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By William E. Foreman

Editor's Note: For purposes of uniformity throughout this book, Coal Preparation, 5th Edition, the editors have advocated the use of the U.S.A. Sieve Series of testing sieves (see Table 6-2) as the testing sieves of modem choice. The adoption and use of the U.S.A. Sieve Series and its forerunner, the Tyler Standard Screen Scale, has for over seventy-five years introduced uniformity into reports; has simplified the comparison of results; and has provided control for operation of modem coal preparation circuits. While a full explanation of the differences, and more importantly the similarities of these two measuring systems cannot be stated here, it is felt that a brief clarification of terms is in order. The difference between the U.S.A. Sieve Series and the Tyler Standard Screen Scale Sieve Series is the identification method. Tyler Screen Scale sieves are identified by mesh designation with the width of opening varying by the square root of two, or 1.414 times the width of opening in the previous sieve. The U.S.A. Sieves are identified by openings in millimeters or microns and also arbitrary numbers which do not necessarily mean the mesh count; this series uses width of opening variations in the order of approximately the ratio of the fourth root of two, or 1.189. Tyler Standard Screen Scale and U.S.A. Sieves can be used interchangeably, and to avoid confusion the nameplate of all Tyler Screen Scale sieves show the U.S.A. Number, while all U.S.A. Sieves show Tyler Screen Scale mesh equivalent numbers on the nameplate. INTRODUCTION Sizing is the process of separating mixed mineral particles into groups of particles all of the same size, or into groups in which all particles range between definite maximum and minimum sizes. This chapter applies the modem mechanical screen and the liquid-solid cyclone (hydrocyclone) to the process of sizing solid particles as applied to coal preparation. Screening is a mechanical process that separates particles by size. Modem coal preparation is made possible by efficient sizing. Sizing of coal is defined in terms of the opening through which an individual particle will or will not pass, or as two openings, the larger of which passes the particle and the smaller of which retains the particle. Screening accomplishes sizing by passing coal of a wide range of sizes through a series of screens, each of a decreasing size. The individual screen discharges are then directed into different screen products for subsequent sale or processing. Screening in modem preparation plants is done for the following reasons: 1. Removal of fine coal before a size reduction step. 2. Size separation of the coal into a coarse and fine fraction for sized products or for processing in coarse and fine coal circuits. 3. Recovery of heavy media from heavy media coal cleaning circuits.

Jan 1, 1991

By John W. White

Anthracite mine refuse, or culm dump material as it is sometimes called, is the waste material resulting from the sizing and cleaning of run-of-mine deep and strip-mined anthracite coal. It may also contain mine rock, carbonaceous shale, pyrite, and other debris from mining operations. This material is generally stored in piles or banks, some of which are over 100 years old. Many of the older banks contain a considerable amount of good coal, particularly in the finer size ranges, since these sizes did not have any particular economic value in the early days of anthracite mining. Today, the refuse material from a cleaning operation must be piled in an orderly fashion and in such a way as to minimize the tendency to ignite. There are well over 400 of these banks in the anthracite region containing over 1100 million tons of refuse located in the north-eastern part of Pennsylvania. The banks range in size from a few thousand tons of material up to as much as 13 million tons. Most of

Jan 1, 1972

By Casandra Gamez Gonzales, Angelina Anani

Copper, the newest addition to the critical mineral list, is an essential metal whose electrical and heat conductive properties label it as a vital mineral for the creation of renewable energy sources and the reduction of Greenhouse Gases (GHGs). However, despite copper’s leading role in the transition to sustainable energy and mining practices, the mining industry has faced various battles in the extraction of this valuable material. These challenges are based on mining’s negative reputation and extensive impact on the environment, nearby communities, and human rights. To ensure the survival of mining in the future and achieve mineral demands, an emerging topic that has initiated the revolution of the traditional sector into a more environment- friendly and transparent industry, is Environmental, Social, and corporate Governance (ESG). ESG has motivated companies to seek growth opportunities and standardize risk accountability and transparency based on its collective framework that creates, modifies, and implements local, national, and international standards. These standards focus on improving environmental, social, and governance issues faced by companies and their projects. ESG has served as a guideline that investors utilize to assess companies and promote sustainability, responsibility, and disclosure to create positive and balanced relationships with stakeholders and the environment. Nonetheless, concerns have been rising which state that ESG is negatively impacting the mining industry by targeting what fuels the industry and world: ore deposits and their resources. Therefore, this research focused on answering the following research questions: what are the impacts of ESG on the copper supply chain and how will stricter ESG standards affect future copper production?

