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By C. A. Pryor

The aggregates industry is the largest minerals industry in the United States producing over 2.6 billion metric tons of crushed stone, sand and gravel annually. Approximately 5% of that production is fine material, passing a 75-micron mesh sieve. Of that amount, about 77% is not sold and represents one of the major industry issues. The material accumulates in stockpiles and settling ponds having an operational and economic impact on the site’s bottom line. Many factors cause this material to be produced: from blasting and processing techniques all the way to end use specifications.

Jan 1, 2002

By Holger Cordes

X-ray diffraction has long been used for qualitative and quantitative mineral analysis but Rietveld data analysis is still an under utilized method for mineral exploration and processing applications. In this full-profile approach the structural parameters of each mineral phase, together with experimental parameters, are refined by least-squares methods to minimize the difference between observed and calculated diffraction patterns. The result is a standard-less, quantitative analysis of the mineral abundance in the sample that is more accurate and considerably faster compared to traditional methods. The TOPAS software package combines a user-friendly interface with a unique approach to resolve overlapping peaks. Automated analysis options are also available and significantly reduce analysis time for routine samples. Several examples on a wide range of naturally occurring rock types are shown that illustrate the capabilities and limitations of the method. The examples include several options for the quantification of amorphous constituents like volcanic glasses.

Jan 1, 2006

By R. M. G. Machunter

Computer models of metallurgical circuits are extensively utilised in design, and prediction of overall plant separation performance. As always, in the final optimised flowsheet design there is a compromise between the recovery of values and grade of the circuit output. This paper mathematically examines various circuit options for the generation of a heavy mineral concentrate from a generic mineral sands wet concentrator plant. Based on data derived from testwork, any particular mineral sand has a unique release curve describing the separation performance of the heavy mineral suite. Models are constructed that combine particular stage output streams as feed to other stages in various configurations. The ramifications of each option are discussed and reasons why one particular option is selected over the others examined.

Jan 1, 2005

For years traditional optical microscopic techniques have been used successfully to carry out mineralogical studies on processing products. Essential information could be obtained by supplementing microscopic data with X-ray powder diffraction data, chemical analyses, etc. However, most of the time the mineralogists working on plant related issues, would supply qualitative information to the metallurgists, due to quantification not being possible in the available time. Since the late-80s, the use of semi-automated to automated techniques for mineral quantification has impacted positively on the use of mineralogy for optimising processing plants. Rustenburg Platinum Mines (now Anglo Platinum) were the first mining company to purchase a Qem*Sem in 1987. With the success achieved in quantifying the minerals in the concentrator streams of the Rustenburg Platinum operations, a second instrument was purchased soon after. These instruments have proven invaluable tools in understanding the flotation behaviour of the sulfide and gangue minerals in the various reefs of the Bushveld. Restrictions in the resolution of these earlier instruments, as well as the time involved in searching for and correctly identifying the fine-grained platinum-group minerals (PGM), meant that these investigations focused on the deportment of the more abundant base metal sulfides, rather than on the actual PGM. The Mineral Liberation Analyser (MLA), which became available in the late 1990s, was well suited to detect and analyse minerals occurring in trace amounts such as the PGM. Anglo Platinum was the first mining company to purchase such an instrument and now has fourteen systems operating at the AR Crown Mines site. One of the applications of these systems involves the study of feeds, concentrates and tailings from the various concentrators on a monthly basis. These routine investigations provide information on a variety of mineralogical parameters, including liberation, association, and grain size. Results are used to emphasise areas for improvement, and specifically underline those areas where improvements will have the most impact on recovery. After new or different technologies have been implemented, mineralogical characterisation of the different process streams is an essential component in the assessment of the impact of these changes on flotation performance. In addition, the knowledge is databased for future reference to draw trends across the various concentrators around the Bushveld complex, and is also used for comparative studies when plants experience high losses to tailings. Due to the success of these investigations the question was posed whether it was possible to obtain data on a daily basis, as compositing samples could hide the impact of daily events. Although the instruments currently used are suitable for a research environment, these are not ideal for mine-site implementation. For that reason Anglo Platinum, together with FEI embarked on a development program to develop a system that can be implemented on-site to measure the important mineralogical characteristics on a daily basis. Important requirements for such a system include time-to-data, ease of use and regular quality control. Highlighting some results from concentrator studies, the presentation will review the progress on the development of automated mineralogical techniques for fast, automated mineral measurements. This is an abstract only. No full paper was prepared for this abstract.

