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By C. Guan

Since it was patented in 1942, the Crago process with fatty acid rougher flotation followed by deoiling and amine cleaner flotation has become the standard for phosphate flotation in Florida and North Carolina. This paper outlines the basic fundamentals involved in this proven technology. Included are the mineralogy of the flotation feed, the solution chemistry and the interfacial phenomena. The process variables affecting the performance of this technology are also discussed.

Jan 1, 2009

By E. L. Thyse

Keywords: Pyrometallurgy, converter, nickel, matte, distribution Metallic elements occupy a wide range in granulated nickel converter matte phases. The distribution of these metallic elements, particularly during crystallization path events, appears to be poorly understood. The present study serves to investigate the distribution of Fe, Co, Ni, Cu, and Pb between nickel-sulphide, copper-sulphide, and alloy phases. A novel combination of thermo-chemical modelling, electron microscopy, and electron probe microanalysis was applied to understand crystallization path events and the associated metallic element distribution. This study has demonstrated that major Ni incorporated during copper-sulphide crystallization would serve to mobilize minor Co towards distribution in copper-sulphide phases. In addition, solid solution substitution of Cu by Ni is manifested by compositional zoning of copper-sulphide phases. The role played by Ni during alloy crystallization suggests that minor Co was also mobilized, along with an increase in principal Ni. Fe, by contrast, seems to be incompatible with principal Ni. In addition, solid solution substitution of Ni with PGEs and Cu is manifested by compositional zoning of NiCu-alloy phases.

Jan 1, 2011

By D. M. Wyslouzil

"Micron or sub-micron size gold inclusions in sulphide minerals cannot be extracted by conventional cyanidation. The gold surfaces must first be exposed by decomposition of the sulphides. As an alternative to roasting, pressure oxidation was found to be a most satisfactory method to decompose the sulphides and expose the gold particles. For cyanidation the pressure oxidation pulp has to be neutralized and stabilized with lime. It was found that thiourea can extract the gold directly from the pressure oxidation pulp without pH adjustment and oxidant addition. The main obstacles against the common use of thiourea are circumvented by a recently described control method of the emf during leaching.INTRODUCTION Amalgamation and cyanidation are the most conventional processes for gold extraction. The prerequisite for gold extraction is the possibility of gold surface to be contacted by mercury or by the cyanide solution. Encapsulated gold has little chance of contact and this leads to poor extractions.The reasons why a gold ore may be refractory are: micron or sub-micron size gold particles included in the sulphide minerals, such as pyrite and arsenopyrite; presence of and association with antimony, arsenic, tellurium and carbonaceous minerals. Some alternative processes, such as double oxidation(1,2), pretreatment with lime , H202, chlorine and Caro's acid, roasting and thiourea leach, have solved some of the problems of ""refractory"", but the sub-micron gold in sulphide minerals still shows little response. Roasting and the cyanidation of the calcine was one of the most successful approaches for this type of gold ore.There are two disadvantages to the roasting process: (1) the generation of sulphur, arsenic, antimony and mercury containing gases is undesirable and the control is extremely expensive; (2) gold particles might be fused in the roasted product and the oxidized base metals in the calcine might reduce the cyanidation efficiency. In recent years the pressure oxidation process has been considered as one of the more effective and satisfactory methods to decompose the sulphide minerals and expose the gold surface to the cyanide leach solution. The pollution problem could be better controlled and the gold extraction is more amenable."

Jan 1, 1985

By N. A. Abdel-Khalek

The amenability of carbonate separation from a sedimentary phosphate ore using a bioflotation process was studied. Two types of bacteria were chosen for this study. The experiments were performed using oleic acid as collector. The flotation experiments were carried out using statistical designs for optimizing the main operating parameters. A concentrate containing 0.78% MgO and 30.15% P2O5 with a recovery of 92.31% was obtained from a feed containing about 2.45% MgO and 27% P2O5. These specifications could not be obtained using conventional flotation experiments under similar conditions in the absence of bacteria. Measurements of zeta potential, adsorption of bacteria and collector, as well as froth power, were performed to explain the role of microorganisms in the surface modification of both dolomite and phosphate and in their interaction with the collector.

