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By R. Reddy Kallu

Prior to July 2007, the only accepted method by MSHA for evaluating the mine seal design and performance is the full-scale explosion tests conducted in the NIOSH?s Lake Lynn Experimental Mine (LLEM) for deeming a seal design suitable for use in U.S. coal mines. Since the new regulations came into effect use of these conventional full-scale explosion tests for evaluating mine seals for the new elevated design standards may not be practicable. Generation of such high explosion pressures in experimental mines is dangerous and may cause permanent damage to the testing facilities. Further, they require significant amount of time, labor and money. Considering these factors, there is a need to develop scientific methods for evaluation of new seal designs and for understanding the dynamic seal response. This paper tries to address the reinforced concrete (RC) seal design using the three dimensional finite element based explicit software ABAQUS. Full-scale explosion test data available from NIOSH?s LLEM on 20 psi reinforced concrete seal is used for validating the numerical models. Further in this paper, based on the results from the validation models, a reinforced concrete seal is designed for 120 psi design standard for typical entry dimensions.

Jan 1, 2009

By Wisecarver D. W.

Today the longwall is getting increasing attention in the United States as an excellent way to mine coal. This is not to say it is the best way in every mine because conditions, capital costs, and markets may well dictate another method. However, operators with working longwalls are often showing preference by phasing out room-and-pillar sections and replacing them with longwall. In the United States there are about 90 longwalls in operating coal mines and the number is increasing. In Europe, 95% of underground coal mining is by longwall compared with only 5% in the United States. In the Western States about 25% of the underground coal mines use longwall mining. There is logic behind the increase in longwalling. Compared to room-and-pillar mining, straight single-pass longwall has important advantages that show up in underground coal mining in any part of the country.

Jan 1, 1978

By Arun Kumar Singh

Wide variation in the nature of the coal seams and the surrounding rock mass of the Indian coalfields and very little information about the associated stress fields were observed to be the major hurdles in the straight forward application of a continuous miner (CM) based mechanised depillaring approach. Due to various techno-economic reasons, a considerably large number of coal seams have been developed and are standing on pillars in India. The development of pillars is done as per Indian coal mines regulation, which results in pillars of relatively large size. In fact, the large size of the pillars provides stiff natural support to control caving of the massive overlying strata. However, the size of these pillars is not conducive for the single pass pillar stripping technique and, therefore, there is a need for pillar splitting before pillar extraction/retreating. Splitting of the pillar may reduce the competency/stiffness of the pillar, which creates a chance of overriding during final extraction below a massive roof stratum. This paper first discusses the existing coal mining scenario in India followed by a brief presentation of geo-technical details of pillar extraction at the three sites where a CM has been introduced for depillaring/pillar retreating in the country to date. Based on past rock mechanics experiences with conventional depillaring faces, stability issues of the pillars, fenders, and stumps in and around the depillaring face are discussed. This may prove to be an important factor in the success of future CM faces. It is recognized that the application of the modern strata movement monitoring techniques may improve operation safety by providing valuable qualitative and quantitative information that can be used to improve the design of modern concepts like roof bolt based breaker line support during pillaring.

Jan 1, 2009

By G. R. Struble, J. R. Marks, A. B. Brown

The center of mining at the Homestake gold mine in Lead, SD, is moving deeper every year. As a result, it has become necessary to upgrade the ventilation system. This paper describes the first phase of a scheduled two-phase upgrade - installation of a 2.2-MW (3000-hp) centrifugal fan. The higher pressure fan is required to route larger airflows into the deeper production levels. Selection of the fan began by specifying the necessary operating point to provide these larger airflows. Special site work had to be done on the surface to accommodate the new fan structure as well as underground to reroute airflows.

