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By R. R. Klimpel

"SYNOPSISA discussion of the importance of flotation rate in the analysis of mineral flotation is presented. In particular, the highly interactive nature of the flotation ""system"" is emphasized where there are components of chemistry, equipment, and operating conditions simultaneously involved. It is further shown that: 1) flotation rate must be measured in order to economically optimize the performance of an industrial flotation circuit, 2) that consistent patterns exist in both flotation rate and equilibrium recovery when changing various settings of the system components, 3) that knowledge of these patterns is necessary in order to avoid making system changes that are either self-compensating or dramatically re-enforcing in some particular aspect of performance, and 4) the rate related role of the chemistry component (e.g.frothers and collectors) is often much bigger than is sometimes realized (especially in a negative sense involving overdosing of reagents). INTRODUCTIONFroth flotation is widely usedl-6 in mineral beneficiation processes as a method for separating different types of finely divided solids present in a liquid (usually aqueous) suspension. The approach is based on the contacting of solids with upward moving air bubbles in an agitated vessel where the solids are exposed to chemicals (collectors) which create a condition favoring the attachment of a certain portion of the solids to the air bubbles. This selected portion is then removed in a froth stabilized by chemicals (frothers) and subsequently recovered from the flotation vessel. Depending on the settings of the various components of the flotation ""system"" (see Figure 1) it is possible to achieve a wide range of flotation performance."

Jan 1, 1984

By K. Liddell

Current practice for the recovery of platinum group metals (PGM) from flotation concentrates is by energy-intensive smelting processes followed by separation and refining of the base and precious metals. Energy costs are rapidly increasing in South Africa and this trend is forecast to continue in future years. Moreover, the smelting operations are highly susceptible to deleterious constituents, particularly chromite; and the increasing tonnages of UG2 chromititic ore being mined results in an increasing chromite content of smelter feeds. Hence there is a substantial incentive to assess and implement alternative processes to smelting for the treatment of PGM concentrates. The Kell process is a patented hydrometallurgical alternative to smelting that is totally insensitive to the chromite content of the feed concentrate and comprises three commercially proven unit operations (pressure oxidation leaching of base metals and sulfur, roasting and chlorination of precious metals). The Kell process provides the opportunity for existing and new PGM producers to significantly reduce their energy consumption, and in particular their consumption of electricity, by removing the need to smelt PGM concentrates. Energy costs, greenhouse gas emissions and installed power requirements are also much reduced. Compared with smelting and refining these reductions are calculated as: ? Total energy consumption-50% reduction ? Electrical energy consumption-84% reduction ? Energy consumption costs-76% reduction ? C02 emissions-70% reduction ? Installed power requirement 92% reduction. The data obtained from simple laboratory batch amenability testing can be readily applied to the Simulus mass and energy balance simulation procedure to determine energy and reagent consumptions, equipment selection and process optimization. The applicability of Kell to treating low-grade 'dirty' concentrates with high UG2 content as well as to polymetallic concentrates containing base metals as the major payable metals with subordinate PGM means that these savings can also be expected when the process is used for treating a range of concentrate types and grades. Keywords PGM,UG2, Merensky, smelting, chromite, electricity, hydrometallurgy, Kell Process, Eskom.

Jan 1, 2011

By J J. Batchelor, J B. Metson

Titanium (ilmenite) concentrate was extracted from a New Zealandilmeno-magnetite deposit. Tailings from the existing processing line at the Waikato North Head ironsand concentration plant were used as a raw material feed. The titanium bearing mineral extracted was defined as intergrowths of ilmenite and hematite in the size range below 150 um. The Owen-Honda equation was used to determine the conditions forilmenite/hematite magnetic separation. Three distinct regions of magnetic field strength for the mineral separation have been defined. Theoretical estimates from this calculation have been confirmed experimentally. Ilmenite concentrate was obtained using medium field magnetic andelectrostatic separation. The final material contains 40.6 - 42 per cent TiO2 and 39.1 - 39.8 per cent Fe (total). The actual yield from extraction was about seven per cent of the Zircon, leucoxene and monazite were found as byproducts of thetitanium concentration process. Preliminary experiments have shown the viability of industrial zircon benefication.

