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By G S. Beros, K M. Edwards

Over the past 20 years drum scrubbers have become a widely adopted technology within iron ore beneficiation plants. Generally, the drum scrubbers in use are considered high-capacity machines capable of accepting larger-sized feed material. Together with a water addition to a desired pulp density and a mild energy input, these large rotating machines effect an attritioning action that removes water soluble clays and other deleterious materials. Within the Western Australian iron ore industry, drum scrubbers have been successfully applied to Channel Iron, Marra Mamba, Bedded and Detrital orebodies. The introduction of drum scrubbers has enabled Western Australian producers to satisfy the substantial increase in demand for iron ore from Chinese steelmakers by making the lower-grade sections of the above orebodies economic. However, despite being a relatively simple unit process, the requirements for successful design and operation of these machines are not fully understood. This paper draws on the collective experience of both authors to provide some points to consider for incorporating drum scrubbers into iron ore beneficiation plant flow sheets.

Sep 18, 2023

By Thomas L. Hutchinson

The mechanical design of a roof support is basically a matter of a statics and dynamics problem, assuming of course, that the imposed loads and mining conditions are known. Here in the Appalachian coal fields the general conditions are known well enough to allow the majority of the proposed new faces of longwall to be furnished with standard commercially available supports equipped with suitable variants and options. While not trying to negate the primary importance of thoroughly investigating a potential face and the selection of the correct equipment for that face, it still becomes clear that an equally important aspect of the design of an adequate ground control program has in the past too of ten been overlooked, having been overshadowed by the ?endless? selection process of the roof supports proper. The equally important aspect which this paper discusses is the overall design of a mining system, which design incorporates not only the size and capacity of the equipment but the following points as well, namely: Equipment adaptability to mining scheme, Equipment va. human constraints, Operation at the designed levels, and Coordination of operation, maintenance and support design. Unless the coordination of these factors is considered in the design and selection of the equipment, a lopsided and inefficient operation is possible. How can we afford to put an 8-10 million dollar investment up to chance as to whether it will yield optimum results or not?

Jan 1, 1981

By A. A. Dor

Out of nine new major iron ore concentrators put in operation during the last three years, or expected to be commissioned in 1968, seven incorporate primary grinding mills and have a total design capacity of 13,150,000 ltpy of pellets, while only two include conventional rod and ball mill grinding circuits for a total design capacity of about 6,100,000 ltpy (Table I). This evolution in the application of primary grinding to hard, fine grained magnetite ores represents an important development in the technology of mineral processing. It has been the outcome of comprehensive testwork in the laboratory and in pilot plants.

Jan 11, 1968

By J. C. Schneider, G. Van Weert

Hydrochem Developments Ltd. has developed and put into full scale operation a novel type of vertical flotation column incorporating a multiplicity of mechanically agitated stages. Characteristics of this flotation column include a low height to diameter ratio, high upgrading factors and the possibility of modifying geometry and operation to specific flotation requirements. A commercial unit is currently handling up to 100 tpd rougher concentrate at Dickenson Mines Limited, Balmertown, Ontario. Design parameters and plant performance will be discussed.

Jan 1, 1988

By M. Neven, R. A. Steane, E. Lam

"The Key Lake uranium mill is located in Northern Saskatchewan. It treats a high grade, complex uranium and metal sulphide ore. The plant and process are in many respects unique, because commercial treatment of this type of uranium ore had never been done before. The process and engineering design was based on extensive laboratory test results. A pilot plant testing stage was omitted because of confidence in the test results and time constraints to bring the plant into production.The bench scale testwork on exploration drill core samples along with preparation of the feasibility study and environmental impact statement were carried out between 1976 and 1979. The contract for detailed engineering was awarded to Wright Engineers of Vancouver in late 1980 and in August of 1981 following a public inquiry, approval to proceed with construction was granted.Construction began immediately, and during the winter the foundations for many of the plant buildings were poured and by the beginning of the following winter the buildings had been erected and installation of equipment began. Despite a six month construction worker strike in 1982, the crushing plant started up in June of 1983 and ore processing commenced in October of that year, approximately 3 months behind the original schedule.This paper describes the mill design and compares the expected performance, with the operating experience. Emphasis is directed towards flowsheet and equipment changes made since start-up, operational difficulties encountered and further improvements envisaged. Auxiliary systems are only discussed where they directly affect mill operation."

