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By O. M. Arafat, J. A. Finch

Since its development, the functional performance equation for ball milling (McIvor, 1988) has facilitated a new understanding of industrial circuit cause and effect relationships, leading to significant strides in operational performance. Success stories of this approach to plant circuit performance improvement are now too numerous to list. Finch and McIvor (circa 1986) also discovered that the functional performance mill grinding rate at the size of interest was the same cumulative grinding rate that is calculated from mill feed and discharge size distributions using a first-order rate equation. By calculating these cumulative grinding rates for all screen sizes, a complete ball mill model is generated (as used by Finch and Ramirez, 1981). Others in industry, Hinde and Kalala (2009), for example, have noted the same. Lacking the complexity needed to maintain their interest, most researchers have ignored this model, broadly opting instead for Epstein’s (1948) characterization of grinding as a chemical reaction, combining selection rate and breakage size distribution functions. The much simpler ball mill model has previously been incorporated into a proprietary circuit modeling program (McIvor, 2005) and used for plant improvement work (for example, see McIvor and Finch, 2007, and McIvor, 2014). Now, by combining this business-friendly ball mill model with optimization criteria from functional performance analysis, a circuit modeling system (including the needed supplementary steps to assure successful plant implementation of circuit design changes) is at the disposal of every plant metallurgist, grinding equipment/ material provider and circuit designer.

Jan 11, 2017

By M. T. Webster

Views about the proper aim of public policy are, of course, matters of perspective and debate. Regardless of perspective, one would assume some consensus around the view that public policy ought to encourage mine operators to seek independent and critical assessments of worker safety and health at their operations through voluntary auditing. However, a review of the law on this topic shows that there is little to no manifestation of such a policy. Indeed, the balance of this paper, with a couple of exceptions, is devoted to the existing legal pitfalls that should be considered before a safety and health audit is conducted at a mine. While attorneys, particularly litigators like the author, might tend to focus on the potential problems that could arise from any given situation, the fact that most of this paper is devoted to potential legal concerns associated with auditing is a realistic reflection of the current state of the law. Specifically, this paper addresses the interplay between voluntary safety and health audits conducted at mines regulated by the Mine Safety and Health Administration (MSHA), and the administrative and civil legal issues related to such audits. The paper first provides an explanation of how and by whom an audit is conducted. The paper also addresses whether voluntary safety and health audits may be considered privileged and kept confidential in administrative and civil proceedings. Finally, selected legal issues related to such audits that could arise in administrative and civil litigation are discussed.1

Jan 1, 2012

By W. L. Hollinshead, Alwin Poltinger

GENERAL Tunneling by hand digging is as old as the history of humans. Mechanized tunneling did not begin to replace manual methods until around the beginning of the 19th century(Brunel patent, 1818). It brought with it a higher degree of safety for the workers and a much higher rate of boring. But for any kind of tunneling, an accurate and feasible method of survey must be accomplished during mining. That means, that for each tunnel project the most efficient survey method must be devised. The method to be defined depends on the spatial curve, diameter, speed of tunneling method, purpose of tunnel and contractual accuracy. The final accuracy of a finished tunnel is heavily dependent upon three critical elements: 1. Quality of the above ground survey 2. Tunnel traverse and directional transfer from above ground 3. Guidance for the mining job. Combining The Survey And The Guidance System Since the guidance system (GS) is one of the critical factors in the determination of the tunnel final accuracy, it is necessary to analyze how the directional control and tunnel traverse measurements can be effectively integrated into a GS. Any guidance system, whether manual or high technology, must continually detect and compensate for movement of its theodoliteor laser station standpoint. Movement beyond a preset allowable amount must generate a warning or error message to the user. Additionally, optical refraction can interfere with the results. Refraction will have an effect on any kind of optical GS. Therefore, careful selection of target and standpoint locations can minimize, but not completely eliminate, the influence of refraction. Some GS technologies, such as Gyro-based systems, are immune to the effects of refraction, but have other, methodical errors which will be described later in this paper. GUIDANCE Overview Why is a guidance system necessary? A GS, whether manual or automatic, compares the design direction and slope of a tunnel with the current position of the mining

Jan 1, 1997

By G. F. Revey

All underground operations have limiting factors that influence overall profitability. Hoisting, hauling, available headings, labor, milling capacity and other factors limit how much material can be removed from an underground mine. Consequently, when mines use limited labor to handle the additional rock from overbreak and to perform extra ground support tasks, productive activity is replaced by non-productive work. Mining economics are further penalized when overbreak causes dilution of ore grades. This paper reviews organizational systems that mines have used to create environments which foster the creation of successful overbreak control programs. Actual case histories document the various quality improvement techniques, worker incentives, and practical project management systems used by these mines. A brief review of controlled blasting technology sources and overbreak measurement tools is also included.