Jan 1, 1987

By Ulrich Maidl

The use of EPB shields in the so-called mixed face conditions has set new demands to man and machine in EPB shield tunneling. EPB shields were initially conceived to drive in the pressurized closed mode in soft ground, whereas hard rock TBMs were designed to work in the unpressurized open mode. The present use of EPB shields in hard rock and mixed face conditions requires the combination of both technologies by finding best compromise solutions. This paper deals firstly with the geotechnical and mechanical interactions between machine and ground. Further on the critical points such as tool wear and tool replacement are exposed, together with a proposal of best solutions.

Jan 1, 2003

By Shoung Ouyang, Pinnaduwa H. S. W. Kulatilake

Available literature on the topic is reviewed. Methods are suggested to improve the presently available techniques to perform probabilistic modeling of shear strength parameters for rock discontinuities. The Mohr-Coulomb model and a power law model are used as strength criteria to model shear strength of rock discontinuities. Use of various regression techniques for point estimation of shear strength parameters from direct shear data are discussed. Goodness-of-fit tests for bivariate beta and bivariate normal distributions are developed, and the applicability of them to represent the distribution of shear strength parameters is tested through examples. Both distributions seem to have potential to represent the statistical distribution of strength parameters.

Jan 1, 1986

By James J. Scott

To the safety engineer, mine planning engineer, and mine inspector associated with an underground operation, stability of the underground structure is of the utmost importance. In the United States in 1961 rock falls killed 167 miners, crippled many more, and cost the industry a fortune in lost equipment and production. Much research has been carried on to try to find ways to eliminate this loss of life and property. Within the past few years the interest in rock mechanics as a science has been at its highest point, Private industry, government agencies, universities and foundations have launched studies to gain a better basic understanding of the stability of underground openings.

Jan 1, 1966

By R. G. Swanton

The Bureau of Mines is investigating the leaching of phosphate values from Florida phosphatic clay wastes using sulfuric acid (H2SO4) as the leaching agent and methanol as the solvent. Acid-alcohol leaching studies were done using pure crystalline apatite to investigate potential causes for low extractions. It was found that a barrier layer formed on the surface of the apatite. Initial discovery of the barrier layer was made by analyzing pure apatite samples before and after leaching using an optical microscope. Subsequent Fourier Transform Infrared (FT-IR) analyses proved the coating was calcium sulfate hemihydrate (CaSO4-1/2H2O) and that unreacted apatite existed beneath the coating. Scanning electron microscope (SEM) photographs depict the CaSO4-1/2H2O morphology as long slender crystals adhering to the apatite surface. It was also shown that grinding the leached tailings and leaching again in the H2SO4-methanol system resulted in additional phosphate extraction.