Jan 1, 1986

By L. A. Mills

After three years of experience in operating the pilot plant for the Noranda Continuous Smelting Process, the decision was made, in March 1971, to build an 800 ton per day commercial plant at Noranda, Quebec. The de- sign and layout of the plant is discussed and the installed equipment described. Experience previously gained in the pilot plant is mentioned when it has been used in the choice of equipment or plant layout. The full- scale reactor was started up in March 1973 and the operational datacollected and the experience acquired during the first 30 months of operation are described. This includes operation to produce both high grade matte and copper. Areas discussed include refractory wear, fuel consumption and throughput of copper concentrates. Changes made to original equipment and methods of operation are discussed, together with the reasons. The ad- vantages of using solid fuels to handle inert materials and to maximize converting air flowrates and concentrate throughputs are described. Relative efficiencies of oil and natural gas are compared. The addition of oxygen from a 94 ton per day oxygen plant to the reactor converting air was started in August 1975 and the initial operating results are included.

Jan 1, 1976

By K. R. Wood, G. W. McDonald

"The tailings disposal system at Les Mines Selbaie includes dewatering of tailings in a high-capacity thickener, followed by point discharge of the thickened solids to form a stable conical pile. Tailings water drains to ponds formed behind engineered dams, prior to either recycling f or process use or discharge to the environment. Design and economic considerations of the system are discussed. Construction, start-up and operating experiences are also presented.Introduction Les Mines Selbaie is located in the Abitibi region of northwestern Quebec, approximately 700 km north of Toronto and 150km south of James Bay. More locally, the Detour gold mine is 60 km to the west while the Noranda smelter is 220 km to the south.The deposit was discovered as a result of a Questor INPUT Mark VI geophysical survey in 1973, followed by diamond drill programs from 1974 to 1976. Three mineralized zones were delineated and underground exploration was carried out on all three. A production decision for the 'B-zone' copper-gold-silver orebody was made in July 1979. The underground operation started in July 1981, with full production of 1500 t/d being achieved in May 1982.During the planning phase, every effort was made to ensure that the operation would be environmentally sound . The design included the provisions of the then newly proposed provincial environmental guidelines. The tailings disposal system formed the most significant part of the environmental program due to the large volumes of solids and water effluent. In addition, the design allowed for future expansion of the system to accommodate mining of the other zones, thus minimizing future costs and disruptions."

Jan 1, 1986

By Per H. Fahlstrom

The story of the Aitik mine begins in the early thirties. At that time blocks of low grade chalcopyrite impregnations were found in Swedish Lapland not far from the present mine, some 40 miles north of the arctic circle in the vicinity of the iron ore field at Gällivare. The ore prospect was viewed upon several times. By means of geophysical studies and an extensive diamond drilling programme during the end of the fifties and the beginning of the sixties a huge low grade ore body was discovered under the muskeg overburden. In 1965 55 million tons of ore with 0.5 % Cu was known to a depth of 160 ft. In 1970 the ore reserves had increased to 165 million tons with 0.40 g, Cu at a depth of 400 ft. Decision to develop the mine and to start production at an annual production of 2,2 million tons was made in 1965. A mine and concentrating plant, the A section, went on stream in 1968. In 1970 decision was made to expand the production with 3,3 million tons pr year. A second section of the plant, the B section, went on stream during the end of 1972 and the beginning of 1973 The production in the initial plant has been increased to 3,1 million tons pr year and during 1974 the combined A and B sections are expected to treat' about 7,2 million tons of ore. The two sections will treat 10,000 and 13,000 tons per day.

Jan 1, 1974

By A. de Ville d’Avray, G. Guezennec, P. Wavrer, E. Braak

The aim of the European CEReS project was to develop an innovative copper recycling route based on the coprocessing of coal production waste by bioleaching and printed circuit boards (PCBs) from Wastes of Electrical and Electronic Equipment (WEEE). Coal waste is processed by bioleaching in stirred tank reactors, and the resulting bio-lixiviant solution is used to extract copper from PCBs pre-treated by catalytic cracking. Copper is then extracted using solvent extraction, stripping and electrowinning. The whole process flowsheet combines thermal, biotechnological, physical and hydrometallurgical operations. Once the process concept has been validated at laboratory scale, a simulator of the whole process has been built in the USIM PAC software platform. The tool enables to improve the analysis of the results of the lab-scale experiments and to design industrial-scale scenarios by simulation. The results of such simulations allow to estimate the economical interest and to perform environmental impact assessment. After presentation of the CEReS project objectives and main results, the paper describes the methodology used to build the simulator and define the scenarios corresponding to feasible process routes. The main results of the simulations are then presented with technical, economic and environmental point of views. INTRODUCTION Because of rapid technological innovations in the electronics industry, electronic waste represents the fastest growing waste stream in the world, especially in developing countries (Işildar et al., 2018). Meanwhile, the global copper demand is expected to go on rising in the future. As significant amounts of copper are present in end-of-life printed circuit boards (PCBs), it becomes a necessity to develop efficient copper recycling routes. Metal refining from e-waste is traditionally performed by pyrometallurgical processes. However, the hydrometallurgical processing of PCBs, which has been shown to be technically feasible at laboratory scale with a wide range of leaching reagents, could be a less energy intensive and more flexible alternative (Tuncuk et al., 2012). However, a large amount of leaching reagent is required to leach the metals from PCBs.

