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By F. Karakas

In this investigation, one of the most energy consuming stage of the cement manufacturing process, grinding stage, was studied. The aim of the study is to reduce the energy consumption. Optimum operating parameters were determined. Experimental studies were performed at three differ-ent stages. Grinding of limestone, clay and marl which are the main components of the cement, to approximately below 90 microns, was the first stage of the cement grinding. At this stage, effect of feed size and ball charge were investigated. At the second stage, the Bond work index of clinker and additives (slag, trass, limestone and gypsum) was found separately. After forming composite cement with clinker and additives, the Bond work index of this mixture was also determined, thus the results of separate grinding and grinding of mixture were compared. The Bond work index of mixture was found as 13.59 kWh/t, while the arithmetic mean of the Bond work index values of components was 14.90 kWh/t. Finally, clinker and additives (slag, trass, limestone and gypsum) were ground under the same conditions. At this stage, laboratory type of ball mill was used in order to understand grinding characteristics of the cement components. As a result of the experiments, it was found that energy consumption for the grinding will be lowered if the mills with 38 % ~ 40 % ball charge are used in the cement grinding. Moreover, grinding with mixture of clinker and additives gave better results than separate grinding of these components in terms of energy consumption.

Jan 1, 2014

By O. D. Maurice

Feldspar mining in Canada came to an end during 1972 after many years of continuous activity. The deposits are not exhausted and the domestic demand for this product is expected to continue at about the same level as in recent years. The size of the industry does not justify the installation of expensive equipment in the mills, but it is believed that a modest profit could be made by a small operation using rudimentary methods of separation. Largescale and accurate mapping of the pegmatite dykes could help in planning mining operations for a better recovery of a uniform product.

Jan 1, 1973

Acid mine drainage containing heavy metal ions is a large environmental problem facing the mining and mineral processing industry. The femte coprecipitation is a novel technique for removing heavy metal ions from waste water, recently applied to acid mine drainage. The fenite precipitation is usually performed at high temperature and therefore if applied in conventional manner, it becomes uneconomical to treat large quantities of acid mine drainage. In this paper the ferrite precipitation at ambient temperature-is &died. The possible mechanism of ferrite formation is discussed Experimental results from Noranda Tailing and Berkeley Pit water treated by this process are presented.

Jan 1, 1994

By Joel Chipana, Roberto Laredo, Benjamin Cebrian

Ring blasting is a common production method in underground metal mines. As a drill and blast process, it presents particular features that do not correspond with bench blasting in open pit or underground mining.

Jan 1, 2017

By Lanny Pasternak

"This article is directed at plant production, engineering and maintenance personnel. Seldom does any industrial operation take the time to study the costs involved in the generation of what is probably their most expensive plant utility energy source.IntroductionIn the typical industrial plant in Canada, a 200 hp, 900 cfm, air compressor costs about $60,000* per year to operate (Fig. 1). In 1989 when BC Hydro embarked on their industrial energy management program Airflow Energy Ltd. were asked to spearhead the “Efficiency Compressed Air” portion of that program with a mandate to perform onsite overview surveys and physical hands-on testing of some 300 selected industrial plants throughout British Columbia for compressor efficiencies and wasteful air leaks (Fig. 2). The program duration lasted until 1995, during which time a tremendous amount of data were amassed relating to equipment types, clients’ operating habits, end-use applications and operating costs.During the past six years, Airflow Energy also performed somewhat similar surveys but on a smaller scale in Alberta, Ontario, the United States and the Republic of China. It was no surprise to find some inherent equipment concerns related to efficiency as well as neglected energy wasteful air leaks, so British Columbia was not alone and the problems appear somewhat universal."

