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By Walter P. Hansen

Belt conveyors offer a reliable means and often do the most economical job for providing continuous bulk material transport, whenever the terrain permits their installation. The ore processing, construction and mining industries use belt conveyors to carry all types of material, from small to large tonnages. Most of the conveyors Fluor Mining & Metals, Inc. designs for metallurgical plants are in the in-plant category, of limited length and medium tonnages, and use fabric carcass conveyor belting. Belt widths can range from 24 to 60 inches Generally, the layout and design of these belt conveyors present no unusual problems. However, calculations for belt tension and horsepower, design of materials transfers, and the sizings and layouts of belt pulley stations and their drives are time consuming.

Jan 1, 1979

By Peter W. Harben

Once considered the dowdy country cousins of the glamorous metallics, industrial minerals are shedding their old image. They are neither common nor easy and their time has come in an age of increasing specialization. Consider that of the 45 or so industrial minerals and rocks listed in [Table 1], almost three-quarters have ten or fewer significant suppliers (i.e., those individual countries contributing 2% or more of total world production); in more than half the cases, 85% of world production is accounted for by only five countries or fewer. Curiously, even materials that appear to be virtually ubiquitous like crushed rock and common salt have significant production vacuums. For example, there is a severe lack of sound aggregates along the US Gulf Coast and common salt production on a large scale is virtually absent in central Africa. These examples all underline the obvious, but acute truism that "The single most important fact about mineral resources is that they are not distributed equally over the world" (Flawn, 1966). Just as significant today is that human resources are not distributed equally over the world, and so arise some interesting commercial incongruities. In certain regions raw materials are plentiful but consumers are not, and without a market a mineral deposit is merely a geological curiosity. Elsewhere, there may be a market but no local raw material supply. For example, despite a huge market there is no or virtually no commercial production of chromite, diamonds, and manganese in the United States and Canada, nor phosphate rock, diamonds, rutile, and zirconium minerals in western Europe. In contrast, Australia with its small domestic market is the world's largest supplier of bauxite, diamonds, ilmenite, natural and synthetic rutile, and zircon; the same is true for South Africa which is a leading producer of chromite, manganese, diamonds, andalusite, ilmenite, rutile, and zircon (Table 2). In the commercial world, Nature's uneven distribution is counterbalanced by deep sea international trade.

Jan 1, 1994

By René E. Fuenzalida

The copper market has become highly competitive around the world; therefore, operations efficiency is a must for copper producers. The economic outcome in a day-to-day milling is not evident at the concentrator stage, when traditional procedures are used in operations management, based on the supervision of process variables and metallurgical indices. Therefore, in such a complex business, there is a strong need to devise an approach to furnish concentrator's operators with procedures and tools to state and solve the problems related to operational decision making, leading to maximize the economic return of investment; this is what is aimed to be presented in this paper.

Jan 1, 1998

By Bruce A. Brown

Construction aggregate is the most important nonmetallic-mineral commodity in quantity and value that is produced in Wisconsin. Crushed stone is produced from the Precambrian crystalline rocks and the Ordovician and Silurian carbonates, and sand and gravel is extracted from Quaternary glacial deposits. Dimension stone is quarried from both the Precambrian crystalline rocks and Paleozoic carbonate rocks. Other nonmetallic minerals include industrial sand, lime, roofing granules, terrazzo aggregate, and peat.