Jan 1, 2000

By I. A. Mwamba

Titanium aluminide of composition Ti-47.5 at.% Al was prepared by melting titanium and aluminium of commercial purity with additions of precious metals of 0, 0.2, 1, 1.5 and 2 at.% content. The microstructure, hardness and oxidation properties were assessed. It was found that at 47.5 at.% Al, the microstructure of plain TiAl alloys was duplex, consisting of duplex lamellar grains and ? grains. The lamellar grains consisted of alternating lamellae of ? (TiAl) and a2(Ti3Al), with overall aluminium content in the range of 43?47 at.%. The ? grains had a aluminium content above 50 at.%. The addition of precious metals to the TiAl alloy resulted in the formation of a new phase, with a high precious metal content, occurring mostly in the ?phase, without any major change to the microstructure. Increasing the amount of precious metals resulted in an increase of the new phase amount, at the expense of the ? phase. The hardness of the different alloys was around 300HV10. Overall, the research has shown that addition of precious metals to TiAl resulted in a slight increase in hardness and a significant improvement of the oxidation resistance. This shows that alloying TiAl with precious metals, at the addition levels investigated, does not alter the mechanical properties very much, but improves oxidation resistance.

Jan 1, 2012

By Frank P. Frandina, Michael J. Loehr, Paul E. Gabryszak

The Heartland Corridor Clearance Improvement Project is part of a regional Public-Private initiative to allow double stack container trains a direct route from the Port of Norfolk through Virginia, West Virginia, Eastern Kentucky and into Central Ohio. In the Preliminary Engineering stage, 30 existing tunnels were assessed and 28 were found to need clearance improvements to allow the use of double stack trains. Alternative tunnel enlargement methods were developed to achieve the desired clearance improvements, while maintaining structural integrity and minimizing disruption to train traffic. This paper summarizes the geometric and condition investigations of the existing tunnels, as well as describes the preferred methodologies to achieve the desired clearance. The clearance improvements will be implemented beginning in the summer of 2007.

Jan 1, 2007

By Lijuan Chen

During the detoxification of chromium-containing slag by Achromobacter sp. CH-1, anionic surfactant Sodium Dodecyl Sulphate(SDS) and its mixed systems with different Tween surfactants(Tween 20, Tween 60 and Tween 80) were used to promote the interaction between the bacteria and the chromiumcontaining slag and the rate of acid-soluble Cr( ? ) leached from the slag. The effects were evaluated by the surface tension, the pH of the leaching solution and the leaching rate of total Cr( ? ) from the slag. The results showed that the surfactants systems improved Cr(VI) leaching and its detoxification of chromium-containing slag. The mixed surfactants of SDS combined with Tween surfactant revealed better effectiveness of detoxification than SDS only. When the mass ratio of SDS to Tween 80 was 1:1, the rate of Cr( ? ) leached from the slag increased by 12%.