Jan 1, 1996

By Michael Prince

"Managing slurry is a constant challenge for mining operations. Since slurries are not uniform, the challenge is complicated by varying rheology, velocity, temperature and pressure, all of which affect how the slurry moves through the pipeline and how destructive it is to the system it is flowing through. Picking the right equipment from the outset — the right size pipe, the right size pump and the proper valves for the application — allows mines to operate more efficiently. Better valve designs deliver multiple benefits — they can lower the cost of operations, reduce the amount of maintenance and associated downtime required and are better for the environment. Historically, modulating systems have used ball, plug and pinch valves to manage the flow of slurry, but each of these alternatives has limitations. Ball valves require ceramic lining in order to delay wear, and once a ball valve does wear, the entire valve must be replaced. Similarly, plugs in plug valves should be coated to perform in control systems, and whole valves must be swapped out upon wear. Pinch valves are expensive and only require replacement of the sleeve. However, sleeve replacement involves an extremely arduous process in which the valve is completely taken apart.Traditionally, designers have avoided using knife gate valves (KGV) in modulating systems because KGVs have not been able to hold up under the harsh operating conditions. The throttling that is required in some of these processes rapidly fatigues conventional KGVs, rendering them useless and in need of replacement. Fortunately, innovative design changes have the potential to change established views.Breaking new groundRecognizing the need for improved components, Victaulic took on the challenge of designing a valve that could withstand abrasive slurry systems for a much longer period of time. The first step in this process was to talk to miners, maintenance personnel, process engineers and operators in the field about the limitations of current offerings and then determine design specifications for an ideal replacement.Many of the responses to these inquiries were very similar and reflected challenges with current operations; the primary objective was to find a valve that would be lighter and cheaper than the valves currently in use. In theory, a lighter valve would be easier to replace, and since replacements need to be performed frequently, a cheaper valve seemed like the right idea."

Feb 1, 2019

By P. Bevilacqua

In this paper the possibility to complete the copper recovery and to enrich in PVC a mixture of plastic granules obtained by grinding electrical cables are investigated. The recovery of a large part of the copper still present among the plastic granules was possible by means of a mechanical screening, the finer polymeric fraction was collected, at the same time. In order to complete the copper polymer separation the following techniques were employed. Counter current separation in water, static dense medium separation with zinc chloride solution and copper extraction with nitric acid and subsequent electrolytic deposition. A Tri-Flo® dynamic dense medium separator was employed in order to separate the lighter polymeric fraction, from the heavier polymeric fraction, mainly PVC. Water or a salt-water solution was employed to feed the separator device.

Jan 1, 2014

By S. K. Dimitrov

?Ellatzite Med? is one of the biggest mining companies in Bulgaria, processing about 12,000,000 t of ore per year. Waste materials left after extraction of copper concentrate are deposited in tailings dam ?Benkovski 2?. The hydraulic structure is built according to the downstream method, through hydrocyclonization where the downstream batter and the body of the wall are formed by the separated coarse sand particles of the separated tailings. In connection with the prolonged concession of Ellatzite Med and the enlarged capacity of Benkovski 2, the tailings dam has expanded on to the surrounding terrain. To guarantee a normal hydrocyclonization and build up of a tailings wall during waste deposition from the ore mill, the technological scheme of the hydraulic transport system of Benkovski 2 has been changed.

Aug 1, 2013

By Raymond E. Zimmerman

The use of standard dense-media cyclones is well known, as they have been in use for many years. They are especially well suited for operating at low separating densities and for treating difficult coals containing a high percentage of near-gravity at the point of separation. Very few modifications of the basic design have ever been made. The author recently, however, has been interested in the development of a new type of dense-media cyclone that has been produced in Japan. He has observed the testing of this unit and has collected much data which he feels should be of considerable interest to coal preparation engineers. He feels that this unit, called the Swirl Cyclone, may be of substantial value as an alternate to the standard cyclones. It is certainly worthy of further investigation. There has been relatively little written in English-language publications on the Swirl Cyclone. It was briefly described at the Fifth International Coal Preparation Congress. I It has been described in a general manner by the author in two prior publications. 2, 3 This paper proposes to describe this device in more detail and at the same time submit technical data illustrating its wide characteristics.