Jan 1, 1999

By George J. Simchuk

The selection of a stripping method and subsequently, the stripping equipment, are two of the most important decisions confronting a project engineering staff during the initial feasibility study of a new coal stripping operation. The selected stripping units average from 60 to 70 percent of the total capital outlay for mine equipment and their selection will affect the type, size, and quantity of the attendant equipment, such as loading shovels, drills, haulage trucks, and bulldozers. This paper is intended to report on an in depth study by Utah's Technical Services Staff regarding the selection of stripping equipment for the Goonyella Coal Mine in Queensland, Australia. We will touch briefly, on the objectives considered in this selection; the various alternatives which were explored; the general assumptions that were followed throughout the engineering and design of an appropriate stripping system; and computations necessary to determine the amount and size of stripping equipment. INITIAL EXPLORATION Utah Development Company (presently 90% owned by Utah Construction & Mining Co. and 10% by Australian investors) commenced systematic geological studies of the Bowen Basin coal fields of Central Queensland in 1961. The Blackwater Mine as shown in Figure 1 has since been established in this area and is now producing 3.0 million tons per annum of washed coking coal. Geological reconnaissance was then extended to the northern part of the Bowen Basin and in 1963 Utah's coal prospecting area covered 2444 square miles of Central Queensland. The authority to prospect north of Blackwater has since been trimmed to 810 square miles by relinquishments to the State.

Jan 1, 1971

By Palmer C. Sweet

Kyanite. andalusite, and sillimanite are anhydrous aluminum silicate minerals, and they have the same chemical formula, Al2SiO3. Dumortierite and topaz are also classified as aluminum silicates although they contain boron and fluorine respectively. Mullite (a rare mineral named for its discovery site, the Scottish island of Mull) is produced when kyanite, andalusite, or sillimanite are heated. Synthetic mullite, also classified as an aluminum silicate, is formed by melting alumina and silica, bauxite, and kaolin or alumina, kaolin, and kyanite, depending on the type of synthetic mullite desired. These materials are either sintered in rotary, periodic, or tunnel kilns, or fused in an electric arc furnace. The world's largest producer of kyanite is the United States. Domestic kyanite is presently produced from one company at two sites in Virginia; Kyanite Mining Corporation mines kyanite from Willis Mountain and adjacent East Ridge in Buckingham County in the central Piedmont province of Virginia. Internationally, kymite is produced in Australia, Brazil, India, Kenya, Sweden, and Zimbabwe; the former USSR also produces kyanite (Fig. 1). Andalusite is produced by Piedmont Minerals Company, Inc. in the Piedmont province near Hillsborough, NC. Andalusite is also produced in France, India, the Republic of South Africa, and Spain (Fig. 1). Sillimanite is produced in Australia, Brazil, India, Spain, and the Republic of South Africa; the former USSR is also thought to be a major producer (Fig. 1). Some of the countries produce only for domestic use. Synthetic mullite, made by sintering and by electric arc fusion, is produced by Mulcoa (Mullite Company of America) in Andersonville, GA, and by Washington Mills Electro Minerals Corporation in Niagara Falls, NY. Annual world production of kyanite, andalusite, sillimanite, and synthetic mullite is approximately 672 727 tons (Potter, 1988). GEOLOGY Mineralogy Kyanite is a blue to light-green, triclinic mineral that occurs in long, thin-bladed crystals and crystalline aggregates in gneiss, schist, and pegmatites. The mineral has a hardness of 5 parallel to the long axis of the crystal and a hardness of 7 across the crystal. Andalusite is a yellow, brown, green, or red orthorhombic mineral that occurs in thick, almost square prisms in schist, gneiss, and hornfels. Gem quality andalusite exhibits a strong pleochroism; brownish-green in one direction and brownish-red perpendicular to it. Andalusite also occurs in placer concentrations where it has weathered out of rock. Sillimanite is a brown, pale-green, gray, or white orthorhombic mineral that occurs in long, slender, needlelike crystals in schist and gneiss. Chemical and Physical Properties Chemical and physical properties of kyanite, andalusite, and sillimanite are noted in Table 1. Kyanite is the only mineral that irreversibly expands when heated (calcined to produce mullite) and may offset the shrinkage of most ceramic or refractory ingredients when heated.

Jan 1, 1994

By Wan-Kyu Choi, Arpad E. Torma

The electrochemical reactions involved in a zinc sulfide flotation concentrate leaching with sulfuric acid in presence and absence of Thiobacillus ferrooxidans, as well as with ferric chloride - hydrochloric acid containing media, have been investigated. The cyclic voltammetric measurements revealed that many intermediate electrochemical reactions are involved in the zinc sulfide leaching. Using chronoamperometric and chronopotentiometric techniques, it was found that the leaching process is controlled by solid - state diffusion. The activation energy of solid - state diffusion process was determined by the Price's approach to be 21.3 kJ. The leaching mechanism is discussed in terms of solid - state properties (energy bondings) of the high energy gap solid zinc sulfide semiconductor and energy density states of redox systems of acidic leach media. A generalized model for the mechanism of zinc sulfide oxidation is present.