Jan 1, 2009

By J. Torma-Krajewski, C. Hipes

Although many mining companies apply ergonomic principles, it is usually done either informally and/or reactively. An example of an informal approach is replacing worn equipment (such as seats) with models that have ergonomic features. Another example is modifying a task to eliminate safety hazards. Such approaches reduce risk-factor exposures that can lead to musculoskeletal disorders (MSDs). A reactive approach is followed when modifying a task/ equipment after an MSD occurs. However, neither of these approaches involves a systematic method of proactively applying ergonomic principles to actually prevent injuries or illnesses. This paper discusses how Vulcan Materials Company applied ergonomic principles and implemented interventions to reduce risk-factor exposures.

By P Meehan, R McAree, Z Guan

Equipment maintenance is 30 - 50 per cent of the operating costs for a typical mining company. While this is substantial, its importance is beyond its significance as a cost heading. Modern mining requires large amounts of investment in capital infrastructure and equipment to produce a product sold at a low unit cost. To stay competitive, such a business has to focus on full realisation of its capital investment, ie sustained production at high levels. Maintenance plays an essential role in achieving this goal. Mining companies typically use a mix of breakdown or corrective maintenance, planned maintenance, and some condition-based maintenance. The share of breakdown maintenance has been coming down through more effective planned maintenance and better condition monitoring tools. Planned or preventive maintenance (PM) is playing an increasingly important role in todayÆs mining maintenance. This is the suite of inspection and repair/replacement actions performed at scheduled time intervals as part of a preplanned activity. The activities are scheduled well in advance and, usually, the current wear-state of the machine is irrelevant. For example, the replacement of a major gear may have been planned 18 months in advance; replacement is carried out when the time comes regardless of the actual condition of the gear. The PM costs are significant and include direct cost of parts and labour as well as the opportunity cost of lost production while the machine is under maintenance. It is important to identify the optimum PM effort because over-maintenance should be avoided as much as under-maintenance. A new concept called severity-based maintenance is introduced in this paper. We have seen that measuring equipment ageing in mining merely by counting the engine hours is a very imprecise way of planning and scheduling maintenance because the damage accumulated in one hour varies enormously from operator to operator and with changing pit conditions. We recommend continuous monitoring of duty on all major equipment. This is feasible without having to fit out the machine with an army of sensors because most of the physical sensors required by dutymeters are already installed and maintained as part of the existing performance monitors. While the investment is modest, the potential benefits are huge and can be grouped under three headings:Immediate benefits will come from providing operators with direct feedback on the effect of their behaviour on machine health and training them to use this feedback to correct their operating style. The equipment can operate closer to the limits of capacity, producing more without unduly sacrificing the availability by monitoring and controlling the severity of the operation, ie the duty on the machine. Longer term benefits accrue from establishing correlations between actual time to failure data and measured equipment duty and using these correlations to optimise maintenance effort as well as planning new equipment purchases and warranty conditions.

Jan 1, 2002

By N. Shariatmadari

Two dry docks are currently under construction on the northern banks of the Persian Gulf by Iran Shipyard and Offshore Industries Co. (ISOICO). The construction of these dry docks forms a huge civil offshore project. The foundation system include more than 6500 large diameter (40-48 inch) spiral pipe piles with embedded depth varying from 18 to 25 meters. Extensive geotechnical subsurface investigations were carried out in the project site in order to provide enough information and proper perspective on the underlying soil layers. The results of geotechnical investigation indicated that a 20 m thick dense silty sand layer exist which can be considered as the main bearing stratum. Due to short clear distance between the piles (less than 3 m) refusal occurred for some piles, accordingly led to actual length less than their design length. To verify and in-situ evaluation of piles capacity, static and dynamic full scale loading tests programme were performed. The data from 40 static compression and tension and also 50 dynamic tests with PDA were interpreted and analyzed by current approaches and CAPWAP software. The results of analysis demonstrated that the safety factor of bearing capacity of piles must be increased to reach a safety factor of about 1.8. To achieve this purpose the interaction of combined piled-raft system has been realized.