Jan 1, 1977

By Henning E. Soderberg

Yesterday, air pollution was somebody else's problem -- today, it is everybody's problem. The coal industry with thermal coal drying, is aware of their problem and the necessity of doing an acceptable job; however, there is much to be said as to how good a job is required and what performance limits should be set up. American Air Filter Company has been one of the pioneers in the solution of the thermal coal dryer dust problems, Because of high moisture content, products of combustion and occasional temperature surges, only wet collection has been considered as the practical approach. Our first installation goes back some 12 years with a total to date of 29 Individual wet collectors, each, fabricated of suitable corrosion-resistant material, at 14 operating plants. To eliminate a potential air pollution problem, a performance requirement of not more than approximately one-quarter (1/4) grains per cubic foot in the dust collector discharge was used. In nearly all installations, operating performance surpassed requirements, but discharge stacks were not entirely free of discoloration. However, plant nuisance and air pollution complaints were eliminated. This satisfactory performance was accomplished by medium priced wet dust collectors operating at a 4-6" W.G. pressure drop with cater drain requirements of about 1 gallon of drain water per 1000 cubic feet of air exhausted.

Jan 1, 1962

By Thi Hien Tran, Ngoc Anh Tran, Thi Thu Hien-Dinh, Duy Anh Dao

"Natural graphite exists mainly in three types of amorphous graphite, flakes graphite and lump graphite. Graphite from Bao Ha mine, Lao Cai province is with 11.8 carbon-graphite %, forms in flakes and dense crystals. The paper presents the comparison among enrichment of Bao Ha’s graphite by two types of froth flotation with 90 g/t kerosene oil as collector, 50 g/t montanol 800 as frother, in natural pH, and at 20 wt.% of solid. The differences among three flow charts indicated that using middling flotation and re-middling flotation for the cleaning tails and the scavenger concentrates, the final concentrate was improved and containing up to 94 carbon-graphite % of flakes graphite, up to 82 carbon-graphite % of fine graphite with 93.48 % total recovery, moreover, carbon-graphite in the final tail is 0.86 % with 6.52 % recovery. However, a refining mill and a classification stage were applied before doing the middling flotation stages.1. INTRODUCTIONGraphite (black lead or plumbago) is used in many industrial applications due to its high electrical and thermal conductivity, lubricity, and chemical inertness. High quality graphite can be used in metallurgy, molding, brake linings, batteries, and fuel cells. Graphite, composed exclusively of the element Carbon, is rather common mineral, but fine crystals are rare. Graphite is soft (hardness: 0.5-1 Mohs scale); has a layered, planar structure; occurs in platy or acicular (occasionally) morphology (Minerals.net; Pierson, 1993).USGS (2017) reported, global consumption of natural graphite continuing increase in the period of 2012-2016. In 2016, China used up 35% while produced 66% of the world’s graphite. Graphite mining are being developed in Madagascar, Mozambique, Namibia and Tanzania, but production reduced in Canada from 2015. Based on the statistic of Statista.com shows from 2011 to 2014 and a forecast to 2020, the global graphite demand is mostly in refractories, batteries, others, lubricant/crucible, foundry and pencil, and that is increase every year.Graphite Vietnam lies on the fault of the Red river from Yen Bai to Lao Cai, the reserves is estimated around 29.3 million ton and mostly in Lao Cai province where has Nam Thi graphite mine and Bao Ha graphite mine (MOIT, 2008). Vietnamese graphite products could reached to ~92% graphite carbon (Cg) (Tran Thi Hien et al., 2008). Studied samples was collected in Bao Ha graphite mine, is located in Lao Cai province. Graphite Bao Ha exists in two types as graphite flakes and amorphous (Hoang Thi Minh Thao et al., 2017)."

Jan 1, 2018

By Anthony W. Garson

Good morning, ladies and gentlemen: It is a pleasure to be here this morning as a representative of Dean Witter Reynolds; one of the foremost international investment firms in North America. My colleague, Hugh Wilmer (who will be speaking to you a little later), and I are involved as research analysts in the research and writing of published reports containing recommendations on the buying or selling of North American and South African gold and silver mining shares. Our talk this morning will focus on the gold mining operating costs of North American and South African gold producers. However, I am not going to bore you with reams of statistics on the operating costs of large numbers of gold mining operations; how meaningful would this data be to you? Instead, I will discuss what the investor should look for, and how he should use this knowledge in making his investment decision.