Jan 1, 1990

By Jim Morris, Davin Ishii

The major source of water for Southern Nevada is Lake Mead. However, the existing pump station located on Lake Mead is inadequate for one of the fastest growing areas in the United States. In order to keep up with the increasing demand for water in Las Vegas, a parallel system is being constructed. The intake for this system is being constructed approximately 68.58m (225ft) below the surface of Lake Mead. The lake tap consists of installing casing and secant piles to support the shaft collar, excavating a 21.34m (70ft) deep intake shaft, and installing a3.66m (12ft) diameter steel liner.

Jan 1, 1999

By Simon D. Strauss

This paper discusses the ways in which the metals industries dealt with surplus capacity in the past, primarily the twenty years, 1950 - 1970. During this period, the bulk of metals production in the market-economy countries was controlled by private sector companies. Since then, public sector companies have played an increasingly important role in the metals industries of the market-economy countries. Of course, the change was not overnight. It occurred gradually over a period of many years. Indeed, by 1965, several developing nations had adopted policies of government control of metal operations previously in private hands. The metals industries are so many, so large and so diverse that the constraints of time make it impossible to deal with all segments. To illustrate the problems of surplus capacity in the metals industries during the period, this paper focusses primarily on three metals. One experienced rapid market expansion between 1950 and 1970; one had a growth more or less in line with the expansion of the world economy; and one lagged well behind the pace of industrial expansion. No one will be surprised if aluminum is identified as the metal with rapid growth; copper is identified as the metal that kept pace with the world economy; and tin is identified as the laggard. Individual computations of the rate of growth for these metals show some variations, but most estimates place the increase in aluminum consumption in the market economy countries between 1950 and 1970 at a compound annual rate of about 8%. The corresponding figure for copper is a compound rate of 4%. Tin consumption showed no growth. A widely accepted point of view is that sharply rising demand will force the price of a commodity to increase substantially in order to attract a necessary expansion of supply. The corollary to this is that stagnant demand will hold prices down, as there is no need to stimulate new supply and it may be necessary to force marginal producers out of the market. The experience with aluminum, copper and tin in the years 1950-1970 does not support this theory. In 1950, the average prices in the United States market as reported by the American Bureau of Metal Statistics were 17.74 a pound for aluminum, 21.24 a pound for copper, and 95.54 a pound for tin. The corresponding figures in 1970 were 28.74 a pound for aluminum, 57.74 a pound for copper and 174.24 a pound for tin. Aluminum, with the greatest market growth, rose by 60%, whereas tin rose 82% and copper by 172%. Clearly, other factors were a more important influence on price than was the trend of demand To revert now to the capacity issue, during the period under review aluminum demand was rising so sharply that that industry had no sustained problem with surplus capacity. Instead, if anything, capacity may at times have been a constraint on demand. The industry succeeded in attaining explosive market growth through imaginative research and promotion programs. Some of this growth was the result of substitution of aluminum for other commodities – steel, copper, wood and glass as examples. But much of the growth was the consequence of developing entirely new products through technological innovation. Prior to World War 11, the number of aluminum producers was extremely limited. Alcoa and Alcan in North American and Pechiney and Alusuisse in Europe were the dominant firms. The developing countries had virtually no production and in Japan and Germany production was only a small fraction of the North American output. During the War years the United States had financed the construction of many new facilities. After the war these plants were sold by the government to Reynolds and Kaiser in order to foster more competition in the market. Subsequently many other concerns became aluminum producers, both in the United States and elsewhere and competition for markets intensified.