Jan 1, 2007

By G. Budge

In the extractive industry the term ‘continuous improvement’ (CI) usually means procurement of the latest state of the art equipment. This is generally perceived as the only way to add further value to the supply chain, with the driving philosophy of increased tonnage to dilute operational costs. However, not all market places can facilitate this approach. RJB lives in a fiercely competitive market and has targeted the standard efficiency drivers of rationalisation and stock management with a vengeance; and also operate CMMS (Computer Maintenance Management System), RCM (Routine Condition Monitoring)and CBM (Condition Based Maintenance) methodologies. Ultimately though, these systems are only as good as the people who operate and manage them and to add further value without procurement, people must be re-introduced back into the operation. Through TPM (Total Productive Mining), that is what RJB have set out to do.

Jan 1, 2001

Virtual Reality (VR) simulations are excellent tools for training, education, simulation of abnormal and dangerous conditions in mines and solving complex problems. Although the concept of VR has been around for nearly half a century, it has taken recent advances in hardware and software to bring this technology to within the budgetary reach of ordinary users and researchers. VR is now successfully being used in the minerals industry for: data visualization, accident reconstructions, simulation applications, risk analysis, hazard awareness and training. The Institute of Sustainable Minerals Industry, Advanced Computer Graphics and Virtual Reality Research Group (SMI-VR) at the University of Queensland, established in late 2000, has been involved in developing VR applications for the minerals industry in conjunction with various research centres. This paper illustrates the benefits of using advanced computer graphics and VR techniques in the minerals industry with some examples of applications developed.

Jan 1, 2003

By Nilce Alves Santos, Vânia Lúcia de Lima Andrade, Keila Lane Carvalho Gonçalves, Harold Wyslouzi1

"When confronted with the difficult decisions on advancing an exploration project to the feasibility and construction stages, it is important to know how various regions of the ore body will react in the milling and concentration processes. While bench scale test work is common and inexpensive, the results and information provided are somewhat limited due to the difficulty in accurately predicting the effects of recirculating middling streams or gradual changes in solution chemistry.Conventional Pilot Plants, processing 100 to 1,000 kg/hour of sample ore, provide the detailed engineering data required to develop a final process flowsheet and to size the equipment. They are, however, expensive to set-up and operate, and are really only viable for major projects that are well advancedIn the latter part of 1999, the Mineral Development Center at CVRD (MDC) purchased a new piece of mineral processing equipment which can run continuous flotation tests using drill core samples. To evaluate its performance, and to compare it with conventional testing methods, various types of flotation tests were carried out using two different types of copper ore. The limitations and advantages of open circuit and locked cycle bench tests, as well as the Mini Pilot Plant and the Conventional Pilot Plant were evaluated.Open circuit tests carried out at the bench scale only provide basic information. More complete and trustworthy information is obtained, in terms of the recirculation of flows and reaching a permanent and stable flotation regime, as the dynamics and complexity of the tests increases. The data obtained showed that the MPP’s metallurgical performance was equivalent to that of a conventional pilot plant."

Jan 1, 2002

By Jesús E. Gómez

This work is a continuation of a paper presented in the 32nd DFI Annual Conference, Colorado 2007, titled ?Hollow Core Bar Micropiles - Design parameters interpreted from 260 load tests.? The first paper presented the results of the verification and proof tests performed for the retrofit of two bridges with hollow core bars that used 260 micropiles. It included an interpretation of the unit bond values in the different soils where micropiles were installed. Recently two additional bridges within the same geological environment were also retrofitted using 144 hollow core micropiles. This paper includes the interpretation of the additional data from the proof tests performed and refines recommended values for design of hollow core bar micropiles in soils similar to those encountered in these two projects. The authors believe that the data collected will significantly add to the relatively small existing database on micropile tests and may also be useful during implementation of the LRFD design methodology.

Jan 1, 2008

With the dawning of a new century came the beginning of a new era in the coal industry. Instead of the traditional practice of only buying and selling produced coal in the United States, a coal futures market was established. The New York Mercantile Exchange began trading coal futures in July 2001. But, even in this new era, many of the old is-sues that have beset the coal industry still remain, as was evident in2001. Coal production increased to are cord level during 2001, according to preliminary data from the US Energy Information Administration(EIA). Production in 2001 rose by4% to 1.01 Gt (1.12 billion st), compared with 2000 (Table 1). This barely surpassed the previous record level of 1 Gt (1.11 billion st)set in 1998. Coal consumption remained unchanged. The additional production was used to replenish the depleted stockpiles that had resulted after two years of declining coal production and increasing coal consumption.