Sep 13, 2010

Mr D. Twigg graduated in Metallurgy at the Sheffield Polytechnic, and later obtained a Master of Science degree at the University of Bradford. Mr I.D. Matthews matriculated at Roosevelt High School and joined the No. 1 Parachute Battalion in 1968. He worked in Zimbabwe for 31 years in geological prospecting, civil engineering, and open-pit mining.

Jan 1, 1985

By Lloyd Robert Nelson

The historical progression in installed electric furnace smelting capacity of some 1650 calcium, chromium, manganese, nickel and silicon ferro-alloys furnaces is reviewed. Key increases in the inherent installed electrical capacity, often achieved through uprating furnaces, are identified. Possible factors facilitating such advances are explored, including: specific process engineering and pyrometallurgical enhancements (e.g., improved control over the consistency, size and chemical form of raw materials, extents of preheating and pre-reduction delivered into the furnace; and patterns of feed distribution); furnace electrical configuration (AC or DC; immersed, submerged-, shielded- or open-arc); form of electrode (graphite, self-baking or composite); furnace configuration (circular or rectangular; closed or open and 1-, 3- or 6- electrodes); better engineering and equipment designs (e.g., high-intensity cooling) and state of furnace electrical and metallurgical control systems. A view is presented on the prevailing state of evolution of the Mega-scale in ferro-alloy smelting and opportunities for still further improvements.

Jan 1, 2014

By S. J. Oosthuizen

This paper examines innovation in relation to the availability of anew material: the metal titanium. The paper aims to highlight the need for the inclusion of entrepreneurial innovation as a necessary focus area in the development of a titanium metal value chain. Both the Department of Science and Technology (DST) and the Department of Mineral Resources (DMR) have identified the creation of titanium metals production capabilities as a key growth area for South Africa. Using historical literature as a source of data, the activities of selected innovators who used titanium metal as a central component in their success, were investigated. The origin of the process innovation behind the titanium metals industry, and two titanium product innovations: namely, medical implants and sporting goods, were detailed as case studies. It was found that individual innovators were responsible for the creation, and rapid growth, of the titanium industry and titanium product applications. There is a need to link the current research and development into titanium metals production with individuals and organizations capable of commercializing innovative processes and products.

Jan 1, 2011

By X. (Mike) Yao

Rock mechanics engineers must provide ground support designs that ensure a safe underground working environment. Unexpected falls of ground are unacceptable while ground support systems must be adequate. Ground support must be economic for the area supported and the time frame the opening is in use. While numerical modeling can be used for ground support design, empirical models are still the common useful design tools. Empirical models are best developed and improved from local experiences although some models, such as Stability Graph (Potvin et al, 1992), are in extensive use by the Canadian mining industry. To determine the adequacy of ground support practices at HBMS, a database of 50 fall of ground case histories between 1985 and 2001 was compiled. For each failure, the recorded data included: location, rock type, rock mass conditions, opening and failure geometry, installed ground support and failure mechanism. An analysis of the database was done to obtain an understanding of failure frequency association with rock types, stope geometry and installed ground support, and to assess what support design changes were necessary. The paper describes changes made to ground support and mining practices during the last five years, and the formation of new ground support standards and practices which have been successful in reducing ground falls while providing improved, efficient and economical ground support.