Jan 1, 1989

By Kot F. v. Unrug

In spite of extensive research and accumulated experience from mining operations, appropriate coal strength values for pillar design remain debatable. Coal strengths determined in the laboratory on standardized samples vary widely among various coal seams with poor repeatability. Penetrometric in situ strength testing obtains multiple measurements at multiple horizons within the coal seam to provide a strength profile. Alliance Coal has used that method in many of its mines for pillar design. Pillars in these mines perform well. This paper presents a series of case studies and discussion of issues related to coal pillar design. The analysis demonstrates that the proposed default in situ strength of 900 psi is appropriate when no other data exist. However, in the case of appropriate strength measurements combined with analysis of pillar structural composition, differing values can be used successfully. In areas where the penetrometric derived in situ strength is greater than the standard 900 psi in situ strength, reserve recovery has been optimized as required by law without compromising safety.

Jan 1, 2009

By Andrew T. MacKenzie, Paul A. Rantala

Predictive pastefill rheology (flow characteristic), models have long challenged pastefill practitioners. While the methodology and practicality of recipe formulation is attainable in most locals, the remaining challenge has been to devise a predictive mathematical or empirical model of paste flow characteristics. Flow phenomenon can now be assigned mathematical and physical basis. The authors herein disclose physical and mathematical methods that demonstrate how operators could proceed when designing reliable pastefill systems. Knowledge presented will allow users flexibility in adjusting flow-rates. Laboratory data shows stiff pastefill delivery design can be derived through mathematical relationships of particle size, material characteristics and pipe diameter.

Jan 1, 2001

By Debra W. Struhsacker, Jean Kiel, Jeffrey Thatcher

3.1 INTRODUCTION As heap leach precious metal projects become increasingly common in the United States, federal, state and local regulatory agencies are beginning to take a closer look at the short- and long-term environmental consequences of this recovery technology. From an operator's point of view, there is seemingly a confusing regulatory maze to be navigated and a plethora of permits and approvals to be obtained prior to commissioning a heap leach operation. The degree of difficulty associated with obtaining permits for a heap leach project depends largely upon the state in which the project is located. Permit acquisition is generally easiest in those states most familiar with heap leaching technology. For example, heap leaching is well understood in Nevada, and heap leach operations are relatively easy to permit, although permitting conditions in Nevada have recently become more stringent. However, many states are just beginning to become familiar with heap leach operations. Many of these states such as Idaho, Colorado, South Dakota, Oregon, Montana, Washington and South Carolina are in the process of drafting regulations and establishing guidelines for heap leach projects. In most cases, these regulations specify design and operating criteria as well as reclamation and decommissioning procedures. This chapter provides an overview of the regulatory and permitting aspects of heap leach operations. Permitting requirements for projects developed on federal land are discussed in detail. 'The state and local regulatory atmosphere and permitting requirements for various states are also presented. The chapter concludes with a generic permitting strategy. 3.2 KEY ENVIRONMENTAL CONCERNS The primary concern of most local, state, and federal regulatory agencies is the use, storage and transport of sodium cyanide (NaCn), and potential cyanide contamination of surface and groundwater resources. The toxicity of cyanide to people, fish and wildlife is also an important issue. Unfortunately, in the public eye, cyanide heap leaching has some emotional impacts similar to those associated with radioactivity and uranium mining. This perception and the general lack of understanding of cyanide can lead to unnecessary concern about cyanide contamination, further complicating the regulatory environment.

Jan 1, 1988

By W. J. Stone

In response to concerns over the impact of mining on the hydrologic balance at the Navajo Mine in northwestern New Mexico, a recharge study was conducted using a chloride mass- balance approach. Impact of mining on annual recharge volume was assessed by comparing pre- and post-mining recharge values. The mean regional recharge rate for reclaimed ground (weighted by acreage) is 1.02 mm/a (0.04 in. per year) or twice that for undisturbed ground, 05 mm/a (0.02 in. per year). Comparison of regional recharge volumes for identical areas shows mining increases recharge 92%. The increase is only 80% if no closed depressions are constructed during reclamation. However, the increased rates are so low that there should be no detrimental impact on regional water resources. The chloride method proved useful at Navajo Mine and should succeed at others surface coal mines as well.

