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By Joshua Cole, Joshua Sovechles, Christian Cardoso, Guillermo Bermudez, Martta Hirsi, Joshua Dettamanti, Rabia Abbasi

The implementation of technological advancements in flotation is key to optimize performance in mining operations. Consequently, flotation cell’s performance is highly dependent on the effectiveness of the mixing mechanism. A more efficient flotation mixing mechanism is likely to improve metallurgical performance and optimize energy consumption, which is the motivation for Metso’s journey to develop the latest iteration of FloatForce®. Looking to test the new design at plant scale, Metso approached the Kennecott Copperton concentrator, which is continuously looking for different venues to improve metallurgical performance. In this context, a test campaign was conducted to implement this new flotation mixing mechanism in their rougher circuit during 2024. The industrial trial consisted of several sampling campaigns assessing different operational parameters for comparison purposes around a 300m3 flotation cell. The effect of the new flotation mixing mechanism on the cell’s power draw was also studied. The results of this trial at Kennecott are presented in this paper. Overall new flotation mixing mechanism, FloatForce+ was seen to perform as well as the original FloatForce.

Feb 1, 2025

By K. Terhaar, K. Prisbrey

The objective was to determine operating protocols for a lead and silver column flotation cleaner, being considered for installation at Sunshine Mining & Refining Co.’s Kellogg mill in Northern Idaho. In this column, tetrahedrite and galena were floated, and pyrite and other gangue minerals, including siderite and silica, were depressed. The procedure was to develop a dynamic simulation using a linear transfer function approach. The transfer function related cause and effect variables such as the influence of collector and depressant dosages on recovery and grades. Bench-scale flotation tests followed by pilot column testing provided the data used to develop a linear transfer function. The transfer function was derived using a spreadsheet. This model was applied to simulate how the flotation column could be made to respond to disturbances in feedgrade. The results were that xanthate, zinc sulfate, and sodium cyanide were found to be suitable controls for grade and recovery. Simulations showed the best sequence of manipulations of these reagents, and these sequences were useful for future operator training. The conclusion was that linear transfer functions were able to simulate lead and silver recovery, develop scenarios for operator training, and provide a foundation for future on-line control.

Jan 1, 1999

By L. H. Banning

Recent dry-top electric smelting tests at the Northwest Electrodevelopment Experiment Station, Albany, Oreg., indicate that a high-titanium slag and a good grade of pig iron can be produced from alluvial Idaho ilmenite. A total of 120 tons of concentrates were smelted during this investigation, to yield an average of 0.5 ton of slag and 0.3 ton of pig iron per ton of ilmenite. Power consumption averaged 1,400 kv.-hr. per ton of ilmenite, at a feed rate of 400 to 500 pounds per hour, when operating at an electrical energy input of 290 to 370 kilowatts. The optimum operating voltage appeared to be 110 volts, phase-to-phase. Graphite electrode consumption averaged 15.6 pounds per ton of ilmenite smelted. Magnesite furnace refractory withstood the corrosive action of the hot metal and slag better than carbon refractory.

Jan 1, 1955

By Deno M. Pappas

This report presents results of a U.S. Bureau of Mines study of longwall gob material. The objective of this work was to determine material stiffness properties of the gob for use in numerical models of rock mass response to longwall mining, Photographs of actual mine gob were digitized to obtain approximate particle size gradations of gob material. The gradation curve was shifted down to a laboratory scale, and 20 uniaxial compression tests were conducted. Varying the maximum particle size was not found to affect the stress-strain behavior, but changing the gradation appeared to influence the stress-strain behavior. The stress-strain relationship of the simulated gob material was nonlinear, the stress-secant-modulus relationship was approximately linear, and the stress-tangent-modulus relationship was approximately a second-order polynomial function. Equations were generated from these curves, providing numerical modelers with a means to estimate gob moduli based on the stress level. In addition, the experimental data were statistically evaluated using multiple regression analyses, producing a series of equations to predict the secant and tangent moduli from the given stress level, bulking factor, rock strength, and thickness-to-width shape ratio of the particles.

