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By A. I. Johnson

This paper describes," the application, of a modular or building block approach to the analysis, design, and control of complex mineral treating processes. The main purpose of the paper is tutorial, to show the reader how such processes can be modeled using a modern digital computer" and, not to discuss in any detail the results that may be achieved in such studies. It is proposed that, the main techniques be illustrated by reference mainly to the Bayer process for alumina extraction and purification; in cooperation with the Aluminum Company of Canada Ltd. the author and his Colleagues at McMaster University and their students have studied this, process as a means of applying new computer techniques to extractive metallurgical processes. The plant described was studied by the author and his colleagues as a senior undergraduate project in cooperation with the Aluminum Company of Canada. It is one of several studies that have been carried out with Canadian industry. (1)

Jan 1, 1972

By R. Y. K. Yang, O. Olajide, E. H. Cho

"This study focuses on partial leaching of coal pyrite with sodium sulfite in order to increase its degree of liberation from the coal matrix, which might help to increase the removal of coal pyrite, together with trace elements of arsenic (As), selenium (Se) and mercury (Hg) by froth flotation. The U.S. Bureau of Mines’ two-stage reverse flotation process was applied to further reject coal pyrite in the second stage, where pyrite was floated while coal was depressed. The results show that the leached coal flotation with sodium sulfite produced lower pyritic sulfur content in the clean coal by approximately 25% compared to the flotation of unleached coal. The synergism mechanism between the leaching and the two-stage flotation is delineated. The rejection of trace elements (As, Hg and Se) after the two-stage flotation process with unleached coal followed approximately that of pyritic sulfur (64.6%). However, after the two-stage flotation with leached coal, the rejection of Se was as high as that of pyritic sulfur (77.9%), while the rejections of As and Hg were 20% lower than that of pyritic sulfur, or followed approximately the same rejections obtained through the two-stage flotation with unleached coal.IntroductionSO2 is a reducing reagent, but when it is combined with oxygen in an acidic solution, it will become a strong oxidizing reagent for leaching coal pyrite. Sundaram et al. (2001) found that the reagent could leach coal pyrite to produce ferric iron, which, in turn, catalyzed the oxidation of SO2. Similarly, Cho et al. (2009) found that the reagent could leach pyrite as well as mercury from coal. In the present study, coal was preconditioned by partially leaching coal pyrite in water-coal slurry with sodium sulfite at 48° C. The partial leaching of coal pyrite may enhance its degree of liberation from the coal matrix and give a chance to be rejected more effectively during the flotation.The two-stage U.S. Bureau of Mines’ reverse flotation process (Miller, 1975) was used in this study. The first stage is conventional flotation, in which coal is floated while material with higher ash and pyrite content remains in the cell. Kerosene is used as a promoter to float the coal and MIBC (methyl isobutyl carbinol) is used as a frother. In the second stage, the floated coal from the first stage is depressed using a starch-based reagent, while coal pyrite is floated using potassium amyl xanthate. In this second stage, the liberation of coal pyrite from the coal matrix seems to be an important factor for successful rejection of coal pyrite."

Jan 1, 2015

By H. Colijn

Feeders are used to provide a means of control for the withdrawal of bulk materials from storage units, such as bins, bunkers, silos and hoppers. This control function can only be performed properly as long as the bulk materials flow by gravity to the feeder in a uniform and uninterrupted fashion. A feeder can do many things, but it should never be considered a suction pump: During the past few years various papers have been written and presented on feeders and their application. 1,2,3,4,5,6,7,8,9)* It is not the intent of this paper to cover the same ground, and the readers are therefore ad¬vised to consult the referenced publications for supplementary information. This paper will be confined to some specific design criteria of bin feeders, such as feeder load and power requirements. Special attention is given to the basic design criteria of vibratory feeders.

