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By H. Sevim, M. K. Mohanty, Y. P. Chugh

The economics of “Conventional” and “Advanced Fine Coal Cleaning” (AFCC) circuits for refuse pond reclamation as well as active mine/preparation plant applications have been evaluated. The benefits of innovative tailings management schemes on the profitability of mining enterprises have also been evaluated as a part of this study. Analyses have been conducted for scenarios involving generation of two different product qualities of 5.81%, a quality that was obtained during AFCC circuit operation at SIU, and a more typical 8% product ash. The inability of the conventional circuits to achieve profitability while producing the lower ash content product is revealed from this approach. The spiral-only circuit is unable to produce a 5.81% ash product. A different version of the same circuit involving spirals and column flotation produced the desired product quality but could not maintain profitability. The AFCC circuits on the other hand, achieve net present values greater than $6 million, with return on investment in excess of 50%, in the water-only as well as dense medium mode, with and without tailings management. Addition of tailings management system to any of the circuits is found to enhance the project economics. The comparison of water-only and dense-medium applications of the AFCC circuits indicate a better suitability of the dense-medium circuit for producing premium quality products. Application of AFCC circuits in active mines offer better economics compared to applications in refuse pond recovery operations. The superior project economics are a result of reduced overhead cost and use of existing material handling facilities. Sensitivity analysis reveals the significance of capacity utilization on project economics.

Jan 1, 2002

By Eduardo Nunez, Asim Tuzun, Dan Graffi, Glenn MacPherson

"In preparation for the milling of a new nickel and copper mine ore, Nickel Rim South, Xstrata’s Strathcona Mill is undertaking numerous process improvement projects. Within the grinding circuit, several projects are under development and an automated grinding control strategy, consistent with the operating objectives, was identified as a key requirement. The grinding strategy is to maximize the throughput (quantitative objective) while maintaining the cyclone overflow within specifications (qualitative objective).This paper describes the implementation of a robust grinding control strategy using the existing control system. The implemented controls maintain the cyclone overflow density at the desired target, while continually optimising the rod mill feed rate to allow maximum throughput. This approach has the added benefit of improving the stability of the rougher flotation circuit down stream of the grinding and improving energy efficiency of the rod and primary ball mills. This paper discusses the comparison of the before and after the implementation of results.INTRODUCTIONThe grinding process is a size reduction operation used in the mining industry to liberate the valuable minerals from the gangue. Grinding is one of the most important and expensive processes in a concentrator (Xi-song, 2007; Pomerleau 2000; Najim 1995), often accounting for around half of the total operating costs in base metal concentrators (Wills, 1990), which has led to a focus on development and implementation of control and optimisation strategies. The grinding process prepares the ore for the subsequent concentration step, which for sulphide base metal operations, is predominantly flotation. The performance of the concentration (flotation) is very much determined by the feed characteristics of the slurry coming from grinding. The valuable minerals recovery process in flotation is very much influenced by the grinding process and the liberation of the desired minerals from the gangue minerals (McIvor, 1991).The true objective of grinding is to obtain a proper liberation of the minerals as defined by a particle size distribution referenced typically by d80 (80% passing size of product). Besides achieving the desired mineral d80 size, it is clearly desirable to produce as narrow a size distribution as possible to squeeze the maximum amount of the mineral value into the highest recovery region (McIvor, 1991). This is an important criterion for the mill in economically optimizing the grade and recovery for the concentrate product. It is important not to over or under grind, while keeping the specific comminution energy as low as possible (Nunez, 2005) to achieve the target liberation. In other words, maintain an optimal throughput depending on the ore conditions to the capacity of the grinding mills, while providing the flotation process with a constant and narrow size distribution, at a cut size selected to meet the metallurgical requirements (Bascur, 1991)."