Jan 1, 2002

By Arthur M. Langer

Since the promulgation of the first Federal Asbestos Standard by the Occupational Safety and Health Administration in 1972, other federal agencies have modified the standard to better carry on their own unique missions. The instruments used to identify and measure asbestos, the sampling protocol, and the criteria used to define asbestos, have been modified to some degree. The Mine Safety and Health Administration regulates and controls asbestos dust in the mining and mineral commodity industries. However, crushed stone and processed ores contain mineral fragments that are frequently difficult to distinguish from asbestos. Mineral nomenclature, instruments for particle analysis, and sampling strategy must be accommodated to some degree to make asbestos control workable and meaningful. Precedent in other agencies has made consideration of these changes possible. Newly identified amphibole asbestos minerals have further complicated the agency?s regulatory charge. Changes in its Asbestos Standard are now being considered. Crushed taconite ore in the Eastern Mesabi highlights many of these issues. ©2008 Published by Elsevier Inc. Keywords: Amosite; Grunerite asbestos; Crocidolite; Riebeckite asbestos; Tremolite asbestos; Actinolite asbestos; Winchite asbestos; Richterite asbestos; Arfvedsonite asbestos; Fluor-edenite asbestos; Asbestos defects; Cleavage fragment; Mineral habit; Mesabi amphiboles

Jan 1, 2008

The following paper on the development of processes for the treatment of crude ore, accumulated dumps of tailing and slime at Broken Hill, has been prepared by a committee of the Broken Hill Branch of the Australasian Institute of Mining and Metallurgy, with the object of recording, in chronological order, the developments of the various processes which have led up to the metallurgical practice of the present day.

Jan 1, 1930

By Gordan Marrs, O. Matwijenko

"The Kidd Creek metallurgical site has been highly integrated to maximize revenues from its base metals mines. The site's operations include a Concentrator processing 4.3 million tonnes per year of copper-zinc ore, a Copper complex producing 100,000 tonnes per year copper cathode and a Zinc Plant producing 130,000 tonnes per year of zinc metal. To improve operating efficiency with increasing emphasis on productivity, process control, process automation and process optimization have been augmented and expanded during the last decade.New microprocessor based control systems provided the opportunity for the capturing of an expanded number of process related measurements. As supervisory computers were already in place, databases could be generated with only increased disc space and database management programs required. Once the data had been accumulated and stored, a method was then required for handling, screening and sorting large volumes of information in relatively quick and easy terms in order that the stored information could be used. By 1984, a decision to use personal computers for accounting, engineering and management reporting provided the vehicle necessary to handle this data. Using commercially available software, large volumes of stored process data can be downloaded from existing databases, filtered, sorted, analyzed, graphed, displayed, projected, reported and distributed. All this can be performed in very little time."

Jan 1, 1989

By X. Pan

Slag-metal equilibrium experiments were conducted at 1500ºC and 1580ºC under 0.03 atm, 0.05atm and 0.83 atm CO partial pressures using silica and Cr-oxide crucibles. The complex slags belonged to SiO2-CaO-Al2O3-MgO-FeOx-CrOxand the metal phase to the Cr-Fe-C-Si-(S)systems. The carbon saturation of the metal phase was avoided using oxide crucibles and thus the results are pertinent to ferrochromium refining slags and processes. From equilibrium data and thermodynamic calculations the CrO /(CrO+Cr2O3) ratio in the slag was determined as 0.75, 0.80and 0.86 under 0.83 atm and 0.05 atm of CO pressure at 1500ºC and 0.03 atm and CO pressure at1580ºC respectively. The results clearly demonstrated that a higher chromium content of the metal results in higher Cr in the slag, and chromium in slag decreases with increasing SiO2. The results were also sensitive to the crucibles used as these oxide crucibles saturated the slag either with respect to SiO2or Cr-oxides. It was also demonstrated that the relative amount of CrO in the slag was higher when SiO2crucibles were used in accord with thermodynamic calculations. Iso-concentration curves for carbon and chromium of the metal phase in equilibrium with the slag were drawn on pseudo ternary SiO2–(AI2O3+CaO+MgO)–(Cr2O3+Fe2O3) diagram. The activity coefficients and activities of carbon and chromium of the metal phase were also calculated from the experimental data and available thermodynamics information and were plotted as iso-activity curves in the same pseudo ternary diagram. Keywords: Chromium, slag, equilibrium