Jan 1, 2009

By A Hollweg, K H. Esbensen, M Lischka

Two new splitter designs for intercepting moving streams of matter are presented, the variable cross-stream splitter (vCSS) and the rotary stream splitter (RSS), which are intended for implementation in a fully automated modus. The vCSS facilitates obtaining up to three subsamples with different splitting ratios from automated laboratory flow paths, while the RSS divides the intercepted sample into 16 equal analytical aliquots. The splitters can process a wide range of dry, granular and free-flowing materials (<5 mm). The required weight for each subsample can be set without mechanical adjustments in the case of the vCSS. Typical applications are subsampling/splitting for X-ray fluorescence pelletisation (or fused beads) or splitting for average shift composite sampling or grain size analysis. The vCSS combines the advantages of riffle splitting (three user-defined subsample masses) with miniature bed blending and can accept up to 15 kg in total incoming sample mass. In practice, the automated vCSS can deal with unlimited ingoing mass fluxes, while the RSS is designed to operate at a user-defined fixed subsampling rate (1/16th in the tested version). Both splitters have the potential to be optimised and evaluated according to an application/user-defined total sampling error (TSE) + total analytical error (TAE) threshold. Both splitters were tested under adverse conditions and with compositions involving three components with properties representing typical mass fluxes and components concentrations in industrial and technological systems: phosphate concentrate 89.00 per cent (<500 µm), slag ten per cent (>2 mm) and glass spheres one per cent (750–1000 µm). The slag particles vary widely in particle shape, aspect ratio and surface roughness, while the glass spheres are extremely prone to bouncing and segregation (spillage). This test system is extremely difficult to split and thus constitutes a realistic worst-case scenario. While the vCSS does not comply strictly with Theory of Sampling demands for correctness, both splitters may well be able to deliver fit-for-purpose representative results if/when tested properly. Average relative mass deviations ranged from 1.89 per cent for phosphate concentrate (relative standard deviations of 20-fold repeated splitting) to 4.72 per cent for glass spheres and 13.04 per cent for slag. For the RSS, the average replication experiment splitting variation was 2.89 per cent for phosphate concentrate, 4.82 per cent for glass spheres and 11.1 per cent for slag. Both new automated online splitters would therefore appear to be able to be tuned to fit-for-purpose representivity (defined here as maximum relative reproducibility <5 per cent) for many non-extreme materials; however, it is always imperative to test every new type/class of material empirically. There is a wide commercial potential for important materials and commodities sectors, including food, feed, drugs (pharmaceutical), secondary raw materials, recyclates, agricultural products and seeds.CITATION:Lischka, M, Hollweg, A and Esbensen, K H, 2017. New online/atline splitter designs for laboratory automation – feasibility results, in Proceedings Eighth World Conference on Sampling and Blending , pp 159–166 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2017

By J. R. Allsup

Air pollutants in exhaust gas produced from LP-gas (propane) were studied using both laboratory engines and vehicles. The objective of the study was to evaluate engine parameters relating to the advantageous use of propane as a low-pollution fuel. Some comparisons are made between gasoline, natural gas, and propane. Results show that engines can operate over a wider range of A/F with minimum carbon monoxide and hydrocarbon emission when using propane than when using gasoline. Mixture enrichment using propane is unnecessary during cold starts, thereby eliminating the emission penalty during warmup. Carbon monoxide and hydrocarbon emission using propane are unaffected by ambient temperature. The photochemical reactivity of hydrocarbon emission is considerably lower with propane than with gasoline.

Jan 1, 1972

By Jack Touseull

On November 15, 1972, the Bautsch mine, a lead-zinc mine in Paleozoic dolomites, experienced a massive rock failure involving 3 to 5 million tons. Because this failure was large and extended to the surface, it was included in the Federal Bureau of Mines investigations on "Massive Rock Failures." Analysis of the rock mechanics and mode of failure revealed that failure at the Bautsch mine was the result of the interrelationship of many factors. Factors related to the failure were found to be external and internal to the mining environment. Unlike internal factors, external factors were not apparent and, therefore, many external factors were investigated; some of which are not normally considered in rock mechanics analyses. External and internal factors determined to be of significant importance were: (1) precipitation, (2) fractures, (3) plastic clay layer, (4) topography, (5) rock alteration, (6) bedding, and (7) mining zone dimensions. Because of the conditions at the mine, failure could have been predicted without extensive instrumentation. Application of basic geologic and engineering principles to the internal and external factors could have predicted failure. Alternately, failure would, in all probability, have been delayed by years if, after 1962, mining had been curtailed in the area of failure.