Feb 1, 2024

By M. S. Moats, A. Luyima, W. Cui

"Organic smoothing additives are used to produce dense, thick, high-quality cathodes in copper electrowinning. Glue had been used traditionally and is still used in operations that do not employ solvent extraction to produce the electrowinning electrolyte. With the advent of solvent extraction–electrowinning, guar started to be used and remained in use for many years as it does not affect the phase disengagement in solvent extraction. Recently, however, guar has been replaced by less-expensive saccharide- and polyacrylamide-based additives. This paper is the first of a series of four papers that examine saccharides and polyacrylamides as new additives for copper electrowinning. A review of previous research related to copper electrowinning additives is presented here, along with a selected review of additives in other copper electrodeposition systems.IntroductionThe recovery of copper from solution by electrowinning was first practiced in the early 1900s, but it was the combination of solvent extraction with electrowinning (SX-EW) in March 1968 at the Ranchers Bluebird Mine (Kordosky, 1992) that changed the landscape for the electrowinning process. Most copper electrowinning capacity is now associated with solvent extraction, though some copper is still won directly from leach solutions (Robinson et al., 2013). The ability to produce high-purity copper cathodes from SX-EW has taken the continued improvement of SX-EW technology over the past more than 40 years.One of the technologies that has seen improvement is that of the organic smoothing agents used during the electrodeposition of copper in the tankhouse. These organic additives are added to the acidic copper sulfate electrolyte during electrowinning to improve the smoothness, brightness and density of the copper cathodes. The organic additives that are presently in use are different from those used in 1999 (Jenkins et al., 1999). Over the past decade, many tankhouses have replaced the use of guar-based organic additives with those derived from other saccharides. Until now, there has been no comprehensive publication in the open literature on the behavior of these additives during copper electrowinning."

Jan 1, 2016

By W. M. Tuddenham

It would be most difficult to place a date on the beginning of the revolution in analytical techniques that we have witnessed in recent years; but there is no question that the period since the end of World War II has seen a major change in thinking with respect to control and accounting analyses. For reasons relating to competition, much of this change was brought about in the chemical industries and only more recently has begun to affect directly the mineral industries. In considering the subject outlined in the title of this paper, one might well be tempted to discuss solely the more exotic methods of control and automation which have come into being in the past short while. In this paper, however, an attempt will be made to take a broader view and consider not only the application of newer purely physical methods of control but also those phases of chemical plus physical analyses that have bearing on our industry.

Jan 1, 1962

By J. Ludden

By Sims Some two years ago we began investigating low coke button bituminous coal for use at our Bound Brook, New Jersey plant as a replacement for anthracite. Since August, 1957 the plant has been operating continously on this coal with the exception of a new 200,000#/hr, cyclone boiler. This study was motivated not from our desire to conduct combustion research, but for the sole purpose of reducing our steam costs, The indications were that the economics were greatly in favor of the use of the bituminous coal. The attempts to reduce the costs have developed some knowledge that has enabled this program to succeed reasonably well as will be discussed later by Mr. Ludden. The production of steam size anthracite is dependent upon either the reclamation of old culm banks or the breakage in the production of the domestic sizes. The anthracite industry has not as yet been able to cut, its mining costs to the point where the production of steam sizes has become a profitable business. This has resulted in two basic problems: (1) A constantly rising price in an attempt to have those sizes carry their share of the cost and, (2) Periodic shortages of supply when the demand is good but the market price prohibits the mining of anthracite to produce those sizes only, These conditions have made the long range forecast appear as though the price would go even higher and/or the supply at times be critically short.