May 1, 2002

By Satish Kate

Indian limestone mines which are highly mechanized in operation and supply limestone to the cement plants have been quite successful in devising ways and means to optimize blasting parameters, so as to have best fragmentation, powder factor, and cost of excavation. In primary blasting mechanized or manually mixed ammonium nitrate Fuel Oil is quite popular in dry holes, and in case of watery holes conventional packaged slurry/emulsions are being used. In order to avail the low density characteristics of the ANFO, some limestone mines have also used Saw Dust and Rice Husk along with ANFO. A number of field trials have been undertaken to explore the suitability of mixing rice-husk and saw dust with ANFO. Presently, about 10% of rice husk/saw dust is being used only to expand the explosive column. The main technical consideration for the use of saw dust/rice husk, has been to reduce the final density and increase the occupancy of explosive in the blast-hole. This not only lowers the detonation pressure in the blast holes, but also reduces cost of explosive without compromising on the fragmentation quality. Besides, with sleeping of the charge there is no substantial fall in the blast quality.

Jan 1, 2006

By J. A. Kost

The objectives of this contract were to determine the amount, size, and deposition of float coal dust (74 x 10 microns) generated during the mining and transporting of coal in underground U.S. mining operations. Rock dust distributed by trickle dusters was also sampled. In addition to four belt-transfer points, two continuous and two conventional mining sections were sampled at five mines located in Pennsylvania, West Virginia, Kentucky, and Illinois. Float-dust samples were collected on deposition pans; total airborne dust was collected with MSA Model C personal samplers equipped with Unico filter casettes; Andersen cascade impactors provided relative size distributions of the samples. Production, airflow, and water flow were monitored to examine their effect on dust levels.

Jan 1, 1981

By F. Matanzo

This guide considers only nine of the many wire rope terminations used in the mining industry so use of the information presented for terminations not specifically addressed can be done, but with some risk. The nine terminations considered are: Flemish Loop with Steel Sleeve & Thimble, Flemish Loop with Steel Sleeve, Wedge Socket, Swaged Socket, Turn Back Loop with Aluminum Sleeve & Thimble, Thimble Splice with Four Tucks, V-Bolt Clip with Thimble, Zinc Poured Socket, and Epoxy Resin Poured Socket. The guide uses pull test data, axial fatigue test data, and data on sensitivity to poor workmanship, to rank the nine terminations with respect to these performance measures. A selection procedure is suggested and illustrated with an example. Failure data is used to identify the common modes of failure of each termination and so help the inspector direct his attention to the likely location for a failure and describe what he should be looking for. The data on which this guide is based is included so that as new data becomes available, the ranking order can be adjusted accordingly.

Jan 1, 1978

By Raymond L. Lowrie

Deregulation, as authorized by the Energy Policy Act of 1992 (PL102-486) allows free-market competition in the electric-utility industry. As the act unfolds, though, uncertainties abound about the type, degree and direction of impacts throughout the affected economy — from fuel suppliers to electricity generators and from power distributors to energy consumers. Instead of having a familiar base of captive customers and electricity prices fixed by negotiation with state public utility commissions, utility companies are preparing for open, free-market competition. They are looking at all areas, including fuel supply, to cut costs to remain competitive. Humorous anecdotes are told about utility companies shunning insiders for senior executive positions. Instead, they are opting for people from the telephone or other industries with deregulation experience. And there are light-hearted stories about a trend away from traditional electric-company names, such as the name of a city or state followed by Edison or Power and Light, to space-age names, such as Ameren, Entergy, Illinova or Unicom. No one wants to be left behind or be perceived to be left behind.