Jan 1, 1980

By E. C. Stephens

The eastern Washington— Idaho clay region stretches along the northeast margin of the Columbia basin for 150 mil es. The three better known and developed clay areas are Clayton, Wash., (2 miles north of Spokane); Mica, Wash., (10 miles southeast of Spokane); and Moscow-Deary-Bovill, Latah County, Idaho (about 80 to 90 miles southeast of Spokane) see Fig. 1. Clays from the eastern Washington— Idaho clay area have been mined for more than 50 years. At present Mica, Washington deposits are used by the Gladding—McBean & Co. to make a variety of bricks and ceramic products and Latah County, Idaho clays are used by the A. P. Green Fire Brick Co. to make refractories. The Anaconda Co. made an intensive investigation of the clay deposits in the northeastern Washington-!daho area in 1919 to determine the existence of a supply of raw materials from which alumina could be made. The greater part of the work, which included systematic drilling and shaft sinking, was concentrated at Mica, Wash. This was part of a research project carrted on by the Anaconda Metallurgical Research Dept. under the direction of Frederick Laist and F. Frick and it was terminated in 4920. V. D. Perry, Vice President and Chief Geologist for The Anaconda Co., in 1952 assigned the writer to make a preliminary study of clay and other potential sources of alumina ore in the Pacific Northwest with particular emphasis on those deposits which might be of future importance to The Anaconda Co9s. then new aluminurri plant at Columbia Falls, Mont.

Jan 1, 1961

By William J. Karwoski

To improve rock-burst control in deep vein mining, a field demonstration has been carried out by the Bureau of Mines to test a new rock-burst control concept--rock preconditioning in advance of mining. The procedure is to fracture the major rock-burst-prone zone during the development of each level before production mining. This allows initial mining to begin in a preconditioned zone and later mining from the level below to end in a prefractured or preconditioned pillar zone that is relatively burst-free. This full-scale field demonstration was carried out On the 7700 level of the Hecla Mining Co.'s Star-Morning mine. An expected burst-prone zone along the main vein between 7 and 10 crosscuts, some 250 feet long by 40 feet above and below the level, was preconditioned by blasting a fanlike ring of drilled holes from each crosscut. The drill holes, up to 100 feet long and 4 inches in diameter, were loaded with high explosives and shot. About 4,550 feet of drilling and 9,000 pounds of explosives were involved in the effort. Comparison of preshot and postshot data from monitoring instrumentation indicated that the blasting did fracture the rock in the planned zone and did result in an immediate stress decrease and softening of rock. The field data compared favorably with predicted results from a finite-element computer model simulation of the destressing. Based on observations made during mining and on the data from the Hecla rock-burst monitoring system, there is no doubt that this preconditioning in advance of mining demonstration resulted in much-improved rock-burst control during first-floor mining. It was also concluded that preconditioning the vein was more effective than preconditioning the wall rock.

Jan 1, 1979

By D. B. Lovett

The work described in this report was directed toward identifying and devising methods to minimize the previously observed variability between working level hour exposures and the alpha particle track densities resulting on Track Etch films exposed to mine atmospheres containing radon and radon daughters. The disequilibrium between radon and its daughters was shown to directly affect this Track Etch film calibration factor. The wide range of disequilibrium states possible in mine situations amply explains the variability in the previous tests. A file of published mine atmosphere composition data was compiled and was used, along with atmospheric compositions derived from several theoretical models ref the atmospheric behavior, to evaluate the variability of several dosimeter configurations and concepts. A nonlinear, iterative regression analyse; was formulated that successfully predicted working levels to within 8 to 10% from only the alpha particle activities (Rn, RA, and RaC') data such as are obtainable from Track Etch films over a wide range of disequrlibrium conditions. A model expressing atmospheric concentrations as a function of radon source strength, plate out rate factor, ventilation rate and the fractional re-entry by recoil of previously platted-out daughters was derived and used in the regression program in addition to preparing a set of reference tables and graphs showing the disequilibrium behavior of the atmosphere. Other factors that can affect the Track Etch Film response writ considered and shown to he less crutial than the disequilibrium state. The results of a series of exposures of a dosimeter concept fixture in the Denver Mining Research Center radon chamber air presented and discussed.