Jan 1, 2019

By George Moses K, Mahendran K

Grouting is performed in rock masses in order to increase its strength properties and also to reduce the seepage. In the design of underground structures such as tunnels or caverns located in weak rock masses, grouting plays an essential role. Grouting is a complex process demanding high degree of skill and knowledge in understanding of grout flow and requirements for certain geological conditions. This paper discusses the design process for grouting in rock masses adopted for a cavern project and the practical difficulties faced during the execution at site. The design parameters of grouting includes the injection pressure, grout material properties and stopping criteria. The paper also discusses the various tests performed at site to evaluate the efficacy of the grouting process which was initially defined based on the design and previous experiences. The final grouting scheme suiting to the present geological condition is arrived based on the test results. The practical difficulties faced during the execution and the measures taken to overcome these are discussed in detail. This work shows the importance of state of art in the development of a grouting process based on geological and hydrogeological conditions prevailing at site and can be helpful in grouting design for weak rock masses.

Nov 1, 2022

By Ashutosh S. Dhar

Cast-in-place piles were examined in this paper from the viewpoints of construction quality, axial capacity, and load-displacement responses. The results of ten 450 mm diameter (18? f) bored piles, installed in a soil deposit of silt to medium dense sand using the method of percussion drilling, were tested under static loads. The results of the pile load tests were used for evaluation of various design methods of calculating pile capacity. The study revealed that the design methods based on the concept of critical depth underestimated the ultimate skin fiction. Thus, the applicability of the critical depth concept for design of bored piles under the soil condition considered may be unreliable. The estimated skin friction factor, ß, was too low in these methods. The Tomlinson method and the Neely method provided the best prediction of the ultimate skin friction. The methods used for calculating end bearing resistance were found to provide a conservative estimate of the resistance. During pile load tests, a settlement of 5 to 6 mm was required for full mobilization of skin friction for the piles in loose sand, while larger settlements (> 10 mm) were required for piles in denser soil. The ultimate skin frictional resistance was observed to be low for piles in loose sand.

Jan 1, 2006

By Francis Kendorski

The Skyline #3 Mine of Canyon Fuel Company in Utah was planning longwall mine development adjacent to and downdip of older mine workings known to be flooded. Barrier pillar geometries and widths were proposed by mining company personnel. Hydraulic conductivity testing suggested that the general characteristics of the local coal seam, dikes, and faults are only weakly conductive and that leakage through the barriers, if any, would be minor. The mechanical performance of the proposed barrier pillar design was evaluated according to (1) published empirical design methods and (2) numerical stress modeling. Comparison of the proposed design, with the range of barrier widths derived from the empirical methods, served as a first-order check on the adequacy of the proposed design. Numerical modeling was used to evaluate conditions site-specific to the Skyline #3 Mine and barrier geometry. Models were developed to quantify the relationship between barrier width and the abutment stresses onto the future workings. The models were also used to estimate the stress distribution within the barrier pillars. The hydraulic performance of the proposed barrier pillar design was evaluated according to (1) published empirical design methods for hydraulic impoundments, (2) empirical method estimates of seepage through coal barrier pillars, (3) numerical hydrogeologic flow modeling, and (4) numerical strain modeling. Using the techniques described above, and based on relevant industry experience, underground observations, knowledge of local geologic conditions, hydrogeologic measurements, and analytical results, the level of geomechanical risk associated with the barrier design as proposed was considered low and the level of hydraulic risk was considered moderate. The largest uncertainty that remained was the possibility that unfavorable geologic structures, such as faults and dikes, would act as conduits for leakage of impounded water into the new workings. Although the study indicated only minor steady-state leakage would occur through a small number of known structures, the presence and full leakage potential of threatening structures in the barrier could not be reliably known until the barrier was mined. One longwall panel has been completed adjacent to the barrier with no evidence of water flow even in fractured zones. Thus, as predicted by the modeling and analysis, it appears that abutment stresses imparted on the barrier during mining did not substantially alter the natural hydrogeologic characteristics, or leakage potential, of the barrier. The longwall coal mine water-barrier pillar design and performance are considered a success.