Jan 1, 1968

By Keith A. Heasley

Historically, the surface subsidence over underground coal mines has been predicted using empirical profile or influence functions which have little or no connection to the actual mechanics of the subsidence. Without a mechanistic basis, establishing the exact site-specific parameters to use in these empirical methods has been problematic. A practical subsidence predictive method based on mechanics has the appealing capability of allowing the determination of site-specific parameters from fundamental properties of the overburden with minimal field calibration work. This paper presents several case studies where a mechanics-based, boundary-element program is used to back-calculate the surface subsidence associated with various panels at several Northern Appalachian coal mines. The program used in this case study is called LAMODEL, and it incorporates a frictionless, laminated overburden into a general purpose displacement-discontinuity code primarily designed for calculating the stresses and displacements in coal mines or other thin scam or vein type deposits. In this paper, the program is used to calculate both the underground convergence and the resulting surface subsidence at five longwall panels and a room-and-pillar section. The fitted subsidence from the model is compared with the field measurements and analyzed. The results from the case studies in this paper demonstrate that the laminated model with calibrated properties can easily provide moderately accurate subsidence predictions and is fairly flexible for fitting measured subsidence. However, additional subsidence predictive case studies arc recommended in order to ultimately evaluate the potential of the laminated overburden model for practical subsidence prediction

Jan 1, 1999

By Richard C. Marshall

The heightened concern over the environment which has developed in recent years has caused activities on National Forest lands to come under more intense public scrutiny. This has been especially true for activities oriented toward the production of commodities. Cattle grazing, mining, timber harvesting, and oil and gas leasing and drilling have all been increasingly subject to appeal and litigation. As a result, environmental analyses being conducted by the Forest Service have become more comprehensive, and measures to reduce or eliminate adverse impacts on resources have been given more attention. The costs of such environmental mitigation measures can be significant even when viewed in the context of the millions of dollars a company may spend, for example, to develop a mine. Using the Montanore Project in northwestern Montana as a case study, this paper examines the costs of alleviating some of the detrimental effects which may occur as a result of a mining operation. Although many of the general issues that have been raised about Montanore are common to other mineral projects, the scale of the project, as well as the fact that the ore body is within a wilderness area, the site is in grizzly bear habitat, and the surface waters are considered to be pristine, all combine to make Montanore particularly challenging from an environ- mental standpoint. Much of the information which follows is contained in the most recent version of the Draft Environmental Impact Statement (DEIS) which is scheduled to be published in several weeks. Based on agency and public comments, some of the information presented in the paper will change before the Final Environmental Impact Statement is issued in 1991.

Jan 1, 1991

By L. Alagha, J. L. Corchado-Albelo

To address the U.S. Department of Energy’s critical minerals strategies regarding rare earth elements (REE) in the U.S.A. This study evaluated apatite-rich mine tailing from the historic Pea Ridge Iron Mine (PR) for possible enrichment of REE by the froth flotation process. Comprehensive characterization studies were performed on the tailing samples to quantify the REE content, identify the REEbearing minerals and their liberation behavior. The aforementioned characterization studies were: x-ray fluorescence analysis (XRF), inductively coupled plasma mass spectrometry (ICP-MS), and TESCAN’s Integrated Mineral Analysis (TIMA). The ICP-MS analysis showed that the concentrations of heavy-REE and light-REE were 8000 ppm and 3000 ppm, respectively. TIMA showed that monazite was the major REE-bearing mineral. Additionally, it was shown that monazite and other REE-bearing minerals were strongly locked within larger apatite grains. Findings from the characterization studies suggested that REE could be enriched using phosphate minerals’ direct froth flotation process. Flotation feasibility tests were performed using selected organic and inorganic iron oxides’ depressants, including polyacrylamide (PAM), in-house synthesized hybrid polyacrylamide (HyPAM), chitosan, sodium silicates, and corn starch. Results showed that the depressant’s efficiency at pH 9 was in the following order: HyPAM > chitosan > PAM > sodium metasilicate > corn starch. Zeta potential studies on the selected depressants indicated that chitosan had the highest adsorption on magnetite’s surface at pH 7. Therefore, additional batch flotation experiments using chitosan as an iron oxides depressant were conducted as a function of chitosan dosage. Results indicated that the highest P2O5 recovery of 55% and grade of 28 wt.% were obtained at 150g/t of chitosan. However, the concentrate’s highest total REE enrichment of 1.07% was achieved at a 200 g/t dosage of chitosan. The low enrichment of REE highlighted the complex mineralogy of the PR tailings and the need to implement additional beneficiation strategies before and after the froth flotation process.