Jan 1, 1991

By K. Hanumantha Rao, K. S. E. Forssberg

The separation of feldspars from quartz has been the subject of numerous studies since 1930 and the flotation process so far proved to be the most suitable method. In the conventional process, feldspars are separated from quartz using a cationic collector and hydrofluoric acid as an activator of feldspars. There is no general agreement on the mechanism of fluoride activation of feldspar surfaces and the role of fluoride ions is briefly discussed. The use of HF is no longer acceptable due to environmental and health problems, and a few new reagents schemes have been reported. The available evidence shows that the success of these new reagent schemes is very limited. A new reagent scheme which is environmentally safe and cost effective for the separation of feldspars from quartz is yet to be resolved.

Jan 1, 1994

By J. B. Ackerman, C. S. Bucans

The Sunshine Mining Co. has recently started up its new silver refinery in Kellogg, ID. The new plant recovers silver anc copper values from a high grade tetrahedrite concentrate using hydro- metallurgical processes. The plant and process are both new and have gone through the initial startup phase during the first six months of 1985. The full scale plant was developed from laboratory test work. While the metallurgy of the process worked as expected, the material handling problems were difficult to over-come. As might be expected, those parts of the plant that represented available technology started up easily, while the parts that represented new technology presented the most difficulty. Topics covered in this paper include: 1) insufficient type and amount of agitation in the leach vessels, 2) discharge of a non- homogeneous slurry from the leach vessels, and 3) problems associated with very low flow rates in slurry lines.

Jan 1, 1987

By Carl Heising

Longwall workings in the Federal Republic of Germany are situated in deep depths. Coal deposits are characterized by a sequence of many seams and manifold geological disturbances. Hence result special requirements on the layout of workings, the methods of coal getting, supports, mine ventilation and dust control. As for the application of dust control the large quantities of fresh air and, this, the high air velocity and the limited water contents in the run-of--mine coal must be taken into consideration. The principle of our methods of dust control is to avoid, if at all possible, the development of dust and, if this is not possible, to suppress the dust even during its development. In nearly all coal faces, the method of water infusion prescribed by our Mines Inspectorates is applied. Continuous water in- fusion is preferred. For water infusion in the coal face, intensive developments as to the process and as to the tools and apparates to be applied were done. The German coal mining industry differs between cutting coal getting and stripping coal getting. Water spraying to the tracks of coal ploughs as well as internal and external water feed to the loader required special activities of further development in past years. There are possibilities to still improve such methods in future. A new important field of applying dust control developed from the application of powered supports. In this field, water spraying prevails. Wet methods of dust control are prefered also in the conveying and loading of coal and at through-flow crushers, however, as far as possible, combined with a covering of the working points where dust develops. Devices for the collection and sedimentation of dust, so-called dust exhausters, are used also with crushers In advanced headings, dust control is performed solely by water. Gateroads kept on or behind the coal face line call for new methods of dust control which are at present under development.

Jan 1, 1980

By Faruk Oksuz, Clay Haynes, David Egger

The United States Army Corps of Engineers (USACE) has committed to solve a major drainage problem in the suburban Chicago community of Griffith, Indiana. The Cady Marsh Ditch is currently undersized and on occasion spills its banks causing flooding and economic setbacks to the community. Preliminary studies have identified both tunnel and surface solutions as being attractive and viable. The USACE has decided that this project is an opportunity to use the design-build contracting approach to maximize ingenuity in project approach and to allow the market to dictate whether a surface or subsurface solution is most attractive. The tunnel would be over one-mile in length through sands, gravels and clay. Water control will be an issue during tunneling. The paper will explore the contracting approach to the project and the adaptation of Underground Technology Research Council (UTRC) guidelines for underground contracting to a design build project. The roles of Owner, Owner’s consultant, and design-build contractor will be defined as interpreted by the USACE and key contract provisions will be described and contrasted with a traditional design-bid-build approach to tunnel construction.