Jan 1, 1997

By M. Sagheer

An 8.5-km (5-mile) conveyor has gone into operation in western Turkey to eco¬nomically transport crushed lignite from the mine area to a power plant. This conveyor has replaced trucks as the principal mode of transporting the lignite. One principal element of Turkish govern¬ment policy is the country's commitment to increase electricity supplies for mining and other industries. Lignite is an important source of electric power supply in Turkey. Production was about 48 Mt (53 million st) in 1987, amounting to more than 20% of the total power supply in Turkey. In the western Anatolia supply network, it plays a major role for power generation. Deposits are located in the Soma region of western Turkey. The lignite is of low quality, deposits are scattered, and the terrain is dif¬ficult and hilly. These conditions demand an economical and technically feasible method of transporting the raw material from mining areas to the central thermal power plant. The Soma power plant is located about 120 km (75 miles) northeast of Izmir, near the coast of Aegean Sea. An overland conveyor of a unique design has gone into commercial operation at the Soma power plant facilities of the Turkish state electricity organization, Türkiye El¬ektrik Kurumu (TEK). The conveyor re¬places truck transport to ensure economical use of the lignite deposits. Computer-aided design (CAD) added more precision, qual¬ity, and flexibility of engineering in design activities. It also helped quick realization of the project that was executed in cooperation with the German company Krupp Industri¬etechnik and the Turkish firm Gama Endüstri AS. Unique features The conveyor includes several major features rarely combined in a single flight: Overland long distance conveyor. • Horizontal curves. -Steep vertical concave and convex curves to match the difficult terrain. Down-hill conveying. Frequency converter drives with vari¬ able belt speed. Generating operation mode to backfeed the energy to the network. Layout The 8.5 km (5 mile) long conveyor takes the -200 mm (-8 in.) lignite from the primary crushing plant located near the mine to the central, final crushing plant located in the stockyard area near the power station. The drive and belt tensioning assemblies are situated near the tail end of the flight. The high voltage switchgear is housed in a room in the primary crushing plant build¬ing upstream from the conveyor flight. The frequency converters are installed in the low voltage switchgear room located below the control room within the primary crushing plant building. Conveyor design The conveyor includes two 4 km (13,120 ft) radius horizontal curves, one left-hand and the other right-hand. The minimum radii

Jan 1, 1989

By Nasser Madani, SULTAN ABULKHAIR

The abstract of the paper discusses the challenge of quantifying iron content in a coal deposit in Kazakhstan. The iron dataset is limited, coming from only three drill holes and some stope samples, while a large amount of geological information is available from legacy drill hole data. The paper proposes a workflow using multiple-point geostatistics to model geological domains and two-point geostatistics to model iron content within these domains. The results show that the direct sampling (DeeSse) algorithm effectively reproduces the complex seam layers, and sequential Gaussian simulation models the iron within each domain.

Mar 30, 2022

By H. D. Van Veldhuizen

The Multilateral Investment Guarantee Agency(MIGA) is part of the World Bank Group, and has as its mission the facilitation of foreign direct investment by providing political risk insurance (guarantees) to foreign investors and lenders. As a development institution, MIGA is required to ensure that the projects that it insures will bring development benefits to the host country. Demonstration of this includes review and analysis of the environmental and social soundness of a prospective investment. Environmental guidelines and policies developed by the World Bank Group are important components both in analyzing the environmental and social soundness of a prospective investment and in risk management. MIGA has recently formalized and adopted environmental assessment and disclosure policies. The approach taken by MIGA to environmental review of investments and implementation of these policies is described in this paper.

Jan 1, 2000

By A. L. Anderson, J. T. Rybock

Lime, soda ash and similar precipitants have been the industry standard for treatment of acid rock drainage (ARD) because of their proven ability and low per-gallon operational cost. However, these methods carry serious environmental drawbacks and high life-cycle costs. KEECO’s Silica Micro Encapsulation (SME) technology has all the positive characteristics of conventional ARD-treatment systems but none of the drawbacks. SME achieves highly effective treatment in a single step, provides options for ARD prevention and recovery of metals, requires lower capital expenditures, generates smaller volumes of higher-density sludge, consistently passes leach tests, and eliminates long-term liabilities associated with potential metal remobilization and hazardous waste landfilling.