Jan 1, 1958

By Charles O. Frush

This paper presents a summary of the current employment practices with respect to recent graduates in Mining Engineering, as observed at the Colorado school of Mines. Because our experience is limited to our own group of students it prob¬ably does not correspond exactly to that experienced at other mining schools, but because the Colorado School of Mines graduates approximately 15 per cent of the men in this field our experience is probably representative. We have chosen to limit the information presented here to that pertaining to the period since July 1, 1960. This corresponds to the experience with the class of 1961 and to the experience of the class of 1962 up to the end of the first semester of the senior year. There were 36 mining engineering degrees given in 1961 In a class numbering 43 senior. We expect to give 30 first degrees in 1962 in a class numbering 44 seniors.

Jan 1, 1962

By Kiran B. Chaudhuri

The Kivcet process is technologically the most advanced of the new lead smelting processes which have been developed over the past decade construction of the first commercial scale Kivcet lead smelter which has been designed by KHD Humboldt Wedag for Sociedad Complejo Metalurgico de Karachipampa is at present nearing completion in Bolivia. Some of the measures taken to minimise emission of harmful elements as well as methods employed to minimise energy consumption in the design of the smelter, are presented. Results of recent testwork which have added to the flexibility of the process are summarised.

Jan 1, 1982

In the grand scheme of things, the 9.5-t (21,000-lb) shipment of molybdenum concentrate that left Freeport-McMoRan?s Climax Mine site on May 10, 2012 was not unlike the thousands of others that have been hauled away from the site during the last century, except for the fact that this shipment marked the official rebirth of one of America?s greatest mines. For nearly two decades, 17 years to be exact, there was no production from the mine that was once the largest underground mine in the world and was so important to the Allies? effort during World War II that it was assigned the highest priority of any mine in the United States by the War Production Board. The economic recession in 1980 put an end to the mine?s success, and the Great Recession of 2008 nearly derailed the mine again. But, like the nearby town of Leadville, CO, the mine survived thanks to an investment of more than $700 million by Climax Molybdenum Co., a Freeport-McMoRan company, to bring the Climax Mine back into production.

Jan 1, 2012

"INTRODUCTION In recent years, there has been increasing focus on environmental and social impacts of the extractive industries, climate change and resource scarcity. The concept of the circular economy aims to replaces the “take-make-dispose” economic model with one that eliminates waste of all kinds and is restorative by design. Such closed-loop systems implicitly aim to reduce the quantity of primary extracted materials entering the economy, thereby affecting supply and demand dynamics, hence mining industry economics. For the metals industry, the ability to engage in, or adapt to the circular economy can be heavily affected by industry structure and geographical factors. Eco-efficiency initiatives that reduce waste and environmental impact may help the mining and metals industry align with some of the goals of the circular economy. This paper focuses on base metals, and explores case studies in copper, lead and zinc. It analyzes primary and secondary metal production, and recycling. It examines company structures and how these affect engagement with the circular economy. CIRCULAR ECONOMY PRINCIPLES Ellen MacArthur Foundation (2012) describes the circular economy as “an industrial system that is restorative or regenerative by intention and design”, which “replaces the ‘end-of-life’ concept with restoration”, and “aims for the elimination of waste through the superior design of materials, products, systems, and, within this, business models”. The concept is systems focused. For materials such as metals, a series of loops are considered, including maintenance of devices, reuse, refurbishment and recycling. Potential methodologies to achieve circular economy outcomes include disassembly and reassembly of manufactured goods, leasing rather than buying major appliances, and converting to renewable energy sources. The circular economy is partially aligned with the principles of eco-efficiency, which relate to reducing the environmental impact per unit of a material produced. PRIMARY AND SECONDARY METAL PRODUCTION Base metals (copper, lead, zinc and nickel) are essential ingredients in modern economies and are key commodities produced by the global mining industry. Metal production can be categorized as primary or secondary. Primary metal comes from the processing, smelting and refining of metal content extracted from ores, while secondary production comes from metals recovered from recycled streams (e.g. recycled lead-acid batteries, copper wire scrap, etc.). Metals are stored in natural, anthropogenic in-use and anthropogenic waste stocks. An example of the stocks, flows and processes associated with global copper extraction and use is shown in Figure 1."

Jan 1, 2018

By Heinz Petry

In deep strip mines the job of moving overburden may be so much bigger, and more costly than the removal of coal or ore that the operation is often called dirt mining. Constant improvement in stripping machines and techniques of using them is needed to offset rising costs and to increase production in mines that are now operating, and to make it economically possible to work deeper or thinner deposits.