Jan 1, 1991

By John J. Stetler

Introduction Samarco Mineracao S.A. is a Brazilian corporation jointly owned by S.A. Mineracao da Trindade (SAMITRI) and Utah International Inc., with 51% and 49% interests respectively. Headquartered in Belo Horizonte in the state of Minas Gerais, Samarco owns and operates an open-pit mine capable of producing 10 Mt/a (11 million stpy) of iron ore; a concentrator rated at 7 Mt (7.7 million st); a 12-Mt (13.2-million st) capacity pipeline transportation system; a 7 Mt (7.7 million st) filtering and pelletizing plant; and a harbor facility. The mine, concentrator, and initial pipeline pump station are located at Germano, near the town of Mariana, about 300 km (186 mi) north of Rio de Janeiro by air. The pipeline terminal, pellet plant, and harbor are at Point Ubu, 70 km (43 mi) south of Vitória the capital city of Espirito Santo State, and about 300 km (186 mi) by air east of the mine. The 396-km (246-mi) pipeline uses 508-mm (20-in.) pipe except for a 53-km (33-mi) section where 457-mm (18-in.) pipe is used to absorb and control slack flow through increased velocity in one of the areas along the route. Iron Ore Slurry The hematite iron ore concentrate produced at the Germano plant is processed by grinding the average 53% run-of-mine itabirite iron ore to -150 µm (100 mesh) for gangue liberation. It is treated further by cyclones to remove the 10 µm (1250 mesh) slimes to prepare the ore for flotation. During the multistage cationic flotation operation, the silica is reduced to make low silica (-0.9%) concentrate for the direct reduction (DR) iron-making process or to make normal silica (-3.5% +2.5%) concentrate for the blast furnace (BF) iron-making process. The concentrate then is reground further to meet the particle size requirements for pelletizing. The reground hematite concentrate is screened in closed circuit with the regrind mills for close control of the maximum particle size, not to exceed 3.5% +75 µm (200 mesh) for pipeline wear protection. Thickened concentrates at 70% solids are pumped to four 5-kt (5,510-st)(dry) agitated slurry storage tanks that hold the feed before it goes to the first pipeline system pumping station. Pipeline Capacity The pipeline system was designed to transport 12 Mt/a (13.2 million stpy) at 65% solids with an average minimum safe operating velocity of 1.5 m/s (5 fps). The pipeline will transport 5 Mt (5.5 million st) in 1982. The system, therefore, is moving the slurry in 13-kt (14,330-st) batches, dispatched at intervals to move 20 kt/d (22,050 stpd). In operation, the pipeline has exceeded its 93% availability design factor. Pipeline Facilities Pump station No. 1 is located at the Germano minesite 1 km (3,330 ft) above sea level. It has the following principal equipment: • four 5 kt (5,510-st) (dry) agitate slurry storage tanks; • two centrifugal charge pumps (one stand-by); • a 217-m (712-ft) safety loop; • seven mainline positive displacement triplex plunger pumps (189 m3/h, or 832 gpm, at 14.9 MPa, or 2,162 psi, maximum output pressure); • four corrosion-erosion spools; • a control and command center. Operation The output at pump station No. 1, with 66% solids, is pumped 151

Jan 10, 1982

By David M. Shaw, John C. Franklin

A 32-channel warning system for high working level, fan operation, and airlock-doors has been constructed. The working level monitors have a microcomputer for accumulating the pulses, converting to working level, and triggering an alarm at a variable set point and at one working level. The system also detects when underground fans lose power or air doors are open. The system can detect changes in air velocity which indicate surface fan failures or changes in the ventilation system. Using this alarm system, the ventilation engineer will be alerted prior to excessive levels of radon daughters being reached so corrective action can be taken.

Jan 1, 1981

By J. G. Groppo, J. G. Justice, B. K. Parekh

Removal of particulates and/or metal ions from mineral/coal processing waste water is a necessity from the environmental point of view. This paper describes application of a novel AC- electrocoagulation technique to remove the particulates as well as metal ions using AC power. A series of laboratory tests conducted on a stable black water sample obtained from a sub-bitminous coal operation provided a clear supernatant (-10 NTU) from the suspension. The process also shows promise in removal of up to 90 percent of phosphate ions and other metal ions (copper and nickel) from solution. A preliminary economic evaluation of the process will also be included.

Jan 1, 1992

By Richard C. Mayberry

Phosphate reserves have been and still are a controversial subject. Some published estimates are particularly conservative and have caused concern in government and political circles that southeastern phosphates are a dwindling resource. "Ores and ore bodies" are a function of economics that relate to a time/demand factor. The history of phosphates and other mineral commodities is one of mineral deposits (resources) ever becoming ore (reserves) via a long term logic based on price, supply, and demand factors operating through time and improved technology. Projections indicate that southeastern phosphates are sufficient for several centuries of operations at present production rates.