Jan 1, 2003

By M. Karmis

The algorithms for the mathematical modeling to predict productivity of underground room-and-pillar mining systems are well known and documented. These algorithms consider the time-varying relationships between mining equipment for a given geometty of operations as well as other constraints. This paper presents WebConSim, a newly developed, Web-based, user-friendly computer simulation tool for the Windows environment. The simulator is easily customized for use by field engineers, planning engineers and management and will help mine operators plan the optimum mining sequence for different mine geometrie and equipment layouts. Program output includes production data and equipment utilization indices, as well as time driven event chains that can be used for virtual reality presentations.

Jan 1, 2002

By R. Allan Wallis

In the past mining engineers have tended to rely heavily on the advice of fan manufacturers in relation to fan equipment issues. A more adequate approach was advocated in a paper [ Wallis, 1965 ] submitted to the Eighth Commonwealth Mining and Metallurgical Congress held at Surfers Paradise, Australia during 1965. At that time Mount Isa Mine were in the process of installing 3 large 6096mm (20ft) diameter vertical axial flow surface fans of an advanced type [ Mathews et al, 1967 ]. The preliminary feasibility studies prior to preparing the detailed job specification for this project were extremely thorough with the result that it was possible to include detailed information and instructions in the document, ensuring the procurement of equipment that was satisfactory in all respects. Full advantage was taken of expert services provided by external organizations during the large coordinated multi-disciplinary exercise. My continuing activity and development in relation to the technology of axial flow fans is now at a stage where all known design and performance data are accessible through CAD programs [ Wallis and Kipp, 1987 ]. The extensive calculations that were necessary in 1983 can now be carried out in a mere fraction of the time, and with complete confidence. Model testing in order to validate the fan and duct design proposals is, in my view, no longer essential. The first of the computer programs enables a mine ventilation engineer to study a large number of alternative axial fan arrangements for comparison with the centrifugal alternative. By entering the volume flow rate, fan pressure and air density, he can then with ease, and rapidly, investigate the effect of various blading arrangements, downstream evasee area ratios, and hub ratios, on fan diameter and speed, with their related attainable fan efficiencies. This procedure had its origin back in the 60s when I was advising mining companies on new fan equipment. At that time such an investigation was quite lengthy and lacked the precision and completeness that is now available within the present programs. To obtain the major benefit from these outputs, it is most important not to be disconcerted by the three very important nondimensional parameters, namely, the tip flow coefficient (LAMt), the fan pressure coefficient (Kt or Kit), and the swirl coefficient (Es and/or Ep) as these are important when assessing the various design proposals. When seeking an understanding of the role and importance of each of these variables, ample help is provided in the user manual; the design recommendations are summarized in the help screens which are readily accessible within the design programs.

Jan 1, 1989

By I. H. Keith

INTRODUCTION The following papers describe the extraction of nickel in the form of ferronickel from the Dominican laterites. The Falconbridge process was developed initially in the Falconbridge Metallurgical Laboratories and subsequently in several successive stages of pilot plant operation in the Dominican Republic. In the course of this work we came to believe that there is advantage in piloting on site. Mining, metallurgical and geo-political considerations all have major impact and that belief has been borne out by commercial plant experience. Lateritic nickel ores differ substantially, even within the same orebody, in their amenability to extraction methods. The Falconbridge process takes account of the heterogeneous nature of the deposit. Three years of geological field exploration led to ten years of process development after it was realised that the then known metallurgical processes would not give economical extraction from the Dominican ores. In addition to establishing the viability of a novel pyrometallurgical approach, it was necessary to verify design parameters for a very considerable scale-up to prototype commercial operation. The plant was eventually constructed within the original estimates of time and cost. Unique features contributing to the technical and commercial success of the project are described. Additionally, some bold extrapolation based on pilot plant work, eventually proved to be quite conservative. The mine is not a conventional open pit operation, but is perhaps better characterised as an earth moving job. Novel application of mobile equipment led to great flexibility in the mine, where operation of several mining fronts is essential to maintaining uniformity of ore feed to the plant. The practical aspects of almost total acceptance of the oversize run-of-mine material through a high-capacity unit,

Jan 1, 1979