Jan 1, 1962

By Peter F. Mataich

The phosphate mining industry is a highly competitive one, one in which survival depends on the plant's ability to produce at costs equal to, or below, the competition. The solution toward getting costs down is usually one of scaling up the plants to get the most tons through at the lowest possible cost. Control of these plants has been an art. Few of them are well instrumented because until a few years ago reliable instrumentation was non-existent. International Minerals and Chemical Corporation was a pioneer in applying computer techniques to ore reserves analysis and mine planning and the success in these areas led to the question of whether we could not extend the advantages of computer processing into the plant itself. There was a great deal of doubt on the operator's end that this could be done successfully because of the lack of instrumentation and the fact that plant control was largely an art that was learned only after many years of experience. However, in 1965 the instrumentation picture began to look up and the new generation of process computers just coming on the market were considerably lower in cost than the previous ones. A preliminary study of the installation costs and the probable benefits that could be realized from computer control convinced us that a process control computer should be seriously considered for a new phosphate mining plant which was being designed.

Jan 1, 1969

By D. Arku

The increased use of sensors to facilitate automation has led to an explosion of data. As data sets grow in size, their use becomes more complex. Therefore, there is an incentive for reducing the size of the datasets, as long as this does not compromise information gleaning. With this in mind, this project explored basic aggregation as a viable alternative to amassing large amounts of data. The goal of the project was to determine if one would arrive at different conclusions had they analyzed aggregated data instead of raw data. In a mine, operational data is typically used for tracking process statistics, correlation between factors, autocorrelation and multivariate models (for a factor of choice). Therefore, this project compared results from such analyses when it was conducted with aggregated data (AD) with the results of analyses conducted with raw data (RD). The data consisted of one-minute-apart readings from a semiautogenous grinding (SAG) mill on the horsepower, feed rate (tons per hour), rotations per minute (rpm), noise, recycle (tons per hour), density (% solids) and bearing pressure (psig). This data was aggregated by averaging five and 10 continuous (one-minute) observations. Changes in statistical measures between the two approaches were typically within 5% of each other. Differences in correlation coefficients between RD and AD(s) were also within this range. Autocorrelations present within RD were preserved in AD, as long as the time lags were scaled for the amount of aggregation. Regression and neural network models were also developed for power consumption. The prediction performance of developed models was similar whether one used raw data or aggregated data. Overall, it appeared that aggregating the data based on 5- or 10-minute time spans would not have resulted in conclusions (from simple or complex analyses) being different from using raw data. In other words, whether one had used raw data or aggregated data, the conclusions would have been the same, suggesting that time domain aggregation, a common industry practice, is a good alternative to storing high-density data in this case.

By W. Perkins

The Smoky Canyon Mine has recently installed a PROMPTED GAMMA NEUTRON ACTIVATION ANALYSIS (PGNAA) on-line analyzer as part of a long-term advanced process control program. The on-line analyzer was adapted from a continuous dry analyzer and a large on-stream wet analyzer to a compact, multiplexed 3" slurry analyzer. The analyzation feed system utilizes a multiplexer system to accommodate up to fourteen (14) different plant process streams. The corresponding sampling system also provides for dewatering of sample streams too dilute for timely analysis. Key analysis includes, but is not limited to, phosphorus, aluminum, magnesium, calcium, and potassium. This data currently allows plant operations to be manually evaluated and controlled. Future development of a plant-wide supervisory control system will utilize the data for plant operations. This paper discusses the design, installation, and operation of the PGNAA on-line analyzer at the Smoky Canyon Mine.