Jan 1, 2010

By Elmer W. Pehrson

Minerals have played a prominent role in the affairs of man and nations since time immemorial but with the advent of the industrial revolution, expanding use of the products of the mineral kingdom became synonymous with the material progress of mankind. Individuals and business groups have recognized this fact so have been aggressive in searching for and utilizing mineral resources, with notable success. Indeed, their achievements are primarily responsible for the present Machine Age. On the other hand, until recently the body politic has failed to grasp fully the essentiality of minerals although, at times, access to mineral supplies has been an important factor in the political maneuvers of nations. This chapter is concerned primarily with the broader political and economic relationships of mineral resources to the world economy, and with the internal and external actions of nations in the field of minerals. Many factors that condition the mineral economy of regions and the world as a whole, influence the internal and external affairs of individual nations. The more important of these are: 1. The nature of man's dependence on minerals. 2. The problems resulting from the unique characteristics of mineral occurrence. 3. Geopolitical concepts. 4. Minerals and world power. Actions of individual nations affecting their mineral economy seek two basic objectives: 1. Attainment and maintenance of prosperity. 2. Military security. Other objectives may be cited but on careful analysis they become integral parts or extreme phases of the two points noted above. For example, the twentieth century aggressions of the USSR, Germany, Italy, and Japan might be considered as direct bids for world power but they also can be interpreted as exaggerated or mistaken efforts toward military security and peacetime prosperity. Similarly, trade barriers, nationalization of industries, foreign exchange manipulations, taxation, monopolistic prac-

Jan 1, 1964

By A. T. Iannacchione

The Bureau of Mines established geologic factors affecting the mining of the Lower Kittanning coalbed to aid in coalbed minability studies and examined the occurrence of "wants" (places where coal is missing) and types of unstable roof rock strata. Trends established from mapping, including prediction of areas of high methane emissions, were extrapolated to unmined areas. 'Wants' in the coalbed are of two types: Erosional and depositional. Erosional features occur where north-south-trending sand-filled channels cut into the coalbed. Variations in depositional environments have caused the coalbed to "split" into several thinner units. Slickensides, commonly indicative of unstable roof, are adjacent to and on the underside of sandstone channels; they were caused by differential compaction and by soft sediment sliding along the contact between the sandstone and adjacent shale. The frequency of unstable roof also increases where the interval between the Middle and Lower Kittanning coalbed is less than 30 feet. The zones of weakness at the contacts above and below the Middle Kittanning coalbed are the controlling factors for unstable roof in these strata. Methane emissions from the coalbed are controlled primarily by depth, fracture permeability, and rank of coal. Local geologic factors are coalbed thickness, associated rock strata, structure, and proximity to outcrop.

Jan 1, 1979

By Thomas Trochalides

Newtown Creek Water Pollution Control Plant in Brooklyn, NY is the largest of 14 Water Pollution Control Plants in New York City. It services over 1 million people with a current processing capacity of 310 million gallons daily. Upgrades to the plant have been underway since 1998. This paper details the foundation elements installed in three separate contracts during 2009: NC-41F, NC-36G, and NC-47G. The elements are Concrete-Filled Pipe Piles, H-Piles, Steel Sheet Piling, Secant Walls, Drilled Caissons, and High Capacity Micropiles. Soils on the site consist of fill over organic silty clay and silty sand. Beneath the organic layers lie lake sand and varved silt and clay, sitting atop glacial till and rock. Due to Federal Mandates, certain plant capacity and secondary treatment requirements had to be met by specific dates. Failure to meet the requirements would have an adverse affect on the NYC areas being serviced. Further complicating the project, the existing plant operations had to be maintained throughout the entire construction phase. To accommodate the constraints of the project, new specialty equipment and several key redesigns were used to maintain construction schedules