Jan 1, 1976

By H M. Ahmed, W S. Dunbar

Construction of cave mining systems requires significant capital expenditure and long-term commitment of human, equipment and material resources before production commences. Risks and uncertainties of these large-scale mining projects are significantly higher than for small-scale projects. This is due to the complexity and interactions of the construction schedule components and the large scale and uniqueness of such projects. One way to successfully manage construction uncertainties that would lead to schedule delays is to include a reasonable cost contingency in the budget estimation. A real options approach based on the least-squares Monte Carlo (LSM) method is used to estimate cost contingency associated with schedule uncertainty in mass mining projects. Cost contingency is estimated as the cost of potential project crashing (acceleration) decisions, which pays for not extending the schedule. While such a significant undertaking is expected to be subject to some delays, these can have an enormous impact on the economic value of such projects. The value of the crashing option was explicitly formalised into the process of valuation, as it is assumed to be a single option being considered in the valuation at every decision point prior to the construction completion date. As a part of the proposed method, a stochastic function for the percentage of remaining scope of work for the remaining duration of the entire project was integrated into a framework of numerical simulations. This ensured that this function can implicitly account for sources of schedule uncertainties for projects represented by multiple and overlapping work packages. The LSM method was applied to a real case scenario in an operating block cave mine, with modified scale and features. The results yielded by the LSM method indicated that significant changes in capital budget allocation stem from variation in a contractor’s risk perception and confidence level of estimated delays.CITATION:Ahmed, H M and Dunbar, W S, 2016. Budget estimation and contingency allocation of block cave construction using least-squares Monte Carlo real options, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 801–808 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By G. Apsey

Eutectic freeze crystallization (EFC) is a novel technique for the recovery of pure salt and pure water from hypersaline waste brines. It is therefore a promising technology for the treatment of industrial waste waters. The impurities caused by crystallizing salt out of multi-component brines by EFC have not yet been investigated, however. To these ends, the selenium impurity found in sodium sulphate, produced from the waste brine of a platinum operation, was investigated. It was believed that the similarity between sulphate and selenate ions allowed isomorphous substitution of selenate ions into the sodium sulphate crystals, which was the likely cause of impurity uptake. It was found that the presence of sodium chloride in the industrial brine promotes the uptake of selenium, while ionic strength of the brine and mass deposition rate of sodium sulphate did not have a significant effect on the selenium uptake. Isomorphous substitution is predicted to be the most significant mechanism by which all impurities will be taken up when applying EFC to other industrial waste brines.

Jan 1, 2013

With increasing demand for real-time monitoring of mine parameters, the requirement for appropriate data management in many mining applications is also increasing. This includes atmospheric monitoring in underground coal and metal mines. Although a number of different (real-time) monitoring systems have been installed in underground mines, they all typically share the same systems or sub-systems, where each sub-system may include both custom hardware and / or software components. In addition, monitoring components installed in underground coal mines in the USA should also be intrinsically safe and approved by the US Mine Safety and Health Administration. Real-time analysis adds complexity to the system since data validation and storage should be completed independently of filtering, data reduction operations, or visualization. Real-time processing may include statistical evaluation, trending, cross-correlation, and real-time alarm or warning generation. This paper presents the concept and design of an integrated system under development for atmospheric monitoring in US coal mines.

Jan 1, 2014

By Richard J. Mainiero

The Bureau of Mines conducted research to evaluate the optimum design for a rock-breaking explosive charge that could be fired unconfined in a gassy or dusty coal mine without the danger of igniting the flammable atmosphere. Charges of various shapes, with and without cavities, were tested in a gallery using 3-by 3-by l-ft concrete blocks as simulated boulders. For these tests the optimum charge, in terms of cost, weight, and convenience in handling, consisted of a flat l-1/2-lb charge of permissible explosive seven-eighths of an inch thick and 7 in in diameter encased in a l/2-in thick layer of fine salt (NaCI). This work demonstrated that it should be possible to produce an inexpensive explosive rock-breaker charge that would be safe to use in underground coal mines.

