APPEARS that the phenomenon of ion exchange by which saline water was converted to sweet was known to Moses and Aristotle. However, the credit for the recognition of this process is generally attributed to Thompson (1850) and Way (1850), who reported that when a soil was treated with either ammonium sulfate or ammonium carbonate solution, most of the ammonia was adsorbed and calcium was released. It was later proved by Eichorn (1858) that the adsorption of ions from ground waters by clay constituents was a reversible process. The first attempts to utilize ion exchange phenomena was in the field of water softening around 1906, using natural and synthetic silicates. In 1935 Adams and Holmes in England observed that crushed phonograph records (phenol-formaldehyde and amine-formaldehyde resins) were capable of exchanging ions.

Jan 1, 1970