Jan 1, 1981

By J. Schoenbacher

Park City Municipal Corporation (PCMC), long before being recognized as an Olympic venue was known as one of the great American silver mining towns. During a century of active mining, the Park City mining district produced millions of ounces of silver in addition to a substantial amount of mine tailing waste. Since 1985 the City has been remediating these impacts with state and federal oversight. One particular challenging CERCLIS site, that was previously a historic mine tailings pond is known as Prospector Square Development (CERCLIS Listing Silver Creek Tailings UTD98051404). This site has been very challenging due to the metals that impact the shallow ground water that eventually drain into the Silver Creek Watershed. To address the water quality impairment the City and Missouri University of Science and Technology teamed up to investigate the feasibility of constructing a horizontal-flow wetland to treat this pollutant source. This effort began with the building of a pilot cell in June of 2004 and lead to the construction of a full scale horizontal-flow wetland in the fall of 2008. The design of the pilot and full scale biocell was based upon lab-scale research conducted by the Missouri University of Science and Technology. In October of 2008, the Prospector Drain effluent was introduced to the system and to date analytical results reveal that the biocell is treating the Prospector Drain outfall below the Silver Creek Total Maximum Daily Load (TMDL) endpoint goals for zinc .39 mg/L and cadmium .00075 mg/L. The water chemistry of the influent, that originates from the historic silver mine tailings pond, is impaired with zinc and cadmium and has low iron with a pH of roughly 6.5. The construction of this unit encountered many challenges related to constituent relations, regulatory scrutiny, constructability and start-up. Nonetheless, since implementation this unit is considered a success for improving water quality within the Silver Creek Watershed.

Jan 1, 2011

By William D. Cassity, Batric Pesic

Introduction Gold mining on an industrial scale is becoming increasingly dependent on low-grade refractory sulfide ores that contain large amounts of pyrite (FeS2) and arsenopyrite (FeAsS). Gold is usually present as sub-microscopic particles dispersed evenly throughout the sulfide matrix. Without some form of preoxidation, efficient recovery of this finely disseminated gold through cyanide leaching is hampered because the surface of the sulfide particle becomes passivated and impervious to penetration of the cyanide. Traditional methods for recovery of refractory gold from arsenopyrite ores include roasting and autoclave leaching. A modem alternative method is to preoxidize the mineral using the bacterium Thiobacillus ferrooxidans prior to attempting to re- cover the gold through cyanidation. The bioleaching of arsenopyrite ores presents a problem in the mobilization of large quantities of arsenic, present both in the +5 and +3 ionic states. Dissolved arsenic species pose a dual problem: they are -1 to the bioleaching process itself through inhibition of bacterial activity, and they also pose an environmental threat. The arsenate anion (AsO2) has been shown to be more toxic to living organisms, including Thiobacillus ferrooxidans, than the arsenate anion (AsO43) (Collinet and Morin, 1989). There is some disagreement as to the fate of arsenite in bioleaching solution. Mandl, Matulova, and Docekalova (1992) reported that dissolved arsenite concentration was constant during a long-term bioleaching study of chalcopyrite using Thiobacillus ferrooxidans. Torma and Oolman (1992) report that Thiobacillus ferrooxidans has been found capable of oxidizing As3+ to As5+. The solid products of arsenopyrite/pyrite bioleaching include jarosite (MFe3(SO4)2(OH)6 where M can be K+, Na+, NH4+ or H3O+), scorodite (FeAsO4.2H2O), ferric hydroxides, and ferric hydroxysufites (Carlson et. al., 1992; Van Breemen, 1982; Lazaroff et. al., 1982). The particular species formed is a function mainly of pH. Little study has been performed on the effect of solid products on bioleaching. Pesic and Kim (1993) showed that Thiobacillus ferrooridans cells served as a nucleation sites for jarosite particles, which grew rapidly and eventually killed the cell. Most bioleaching studies are performed at low pH&apos;s (<2.0) under uncontrolled conditions. By studying bioleaching of arsenopyrite under controlled pH conditions and at higher pH&apos;s (2.0 to 3.0), the distribution of iron and arsenic between the solid and liquid phases can be controlled, and their effects studied. The objective is to develop a bioleaching process that operates at high efficiency while keeping amounts of dissolved heavy metals low. Pesic, Stohok, and Torma (1993) demonstrated the usefulness of this approach in the leaching of cobaltite (CoAsS) concentrates. Materials and Methods The focus of this study was the bioleaching of arsenopyrite ore by Thiobacillus ferrooxidans. The parameters studied included the effects of pH, and the effects of arsenate (AsO43 and arsenite (AsO2). pH studies included pH set initially but not controlled, and pH controlled continuously with NaOH or LiOH. Bioleaching results from two strains of Thiobacillus ferrooxidans with different adaptation histories were compared. Bioleaching experiments were conducted in 150 ml stirred glass reactors using a strain of Thiobacillus ferrooxidans adapted to arsenopyrite ore, supplied by the U.S. Bureau of Mines. These bioreactors were innoculated with stock cells grown on arsenopyrite ore for 14-16 days. Typical elemental breakdown for this ore was: As, 9.90%; Fe, 18.60%, Stot, 9.26%; Suifide, 7.50%; SiO2, 25.90%. Mineralogically, the ore contained both arsenopyrite and pyrite. Bioleaching efficiency was measured by withdrawing bioleach solution samples at selected intervals, filtering, and measuring the amount of dissolved cobalt, iron, and arsenic by atomic absorption spectroscopy. Because the precipitation of iron and arsenic at higher pH&apos;s would lead to unreliable results, a 100 mg tracer of cobaltite concentrate from the Blackbird mine in southern Idaho was added to solution. Dissolution of the cobaltite tracer was used to indicate bioleaching of the bulk arsenopyrite ore. Cobalt has been shown to be stable in solution even when iron and arsenic were precipitated (Pesic, Storhok, and Tonna, 1993). The pa-

