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By D. W. Ashman

Today the electrolytic zinc industry is facing unprecedented environmental pressure and low metal prices. Zinc plants have to decide how they will dispose of iron residues in an environmentally friendly way without major capital expenditures. Only low-cost producers will survive, so companies must continuously improve to stay competitive. Therefore, the challenge of the process engineer is to find innovative solutions to the industry's problems. This paper reviews the status of electrolytic zinc processing and provides some insight into how the industry will respond to the pressures facing it

Jan 1, 1993

By D. W. Fuerstenau, G. S. Sudhir, P. C. Kapur

Quartz-limestone feed mixtures were ground in a laboratory-size, choke-fed, high- pressure roll mill. As compared to individually ground minerals, the harder component (quartz) in the product mixture is coarser, and the softer component (limestone) is finer. An energy split index is introduced for quantifying the disproportionate split of the mill energy between the feed constituents. This index is incorporated into a grinding kinetic model for simulation of the product size distributions of the mineral components as a function of energy input to the mill. The self-similar character of the size distributions is analyzed and an energy-size reduction relationship for the roll mill is highlighted.

Jan 1, 1992

By Thomas Fenner

Surface and underground mining operations are often hindered by unknown tunnels and slopes and the precise locations of adjacent workings. Mine safety and planning are adversely affected especially in previously undermined areas where historical records are incomplete or nonexistent. The results of several ground penetrating radar (GPR) studies for the detection of known mine tunnels in underground coal, salt and gold mines are presented. A case study to locate unknown, abandoned mine workings at a surface gold mine successfully located all workings to a depth of 11 m (36 ft).

Jan 1, 1996

The application of Kirchoff's laws to two adjoining mine ventilation network meshes containing fans results in the construction of two general quadratic equations. These equations may be solved to give the resultant airflows and hence fan duties within the system for given network parameters and fan characteristics. This technique has a wide application for calculating the duties of fans in various combinations within a mine ventilation system. Recent difficulties in economically maintaining environ- mentally safe conditions in underground working areas distant from main ventilation fans has led to increasing interest in the use of controlled partial recirculation of ventilation. This paper develops a recirculation model which can be solved directly using mathematical techniques obviating the need for iterative techniques such as the Hardy-Cross method. The advantage of a direct mathematical analysis is that mathematical algorithms may be constructed to completely describe the ventilation system under a wide range of operating conditions. This technique is applied to controlled partial recirculation ventilation systems to demonstrate its advantages for mine ventilation planning.

Jan 1, 1989

By Norbert Patzelt, Johann Knecht, Wolfgang Baum

High pressure roll grinding (HPGR) is a mature but still expanding comminution technology. In the metals mining industry, HPGR is slowly gaining acceptance as a cost-efficient, high-throughput alternative for plant optimization. The increasing need to treat ores with progressively lower grades, complex mineralogies, refractory metal occurrence and variable rock types requires an energy-efficient comminution technology that reduces metallurgical problems inherent in conventional crushing and grinding, while stabilizing leach and flotation circuits and increasing metals extraction. This paper will summarize our latest HPGR pilot test results for gold and copper projects in the United States and South America and their confirmation through the first HPGR operation in copper mining. This paper will also stress the use of the high pressure grinding roll as a metallurgical tool. The application of HPGR for the treatment of heap leach SX-EW ores, semi-refractory gold ores, waste rock material and concentrator feeds will be illustrated.

Jan 1, 1998

By Steven J. Schatzel

A study was made of frictional ignitions in the underground coal mining industry from 1980 to 1992. The population of frictional ignitions was correlated to a variety of potential contributing factors including the mined coalbed, geographic location, mine production, methane gas emissions, and the type of mining equipment in use. The number of frictional ignitions reported in 1991 and 1992 surpassed the annual totals in all previous years included in the study. Most frictional ignitions occur during cutting operations at a coal face by a continuous miner. The average coal production of mines experiencing frictional ignitions is greater than the average of all underground coal mines throughout the survey period. Methane drainage may have produced a drop in the ratio of gas emissions to coal production (E/P) in mines experiencing frictional ignitions.

Jan 1, 1995

By L. Henry Smith, David C. Arthur

The Williams Mine is Canada's largest gold producer, with annual production of 14,000 Kg (450,000 ounces) from 2,300,000 tonnes of ore. Highly mechanized and automated underground mining practices are employed in order to achieve and maintain high levels of productivity and minimize costs. The Mine Ventilation System is modified to include a new Vent Raise and Variable Pitch Vane-Axial Fan. This addition allows several fan installations underground to be decommissioned. A substantial net savings in installed horse power is achieved. Heating costs associated with underground ventilation air are a significant portion of mine operating costs. Air heating costs are substantially reduced by recovering heat from upcast exhaust air, mine water and compressor cooling circuits. This waste heat is used to supplement propane fired air heating systems for underground ventilation air. An additional benefit is the availability of a heat sink for summer cooling of the compressors. System design, energy savings data and payback calculations are presented.