Jan 1, 2009

By J. E. Hawley, Y. Rimsaite, T. V. Lord

"IntroductionIN THE COURSE of. a spectrographic investigation of the platinum metal .content of various minerals in sulphide ores, the use of • fire-assay beads dissolved in gold-amalgam ( 1) was found suitable for the quantitative determination of palladium and platinum. Later work on platinum and bismuth-rich beads showed however, that these could not always be readily mixed uniformly in the amalgam. Accordingly another technique was sought which would allow the simultaneous determination of gold, silver, palladium, platinum, rhodium, and bismuth, the last .a common contaminant in fire-assay beads. The method evolved, which consists of dissolving fire-assay •beads in .lead, resembles in several respects the method of Scobie (2) in which silver was used. It has equally good sensitivity arid reproducibility, and allows the determination of silver as well as the other metals mentioned. The 'mutua1 standard' method of calculation (3a) is used to determine actual quantities present. This method has been applied to sulphide and arsenide minerals and •ores• of nickeliferous and non-nickelferous deposits• of both pre-and post Cambrian age, and, following a suggestion by Dr. G. S. Hume and the late Dr. H. V. Ellsworth, Geological Survey of Canada, has also been used for a peculiarly rich platiniferous uranium oxide ore from the Nicholson property, Lake Athakaska, Sask. More recently, the method has been .tested for the determination also of iridium and ruthenium and results indicate it may be applied, as• well to osmium."

Jan 1, 1953

By T. R. Ellis

Considerable movement is afoot internationally to rationalize standards and regulations relating to valuations and the qualifications for valuation professionals. In July 2000 the International Valuation Standards Committee released expanded standards, and additional important improvements are planned by 2003. Possible updates to the International Accounting Standards (IAS) and potential adoption of IAS by the U.S. could significantly impact minerals appraisers. Standards designed specifically for mineral asset valuation are under development in Canada and the U.S., with Australia’s internationally respected VALMIN Code providing the benchmark. In the U.S., the all-encompassing Uniform Standards of Professional Appraisal Practice (USPAP) is annually modified and continues to gain deeper acceptance, while the SEC holds fast to its antiquated rule prohibiting reporting of a quantitative estimate and value for non-reserve mineralization. Some important international trade agreements are driving actions to free the trade in professional services. In July 2000, an international workshop was held to initiate discussion on minimum qualifications for appraisers to work internationally. Pressure for uniform minimum qualifications and rules for professionals internationally will continue to build. The U.S. is historically among the slowest countries to implement such initiatives, with its state level licensure barriers having the potential to cause some of its professionals to be stranded in an international backwater. Structural change is needed in Australia’s VALMIN Code to remove conflict with the latest International Valuation Standards. The mineral valuation standards developers of Australia, Canada and the U.S. should work jointly on updating VALMIN for global use.

Jan 1, 2001

By P. Tong-jiang

We studied mineralogical characteristics of the vermiculite samples from seven mines in China. We found three types of interstratified structures in the investigated samples: 1:1 regular interstratified structure, segregated interstratified structure, and random interstratified structure. The vermiculite samples from six mines are mainly composed of phlogopite?vermiculite interstratified minerals, and the samples from the other mine are composed of chlorite?vermiculite interstratified mineral. The samples with phlogopite?vermiculite structure have high contents of K2O, TiO2 and Na2O. The samples with chlorite?vermiculite structure have the highest contents of MgO and Al2O3. The cation exchange capacity of the samples is 17.3?99.0 mmol/100g.The exchangeable cations of phlogopite?vermiculite samples from Weili Mine mainly include Na+ and Ca2+, while those of phlogopite?vermiculite samples from Tongguan Mine mainly include Mg2+ and Ca2+. The thermal expansion ratio of the samples is between 9 and 32. The exfoliated vermiculite products from Weili Mine have the best mechanical strength.