Jan 1, 1995

By Ireneusz Tomza, Jolanta Lebecka

INTRODUCTION Radioactive deposits were observed in 1972 in some of the Upper Silesian coal mines. They were located mainly in the drains in galeries and on the inside surfaces of water pipes. They also caused some problems by accumulating in water pumps. It has been postulated that the deposits are produced by natural radioactive waters seeping from the rocks. Investigations were initiated to answer the following questions: - What is the composition and the amount of radioactivity in the deposits? - What radioisotopes are present in the water? - How are the radioactive deposits formed? - Do the radioactive waters also occur in other mines? - How does the radioactivity of the water depend on chemical composition? - What is the origin of the radioactive water? - Does the water and the deposits cause radiation hazards for miners? -How can the radiation hazard be reduced? METHODS OF MEASUREMENT Determination of Radium Isotopes in Water The commonly used methods of radium determination in water are either based on measurements of the radioactivity of 222Rn which is in equilibrium with 226Ra, or on the detection of alpha particles of the radium radioisotopes after chemical separation of radium from the water sample. The method based on radon activity measurements is very sensitive and does not require any chemical Separation, but it can be used for determination of 226Ra from the uranium series only, because the thorium daughter 220Rn has too short a half-life (55s to yield the required accuracy. The method developed by Goldin, 1961 [2] involved alpha-particle measurements in thin layers of RaS04 and BaS04 separated from the water. This method is not convenient for saline water and water with high barium concentration because the amount of barium carrier in this case is too large to obtain a thin layer of precipitate with sufficient activity. The Upper Silesian carboniferous waters are often saline with high barium content, so the method described by Goldin was not convenient for this case and it was necessary to change the detection system and modify the chemical preparation. The procedure developed by the authors for the determination of radium isotopes in water was as follows: - Depending on the Ba2+ content and the required sensitivity of measurement, a water sample of 200 cm3 to 3 dm3 was taken. - 10 cm3 of 0.25 M citric acid and 5 cm3 15M ammonia was added to form complex Ba2+ ions and avoid the immediate precipitation of BaSO4. (This was repeated as long as the addition of BaC12 did not form a precipitate.) - 1 cm3 of 1N solution of Pb(N03)2 as a carrier for radioactive isotopes of lead and 10 cm3 of 0.1 N BaC12 as a carrier for radium were added. - The sample was heated to the boiling point and the precipitation of RaS04, BaSO4 and PbS04 with 50% H2SO4 was carried out. - After several hours the sample was centrifuged and the precipitate was purified by washing with nitric acid and distilled water. - The precipitate was then redisolved in 20 cm3 0.125 M Na2EDTA and 3 cm3 6M ammonia and reprecipitated from the solution by dropwise addition of acetic acid to d pH of 4.5. At this value of pH, precipitation occurs only for the barium and radium sulfates, while lead and all other radioactive elements remain in the solution. The date and time of deposit precipitation was recorded. - The final barium-radium sulfate mixture was washed with distilled water and transferred to standard measurement vials. - Each vial containing a deposit had 6 cm3 of distilled water added and was then shaken vigorously. 12 cm3 of liquid gelling scintillator (INSTA-GEL UNISOLV-1 type) was then added and the vi 1 was shaken again. After a while the scintillator turns into a milky gel in which the deposit is uniformly distributed. - The standard sample of 226Ra was prepared in the same way. - The activity of the samples was measured using a liquid scintillation spectrometer. (In this case the TRICARB 3320 produced by Packard Instruments, was used). Tests run on standard radium solutions provided by Amersham Radiochemical Centre indicated that this method of measurement enables one to achieve an efficiency of almost 100% (within measurement error). For alpha particles no quenching effect was observed for the BaS04 concentration in the range up to 80 mg of BaS04 per 1 cm3 of liquid scintillator coctail (Fig. 1). This provides a sensitive determination of radium in water with high barium content and also in saline water. In saline water the solubility of barium sulfate is much higher than in