Jan 1, 1984

By W. H. Yong

The molybdenum ores currently utilized in China are mostly molybdenum sulfide ores, whereas oxidized molybdenum ores have not been exploited and utilized efficiently. The aim of this article is to study the applied mineralogy of an intergrown iron-molybdenum oxidized ore in order to provide a mineralogical basis for the ore beneficiation research. The ore occurred in a surface oxidized zone seam and contained 23.65% Fe2O3 and 1.58% Mo. Various characterization techniques were employed to study the chemical composition and mineral composition of the ore, the particle size distribution of the minerals in the ore, and the tex-ture and structure of the ore. The results showed that the iron-molybdenum ore occurred in a wet, soft and earthy state. The ore was composed mainly of several oxidized minerals and colloidal min-erals, including wulfenite, barite, limonite and quartz. Wulfenite was one of the major and stable components in the ore and occurred as a separate mineral. Wulfenite, barite and quartz were granu-lar minerals with particle size ranging from fine to coarse but mainly in the fine particle range. Li-monite showed a crust and honeycomb-like colloidal state and composed the framework in the ore for the formation of the other minerals. They filled the pores in the framework and the size of the pores affected the size of the minerals formed in the pores and hence the recovery of wulfenite in ore beneficiation. According to the applied mineralogical properties of the oxidized molybdenum ore, a promising ore beneficiation process was proposed as follow Magnetic separation should be carried out first to separate the magnetic iron minerals and then the molybdenum mineral will be recovered by gravity concentration or a combination process of gravity concentration and flotation, depending on the distribution of the molybdenum mineral in the product of the magnetic separation.

Jan 1, 2014

By T Craske, J Sykes, T C. McCuaig, M Jessell, A Trench

The prevalent strategic approach in the mining industry is one of planning. However, it is widely recognised that planning does not work in complex and uncertain situations (Mintzberg, 1994), such as those associated with ‘above ground’ non-technical orebody complexity (Trench, Packey and Sykes, 2014). Mintzberg, Ahlstrand and Lampel (2009) suggest the focus instead should be on strategic ‘thinking and doing’ and using the many ways to think about strategy to make sense of complex, uncertain, and unique situations. They therefore place great value in cognitive flexibility. Scenarios development utilizes several different thinking styles and thus assists with this type of flexible strategic thinking (Figure 1). The ‘Centre for Exploration Targeting (CET) Scenarios’ were developed with the ‘Oxford Scenario Planning Approach’ (OSPA) (Ramírez and Wilkinson, 2016). The OSPA aims more to improve the thinking skills of decision makers, rather than forecasting per se (Wack, 1985a, 1985b). As such, this paper focuses less on the content of the scenarios and instead on the practical value of scenarios in strategizing. CITATION: Sykes, J, Trench, A, McCuaig, T C, Jessell, M and Craske, T, 2018. Strategic thinking about long-term ‘above ground’ orebody complexity using scenarios, in Proceedings Complex Orebodies Conference 2018, pp 60–64 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