Feb 27, 2013

By Clayton R. Morlock

Airblasts have been monitored at four coal strip mines and at a limestone quarry. Thirty-seven production blasts have been monitored with three seismographs, resulting in one hundred and eleven complete air pressure records. Instrumentation selection use is described. Data analysis includes an assessment of the predictability of peak overpressures by means of the cube root scaled distance law. It is found that predictability for the cases studied here is not good. An extensive discussion of possible explanations is included. A detailed analysis of the frequency content of the observed airblasts, of considerable importance in evaluating potential annoyance problems, has been made for all records. A computer program has been written to simulate airblasts induced by multiple-hole blasts. A series of small experimental blasts have been detonated and monitored in order to allow an assessment of the program. It is clear that airblasts, especially when induced by very small charges and monitored at very close distances, are highly sensitive to detonation times. Retrofitting of airblast records occasionally was possible, but considerably improved field work is required to validate or refute the computer model.

Jan 1, 1983

Although not fully accepted in South Africa, the Theory of Sampling originally proposed by Pierre Gy is fast becoming the cornerstone of sampling practice throughout the world. The growing acceptance of Gy?s Theory of Sampling in South Africa can be attributed to a number of factors, chief amongst them being the development of a tradable mineral asset market, the promulgation of the Mineral and Petroleum Resources Development Act (MPRDA), the growing number of commercial and academic courses that are offered on sampling, and the regulation of the industry through internationally acceptable guidelines and rules for reporting and trading in mineral assets. The size of the South African minerals industry and the dependence of our economy on mineral production have also meant that correct sampling is of key importance to mineral trade. ISO standards have been the principal guides for producers of mineral bulk commodities who produce to customers? specifications, whereas Gy?s insights have been most readily accepted by precious and base metals producers whose product is sold into metal markets. Understanding of small-scale variability is essential in the precious and base-metal industries, but detailed studies of the effects of heterogeneity have not been as productive in the bulk commodities. Sampling practices at different stages of mineral development from exploration, face sampling and grade control, ore processing and handling, metallurgical sub-sampling, point of sale sampling, and sampling in the laboratory are considered in the gold, platinum, ferrous metal, and coal industries. A summary of the impact of poor sampling in these industries is presented. Generally it appears that poor sampling practice is most likely to erode mineral asset value at the early stages of mineral development. The benefits of good sampling are considered, especially with regard to the financial implications of bias and error on large and consistent consignments of bulk commodities. Keywords theory of sampling, sampling errors, ISO standards.

Jan 1, 2014

By J. Nesset, F. Rosenblum, P. Spira

Sulphide concentrates may exhibit self-heating to various degrees during storage or shipping, the worst cases presenting a serious hazard from fire and SO2 emission. Based on measurements of heating rates on a wide variety of concentrate samples in a special apparatus, combined with field experience, a methodology has been developed which allows concentrates to be rated for their heating potential. This has proven to be very useful in practice, for example, in deciding on the need to take preventive measures. Oxidation under ambient conditions in the presence of moisture initiates heating locally within a stockpile. In the case of highly active materials, such as those that contain abundant pyrrhotite, heating may progress through three stages to temperatures well above 500°C. However, most concentrates show little or no propensity to self-heat. Heating rates were used to estimate values of the heat output, or self-heating capacity (in joules per gram), which sustains the process at each stage. Thermal data from differential scanning calorimetry are also reported. Variables which affect self-heating are discussed and an actual case of heating control on a stockpile by covering is described. A simple apparatus which can be used to simulate stockpiling conditions has been tested successfully and is proposed as a convenient test system.