Jan 1, 2000

"Editor’s note: Each year, Mining Engineering features an industrial minerals review. Several people put in a fair amount of time in developing the material for this issue, all the while doing their own jobs. Thank you to the industrial minerals annual review editor, to the Industrial Minerals and Aggregates Division technical committee chair and vice chairs, and to the authors of the individual commodity profiles.Jim Norman, member SME, of Tetra Tech, is the industrial minerals annual review editor.Vishal Gupta, member SME, of EP Minerals LLC, is chair of the Industrial Minerals &Aggregates Division’s Technical Committee.The technical committee vice chairs include:• Vishal Gupta, member SME, of EP Minerals LLC, Agricultural Materials.• Joe Garska, member SME, of Imerys, ceramics and refractory materials.• Stanley Krukowski, member SME, of the Oklahoma Geological Survey, chemical raw materials.• Russell Winn, member SME, of R.E. Janes Gravel Co., chemical raw materials.• Justin Zdunczyk, member SME, of Pike Industries, construction aggregates.• Jerry Gauntt, member SME, of Golder Associates, fillers and pigments.• Ebrhaim K. Tarshizi, member SME, of the Michigan Tech, sorbents, filters and process aids.• Daniel T. Eyde, member SME, of St. Cloud Mining, specialty minerals.Their help makes possible this July industrial minerals issue. On behalf of ME readers, the editors thank them.Virta, R.L. U.S. Geological Survey, National Minerals Information CenterFour companies - H.C. Spinks Clay Co., Inc., Imerys, Old Hickory Clay Co., and Unimin Corp. - mined ball clay in four states in 2013. On the basis of preliminary data, production was 1 Mt (1.1 million st) with an estimated value of $47 million. Production increased by 3 percent in tonnage from 973 kt (1.1 million st) with a value of $45.1 million in 2012. Tennessee was the leading producer state accounting for 64 percent of domestic production, followed by Texas, Mississippi and Kentucky. About 67 percent of total ball clay production was airfloat, 22 percent was crude or shredded and 11 percent was water-slurried.ConsumptionIn 2013, domestic ball clay producers sold clays to the following markets: ceramic floor and wall tile (44 percent); exports (21 percent); sanitaryware (18 percent); miscellaneous ceramics (9 percent); fillers, extenders, and binders, and unspecified uses (4 percent each), based on 2012 end use patterns and current markets. Other markets accounted for less than 1 percent of the remaining ball clay sales or use. Sales reported for the manufacture of fiberglass or most filler, extender, and binder applications were likely to have been mainly kaolin mined or purchased by the ball clay producers.PricesThe average value of domestically produced ball clay was approximately $47/t ($43/st) in 2013 compared with $46/t ($42/st) in 2012, on the basis of a preliminary survey of domestic ball clay producers. The unit values of exported and imported ball clay were $126/t ($114/ st) and $373/t ($338/st), respectively, in 2013, compared with $62/t ($56/st) and $314/t ($285/st), respectively, in 2012. Unit values for most large export shipments increased in 2013, and a larger number of low-tonnage, high-value export shipments were shipped in 2013 than in 2012, resulting in a doubling of the average export value. Two low-tonnage, high-value shipments in 2013 accounted for the increased value of imports."

Jan 1, 2014

By E. Hughes, D. Akers, D. Stopek

The Upgraded Coal Interest Group (UCIG), focuses on clean, low-cost options for coal-based power generation via pre-combustion, co-firing and reburn options. Its mission is to preserve and expand the economic use of coal for energy. By reducing the fuel costs and environmental impacts of coal-fired power generation, existing units become more cost effective and thus new units utilizing advanced combustion technologies are more likely to be coal-fired. Two great forces are reshaping the power generation industry, the Clean Air Act Amendment and deregulation of generation. The Clean Air Act Amendment is forcing change by making it necessary for power producers to plan for reducing emissions of sulfur and nitrogen oxides and possibly trace elements. At the same time, deregulation of generation is forcing utilities to focus their attention closely on the short term impact of any change on cost of power. Fuel is a utility's largest cost element; maximum fuel flexibility will be a utility's best weapon in an environment of rapid change. In a regulated environment, a utility was limited in how involved he might get into fuel supply, in a purely deregulated environment he need only be guided by the impact on the bottom line. It is clear that these two forces will promote a close look at factors such as coal upgrading which can have an impact on the availability of low sulfur coal or emission of NOX and trace elements.