Jan 1, 2007

By E. F. Draskovich

In 1984 a high temperature heat recuperation system was installed in the pellet plant of the National Steel Pellet Company located in Keewatin, Minnesota. The system is similar to those of Cleveland Cliffs Empire and U.S. Steel's Minntac operations. It recovers hot process air from the cooler by induced flow, and directs it to an intermediate zone between the drying and preheat zones on the grate machine. This system recently underwent further modifications in April 1985, following initial operation in 1984. The M. A. Hanna Company, which manages the property, developed the design criteria and made the subsequent recommendations for modification through its research facility in Nashwauk, Minnesota.

Jan 1, 1986

By Kimberly Morrison

Strategically located within the Uravan Mineral Belt District of western Colorado, the Piñon Ridge Project is the first new uranium mill being proposed for construction in the United States in over 25 years. In 1992, dramatic changes to the US regulatory environment for uranium ore processing occurred making regulatory compliance an increased challenge for a new facility. Proposed as a 6.3 million tonne uranium milling operation, the mill will receive ore from a number of mines in the region. The project includes design and permitting of a uranium/vanadium processing facility, tailings cells, evaporation ponds, and ore stockpile pads. The focus of this paper is to provide an overview of the US regulations and how these regulations were applied to design of the mill facilities, as well as provide a status update on the project as the mill license application was submitted to the Colorado Department of Public Health and Environment (CDPHE) in November 2009.

Aug 1, 2010

By B. P. Watson

Crush pillars have been incorporated into a mechanized, low-profile trackless system at South Deep Gold Mine. These pillars had to be designed to fail near the face and to ensure that pillar failure is contained within the pillar, to avoid bursting and the risk of high loads being generated during a seismic event, respectively. PoweRite backfill bags were recommended to maintain the integrity of the pillars; except in the main access drives, where the sidewalls were to be supported on 5.6 mm diameter weldmesh and yielding anchors. The results of a trial site investigation exceeded expectations, showing a residual pillar strength of about 37 MPa for a newly formed pillar and 8 MPa for a pillar subjected to seismicity and a closure of more than 300 mm. The introduction of these pillars has improved the rock mass conditions because of the active nature of the support, compared to the previous passive backfill method. Importantly, the pillars have increased mining efficiencies and improved face availability. A potential cost saving to the mine of R140.9 million could be realized over a period of 10 years.

Jan 1, 2014

By Brian H. Greene

The U.S. Army Corps of Engineers, Pittsburgh District, is in the final phases of modernizing the locks and dams on the Monongahela River. One facet of this modernization is to replace the existing Locks 4 located on the Monongahela River approximately 40 river miles upstream from Pittsburgh, Pennsylvania. The existing locks consist of a 56-foot x 720-foot main chamber and a riverside 56-foot x 360-foot auxiliary chamber built in the 1930s. Two new lock chambers, each 84-foot wide by 720-foot long, will be constructed at the location of existing Locks 4 and will be named Charleroi Locks. The purpose of the new project is to facilitate navigation on the lower Monongahela River. Pittsburgh is currently the second largest inland waterway port in the nation, and the new locks will be an important component of the navigational infrastructure. The existing lock walls are of mass concrete construction and are founded on wooden timber piles driven to rock through alluvial sands and gravels. The new lock walls were designed to be supported by approximately 300 reinforced concrete drilled shafts, varying in diameter from 4 to 6 feet. To handle axial loads, the drilled shafts were designed for end bearing, with some skin friction. The tips of the shafts will be founded within competent rock. Since the walls will undergo lateral loads, the drilled shaft design also had to consider this loading condition. Some of the drilled shafts will be installed within coffer boxes, which will incorporate a tremie concrete seal down to top of rock. Complicating the design even further was the fact that some portions of the new walls will be supported by shafts that extend some 9 feet above top of rock through alluvial soils, producing a cantilever effect. The first phase of the new lock construction was initiated in the summer of 2005 with a contract awarded to replace the river wall. This required shutting down the existing riverside lock chamber and diverting all river traffic to the longer existing land chamber. The foundation of the new river wall will use 144 drilled shafts. To optimize the design embedment of drilled shafts in rock for the river wall, an exploratory drilling program was conducted by the contractor in July and August, 2005. Based on the quality of the sedimentary bedrock, the shafts will be embedded in rock from 31 to 38 feet. To achieve adequate end bearing resistance, the tips of each shaft will extend through predominantly claystones into a more competent siltstone unit for a minimum embedment of one foot. The contractor also performed an exploratory pile driving program to aid in the construction of the drilled shaft casing and the cut off walls that will encapsulate the river wall. Two demonstration drilled shafts located outside the footprint of the new river wall, will be constructed prior to the drilling of any production shafts. The demonstration drilled shafts will verify that the contractor is able to meet the design criteria and quality requirements of the contract. The river wall contract is currently underway and is scheduled to be completed in 2010.