Jan 1, 1982

By J. D. Noll, S. E. Mischler

Measurement and sampling of diesel particulate matter in mine air presents a challenge due to the complexity of the diesel aerosol. The results of a series of tests carried out by the National Institute for Occupation Safety and Health, Pittsburgh Research Laboratory, in an underground mine were used to evaluate several measurement methods that are currently used to characterize particulate matter emitted by diesel-powered equipment. This paper presents an overview of these techniques and examples of the results along with a discussion of the advantages and information gained by each technique. The measurement methods discussed include particle size measurements using a scanning mobility particle sizer, total particulate matter measurements using a tapered elemental oscillating microbalance, a size selective sampling method for workplace and personal exposure assessment and a size-selective high volume sampling method for carbon analysis.

By P. A. Rey

Water recycle is an important part of the coal preparation process. This study was directed toward: (1) a survey of current practice and an evaluation of both the solid and liquid components of blackwater, (2) an experimental study of blackwater flocculation, and (3) a fundamental analysis of the flocculation process. The solids contained in the blackwater discharge to the fine refuse thickener of a coal preparation plant were found to contain, on average, 56% coal and 44% mineral matter. The mineral matter was largely illitic clay, while the water phase contained relatively large amounts of S04 and Ca++. Detailed studies were made of both natural and synthetic flocculants and the influence of polymer type and pH on the settling rate, turbidity of the supernatent liquid and sludge volume of the settled solids. More tundamental studies were made that clearly indicate the need for controlled mixing of polymer into the suspension to be flocculated, and the need to evaluate, more closely, the structure of the flocs formed during the process. Research recommendations are given.

Jan 1, 1983

By Stephen A. Gasiorowski, Frank J. Hrach, James D. Bittner

Separation Technologies, LLC (ST) has developed a processing system based on triboelectric charging and electrostatic separation that provides the mineral processing industry a means to beneficiate fine materials with an entirely dry technology. The environmentally friendly process can eliminate wet processing and required drying of the final material. The process requires little if any pre-treatment of the material other than grinding and operates at high capacity - up to 40 tonnes per hour by a compact machine. Energy consumption is low, approximately 1 kWh/tonne of material processed. Since the only potential emission of the process is dust, permitting is typically relatively easy. In contrast to the other available electrostatic separation processes that are typically limited to particles greater than 75 µm in size, the ST belt separator is ideally suited for separation of very fine (<1 µm) to moderately coarse (500 µm) materials with very high throughputs. The triboelectric particle charging is effective for a wide range of materials and only requires particle-particle contact. The small gap, high electric field, counter-current flow, vigorous particle-particle agitation and self-cleaning action of the belt on the electrodes are the critical features of the ST separator. The high efficiency multi-stage separation through charging / recharging and internal recycle results in far superior separations and is effective on fine materials that cannot be separated at all by the conventional electrostatic techniques. Since 1995, this triboelectric process has been extensively used for the beneficiation of coal fly ash with eighteen separators in place and over 100 machine-years of operation at locations in North America and Europe. The technology has been also successfully applied to the beneficiation of a variety of minerals including calcium carbonates, talc, and potash.

Jan 1, 2012

By T. A. E. Breen

A new high intensity grinding technology has been developed and is now being commercialized by Hicom International of Australia. This has led to the development and manufacture of Hicom 120 grinding mills which are now being sold internationally for a range of mining industry applications. The first commercial process application has been for the diamond sector, where the ability of the mill to remove host kimberlite rock by attritioning, with no damage to the thereby liberated diamonds, is seen to be a most beneficial attribute. There are, however, many other mineral industry applications for this mill. The design of the Hicom mill is unique. Based on a high speed centrifugal motion of the grinding chamber, very high power intensity is delivered to the grinding process. Most significantly, a high acceleration field, 50 times stronger than gravity is produced, creating very high power input per unit of mill volume, and exceptionally fast particle breakage rates, typically 50 - 100 times greater than those in conventional tumbling mills. A mill developing such forces has significant implications to comminution technology and practice.

Jan 1, 1999