Jan 1, 1981

By W. E. Lindquist

Roasting of refractory gold ores has the primary goal of oxidizing sulfides and organics to improve gold recoveries prior to leaching. Commercial installations currently utilize bubbling and circulating fluidized beds. The principle of flash roasting is aimed at a more cost effective method of whole ore roasting for large throughput applications. Results of pilot plant testing and scale up to commercial design will be discussed in further detail in this paper.

Jan 1, 1993

By Eugene E. Hively

The Tower Kill is a vertical "stirred" ball/pebble mill recently introduced in the Western Hemisphere. This device offers a significant power savings on wet fine grinding applications when compared to conventional tumbling mills. This paper describes the laboratory application of this mill wet grinding hydrated alumina to products of 50 percent passing 2 to 6 microns.

Jan 1, 1983

By J. H. Rowland

Four different types of fire suppression systems were evaluated in large-scale fire experiments to study the effect of air velocity on the effectiveness to extinguish conveyor belt fires. The four different types of suppression systems were water sprinkler, deluge type water spray, and two different dry chemical fire suppression systems. The large-scale fire tests were conducted with 72-in-wide fire resistant rubber belt that met the Mine Safety and Health Administration flame resistant requirement specified in Title 30, Code of Federal Regulations, Part 18, section 18.65 (also known as the 2G Flame Test). Each fire suppression system was tested at air velocities of 500-550 feet per minute (fpm) and 1350-1500 fpm. Two tests were conducted at both air velocities for each fire suppression system. Both of the water-based fire suppression systems were able to suppress the fire to the point that a miner could extinguish it with a fire extinguisher. However, the amount of water needed to suppress the fire to the point where a miner could walk up to extinguish any smoldering belting was greater than the current MSHA regulations require. MSHA regulations only require 10 minutes of water supply to the suppression system. In the test set up neither of these systems would have suppressed the fire had the water been turned off to the system after 10 minutes. The dry chemical suppression systems produced mixed results. Dry chemical suppression system A did not suppress the conveyor belt fire at either air velocity. Dry chemical system B suppressed the fire at 500 fpm air velocity, but produced mixed results at the higher air velocity. Details are presented on the large-scale fire test set-up, arrangement of the fire suppression systems, and conclusions regarding the effect of air velocity on fire suppression system design and performance. Disclaimer: The findings and conclusions in this report are those of the authors and do not necessarily represent the views of NIOSH.