Jan 1, 1996

By J. P. BONARDI, C. W. Davis, R. B. Moore, J. W. MARDEN, S. C. Lind, J. E. Conley

The rare metals are becoming increasingly important to our industries. Rare-metal alloys have properties which indicate that we are only on the threshold of the possibilities of their utilization, not only in making nonferrous alloys, but also as special steels. Not only are their uses broadening rapidly, but the metals are affecting our industries in other ways. The oxides and some salts are used as pigments; others have medicinal value. The pure metals are made into filaments for incandescent lamps, and targets for X-ray tubes. By their efficient use in alloys, the weight of automobiles is reduced, • and the wear and tear on tires and roads is thus minimized; in machine shops they help to give greater efficiency to tools and reduce production costs. Their development has marked a milestone in the progress of civilization. There has been considerable uncertainty regarding analytical methods for the rare metals. A great deal has been published, but the weak and the strong points of the various methods have not been investigated as carefully as is needed. The Bureau of Mines at its Rare Metals station in Colorado necessarily had to do a great deal of analytical work in connection with the metals covered by this bulletin, which aims to give the results of the experience so acquired. No claim for much originality is made, although some published methods given have been modified, and some new ones have been developed by members of the staff. The principal methods available were studied critically, and it is to be hoped that the work will assist those interested in analytical work in connection with the metals named.

Jan 1, 1923

By Samuel Frimpong

Synthetic fuel is a liquid hydrocarbon fuel synthesized from unconventional resources, such as tar sands, heavy oil, coal, and oil shale. These unconventional resources are immense and will be a major energy source for the 21st Century as the availability of conventional crude oil and natural gas declines. The authors review the available global distributions, production data, research frontiers, and current research organizations involved in tar sands, heavy oil, coal, and oil shale. Tar sands and heavy oil is mainly deposited in Canada, Venezuela, and the United States. Oil shale reserves are found in United States, Jordan, China and Australia. Coal occurs in United States, Russia, China, Canada, and Australia. Major research and development efforts are focused on reserves identification, transportation technologies, production cost modeling, bitumen extraction process improvements, coal liquefaction technologies, elimination of pollutants, greenhouse gases, and safeguarding human health and the environment. This review forms a major source for educating the public about these important energy sources, and the need to develop environmentally sound technologies and policies for their extraction.

May 1, 2007

By Andrew B. Cecala, Emily J. Haas, Jay F. Colinet

A sociotechnical system (STS) creates a framework that allows an examination of how social and technical factors affect organizational outcomes within a specific environmental context. STS has been rigorously studied with a primary research focus addressing worker-technology interactions. Although these interactions are important, the social processes and interactions that occur whenever any technical or environmental change is introduced into the system have been undervalued. If social processes are better understood, mining organizations could efficiently prepare and stabilize for such changes. With this goal in mind, we sought to extend STS theory through applying principles of meta-design to analyze the results of two case study interventions. Specifically, we studied the impact of an unregulated dust control technology (the Helmet-CAM) and a regulated dust control technology (the Continuous Personal Dust Monitor) on factors within an STS including employees’ knowledge of, communication about, and use of technology to mitigate respirable dust sources. The results are presented in a way that first, addresses the overarching principles of meta-design STS including organizational participation, flexibility, and communication and second, examines how technology implementation processes differ when the organization is complying with a formal, higher-level requirement. Results show that a prominent focus on the social factors within an STS framework could help reduce unpredictability on the technical side and may improve communication within the system to help reduce adoption time, especially if and when accompanying a new, formal work process.

By Jr. Gabler

Because of concern over the availability and reliability of an uninterrupted supply of manganese and other materials, the U.S. Congress requested that the U.S. Bureau of Mines (USBM) study the /low of strategic and critical materials in the economy to delineate and quantify the production areas where metal values are lost. As a result, the USBM developed a generic computerized commodity flow model that is readily amenable to updating. The original model developed for cobalt, with slight modifications, was used to track the flow of manganese. This report follows the flow of manganese through its metallurgical and chemical applications and highlights areas where significant losses occur owing to downgrading, export, or disposal. The study indicates that materials containing 695,000 short tons (st) of manganese were consumed domestically in 1990. Scrap recovery specifically for manganese recycling was insignificant. However, considerable manganese was recycled through processing operations as a minor component of ferrous and nonferrous scrap and steel slag. The major loss category is manganese lost in steel processing, 323,156 st or 46 pet of the 1990 apparent consumption. Most of this loss reports to steelmaking slags. Recovery from slags is technically feasible, but is not economically feasible.