Jan 1, 2010

Jan 1, 1881

The Pittsburgh (Pa.) and Spokane (Wash.) Research Laboratories are among the world?s foremost mining research establishments. Once a part of the former U.S. Bureau of Mines (USBM), which was abolished by the U.S. Congress in fiscal year 96, health and safety research at these laboratories was transferred to the National Institute for Occupational Safety and Health (NIOSH). NIOSH is the Federal agency responsible for conducting research and making recommendations for the prevention of work-related illness and injury. The Institute is part of the Centers for Disease Control and Prevention within the U.S. Department of Health and Human Services. Over the past two decades, the Pittsburgh and Spokane Research Laboratories have produced sustained technological achievements in mining health and safety, including? ? Development of novel respirable coal dust control technologies and more effective monitoring techniques to reduce worker exposure to hazardous mine dusts. ? Improved ground control technologies to warn and protect miners from the dangers of coal mine roof collapses and other hazardous strata conditions. ? Improved ergonomic design criteria and training methods to protect mine workers from injuries and fatalities associated with equipment and manual tasks. ? Development of enabling technologies that allow miners to control their mining equipment from a physically safe, protected work area away from respirable dust, harmful noise levels, and roof collapses. ? Improved mine fire detection and extinguishment techniques. ? Development of smaller, lighter, and safer emergency breathing devices.

Jan 1, 2007

By Rambabu Pothina, Rajive Ganguli

The economics of a mineral processing circuit is dependent on the numerous sensors that are critical to optimization and control systems. The sheer volume of sensors results in mines not being able to keep the sensors calibrated. When a sensor goes off calibration, it results in errors which can severely impact plant economics. Normally, these errors are not detected until the error grows and becomes a large (“gross”) error. Undetected errors are not remedied until the next calibration, which on average are a year apart Beamex (2019) [1] across all industries. Classical statistical methods that depend on linear relationships between input and response variables are typically used to find gross errors, but are not effective for highly non-linear and non-stationary operations in mining and mineral processing industries. Calibration of sensors is time-consuming and generally requires physical intervention that results in equipment downtimes causing production losses. Therefore, in situ detection methods are warranted that do not require physical removal of sensors to compare with standard measurements or well-calibrated sensors. Data-mining based techniques and algorithms have high success rate in tackling such problems. This paper presents results from a groundbreaking multi-year big data research project whose goal was to develop data-mining-based original techniques in a multi-sensor environment to identify when sensors start to stray, rather than wait for errors to grow. The carbon stripping (gold) circuit in the Pogo Mine of Alaska was selected for this project. Maintaining strip vessel temperatures at optimum levels is crucial for maximizing gold recoveries at Pogo, and hence the focus was on the temperature sensors of the two strip vessels. An automated algorithm to detect errors in strip vessel temperature sensors was developed that exploited data from multiple sensors in the strip circuit. This algorithm was able to detect with a high success rate when bias errors of magnitude as low as ± 2% were artificially induced into strip vessel temperature data streams. The detection times of about 1 month were much less than the industry average calibration frequency of 1 year. Thus, the algorithm helps detect errors early, without stopping the circuit. The algorithm alarms can serve as triggers when calibrations are done. Experimental methodology along with results, limitations of algorithms, and future research are also presented in this paper.

By R. C. Troxell

Alternative methods of analyzing data acquired by the Morenci copper concentrator process control instrument-computer system are presented. Experimental measures of ore characteristics, for proposed feed forward control, are introduced. These include on-line indexes of ore hardness, ore density, ore dusting, and ore color. Comparison of metallurgical results before and after computerized process control implementation, allowing for differing ore grades, oxidation, hardness, and fineness of grind, also is described.

Jan 1, 1979

By R. S. Dean

A large metallurgical experiment station at Salt Lake City to house the works of the Bureau of Mines in the intermountain area properly has long been projected. It finally became possible when a Public Works Allotment of $300,000 was set aside for building and equipment. With the new building assured, the Bureau of Mines decided to move the headquarters of its Metallurgical Division from Washington, D. C., to Salt Lake City, Utah. It was felt that this move would simplify they administrative work of the chief engineer of the division, as all stations devoted primarily to metallurgical work are west of the Mississippi. These include Rolla, Mo.; Minneapolis, Minn.; Pullman, Wash.; Reno, Nev.; Berkeley, Calif.; Boulder City, Nev.; and Tucson, Ariz. In addition to these stations will groups, of investigators working on metallurgical problem, are maintained at Pittsburgh, Pa., and College Park, Md. Salt Like City was clearly a more central point for the direction of this scattered work than Washington, D. C. The building (fig. 1, A and B) was designed from general plans worked out by the authors of this paper. Contraction was begun in March of 1939, and by the end of the year the Metallurgical Division had moved, into its now quarters.