Jan 1, 2004

By Brian Reid

"This paper studies the progress made by hydraulic shovel manufacturers over the last few years, particularly in the areas of productivity increase and operating cost reductions.Five years ago, it was widely considered that the unit production cost for a hydraulic shovel in a mining application was double that of a cable shovel in the same application. The hydraulic machine manufacturers have taken up this challenge, and modern improvements in design, coupled with changes in maintenance techniques, have narrowed the gap to the point where it is valid to ask the question ""will the cable shovel exist in ten years' time?"".Historical BackgroundThe history of the cable shovel goes back to the early 19th century and the industrial revolution. Early machines were steam-powered and ran on rails.The ""power shovel"" and the ""dragline"" were the only mechanical means of mass excavation until the early 1950s. Rail-mounted units gave way to crawlers, which increased flexibility considerably. Some shovels were redesigned as backhoes, and some became extremely large when designed as stripping shovels primarily used in North American coal mines.In the early 1950s growth in hydraulic technology spawned the introduction of the hydraulic excavator, which soon began to replace the smaller cable shovels and backhoes used in the construction industry. They were completely self-contained with either a gasoline or diesel engine and, being much lighter, were more readily transportable.As the excavators grew in size from its early models of 0.5 m3 or less, many of the cable shovel models were discontinued. This was not surprising for several reasons, but the most obvious is that both were often made by the same manufacturer."

Jan 1, 1988

Real-Time Integration of Mining and Metallurgical Information for Efficient Use of Energy and Water

Sep 13, 2010

By W Shamu

The mechanical properties of rock samples of identical lithologicalcomposition may vary significantly due to existence of materialdiscontinuities. Laboratory tests were carried out to determine the effect of material discontinuities on rock sample mechanical properties. The investigations consisted of detecting discontinuities, observing the failure mechanisms during uniaxial compressive strength tests, and analysing of the factors affecting the strength. A non-destructive testing method has been adopted to assist in thedetection of discontinuities. Laboratory testing proved that fractures leading to failures initiated on the detected discontinuities. The location, orientation, size, density and extent of the discontinuities contribute to different modes of failure and these affect the mechanical parameters of rock samples. Four modes of failure were distinguished for hard and brittlecylindrical rock samples. These modes were referred to as simple shear failure, multiple shear failure, multiple fracturing and vertical splitting. To evaluate the effect of discontinuities on mechanical parameters, the ratio of uniaxial compressive to tensile (Brazilian) strength was calculated and analysed for the different modes of failure. It was found that the value of the ratio depended on the mode of sample failure. The lowest value of the ratio was observed for shear mode of failure and the highest for vertical splitting mode of failure.

Jan 1, 1999

In North-West Nelson the Riwaka Complex, a linear basic intrusive complex, is exposed for approximately 45 km. Some 500 km south, across the Alpine Fault, a linear zone of similar but less well known basic intrusives that may be correlatives of the Riwaka Complex is exposed discontinuously for about 80 km. The Complex was emplaced at several centres along a major tensional fracture zone that developed in upper Carboniferous to Lower Permian time. This fracture zone probably formed in response to the development of a west dipping subduction zone that gave rise to the Permian volcanic arcs in east Nelson and western Southland. The Riwaka Complex contains three rock suites. The Fractionation Suite, characterized by cyclic mineral layering and small scale cumulus banding is the largest and is divided into the Ultramafic, Hornblende and Plagioclase Series, each of which is subdivided into several units. The Cumulus Gabbros represent a restricted but important suite of unusual composition, while the third suite is the late phase Diorite Suite. Except in the lower units of the Ultramafic Series sulfide mineralisation is widespread. Pyrrhotite is the dominant sulfide with lesser chalcopyrite pentlandite and pyrite. Four significant zones of sulfide accumulation are recognised and discussed in some detail. Evidence suggests that the primary magma from which the Riwaka Complex was derived was sulfur deficient. It is concluded that the sulfur content of the Riwaka Complex was derived from assimilation of sulfur rich wall rocks during intrusive processes.

Jan 1, 1980