Jan 1, 1996

By R. J. Pugh

The coagulation of dispersions of weakly magnetic oxide mineral ultrafines (such as natural hematite or chromite) in an external magnetic field can be described from inter-particle forces. Essentially, coagulation occurs when the short range London-van der Waals interactions and the long range magnetic forces outweigh the stabilizing electrical double layer repulsion. From the classical colloid chemistry theory, we have calculated the various components of the potential energy for different sized particles at a series of ionic strengths and magnetic field intensities. We have related this theoretical analysis to experimental studies where the magnetic field-induced coagulation of ultrafines of natural hematite and chromite in aqueous suspensions was investigated using a laboratory scale electromagnetic solenoid. The experimental results relate the coagulation process (as determined by magneto-sedimentation analysis) to the particle size, the slurry pH and the external magnetic field. In the magnetic fields, maximum coagulation occurred near the pH of zero point of charge (pHzpc) of the minerals (where the electrostatic double layer repulsion was reduced to a minimum) enabling the particles to enter the "primary minimum" energy sink. On the other hand, in cases where the electrostatic repulsion was not suppressed, then the long range magnetic forces enabled coagulation to occur in the "secondary minimum". This caused the formation of chains which appeared to be relatively stable during sedimentation.

Jan 1, 1993

By August V. Castelli

Drilling fluids have changed over the years from water and/or water frequently mixed with local clays to scientifically com- pounded materials (mud). This change has occurred due to changes in drilling methods from percussion to rotary: depth maximum from 21 m in the first oil well to more than 9 000 m; and variety in types of well or hole to gas, oil, water, and mineral exploration. Environmental concerns about the composition of the fluid as to heavy metals and oil on the cuttings has recently caused changes in the materials used in the mud. The drilling fluid should perform the following functions (Darley et al., 1980): 1) Carry cuttings from beneath the bit, transport them up the annulus, and permit their separation at the surface. 2) Cool and clean the bit. 3) Reduce friction between the drilling string and the sides of the hole. 4) Maintain the stability of uncased sections of the borehole. 5) Prevent the inflow of fluids-oil, gas, or water-from permeable rocks penetrated. 6) Form a thin, low-permeability filter cake which seals pores and other openings in formations penetrated by the bit. In addition to these, the fluid should: 1) Not injure drilling personnel nor be damaging or offensive to the environment. 2) Not require unusual or expensive methods of completion of the drilled hole. 3) Not interfere with the normal productivity of the fluid- bearing formation. 4) Not corrode or cause excessive wear of drilling equipment. A number of industrial minerals, chemicals, and other materials are used as additives in the drilling fluid to accomplish these functions. Industrial minerals make up the highest percentage of the additives in a drilling fluid. Drilling fluids are classified according to their principal components: water, oil, and gas. If the major component is either water or oil, the component along with the suspension of solids, cuttings and additives is referred to in the trade as a mud. The largest use of some industrial minerals, such as barite and bentonite, is in drilling muds. For other materials, such as gypsum and limestone, drilling usage is only a small percentage of total demand. RAW MATERIALS [Table 1] lists the industrial minerals used in drilling fluids, their form, specifications, and uses. Each raw material will be discussed as to its mineralogy, physical and chemical properties, and the location of major deposits with respect to drilling fluids. Attapulgite Attapulgite is a crystalline hydrated magnesium silicate clay mineral, prized for its viscosity in saline waters. The particles are needle-like rather than the platelets common to most clay minerals. The specific gravity is 2.5 and the Mohs hardness is 1 to 1.5. Attapulgite is one of the materials sometimes referred to as fuller's earth. The major producing areas in the United States are southern Georgia and northwestern Florida. It also is mined in Spain, Senegal, the Republic of South Africa, Turkey, India, and Australia. Barite Barite is crystalline barium sulfate. It has a high specific gravity for a non-metallic mineral, 4.5 when pure, and is used as a weighting agent. Generally, the specific gravity ranges from 4.20 to 4.35. It is relatively soft with a Mohs hardness of 3 to 3.5 and is not very abrasive. Barite is inert, non-toxic, and clean to handle. Common contaminants are quartz, iron minerals, gypsum, and calcium carbonate. If there is considerable gypsum in the barite, it will thicken the mud. The major deposits in the United States are in north central Nevada, near Battle Mountain. The major producing countries, other than the United States, are China, India, Mexico, the former USSR, Turkey, and Morocco. The major deposits in India and Nevada, and some in China, are stratiform, commonly quite pure bodies in bedded sedimentary rocks.