Jan 1, 1997

By K. Rajamani, L. B. Hales

Much of the process control effort in the mineral industry uses proportional-integral-derivative controllers that require periodic retuning. Retuning hundreds of controllers typically employed in a single plant is a formidable task for the control engineer. Adaptive controllers offer an alternative to this problem, since they are designed to tune themselves. Four schemes of adaptive control-gain scheduling, model reference adaptive control, self-tuning regulator, and optimal adaptive controllers-are discussed with process examples. The control of a ball mill circuit with a multivariable self-tuning regulator is illustrated. This controller encompasses the advantages of the other three controllers and is applicable for a wide range of process variability.

Jan 1, 1988

By P. C. Thakur

In gassy coal mines, some methane drainage is essential for mine safety, but the ratio of total methane drained to total methane produced by the mine can vary from 10 to 70 percent. The volume of methane not captured is diluted by ventilation air and vented to the atmosphere. Since captured methane can be processed and sold, it makes sense to maximize methane drainage from coal mines. This paper describes ventilation and methane drainage schemes to achieve these goals.

Jan 1, 2003

By R. Hogg, R. H. Weiland, P. Bunnaul

The dewatering of flocculated clay suspensions by compression in a centrifugal field was investigated. The results were analyzed with respect to the direct applicability of centrifugal dewatering (as in solid-bowl centrifuges) and indirect applications to gravity sedimentation systems. An important objective of the study was to evaluate the self-weight effect using centrifugal forces to simulate consolidation of deep sediments. Experiments were conducted in which the sediment mass and initial structure were maintained constant while the effective sediment weight was varied by centrifuging at different speeds. The relationship between the limiting sediment density and the applied consolidation stress was found to be the same for both gravity and centrifugal consolidation, indicating that small-scale laboratory tests can be used to predict consolidation in deep beds. The effects of the initial structure were also studied using controlled variations in flocculation conditions. The results imply that, for the flocculated suspensions studied, the longterm consolidation behavior is relatively insensitive to the actual extent of flocculation.

Jan 1, 1995

By Debra W. Struhsacker

Waste characterization plays an essential role in proactive project permitting, design, reclamation, and remediation strategies. Traditional TCLP tests and chemical analyses used in many studies do not provide adequate data to predict the long-term geochemical behavior of the mineralized system. Mineralogic and geologic data are needed to assess the homogeneity of the system, the potential for acid generation or metals leachability, and the amenability of the material to traditional and unconventional closure and reclamation measures. The characterization efforts done from the evaluation stages through final closure can aid in better cost evaluations, more representative sampling, more effective neutralization and waste containment measures, and optimized reclamation designs.

Jan 1, 1995

By S. C. Suboleski, J. W. Oberholzer

This paper describes research being undertaken by the Chamber of Mines Research Organization (COMRO) to assist the continuous miner operator and section foreman in the performance of their jobs. The project will initially provide visual assistance to the miner operator, and later it will semiautomate the mining (cutting) process. Using a technique known as "RF tagging," the project will also provide the section foreman with real-time or near-real-time information about the performance of the loading and hauling units. This data will allow the section foreman to quickly detect problems and take action where appropriate. The project is based upon the application of currently available technology, and in-mine testing results from the first phase are now available.

Jan 1, 1994

By André Vien, Robert Edwards, Rob Perry

A metallurgical control application can only succeed if the system's lowest common denominator, its instrumentation and regulatory control is implemented and maintained correctly. This paper describes the basics of regulatory control implementation including some practical guidelines for instrumentation installation, operator interface design, loop tuning, and continuous loop performance analysis. Tuning and analysis techniques are illustrated by step-by-step industrial examples. A small investment in basic control pays dividends in better overall plant performance and provides a solid foundation for advanced control efforts such as expert systems.

Jan 1, 2000

By John A. Herbst

Mineral processors have evolved from "handbook-based" decision makers to "model-based" decision makers. With this evolution have come significant improvements through increasing productivity, decreasing capital and operating costs and increasing product quality. This paper traces the development of model-based decision-making technology over the last 40 years and documents the benefits resulting from systems optimization using these tools. Some speculation is ventured concerning the future of model-based decision-making tools and their use in the field of mineral processing.