Mar 2, 2022

By CHENCHEN SUN, GUOPING LUO, GUOCHENG ZHANG

Preparation of briquettes by adding CaF2 reagent into the Australian iron ore powder. The structure and morphology of iron ore briquettes during various reduction stages (i.e., Fe2O3→Fe3O4, Fe3O4→FeO, and FeO→Fe) were observed via an ore microscope and scanning electron microscopy. The results showed that CaF2 reacted with SiO2 to form CaO and SiF4 gas during the roasting process. The reduction swelling index decreased from 12.36 to 8.83% when the CaF2 content in the briquettes increased due to CaF2-mediated refinement of the hematite grains during the first stage of the reduction process. Lattice distortion resulting from the presence of Ca2+ in the FeO lattice during the second stage of the reduction process, coupled with an increase in the porosity of the iron ore briquettes and the formation of a low-melting-point slag phase, promoted the anisotropic growth of FeO lamellar crystals, which resulted in an increase in the reduction swelling index from 4.27 to 7.36%. During the third stage of the reduction process, the growth of iron whiskers was promoted by wüstite (FeO) lattice distortion caused by a solid solution of Ca2+ in the FeO lattice; the reduction swelling index increased from 15.61 to 24.72%, resulting in the catastrophic swelling of the iron ore briquettes.

May 27, 2021

By Xiaolong Bi, Shaohua Luo, Longjiao Chang, Shiyuan Cao, Jianan Liu

iliary agent was proposed. The mineralogical transformation and silicon extraction kinetics of laterite nickel ore in alkaline hydrothermal treatment were studied. The effects of reaction temperature (175 ~ 250℃), molar ratios of sodium hydroxide to ore (1.05 ~ 1.2:1), and laterite nickel ore particle size (44 ~ 178 μm) on the extraction ratio of silica were investigated by using the shrinking core model. The results show that the extraction ratio of silica increases with the increase of reaction temperature, sodium hydroxide to ore molar ratio, reaction time, and the decrease of raw ore particle size. The kinetic analysis shows that the separation of silica in laterite ore can be described by internal diffusion model. The apparent activation energy (Ea) of the reaction was 8.87 kJ mol− 1, and the kinetic modeling was established.

Dec 2, 2021

By VIVEK KASHYAP, Evody Tshijik Karumb, PATRICK TAYLOR

The partial reduction of zinc ferrite to zinc oxide and iron (II, III) oxide can enhance the leaching rate of zinc. Zinc ferrite has often been found as a major component of zinc residues and electric arc furnace dust. The Waelz process is an existing process for zinc ferrite processing, which requires a temperature of more than about 1200 °C to produce Waelz oxide containing ZnO. Since zinc residues have been deemed as a potential way for the extraction of zinc and other critical metals, it is important to analyze the reaction kinetics in the temperature range of interest. This manuscript discusses the chemical kinetics of zinc ferrite reduction by hydrogen gas. Several researchers studied the reduction of zinc ferrite with CO; however, unlike CO, the use of H2 gas as a reductant allows partial reduction of zinc ferrite even at low-temperature range (400–600 °C). Thermogravimetric analyses (TGA) experiments were performed in the temperature range of 300–700 °C with 10% and 30% H2, and the data obtained was analyzed using the isoconversional method of kinetic analyses. The standard models used for isoconversional kinetic analysis were chosen from literature and experimental data were fitted to determine the controlling mechanism and calculation of kinetic parameters of reduction of zinc ferrite. The rate of reaction was found to be increasing with an increase in temperature and partial pressure of H2 gas. The reaction could be divided into three stages, where reaction interface contraction was found to be the controlling mechanism at the initial stage of reaction. As the reaction proceeds, product layer thickness increases, and thus, diffusion was found to be the controlling mechanism. Roasting products obtained from TGA experiments were also characterized using a scanning electron microscope (SEM) to verify critical morphological details.