Jan 1, 2009

Careful financial analysis of capital investments has always been a vital task in mining which is one of the most capital intensive sectors of the economy. Furthermore, mining costs have leapt ahead at an astonishing rate in recent years not just due to accelerated inflation, which affects everyone, but also due to the imposition of enormous costs of enviromental regulation and the continuing decline in ore tenor. Not only have unit costs risen, but the amount of effort expended to recover a pound of metal has increased due to the inexorable decrease in ore grades. New low-margin, high-volume mining investments place increasing importance on sound financial planning. Owing to the enormous investments involved, a greater share of individual corporate resources is committed to these projects than is normally the case in other industries. Thus, the consequences of failure are extremely grave, and a close examination of all inputs to the evaluation equation is clearly indicated.

Jan 1, 1979

By J. A. Herbst, H. R. Cooper, R. J. Brison, R. W. Harper, K. P. Ananthapadmanabhan, W. C. Hellyer, B. H. Bergstorm, D. M. Hopstock, H. Rush Spedden, W. C. Hellyner

Scope of Section The physical characterization of an ore or mineral mixture in such detail that mineral processing may be effectively applied to create more useful products is one part of the technology of sampling and testing. In addition, the evaluation of the multitude of separation processes, both physical and chemical, combined with ancillary opera¬tions and performed on samples at a laboratory scale, is another part of the testing procedure. Although analytical techniques provid¬ing quantitative determinations of elemental compositions are an im¬portant and necessary supplement to any testing program, that field of endeavor is a well-developed, separate entity beyond the scope of this Section. Sampling procedures cover the practice of selecting representative quantities of test materials in the field to evaluate mineral deposits, and extend to techniques of obtaining process samples in slurry and bulk ore as part of process evaluation. The same techniques are appli¬cable, of course, to standardized methods of metallurgical accounting. Sampling is also an important facet of successful on-line measurement of slurry properties such as assays and particle size in the practice of automation. However, the sampling methods in this case can be different from those needed for precise testing and accounting pur¬poses. Sampling was well defined in Taggart&apos;s Handbook as "the opera¬tion of removing a part convenient in size for testing, from a whole which is of much greater bulk, in such a way that the proportion and distribution of the quality to be tested (e.g., specific gravity, metal content, recoverability) are the same in both the whole and the part removed (SAMPLE). The conditions of the more stringent definition, that the sample shall be completely representative of the whole as regards all aspects save bulk, are practically never fulfilled when heterogenous mineral mixtures are sampled." Taggart&apos;s Handbook of Mineral Dressing, Section 19, "Sampling and Testing," continues to be a very useful compendium of principles and techniques, particularly as applied to manual methods for han¬dling samples. In the intervening years since its last revision, substan¬tial progress has been made in both the theory and the techniques; thus, this current contribution is designed to be an extension of the earlier work, yet complete enough to provide procedural guidelines to methods of continuing validity. Although basic principles of testing remain unchanged, the meth¬ods of applying those principles have undergone great change. New testing equipment has become available, yielding a greater precision of results. Testing methods have been refined which, in many cases, allows for a valid scale up of flowsheet designs without the necessity of costly pilot or prototype plant development. Justification for a Sampling and Testing Program* The proper evaluation of a mineral property is a complicated process. It often is done on a team basis with the exploration geologist, mining engineer, mineral process engineer (extractive metallurgist), economist, and product utilizer (ceramist, chemical engineer, chemist, metallurgist, etc.) all represented. The mineral processing engineer is a key member because he can provide a go no-go answer to the question, "Can this ore be processed economically?" In addition, his judgment on the response of even the initial sample to processing can be an invaluable guide to the proposed process and its mutations. Since the capital investment and operating costs are so sensitive to the type of process used, the judgment of the mineral processing engineer forms an important part of the early evaluation of the profitability of a new mining venture. This early estimation of the processing approach is all the more important since, for some metalliferous ores, the capital investment for mill, smelter, water supply, and tailings disposal exceeds the cost of the mine. At present, for commodities such as coal, the reverse is true. There is a smaller capital investment