Jan 1, 1940

By James Paone

Drillability of rocks by mechanical means is closely related to the physical properties of the respective rocks, Various approaches by previous investigators on rock drillability are presented, as well as recent techniques studied by the Bureau of Mines. The studies show drillability concepts based on (1) theoretical drilling equations derived from laboratory drilling experiments extended to field drilling results and on (2) a statistical method where multiple regression analysis is used to develop a prediction equation for drillability.

Jan 1, 1966

The mineral chromate is the sole current source of commercial chromium Chromite varies compositionally within limits permitted by the formula ((Mg,Fe,Zn,Mn)(A1,Cr)2O4) No chromate has been mined in the United States since 1961 In the past, almost all the chromate mined in the United States came from Alaska, California, Maryland, Montana, Oregon, and Pennsylvania, with about one-half of all production coming from Montana Primary chromate deposits occur only in certain kinds of ultramafic or closely related anorthositic rocks The two major types are stratiform (layered) and pod-shaped The Stillwater Complex of Montana is the largest known United States resource It is a stratiform deposit where several exposed zones of high-iron chromiferous material extend in length Since there is no commercial chromate mining in the United States, there are no environmental problems related to underground mining

Jan 1, 1975

By H. E. Heide

The serious shortage of domestically produced asbestos during the war prompted the Bureau of Mines to investigate reported asbestos deposits in Alaska. The most promising' appeared to be these in the Cosmos Hills and Jade Hills areas along the Kobuk River in northwestern Alaska. The deposits along the west side of Shungnak River, a tributary of the Kobuk River, were the first to be investigated by the Bureau, in the summer of 1944. Four bulldozer trenches were excavated, from Which a 2-ton sample was taken. This sample was shipped to Rolla, Mo., for testing in the Bureau of Mines laboratory. In the summer of 1945 an investigation of asbestos deposits on Cosmos Creek, also a tributary of the Kobuk River, was begun; the work was completed during the field season of 1946.

Jan 1, 1949

By Tasuku Fuwa, John Chipman

Equilibrium data on the reactions of gases with carbon and oxygen dissolved in liquid iron are reviewed and correlated. A source of error in oxygen analysis of graphitic samples is exposed. New experimental data on the oxygen content of high -carbon iron in equilibrium with carbon monoxide indicate that the activity coefficient of oxygen is decreased by additions of carbon. The carbon-oxygen product decreases slightly with increasing carbon content. In recent years a number of investigations have been reported dealing with the equilibria between carbon and oxygen in liquid iron and gases containing carbon oxides. The laboratory study of these reactions dates back to 1931 with the publication of a paper by Vacher and Hamilton' on "The Carbon-Oxygen Equilibrium in Liquid Iron". The principal object of this study was to obtain data on the reaction shown by Eq. [3] below; their data and others by vacherZ permit evaluation of the other equilibrium constants as well. Subsequent studies have been reported by Matoba, Phragmen and Kalling and by Marshall and Chipman.5 The equilibria may be expressed by the following three equations: C + CO,= 2CO;Kl = Pc° [1] 0-+CO = CO,;K2=-P co, "0.PCO c + O = CO; K3 = In the equilibrium constants, ac and a0 are taken as equal to [% C] and [% 0] respectively in the infinitely dilute solution. At finite concentrations an activity coefficient is introduced such that ac =fc [%C], and so forth. It is to be noted that these equations represent only two independent relations, the third being derivable from any two. Richardson and Dennis have determined the conditions of equilibrium in reaction [I] at temperatures of 1560" to 1760°C. Their results have been confirmed by Rist and chipman7 who have shown how the data may be extended to cover the entire range of liquid compositions at temperatures from the eutectic up to 1760°C. An approximate confirmation has been reported by Fuwa and chipman.' These investigations also established the activity coefficient of carbon which was shown to increase rather rapidly with increasing concentration. For the very dilute solutions the value of Kl is expressed in the equation: log^i = - 7280/T+ 6.65 This equation leads to a value of Kl = 430 at 1540° C in excellent agreement with the average value of Marshall and Chipman.5 It is shown as line 1 in Fig. 1 together with the experimental observations. In the case of reaction [2] the direct experimental results can be supplemented by observations on the corresponding reaction with hydrogen, namely reaction [4]:

Jan 1, 1961

By Fred D. Wright, Stefan H. Boshkov

12.1-BASIC AND PARAMETRIC CRITERIA IN THE SELECTION, DESIGN AND DEVELOPMENT OF UNDERGROUND MINING SYSTEMS STEFAN H. BOSHKOV AND FRED D. WRIGHT The criteria governing the selection of an underground mining system relate to several factors the importance of which varies with geographic location, the state of development of the industrial technology, the economic climate in the Nation and, perhaps, in the world-all these as functions of time. Thus, the best choice of a mining method depends upon sets of definable and undefinable values for numerous factors that may be considered fixed at the precise point in time. Subsequent changes in economic and/or technological developments may necessitate modification or complete revision of the existing mining system. A classification of criteria for selecting a mining system must be based on the broadest definitions. Specific cases may present simple solutions or pose very intricate questions, the answers to which are frequently based on judgment rather than explicit logically reasoned and derived results. Specific criteria may be of negligible consequence in some instances and of overriding importance in other cases. It would be foolhardy to attempt to point out, in the limited space available, all possible variations and interplay of factors, as well as to define the setting in which this interplay can take place. The reader is, therefore, referred to the case histories described in the subsequent parts of this section where actual practice will point out the variability of the problems encountered in the selection of a mining method. A popular thesis suggests that the proper approach to selecting the method of mining should be rooted in the inverse solution, whereby the limitations of the various methods in use serve as criteria to eliminate most of these methods from consideration in the specific case. This narrows the ultimate selection to one or perhaps two most appropriate methods. At this stage, a critical comparison analysis will lead to the ultimate choice. Although such a negative approach un¬questionably is valid in discarding obviously inapplicable mining systems from consideration, it falls short in defining the best system, which in practice quite often turns out to be a variation of a textbook standard, or a combination of two or more such standards. Because the deployment of capital and manpower over a long-term commitment closely follows the selection of the mining system, the decision-maker can well afford to spend a great deal of time and effort in evolving the optimum solution for the peculiarities of his specific case. Within the basic engineering tenets of economy and safety to which the design of a mining system must adhere lie numerous factors of constraint which may be grouped, somewhat arbitrarily but for ease of discussion, into several categories. The criteria that enter into the choice of a mining method derive from the following groups of factors: 1. The shape, size and spatial position of the ore deposit.

Jan 1, 1973

By J. Parreira

This paper presents a deterministic/stochastic model that was created to compare an autonomous haulage truck system to a manual one by calculating and estimating benchmarked Key Performance Indicators (KPIs) such as productivity, safety, breakdown frequencies, maintenance costs, labour costs, fuel consumption, tire wear, and haulage cycle times.

Aug 1, 2013

By R. N. Roby

In the course of the Bureau of Mines investigations for suitable sources of high-aluminum clay for the production of alumina, the Whiteware clay deposit was examined in August 1942 by G.N. Bennett, mining engineer, Bureau of Mines, Montana District Office. This report presents the factual data obtained by the investigation, which also includes data on trenching and drilling, and the results of some refractory tests and chemical analyses of representative samples of the clay later taken from some of the best trench exposures and from adit dumps.

Jan 1, 1949

By L Neindorf

The development and application of paste fill, cement slurry aggregate fill and shotcrete bulkheads at Mount Isa Mines is described. The progressive changes in filling style in the Mount Isa copper mines from a dry fill based cemented rock fill to tailings based paste fill and slurry fills is explained. The development of shotcrete arched bulkheads and engineered drainage system is described. Details on how Mount Isa Mines has achieved approximately 30 per cent cost reduction in backfill operations through innovations are given. The development of a rocky paste fill is explained.

Jan 1, 2005