Jul 26, 2022

By Serdar Aktaş, Özgün Küçükoğlu, Burcu Nilgün Çetiner, Mehmet Hakan Morcalı

This study compares the cementation performance of metallic iron, metallic aluminum, and metallic tin in terms of the reaction conditions and parameters in synthetic antimony chloride solutions. The effects on the antimony recovery (%) caused by the cementators’ types, stirring speed, reaction time, and temperatures were explored thoroughly. The cementation kinetics of antimony were also explored for each cementator. The activation energies were determined to be 10.99, 9.09, and 13.58 kJ mol– 1 for Al, Fe, and Sn, respectively. The results reveal that the reaction is diffusion controlled, and comparable results were obtained for each cementator. At 25 °C, 40 mg of iron powder was found to reduce all antimony ions (i.e., approx. 99% recovery), but even when 100 mg of Al and Sn cementators were used, the antimony recovery did not reach 100%. This result shows that iron is the best candidate to cement antimony out of the solution.

Jan 28, 2022

By Muhammad Azeem Raza, Muhammad Zaka Emad, Muhammad Usman Tahir, Saqib Ahmad Saki, Muhammad Usman Khan

Shotcrete is a key initial rock support component used in underground mining and civil projects. The strength of shotcrete plays a vital role in providing and deciding the support adequacy. The strength of shotcrete is evaluated by its uniaxial compressive strength (UCS) test that is usually conducted on extracted core samples. Shotcrete cores are commonly extracted from the test panels along the direction of its application; thus, its strength perpendicular to the direction of application is often neglected. The true bearing strength of shotcrete is thereby ignored despite the fact that higher stresses act normal to the direction of its application. Although the anisotropic behavior of shotcrete is well reported, no study has reported extensive testing of this scale and nature. This study reports extensive testing of shotcrete cores extracted from tunnels of a mega hydroelectric project in Pakistan. The study reports 7- and 28-days strength tests of shotcrete cores. The research also investigates the anisotropic behavior of steel fiber reinforced shotcrete and suggests that shotcrete exhibits higher strength perpendicular to the direction of its application.

Dec 26, 2022

By Zhiyuan Ma, ZUI WANG, Xincheng Hu, Jianwei Cheng, Junhong Si, Yi Qin, Gao Ke

The harmfulness and destructiveness of mine gas explosion is quite serious, which is the first of all kinds of coal mine disasters. Once the gas explosion occurs, it could instantly generate explosion shock waves, high temperature airflows, and disaster gases, which cause the destruction of underground ventilation structures, disruption of airflow direction in a mine ventilation network, and miners’ deaths by asphyxiation. As an important barrier to prevent the spread of accidents caused by the gas explosion, the safety and reliability of the mine seal affects the mine’s production and the health of workers. Due to the demands of coal mine production and transportation, a large number of longitudinal and horizontal roadway networks have been developed underground. There are not only many flat and straight roadways in the complex roadway network structure, but also a large number of different types of bifurcations and bends. Once a gas explosion occurs, the impact of the blast waves on the mine seal after passing through the complex path is difficult to determine. Therefore, this paper establishes a numerical model of bifurcated and cornered roadways and studies how the impact of gas explosion shock waves on the structure of sandwich mine seal after passing through different types of bifurcated and cornered roadways. The damage state of sandwich mine seal is analyzed. The researching finding could prevent and manage the spread of gas explosion disaster, and improve the disaster mitigation of mine explosion accident.

Jul 11, 2023

By Alper Kirmaci, Taghi Sherizadeh, Dogukan Guner, Cameron Mitchel

Brow hazards are a significant concern in coal mine ribs and form when weak coal sloughs out of a rib face and exposes an overhanging block of more competent rock or coal. Of 36 rib failure fatalities in the last two decades, 36% resulted from rib brow failures. This highlights the need to better understand the mechanisms driving brow formations and failures to mitigate this hazard and eliminate potential fatalities. The research team at Missouri S&T worked to enhance the current CPRR system and include the potential for these brow hazards. We employed physical modeling methods to build a scaled model from critical brow cases observed in the field. The dimensions and properties of the models were scaled down by 14.4 times from the field cases. The results of the physical modeling efforts were used to assist in calibrating distinct element numerical models vital to understanding brow formation and failure mechanisms. Subsequently, three physical models were created and tested to provide data on an otherwise impossible-to-capture event at the field scale. The results of these tests provided formed brow dimensions that agree well with those observed at the field scale. The brow dimensions were 1.25 inches deep into the rib, equivalent to 1.5 feet when scaled up. Similarly, the numerical modeling efforts provided good agreement by capturing a brow forming 1.55 inches deep into the rib. The physical model results further validate the applicability of physical modeling efforts for capturing otherwise difficult and dangerous phenomena in a controlled lab setting.