Jan 1, 2001

By L. C. Bird, N. T. L. Landgren, M. W. Mikhail

"Through funds made available in 1972 by the Nova Scotia Department of Mines and Energy (DME) and the federal Department of Regional Economic Expansion, a program was initiated to recover saleable coal from mine waste dumps adjacent to the existing Acadia wash plant in Stellarton, Nova Scotia.Following evaluation of these dumps in 1972, the Acadia wash plant was modified to treat high-ash material. The first production was recorded in late 1974. By the end of 1979, a total of 738,202 t of dump material had been processed, yielding a total of 205,212 t of thermal-quality coal.The successful Stellarton operation led to considering the possibility of recovering thermal coal from other dumps. Evaluation of the Westville dumps indicated total recoverable reserves of 1,346,617 t averaging 53.8OJo ash.Parameters for plant design were defined from the washability characteristics of the dump material and the results of a bulk test. Two options were proposed; one was to use the existing plant with some modifications, the other was to build a modular mobile plant that could be used at future dump sites in the province after Westville. At the 25% ash level, the potential recovery of coal from the dump was estimated at 41% yield (by weight) or 549,679 t."

Jan 1, 1981

Two new inorganic-organic hybrid polymers, Al(OH)3-polyacrylamide (Al(OH)3-PAM) and Mg(OH)2-polyacrylamide (Mg(OH)2-PAM) were synthesized and successfully applied for the treatment of oil sand tailings. The results indicate that both Mg(OH)2-PAM and Al(OH)3-PAM were unaffected by the change in pH, and could be applied to oil sand tailings with varying sand-to-fine ratio (SFR). The optimum dosages for the Mg(OH)2-PAM and Al(OH)3-PAM were about 330 g/ton and 650 g/ton, respectively for SFR 3.75. The flocculated oil sand tailings dewater quickly producing 66-68% solids. The flocculated tailings produced similar filtration rate before and after shear. Mg(OH)2-PAM treated oil sand tailings produced twice the filtration rates (220 ml/min) compared with Al(OH)3-PAM. This study clearly indicates that Mg(OH)2-PAM and Al(OH)3-PAM is a viable solution while decreasing the mass-production of tailings and increasing the rate of water-recycle.

Jan 1, 2012

By P. Rice, A. Photolo, A. C. Barnard

Introduction -Sampling Tool Project (STP) -History -Results to date -Costs -Questions

Jan 1, 2005

By M. N. H. Khan

CSIRO has been experimenting with supersonic flows as a method of rapidly quenching metallic vapours. Cooling rates above 106 °C/s have been achieved. The supersonic flow conditions are achieved by adiabatic expansion of the vapour through a Laval nozzle into a vacuum chamber. This paper will describe the basic physics of the process, outlining computer fluid dynamic (CFD) modelling of flow in the nozzle, the effects of different flow conditions on the condensation process and discuss the practical design issues associated with operating supersonic nozzles. Results obtained from a CFD model of the nozzle, which compared two methods of incorporating condensation, showed that inclusion of condensation substantially changes the conditions in the nozzle. Most noticeably, the effect of condensation produces a region in the nozzle where the temperature remains almost constant.

Jan 1, 2006

By Ralph J. Holmes, Victor Sharp, Steven J. Spencer, Kevin J. Davey, Jonathan J. Campbell, Peter L. Phillips, David G. Barker

"Improved measurement tools for monitoring and control of AG/SAG mill performance have a high level of interest in industry. Historically, acoustic emission monitoring has been widely used on SAG/AG/ball mills and hydrocyclones to provide new information on the conditions inside these devices affecting their performance. The current work was focused on a new technique using surface vibration monitoring of a number of pilot-scale and production-scale AG/SAG mills to yield insights into the events occurring in the mills. The development of relationships between signal analysis outputs and mill operating conditions can be used for soft-sensor measurement of mill process variables. The technique used an array of accelerometers mounted on the mill lifter bolts linked to a fast data acquisition system which monitored the surface waves generated during operation. Details of the system are presented. Mill operating variables were adjusted systematically to provide a wide range of operating conditions for surface vibration signal collection. The experimental approach is discussed.The signals acquired during the experiments were analysed using a range of techniques. The results show that strong relationships exist between measured vibration power (both total power and within certain frequency bands) and mill load level/power and mill speed. A new method for extraction of power spectral density and band power information on features of interest in a mill rotation cycle is also presented.These results show that single sensor analysis information from the surface vibration system can be used as soft sensor inputs for monitoring process variables such as mill load that until now, have not been reliably measured. System outputs also show considerable promise in the area of condition monitoring. An example of the signal analysis output is presented showing elevated vibration levels in an area with higher resultant wear. Eventually, it is considered that outputs from this system for process variable and wear condition monitoring will be key new inputs to an online AG/SAG mill monitoring and control system."