Jan 1, 2000

By Irwin R. Higgins, Richard S. Dennis

Acid recovery employs ion exchange resin as an adsorption media for the separation of inorganic acids from mixtures of acids and their metallic salts. This technology has been used to treat spent pickling and plating liquors to recover acid for reuse in the bath and to reduce waste acid neutralization costs. Acid recovery can also be used for electrolyte treatment to facilitate valuable metal recovery and to improve product quality. Conventional fixed bed ion exchange (I-X) systems are impractical for acid recovery because of complex control design and large resin inventories needed to process strong acid concentrations. TETRA'S CCIX™ continuous I-X contactor has been used successfully in a simple, continuous operating mode to separate acid from its salt. Efficient separation is enhanced by refluxing which allows acid to be produced as a salt-free product at nearly its original strength. Continuous treatment also recovers heat to the bath and improves metal quality due to consistent acid quality.

Jan 1, 1995

By O. A. Bascur

The problem of setting the proper control objectives and/or having several objectives to be met in the implementation of grinding control strategies can be resolved. The design and implementation of a distributed control system for safe operation of a grinding circuit while maximizing profit is presented. An optimal recovery through- put target for a desired grind is accomplished by advanced control strategies at the DCS level. A mill load constraint control technique provides stable operation with a substantial increase in throughput, while the desired grind index is maintained by an inferential grind control technique without using a particle size analyzer. The integration of crushing/grinding and flotation in the overall design was the key to the success of the project. This synergistic effect was obtained by implementing a computer plant management system in the concentrator. The overall/philosophy was to keep the implementation simple while using new technology creatively.

Jan 1, 1991

By E. K. H. Goh

A reliability-based engineering design approach for the effective design of reshaped spoil dumps was developed with the aim of obtaining structurally reliable spoil dumps at optimum reshaping costs. The aim was also to satisfy environmental erosion standards and community expectations. This approach encompasses the linking up of three major components: erosion appraisal of spoil dump designs, reliability-based engineering design of spoil dumps and costing of spoil dump reshaping practices. This paper addresses the application of the reliability-based engineering- design approach to the assessment of spoil dump designs for erosion control. Included are various types of erosion prediction models and reliability-based engineering-design analytical techniques. Also included is a case study that demonstrates the application of this approach.

Jan 1, 2000

By A. D. Trujillo, R. D. Wunder

The Chino Mines Co., a Kennecott- Mitsubishi partnership, located in Hurley, NM, recently completed a $405 million modernization of its mine, concentrator, and smelter facilities. The mine/concentrator modernization commenced in 1980, and the smelter modernization began during 1982. Modernization of the mine and concentrator facilities involved increasing the mining rate from 98 kt/d (108,000 stpd) to 152.2 kt/d (167,800 stpd). Ore mining was designed to increase production from 20.2 kt/d (22,300 stpd) to 34 kt/d (37,500 stpd). A new concentrator was con- structed near the mine using semiautogenous grinding. The new smelter uses the INCO flash smelting process, increasing capacity by 40.8 kt/a (45,000 stpy) to 99.8 kt/a (110,000 stpy) of saleable copper.

Jan 1, 1988

By Peter Sullivan, Johan van Heerden

Increased use of continuous miners and roadheaders in the underground coal mining industry in South Africa has led to improved productivity and efficiency of operations. Of major concern, however, is the increased amount of airborne dust generated during mining. Dust is a health hazard in terms of respiratory diseases, can impede productivity and is the major contributor to the potential of underground explosions. The concern of the South African coal mining industry with regard to the underground dust problem has led to the establishment of a Dust Control Section in the Coal Mining Division of COMRO. In the field of dust suppression system evaluation and design, collaborative work has been undertaken by COMRO and FLOSEP. This paper gives a review of the application of Computational Fluid Dynamics (CFD) in evaluating and improving environmental conditions in continuous miner and roadheader sections. A brief history of the development of the CFD model as well as a discussion of a typical application is included.

Jan 1, 1993

By R. E. Weeks, D. J. Millenacker

Utilization of true in situ technologies for mining copper in Arizona will involve a complex environmental permitting process. This process is a key factor in determining the feasibility, costs, and implementing time- frames required for development of this innovative mining method. The regulatory structure in Arizona is presently changing due to enactment of the Environmental Quality Act (EQA) of 1986 and development of new aquifer protection rules and regulations. The US Bureau of Mines has reviewed the comprehensive hydrogeologic characterization, ground water monitoring, mechanical integrity testing, well construction, contingency planning, and other regulatory elements that will serve as mechanisms to assure protection of ground water resources. The purpose of this paper is to inform the domestic copper industry of the significance of the new Arizona regulatory structure and its implications for prospective in situ operators.

Jan 1, 1987