Feb 22, 2026

By Richard A. Levins

The imposition of non-market regulations, such as the proposed SO2 standards for coal combustion, will typically lead to less efficient (thus more costly) production in a free enterprise system. For the coal industry these increased costs will occur in several ways, among which are mining less accessible low sulfur reserves and transporting low sulfur coal to distant markets. There are, of course, social benefits of reducing the S02 emissions from the use of high sulfur coal. The social benefits include decreased health risks, reduced damages to property, and certain unmeasurable benefits associated with the aesthetic appeal of clean air. Proponents of Federal S02 standards argue that the benefits gained from reduced emissions will exceed the costs borne by the coal industry and society in general in meeting the regulations. The purpose of this paper is to investigate the degree to which costs of meeting future energy demands from coal will change under different sulfur standards. No attempt is made to estimate the benefits of imposing regulations. Specifically, the impact of SO2 standards on the private costs of meeting regional coal demands, the competitive positions of the nation's major coal producing regions, the degree to which strip mining as opposed to underground mining will be feasible, the amount of coal being processed, and the amount of coal transported over major rail routes will be analyzed.

Jan 1, 1976

By S. Healey, P. Jean, G. Deschenes, M. Fulton

Three years ago, the New Britannia Mine started a project to improve productivity of its cyanidation plant. Results indicated that gold dissolution was strongly influenced by sulphide minerals and that the slower gold dissolution rate had a detrimental effect on overall gold recovery. The leaching strategy had to be modified to address this issue. Changes to the leaching circuit proved to be very successful. The first action was to introduce lead nitrate in the leaching circuit. The strategy of addition of lead nitrate was upgraded in three steps. An on-line free cyanide analyser was installed and the strategy of cyanide addition automated. The enhancement of the leaching kinetics have resulted: an 4% increase of gold recovery, from 87.8% in 1996 to 91.9% in 1999, which represents a reduction of 0.17 git Au in the leach residue; an average of 1330 additional extracted gold ounces per year from 1997 to 1999; a 21 % reduction in the cyanide consumption; the shut down of the cyanide destruction plant; and finally a contribution to the 27% reduction in the overall production cost per tonne of ore.($ 3 per ton). The significant increase of the throughput was instrumental in the reduction of the processing cost. In 1999, the improvement of gold recovery represented an additional gross revenue of $c""l.9 Million. The project is discussed in details in this paper.

Jan 1, 2000

By Raj K. Rajamani, Poly K. Songfack

The slurry transport within the ball mill greatly influences the mill holdup, residence time, breakage rate, and hence the power draw and the particle size distribution of the mill product. However, residence-time distribution and holdup in industrial mills could not be predicted a priori. Indeed, it is impossible to determine the slurry loading in continuously operating mills by direct measurement, especially in industrial mills. In this paper, the slurry transport problem is solved using the principles of fluid mechanics. First, the motion of the ball charge and its expansion are predicted by a technique called discrete element method. Then the slurry flow through the porous ball charge is tackled with a fluid-flow technique called the marker and cell method. This may be the only numerical technique capable of tracking the slurry- free surface as it fluctuates with the motion of the ball charge. The result is a prediction of the slurry profile in both the radial and axial directions. Hence, it leads to the detailed description of slurry mass and ball charge within the mill. The model predictions are verified with pilot-scale experimental work. This novel approach based on the physics of fluid flow is devoid of any empiricism. It is shown that the holdup of industrial mills at a given feed percent solids can be predicted successfully.