Jan 1, 2006

Development of a permanent human base on the Moon for exploration requires a self sustaining system. This entails production and processing of limited amounts of raw material on the Moon. Any mining and construction activities on the Moon can only be performed by a robust excavation machine that can excavate a variety of material from loose surface regolith to consolidated (frozen) regolith with embedded rocks in the mixture. Meanwhile, limited amount of information on lunar regolith is available to develop and optimize a machine for given lunar ground conditions. Therefore, any excavator designed for use on the lunar surface should have the ability to adapt to a wide range of operating conditions. A prototype cutterhead for the lunar excavator was built and tested at the Kennametal facility in Latrobe PA A. This paper discusses the results of initial material characterization as well as full scale tests of a prototype cutterhead inrelevent material. A brief review of anticipated production rates under various assumed ground conditions will also be presented.

Jan 1, 2009

By Joseph Gildner, Donald J. Phelps, Jürgen Laubbichler, Christopher Tattersall, David McAllister

The Beacon Hill Station and Tunnels portion of the Sound Transit Central Link Project consists of one mile of twin rapid transit tunnels, an underground station, portals and ancillary works constructed in an urban environment. Presently under construction, the station will set a number of North American firsts including deepest soft ground excavation carried out using the Sequential Excavation Method (SEM).Located in highly variable glacial soil deposits ranging from soft, water bearing sands to stiff, slickensided clays, the station complex and running tunnels proved to be technically challenging during design. Meeting these challenges necessitated an extensive geotechnical investigation, a trial shaft, and state-of-the-art numerical analyses to develop ground conditioning, pre-support, excavation support and structural design. A comprehensive risk identification and mitigation program, and innovative procurement strategy were incorporated into the design and contract bid documents.

Jan 1, 2005

By Mankosa MJ, Yoon R-H

A reliable scale-up procedure for column flotation must address three important areas of column design, ie column geometry, sparging system and wash water distribution network. The column geometry is dictated by the maximum froth carrying capacity (which determines column diameter) and the bubble-particle attachment rate and particle retention time (which determines column length). The most important factor in the scale-up of an air sparging system is the ability to produce small bubbles in both laboratory and full-scale columns. Other factors, such as energy consumption and maintenance requirements, should also be considered in the scale-up of bubble generators. It is also important to design a wash water distribution system that can properly control the froth stability and maximise the column throughput. Based on these criteria, a successful scale-up example is given.

Jan 1, 1993

By M. J. Davie, D. S. Ross

"The successful design of a new mine water pumping system is in part dependent upon the accuracy with which the operating conditions can be forecast. This paper outlines the data which should be obtained on water quantity and quality. Methods of modifying the quality are also discussed. Some pumping systems for disposal of sludge are described, citing operating examples. The various types of mine dewatering pumps are described in terms of design characteristics as they affect operating efficiency and installation and maintenance costs. Piping system parameters are outlined. Finally, a hypothetical case study of pumping from a depth of 3,000 ft is assessed, with particular reference to capital costs.IntroductionMany mine operators would agree that the pumping system usually receives a low engineering priority during the design stage, and as a consequence causes some of the most frustrating problems during production. For a ""dry"" mine (up to 200 gpm), design of the pumping system may indeed be simple, but outside of the potash industry such mines are not common. For ""wet"" mines, the pumping system is important because it significantly affects the initial capital and on-going energy costs of the mine and, in the area of sludge disposal, the working conditions and production costs. Indeed, a failure in the pumping system usually has serious, and sometimes disastrous, consequences.The intent of this paper is to outline the factors which should be considered in the design of a pumping system and to describe the types of pumps used in mine dewatering and relate them to practical operating systems."

Jan 1, 1980