By G. Castillo, J. Mortensen

"INTRODUCTION Molybdenite is typically produced as a co-product in the copper ore flotation process. At the Rio Tinto Kennecott Concentrator (RTKC) in Copperton, Utah, the molybdenite is initially floated with copper sulfides and other value minerals producing a Cu-Mo concentrate. This is then separated in the molybdenum plant by depressing copper sulfides and pyrite and floating only molybdenite. The molybdenum plant in RTKC comprises the rougher circuit and several stages of cleaning to achieve a certain grade requirement of Mo. The rougher circuit is where the first stage of separation occurs. Cu sulfides and pyrite are depressed in the rougher circuit by adding NaSH under nitrogen and in the cleaner circuit by adding NaSH under air. The depression of Cu sulfides (and pyrite) by NaSH is related to the redox activity1. It is important therefore to maintain a reducing potential in the circuit in order to achieve effective Cu-Mo separation. If the rougher circuit is under air, like RTKC’s molybdenum cleaner circuits, it is harder to maintain the target redox potential because NaSH oxidizes rapidly in the presence of air thereby increasing NaSH consumption significantly. CU-MO SEPARATION AND ROLE OF PULP POTENTIAL The collector adsorption on copper sulfide minerals is through an electrochemical mechanism2. The collector changes the surface chemistry of the Cu mineral allowing it to float. Molybdenite, or MoS2, on the other hand, floats readily in the presence of a frother as it is naturally hydrophobic. Usually, hydrocarbon oil extenders such as diesel or burner oil are added to enhance Mo recovery. In order to effectively separate Cu from Mo, the collector complex on the copper surface needs to be destabilized or desorbed using a reducing agent such as NaSH or Nokes. As long as the circuit is under highly reducing conditions, the collector remains detached from the sulfide mineral surface allowing Cu sulfide depression. Therefore, it is important to measure the oxidation-reduction potential (ORP) continually and maintain the reducing condition with addition of NaSH. For a given collector each mineral will have a characteristic potential or electrochemical window for flotation to occur3, therefore, it is necessary to reduce the potential outside of this window in order to effectively separate Cu and Fe sulfides from MoS2 minerals2. In RTKC plant, the target reducing condition is between -450 to -550 mV to effectively destabilize the collector and depress Cu and Fe minerals. Typically the dosage of NaSH used in the molybdenum plant could range from 6 to 30 gallons/min (gpm). The high dosage of NaSH could pose risk of H2S exposure. RTKC wanted to evaluate alternatives to NaSH in order to reduce its consumption and minimize risk of H2S gas generation."

Jan 1, 2016

By A. McEachern

At the Annual Meeting of this society, held in Halifax last year, a paper entitled "Closed System Breathing Apparatus" was read by I. C. Mackie, metallurgist, British Empire Steel Corporation. Coming from such an authority it was most instructive and illuminating. The purpose of the paper was to emphasize the necessity of a full supply of oxygen and the danger of oxygen shortage in the use of rescue breathing apparatus. In connection with this he pointed out: "In times of emergency, when life is at stake, rescue men cannot be restrained from using their utmost endeavor, and unless the apparatus is adequate to meet the heaviest load, the result may be fatal to the wearer. The body's demand for its oxygen requirement is absolutely imperative and must be granted at once. We can do without food for many days and without water for many hours, but we cannot do without full requirements of oxygen even for a few minutes. Furthermore, the victim of oxygen shortage gets practically no warning. He may fall helpless or unconscious before realizing that he is in a serious condition." Hence the necessity for expelling all the nitrogen from the breathing-bag and filling it with pure oxygen; also filling the lungs of the wearer with oxygen before he begins to use the breathing apparatus. This practice is general at all the collieries under the British Empire Steel Corporation.

Jan 1, 1924

By Leonhard Weixler, Jean Wehbe, Gordian Ulrich, Franz-Werner Gerressen

"As alternative energy industries pick up speed internationally, and as government regulation and restriction limit the use of impact hammers due to environmental limitation from construction induced noise during pile driving operations, unconventional solutions for more complex offshore foundation installations have become a necessity. Manufacturers and equipment suppliers race to develop alternative techniques to accommodate for offshore foundation construction in various soil conditions and at greater water depth. The FLYDRILL, and the Seabed-Drill BSD are two innovative systems for the installation of offshore monopiles with reduced environmental impact.INTRODUCTIONThe FLYDRILL and the Seabed-Drill were born from techniques in the design and construction experiences gained from land based foundation drilling systems over the past 25 years. As the alternative energy industry ventures into uncharted territory of deeper water for offshore wind farms, fast current regions for tidal energy, and increasingly challenging soil conditions and project complexity, the advancement and development of new innovative equipment system and drilling techniques have become a necessity.The systems described herein show the development of the so called “FLY-Drill” system, and the all new “Seabed-Drilling” equipment applied at the first ever made job using a seabed drilling rig.FLY DRILLThe FLY DRILL method is a completely new concept for bored piling. The drilling unit with rotary head, Kelly bar, and drilling tool is suspended by the hoist rope of the base carrier crane. The hydraulic power for the drill unit is provided from the base crane.The drill head is fixed on the casing with a hydraulically operated clamping system during the drilling operation. When emptying the drilling tool, the clamp cylinders are opened and the complete unit is swung sideways."