Jan 1, 2000

By James E. Lawver

At the present time, the Florida phosphate industry is experiencing one of the worst marked slumps in its one hundred year history. Recent agriculture over-production has caused low grain prices such that the net income of U.S. farmers is expected to drop to its lowest level since the 1932 depression. The farmers' low income, along with high interest rates that preclude them from borrowing to purchase fertilizer, make the immediate U.S. phosphate market outlook bleek at best. The export outlook is also pessimistic due to world recession and the U.S. dollar's high exchange rate. In June, 26% of the phosphate industry's workers were laid off for an indefinite period of time. Despite the immediate painful slump, the long-term outlook for the industry looks good. Florida has enormous reserves and will continue to produce a third of the world's phosphate supply simply by making changes in the present system of mining, beneficiation, waste disposal and land reclamation.

Jan 1, 1983

By Yang Song, Li Shaokang, Wang Zhiqiang, Wang Jinjun, Li Guofeng, Su Meixuan

CaCO3, as a component widely existing in natural minerals, is a common impurity. In recent years, triboelectric separation has been applied to the separation of minerals containing CaCO3. However, the CaCO3’ s tribocharging mechanism is still unclear and the charging effect of CaCO3 is not obvious. In order to study the effect of triboelectric charging of CaCO3 particles under different conditions, according to the single particle frictional collision charge-mass ratio formula derived from the condenser model, an experimental platform for particle tribocharging was built in this paper. Then, the formula of charge-to-mass ratio (Q/m) was derived based on the analysis of the particle force. Particle image velocimetry (PIV) was used to record particle motion trajectories to calculate the Q/m of one particle by this formula. In the experiment, the airflow velocity, tribocharge material, and moving distance of the particles were varied to investigate the variation of the particle charge-mass ratio results. The results show that CaCO3 was negatively charged when tribocharging with mental. The particle’s Q/m is positively correlated with the airspeed. When the metal is triboelectrically charged with the insulator, the metal with a smaller work function leads to the insulator particle with a larger Q/m. As the moving distance of the particles increases beyond 230 mm, the particle charge ratio decreases. The particle charge-mass ratio is consistent with the trend of the charge-mass ratio deduced from the capacitance model.

Jun 3, 2023

Talk some about your background. Mining, particularly coal, runs in the family. I come from a mining family, one generation re-moved. Both of my grandfathers worked in the coal mines. My mother?s father had worked as a coal miner in the South Hills area of Pittsburgh after coming to America from Croatia. My father?s father (who died of black lung long before I was born) had been born in America and worked as a mine foreman and superintendent in mines just outside the Pittsburgh area. My father often talked about when, as a child, he accompanied his father underground on Sundays to check the mine pumps. While I never expected to go into mining, I often read some of my grandfather?s books on mining technology that my father had kept. I started college at Penn State and drifted into mining engineering as my third declared major. I was finally realizing the importance of a career choice. I?ve never regretted that decision. One of my children, Mark, has followed me into mining engineering, much to my surprise and pride. Evidently, he had been listening to the many conversations I had with friends and colleagues in the industry and never considered any other career path. He has since married another mining engineer, Kray Davis Luxbacher, so we truly have a mining family and can talk mining when we get together. My other children are in more mundane lines of work and rapidly tire of the mining discussions. I?ve worked for operating companies: Pittsburgh Coal Co. (then a division of Consolidation Coal Co., and a company I believe both of my grandfathers had worked for), Island Creek Coal Co., and a research organization: Occidental Research Corp. I am now with Glenn Springs Holdings Inc., dealing with legacy issues (primarily environmental) related to Occidental?s previous mining operations (coal and minerals). As such, I have a broad view of the industry and the critical changes that are shaping our industry.

Jan 1, 2008

By G. J. Olson

This paper describes the microbiology basics underlying heap and tank biooxidation of metal sulfide ores and concentrates. The primary organisms are identified and described along with the reactions they catalyze and their growth requirements. Also described is the interaction between ore leaching bacteria and the leaching environment in terms of solution chemistry, temperature, and mineral precipitation. Specific factors and agents that stimulate or inhibit growth and activity of ore bioleaching will be identified. Some of these factors are organism-specific and others are generic for microorganisms that grow under acidic conditions. Current knowledge of the limits of bioleaching in terms of dissolved ions in leach solutions, pH, and temperature will be summarized.