for the coal preparation plant than for the mine. In general, both the capital and operating costs escalate very rapidly in the following order: gravity concentration of alluvial deposits (e.g., dredging), gravity concentration of lode ores, flotation, simple hydrometallurgical processes, and complicated hydrometallurgical and pyrometallurgical processes. The latter two processes may cost 100 to 1,000 times more per ton treated than processing of a simple alluvial deposit. This dictates that the valuable mineral be concentrated as much as possible to minimize the total tonnage treated in the more expensive operations. Within each of these ore-processing categories there is a wide range of process sophistication and hence of capital and operating costs. Perhaps the greatest variations are in the chemical processing of ores. These range from the simple leaching of a copper waste dump to very sophisticated hydrometallurgical processing of ores in increasing order of cost. Because the overall cost of a mining venture is so sensitive to the process selected, it is essential that the mineral¬ processing engineer evaluate the ore in the initial stages of the development of an ore body. As better samples become available, he must continually revise his estimate of the process to be employed. The sampling and testing process must be a necessary and continuing activity throughout the life of a project. One fundamental aspect of nearly all mineral deposits is the inherent variability of the mineral assemblage and composition. A utopian goal of any processing plant is to have the process so flexible and so well-defined that an automatic process control system can optimize the economic recovery at all times. Since this is rarely possible, a continuing or at least a periodic testing program is desirable. Variables to be considered are: 1) Ore body inconsistencies. 2) Zonal variations. 3) Feed variations from mining plan or methods. 4) Variable performance of processing units due to wear. 5) Seasonal or other changes affecting processing conditions such as water quality, temperature, etc. 6) Changing market conditions for product quality or byproducts. 7) Technological advances in processing methods or equipment. 8) Increasing demands for environmental control. 9) Changing economics of competitive processes, of supplies, of capital investment vs. labor costs, etc. Sampling Procedures Preliminary Guidelines for Sampling Ore Deposit Studies. t At a very early stage, it is essential that the mineral processing engineer receive a sample of the ore. This may be a portion of the diamond drill core or a split from the trench, pit, churn drill, channel, or sheet sample. Even a grab sample may have some value, but it should be selected by the mining engineer or exploration geologist to be as representative of the ore body as possible within his best judgment. The sample delivered to the process engineer should have been subjected to as little prior crushing as is practical since fine sizes are difficult to concentrate. In addition, finely ground ores are readily oxidized and thus may give misleading test results. Furthermore, ground samples may make it impossible to eval¬uate either the comminution or the coarse-gravity concentration pro¬cesses. For an initial evaluation, a good deal may often be learned from a sample of only a few pounds if that is all that is available. To obtain the maximum information from a sample, its selection should be carefully discussed with the mineral processing engineer. In addi¬tion to being as representative as possible, the mineralogically distinct samples should be carefully segregated rather than composited. Since drastically different processes are often needed to process samples of differing mineralogy, considerable care and time must be exercised during this sample collection step. The segregation of samples showing gross mineralogical differences, such as the oxide caping on a sulfide deposit or a laterized zone, is easy. It is the more subtle changes in mineralogy that can often elude the field man. Yet these differences are often sufficient to dictate that an entirely different type of process be used. Obviously, the selection of these initial samples for ore testing and mineralogical studies requires that it be done by a man of consider¬able experience and judgment. While the mining engineer or field geologist is collecting these samples, he should also note and convey to the processing engineer such details as water quality and availabil¬ity, terrain, potential mill location, tailings-disposal areas, case of transportation, etc. As the property is developed with additional drill holes, adits, etc., larger and more representative samples will be required to develop the ore-processing flowsheet more adequately. If pilot-plant studies are required, a very large sample may be necessary. Though the type and amount of sample collected for flowsheet development investigations vary widely, gathering a representative sample of the ore body is a prime requisite for any process development effort. The process developed for any given ore body is only as reliable as the sample on which the flowsheet was based¬

Jan 1, 1985