Jan 1, 1995

By Stephen R. Pogorski, Nicholas Busigin, Colin R. Phillips

The movement of radon away from its source in porous media is determined by two key parameters: the fraction of the total radon formed which enters the intergranular pore spaces, termed the emanation coefficient, and the transport processes which exist in these pores such as diffusion and convection. The first parameter, the emanation coefficient, is of primary importance since it is a measure of the actual amount of radon which is free to migrate within the media. The effects of particle size and radium concentration on the emanation coefficient were examined using a quartz-pebble conglomerate ore from the Elliot Lake mining district of Ontario. It was found that the smallest particle size examined (<74 µm) had the highest radium concentration and contributed the most to the radon emanation. A one-to-one correspondence between radium concentrations for the various particle size fractions and radon emanation was not observed. Samples were examined using scanning electron microscopy and very small particulates were observed to be present on the particle surfaces. When these very small particulates were removed from the host particle surfaces by rinsing, the radon emanation decreased by a factor of 17. This result indicates that most of the emanation comes from the very small particles. The effect of moisture on the emanation coefficient was examined qualitatively and a trend of increased radon release with moisture content was noted.

Jan 1, 1981

By Joseph W. Kupfner

It is a recognized fact that a good maintenance program is a pre-requisite for minimum delay costs and maximum availability of equipment. To develop such a program and to make it effective, one must establish detailed instructions pertaining to inspections, lubrication, servicing, and/or replacing of various parts. A schedule must also be established for these maintenance checks, whether they be weekly, monthly, or whatever period is essential for the equipment. The number of tasks to be performed becomes monumental, and the administration is beyond error-free human capacity. It is for this reason that the computer must be an essential element in any efficient and economical preventive maintenance program. The evolution of a computerized maintenance program began some 18 years ago in the Mining Division of USSteel. It started with a manual system of preparing cards containing preventive maintenance instructions that had to be performed on some regular basis. We were very quickly overtaken by the massive task of administration and distribution of instruction cards to the users. The task became insurmountable as more mines were added to the system, mines that were spread over a large geographic area. It also became evident that the ability to make changes in equipment assignments and in the "what to do" instructions would require more time than had been anticipated.

Jan 1, 1986

By Maurice Rey

The copper segregation process is designed to concentrate oxidized copper ores or mixed sulfide-oxide copper ores which are refractory to normal and cheaper mineral dressing or leaching processes. Such ores contain copper silicates or highly disseminated copper minerals in a gangue not entirely free from limestone or dolomite. Concentra¬tion by flotation is, under these circumstances, not possible and the acid-consuming constituents do not permit acid leaching. A high temperature treatment at 700-800°C, in the presence of a small amount of sodium chloride and of finely divided carbon, concentrates the copper into easily floated metal by a kind of reducing chloridizing roast. The sulfides, if present, are either oxidized in the heating stage and react like oxides or float with the metallic copper in the flotation step. The ores which have the aforementioned characteristics and which are high grade enough to pay for the treatment are scarce, so that the process has only a limited application. Theory of Copper Segregation Sodium chloride, reacting with water vapor and the acid gangue constituents, produces hydrogen chloride which reacts with the copper minerals. The copper is volatilized as cuprous chloride and immedi¬ately reduced on the coal particles by hydrogen emanating from the volatile matter of the coal and from the water-gas reaction. Hydrogen chloride is

Jan 1, 1985

By Jacek Kolacz, Knut Lyng Sandvik

Fine grinding in an air swept and a grate discharge ball mill working in closed circuit with a forced vortex air classifier has been investigated in continuous laboratory scale. Minerals with different physical properties were ground down to 40, 20, and 10 micron top size. The shape of the product particle size distribution curve was investigated and specific surface (BET) was measured. During production of material with top size of 40 microns in an air swept mill, the capacity was up to 25% higher when compared to a grate discharge mill. This difference dropped to 180A during production of 10 micron top size material. A corresponding decrease in power consumption was observed. An important finding is that by regulation of the air flow rate through the mill, it is possible to achieve products with different specific surfaces and particle size distribution curve steepness. During production of the 10 pm material, the specific surface could be varied in the range 3 to 4.5 m2/g. Such powders could hardly be produced in a grate discharge mill because fine particles coated the grinding media and the lining. On the other hand the internal classification in the air swept mill kept the size distribution of the mill content relatively free of fines. This prevented a similar slowing-down of the air swept grinding process.

Jan 1, 1995