Jan 1, 2003

By L. Thompsen

High-pressure grinding rolls (HPGR) offer capacity increases, savings in operating costs and metallurgical advantages. The first installation of the Polycom HPGR in a copper ore treatment plant occurred in July 1995 at Cyprus Sierrita’s mining complex near Green Valley, AZ (Fig. 1). Until that time, the benefits this technology offers for copper and gold ore were only demonstrated on testwork. In other industries, such as diamonds, HPGR have proven to be reliable in industrial-scale plants and have set a new standard for this kind of ore treatment plant. HPGR are also successfully used for the comminution of coal, blast furnace slag and in cement and pelletizing plants. The installation at the Cyprus Sierrita Mine should prove the economical benefits in commerical-scale copper mining, confirming the results of comprehensive testwork(Fig. 2).

Jan 1, 1996

By M. S. Moats

In the 1990?s, Técnicas Reunidas developed the Modified ZINCEX® Process to recover zinc from ores and secondary materials. The heart of this process was the use of solvent extraction to produce purified zinc electrolyte instead of traditional zinc dust cementation. This development was commercialized by Reunion Mining and Anglo American for primary ore at the Skorpion mine in Namibia with the first SHG zinc produced in May 2003. Horsehead Corporation through Horsehead Metal Products, Inc., its wholly owned subsidiary, is presently commercializing the MZP for the treatment of Waelz oxide. This paper will review open source information about the lessons learned and process modifications that have occurred at Skorpion over the past decade. It will also provide an update on Horsehead?s facility being constructed in Rutherford County, North Carolina.

Feb 23, 2014

By R. P. Gardner

Results of work on the development of a phenomenological model for the continuous flotation process using short-lived radioactive tracer techniques for the determination of model parameters is reported. A model that incorporates a flotation first-order rate constant and a residence time distribution based on the cross flow finite state (CFFS) model has been derived and investigated. The short-lived radioactive tracer techniques necessary to extract the model parameters have been developed as have the necessary nonlinear search methods. The conditions under which all the model parameters can be extracted from a single radiotracer experiment are detailed and illustrated. A microcomputer-based unique data logging system has been designed, assembled, and implemented for collecting the necessary transient radiotracer data. Results are reported for a continuous laboratory flotation system for the two systems mica ore and coal.

Jan 1, 1985

By Osvaldo A. Bascur

Intelligent systems (IS) technologies have received much attention in a wide range of process engineering applications including process operations. With the revolutionary progress in information and computer technologies applying the latest technologies in metallurgical complexes has become a serious challenge to both management and technical teams. Objects and components are changing the way everyone relates to their computer and networks. Goals of real time performance monitoring includes maximizing the profitability by maximizing production, improving efficiency, attending product quality, costs, maintenance, environmental and safety regulations. Designers must consider the greatly expanded desktop computing, Microsoft object technology, Internet and how to build these systems. This paper discusses some opportunities and challenges using objects, components in designing applications and integrating intelligent systems tools. Two examples using performance equations and IS technologies applied to mineral processing are presented.

Jan 1, 1997

By R. W. Smith, D. L. Taylor, K. A. Altman

The importance of metallurgical information in reaching appropriate decisions during the development of mining projects is demonstrated. A financial analysis is calculated using a simulation that includes random number generators. The results are compared to the results of a traditional sensitivity analysis. The traditional analysis is shown to have the potential to overestimate the value of mining projects. The type of statistical distribution selected for the random number generator affects the results significantly. The statistical method of analysis provides insight into the amount of metallurgical testing to be completed and verification of how representative the samples are.

Jan 1, 2000

By Z. Hyder

Simulation and modeling is powerful tool to analyze real time data and can be used to analyze different scenarios using appropriate software that may reduce need of infield data collection process and can predict reasonably accurate results. In this paper the real time data of a mine is used to simulate and model the stresses on the pillars and evaluate the pillar strength and safety factor. The material properties assigned to the model are obtained by testing the representative samples taken from the selected locations of the mine. The mine under investigation has 50 ft wide pillars and 50 ft wide rooms under an average overburden of 650 feet. The effect of reduced pillar dimensions and increased roof span on overall stability of mine and extraction ratio is analyzed using LaModel [1] software. The predicted results of the reducing pillar size are analyzed to compares the current mining practices with the optimized room and pillar size to get better extraction ratio without comprising the safety.

Jan 1, 2011