Jan 1, 2003

By Terra Dinamica, Frank Lucca

This paper discusses blast design for vibration control in tight construction blasting. Topics include blast pattern geometry, blast design formulas, loading, explosives & initiation selection, and utilizing borehole deviation equipment and lasers, and rules of thumb. The paper will also explore vibration prediction, neighbor relations, and related topics, such as blast plan submittal. Various projects from metropolitan construction blasting operations will be used as examples. Examples include blasting in the inner city, next to pipelines, and in housing developments.

Jan 1, 2005

By Janne P. Isohaka, Anssi M. Laaksonen

"Abstract In Scandinavia the use of steel pipe piles in bridge foundations started in the mid-1980s and has increased steadily since. As the piles driven in soft soils are slender, they can fail by buckling. Buckling usually requires taking into account the second order effect in structural and geotechnical design.The purpose of this paper is to derive formulas for demonstrating the theory behind the formulas given in literature for the second order effect of initially bent piles.IntroductionIn Scandinavian countries solid bedrock usually lies at moderate depth. If the bridge site is in an area where the soil above the bedrock is soft, the bridge is usually founded on end-bearing piles resting on the bedrock.The main purpose of the piles is to transfer axial forces into bearing soil. Like columns, piles can lose their stability by buckling when surrounded by soft soil. When axial compression on a slender, initially straight, pile reaches a particular value called the critical load, the pile is subjected to lateral deflection and loses stability. The soil around the pile suffers a corresponding deformation. This soilstructure interaction increases the critical load compared to a pile without surrounding soil.It is very unlikely that piles are ideally straight. Initial curvature along with curvature and deviation caused by the installation of piles causes bending moments to the pile when normal force is applied. These lateral displacements increase when normal force increases. This increase of moment is called asecond order effect.Eurocode and literatureEurocode 7 includes guidelines for the design of piles (Eurocode 3, section 5 includes design of steel piles). However, there are no clear guidelines for considering the second order effects related to piles surrounded by soil. Eurocodes advise doing structural design of piles the same way as in the case of columns. With columns, the second order effect is taken into consideration by multiplying the first order moment with the factor shown below (SFS EN-1992-1-1, 2005):"

Jan 1, 2014

By Martin Langenderfer, Catherine Johnson, Phillip Mulligan, Kelly Williams

The physical geometry of a charge has a direct correlation to the geometry of the shock wave. This relationship appears strongest within the boundaries of the visible fireball. As the shock wave propagates outward past the limits of the fireball, the theory states that the geometry of the shock wave should even out and become more spherical. This paper investigates pressure vs. time at two distances, one ‘Near Field’ at the extent of the fireball and one ‘Far Field.' The two Fields were instrumented with three free-Field pressure probes from PCB oriented at 0, 45, and 90 degrees to the front face of the charge, in the same horizontal plane as the charge. This orientation allows for the comparison of the shock wave from the face and vertices of the charge. All the pressure sensors were connected to a Data Acquisition System (DAS) recording at 2 million samples per second (2MS/s). Two high-speed cameras, a Phantom and an MREL Ranger II, recorded the detonations for qualitative examination of the fireball, and the shock wave. Three charge geometries were used and compared to the shock propagation of a sphere. The other geometries tested are cylinders, cubes, and tetrahedrons. Charges were made from a PETN based sheet explosive. In the Near Field, a lower pressure is observed along charge vertices with highest pressures from each face. In the Far Field, vertices record a higher pressure, possibly due to the shock waves from the adjacent faces intersecting, indicating that shock pressures do not always even out in the Far Field. This paper will describe the methodology and findings of this experiment and attempt to determine causality for trends in the data gathered.