Jan 1, 1995

By Bernadette C. Michalski

THE RAPID GROWTH of the small Albanian mineral industry in the 1950's began to taper off by 1961 and slackened sharply in 1963. The abandonment of Soviet and East European technical assistance programs in mid-1961 greatly affected Albania's mineral development, since four-fifths of all technical aid personnel were engaged in mineral activities. Chinese assistance apparently has not been able to fill the void. Overall mineral production increases during 1961-63 averaged 1 percent per year in value, as compared with 3 percent in 1959 and 5 percent in 1960. Although by world standards Albanian mineral output, except for chromite, is insignificant, it is vital to the country's domestic economy. The mineral industry generated about 14 percent of the gross industrial product in 1962 and employed a notable share of the industrial labor force. In recent years, mineral products have provided about three-fifths of the country's exports by value. Chromite and iron-nickel ores together constituted from one-fourth to one-third of the total export value. In 1963, total trade turnover increased 12 percent over 1962.

Jan 1, 1964

By A. P. Bois, K. Saleh, A. Ghorbal, V. Hajiabdolmajid, G. Ballivy

"The knowledge of the initial stress field is not always sufficient to ensure the stability of mining stopes due to the high-stress variations generated by mining. Monitoring of these openings is then necessary and can provide quantitative information (deformations and stress variations) as well as qualitative information (state of stability).An applied technique for following the variations of stress and deformation in static and dynamic conditions, in relation to the evaluation of the stability of underground openings known as “Cylindre Instrumenté de l’Université de Sherbrooke” (CIUS) is discussed in this paper. In addition, a data acquisition system combined with a rock failure warning system has been developed to be connected to the CIUS for detecting the instabilities, which can endanger the stability of underground openings. Also, the installation of six CIUS and a data acquisition system as well as the selected procedure of programming in a warning system are briefly described."

Jan 1, 2003

By S. K. Palm

The commercial life of a mineral product can be long, but like hitech electronic and software products that soar in sales one day to become obsolete and forgotten a few months or years, mineral products have a life cycle. They are invented, commercialized and eventually decline and disappear from commerce. Diatomite and perlite are produced from mined minerals, but almost none of the products in these industries spring from the earth in finished form. Straight calcined diatomite was invented over 100 years ago and flux calcined diatomite just a few years later. The expansion properties of perlite were discovered and first exploited about 75 years ago. Some applications for diatomite have disappeared or currently face competition from newer products. Dry cleaning was once the second-largest application for diatomite but disappeared over 30 years ago. Both the beer and wine filtration markets for diatomite face increased competition from membrane filters. A pipeline of new, proprietary products is critical to the future of the industry.

Mar 2, 2022

By D. A. Rice

As part of its mission, the U.S. Bureau of Mines continues to develop technologies that will enable cost-effective compliance with environmental requirements. To this end, investigations to improve the kinetics of chalcopyrite dissolution by simultaneous grinding-leaching in ferric sulfate solution were conducted using the Bureau-designed turbo mill. The development of such a hydrometallurgical process would provide a nonpolluting alternative to conventional smelter technology. The effects of mill rotational speed and volume percent solids on the leaching time and energy required for copper extraction from chalcopyrite were evaluated. The results of this laboratory study have shown that the simultaneous grinding-leaching of chalcopyrite concentrate using the turbomill is technically feasible with essentially 100 pet extraction of copper being possible at 90° C. An optimal energy consumption of 1,153 kW?h/st of copper leached was found in batch testing with the mill operating at 400 rpm with a slurry containing 35 vol pet chalcopyrite. This energy consumption, while higher than other proposed leaching processes (about 600 kW?h/st), is of the same order of magnitude. Further refinement of the energy requirements would require additional testing using a continuous circuit. Leaching times of less than 1 h, for 80 pct copper extraction, are achievable using the turbomill grind-leach process.

Jan 1, 2010