Jan 1, 2017

The 14MW SAG mill at Tarkwa, Ghana, experienced a frozen drop charge incident on 10 February 2010. This caused downtime of 112 hours, a repair cost of $200k and production loss of 162,000 tons, corresponding to a loss of $8.9M. A new locked charge protection system was installed on the two Tarkwa mills on 30 July 2010, mitigating this risk. This system calculates the ore angle in real time while the mill is starting up and trips the mill if the ore angle exceeds a trip angle setting. The calculation of the ore angle is derived from the mill motor rotor currents only - no mechanical transducers are required. The head of Gold Fields West Africa, Peter Turner, says of the new system: "This is excellent work and the type of technology that has had and will continue to have, major opportunity cost impacts on our business."

Jan 1, 2012

By J. E. McMenamin, R. B. Hall

"With the emphasis in the past decade on larger and more efficient equipment for open-pit operations, the Normandie mine of the Asbestos Corporation has followed the trend, switching from the smaller type of percussion drills to down-the-hole rigs. One 5 Y2 -in. percussion drill is still in use, but is limited to a ""smooth blasting"" role or to the control of the slope on final benches.In keeping with the times, an attempt was made to eliminate, as much as possible, the use of high explosives and to maximize the percentage of ammonium nitrate -fuel oil mixture. As the concentration of ground water increased with increased mining depths, small pumps were initially employed for the dewatering of boreholes. This proved unsuccessful, and a hole-blowing rig was built and a conversion to plastic liners made. The acquisition of a bulk-mix AN-FO truck has permitted the changeover from an AN premix to an ammonium nitrate prill -fuel oil combination at the borehole."

Jan 1, 1966

By P. Hajiani

"It has been shown that the economics of the hydrometallurgy of a rare earth process depend upon the amount of acid needed to extract the metal per unit mass of the ore. In this paper, we show how to save a significant amount of acid treating a low grade ferrocarbonatite and extracting +99% constituent REEs. In order to save the acid, the alkali earth metals, originated from gangue minerals were removed prior to REE leaching. Moreover, the operating conditions of leaching reactor are optimized to leave iron behind and to leach REE selectively and effectively. Consequently, the hydrochloric acid consumption per ton of ore drops significantly compared to other processes.INTRODUCTIONThe viability of an extractive metallurgy process of rare earth elements (REEs) to produce an intermediate mixed concentrate depends upon a low-cost simple flowsheet (Bogner, 2014). It has been known that regardless of the mineral, the acid consumption is intimately associated with the operational cost (OPEX) of any REE project, particularly when the initial REE grade is low. Besides acid, the other reagents consumed in the process impact the OPEX. This makes minimizing acid consumption in an REE method a critical priority. The acid consumption in different projects has been reported to be equivalent of 100 kg to 1000 kg HCl (100%) per tonne of ore (Average: 500 kg/t HCl 100%) (Bogner, 2014). This value is strongly correlated with the grade of REE in the ore and therefore in the pre-concentrate.Previously, it has been stated that the Montviel flotation concentrate requires about 300 kg HCl (100%)/t ore to attain +99% REE recoveries using direct leaching (Yu, Verbaan, Pearse and Britt 2013). Hence, for an ore feed rate of 2500 t/d ROM, a large acid production plant (744 t/d HCl 100%) would be required for acid leaching of such concentrate. The equivalent Chlor-alkali plant is estimated to cost M$ 150 (CAPEX) and may require 100 MW power. Therefore, there is a necessity to improve the extractive hydrometallurgy and to reduce the acid consumption significantly."

Jan 1, 2016