Jan 1, 2018

By Farrukh M. Mazhar, Philippe P. Martin

Electrical Vertical Sounding (EVS) profiling has proven to be a valuable tool to set the alignment and guide the design of a 17 km-long, 4.7m diameter water-conveyance tunnel in the Peruvian Andes at an altitude of 4,260 m. EVS profiling helped determine where to locate boreholes, and reduce the amount of drilling to 1,200 m of vertical and inclined boreholes. EVS profiling allowed the designer to identify and verify by drilling the existence of zones with difficult tunneling conditions that were avoided by realigning the tunnel. The rock quality was checked by drilling and a combined scheme of excavation by TBM and conventional drill and blast technique was developed for the final design.

Jan 1, 2003

By S. Ganguly, R. Kononov

Carbothermal reduction of manganese oxides and manganese ores in the solid state was studied in hydrogen, helium and argon at different temperatures, ore compositions and carbon to manganese oxide ratios. Wesselsore (South Africa) and two grades of the Groote Eylandt ore (Australia) with different level of impurities were examined. Ores were characterised by XRD, X-ray fluorescence, optical microscopy and scanning electronmicroscopy. Isothermal and temperature programmed carbothermal reduction experiments were conducted in a fixed bed reactor in a vertical tube furnace, with on-line monitoring of gas composition by the CO-CO2 infrared sensor. The reduced samples were characterised by XRD, SEM and LECO analyses. Extent of reduction was calculated using data on the off-gas composition, and LECO carbon and oxygen contents in the reduced sample. Manganese oxides in the ore were reduced to a-Mn and carbides Mn23C6 and Mn7C3 depending on the carbon to ore ratio. The reduction rate of manganese ores in hydrogen was higher than in helium and argon. Key words: Manganese, Carbothermal Reduction, Hydrogen, Argon, Carbon Monoxide, Helium, Kinetics.

Jan 1, 2007

By J. E. Urosek, K. L. Cashdollar, D. A. Beiter, G. J. Shemon

The National Institute for Occupational Safety and Health (NIOSH) and the Mine Safety and Health Administration (MSHA) conducted joint research to evaluate explosion blast effects on mine ventilation stoppings at the NIOSH Lake Lynn Experimental Mine (LLEM). After mine explosion accidents, MSHA conducts investigations to determine the cause(s) as a means to mitigate or eliminate future occurrences. As part of these post-explosion investigations, the condition of underground stoppings, including the debris from damaged stoppings, are documented as evidence of the strength and the direction of the explosion forces. The LLEM data showed that a total pressure of 52 kPa (7.6 psi) destroyed the solid concrete block stopping, ~36 kPa (~5.2 psi) destroyed the hollow-core concrete block stopping, and 9 kPa (1.3 psi) destroyed the steel panel stopping. These results will assist investigators in determining the explosion forces that destroy or damage stoppings during actual coal mine explosions.

By D. S. van Vuuren

Over the last 60 years many different processes were conceived to reduce the cost of titanium produced by the Kroll process. However, success eluded all previous efforts, which were consequently terminated in periods of economic downturn. Recently, the grow thin demand for titanium and the high cost of producing the metal again sparked renewed attempts in various parts of the world to replace the antiquated Kroll process with a more efficient route. The different options to produce titanium are reviewed, classified and evaluated in terms of the fundamentals underlying the technologies, and it is shown that the options considered to be the most likely to replace the Kroll process, are continuous processes to reduce TiCl4 metallo-thermically to titanium powder. Of these, continuous magnesio-thermic reduction of TiCl4 would conceptually result in the lowest-cost and highest-value product. However, when considering by-product salt removal from the titanium product and recycling of the salt as well, sodio-thermic reduction of TiCl4 is better.

Jan 1, 2009