Jan 1, 1994

By E. Siami-Irdemoosa, S. R. Dindarloo

"Pareto analysis was used to investigate the failures database of a Hitachi EX1900 hydraulic shovel over one year of continuous operation. The hydraulic system and hydraulic links, hoses and piping were identified as the most critical system and subsystem, respectively. A three-parameter gamma distribution function was identified as the best fit for a probabilistic modeling of the time between failures (TBFs). This distribution was used in a Monte Carlo reliability analysis of the hydraulic system. Autoregressive integrated moving average (ARIMA), within the context of a time series analysis of the TBFs, was proposed as a viable alternative to the traditional technique of distribution fitting. The mean absolute percentage error (MAPE) metric was used to compare the two models. The MAPE value that resulted from the ARIMA was 66 percent smaller than that from the traditional technique in predicting the TBFs. Resumen ¦ Se usó análisis Pareto para investigar la base de datos de fallas de una pala hidráulica Hitachi EX1900 durante un periodo de un año de operación continua. Se identificó al sistema hidráulico y a los enlaces hidráulicos, mangueras y tuberías como el sistema y subsistema más importantes, respectivamente. Se identificó una función de distribución de tres parámetros gamma como el más apto para un modelado de probabilidades del tiempo transcurrido entre las fallas (Tabes por sus siglas en inglés). Esta distribución fue usada en un análisis de confiabilidad Monte Carlo para un sistema hidráulico. El promedio de movimiento integrado auto-regresivo (ARIMA por sus siglas en inglés), dentro del contexto de análisis de serie temporal de los TBFs, fue propuesto como una alternativa viable a la tradicional técnica de ajuste de distribución. Se usó el porcentaje de la media absoluta de error (MAPE) para comparar los dos modelos. El valor MAPE que resultó de la ARIMA fue 66 por ciento menor que el resultado obtenido con la técnica tradicional de predicción de TBFs."

Jan 1, 2015

By Errol L. Montgomery

The region of metalic ore deposits in northern Chile, southern Peru, western Bolivia, and northwestern Argentina occurs in arid zones at altitudes as high as 4,600 meters. Because surface water supplies are meager, new mines require unexploited sources of water. Prolific groundwater aquifers occur in salar basins in this region of the Andean Highlands. Exploration water wells have been constructed and aquifer characteristics have been tested in eight salar basins. Results indicate groundwater quality is good. Aquifer transmissivity and storage computed from results of pumping tests indicate maximum production water well capacities in excess of 170 liters per second.

Jan 1, 1982

By John B. Mitchell

Approximately 90% of all potash produced is employed as a fertilizer, either directly or with nitrogen and phosphorus. The remaining 10% is utilized in the manufacture of other chemical products, The original source of potassium was wood ash (hence the name potash), However, today the term potash refers to all commercially important salts of potassium. Sylvite, usually found associated with halite, is the predominant economic potash mineral; carnallite a lesser important source of potassium chloride, while langbeinite is important as a source of potassium sulphate. The world's first potash mining operation commenced in Strassfurt, Germany about 1860, Since that time the industry has grown steadily to its present annual volume of about 30, 000, 000 tons of potassium chloride products or 18, 000, 000 tons of K2O equivalent, potassium chloride or "muriate of potash" being equivalent to 63. 1% pure K2O, WORLD POTASH RESERVES ARE NOT EVENLY DISTRIBUTED The earth's crust contains 2 to 3 per cent potassium, mostly in the form of insoluble silicate minerals. The economically important deposits, however, are formed from brines concentrated by evaporation. The world's most important commercial deposits are of Devonian and Permian age, however soluble potassium bearing salts are presently being concentrated by evaporation in several drainage basins, notably Searles Lake, California, Great Salt Lake, Utah' and in the Dead Sea. At least twenty-four countries are known to have reserves of potash: Canada and the USSR have over 80% of the presently known world reserves, (Figure 1)

Jan 1, 1972

By K. Katen

In another situation, Dave Zegeer, the Assistant Secretary of Labor for Mine Safety and Health, whom all of you know very well, would have taken the opportunity to talk with you. In his absence, however, I would like to reference some of his recent comments which may help us to see the issue of mine safety in historical perspective. Dave pointed out that this year is the eightieth anniversary of the Great Earthquake and Fire of San Francisco. The whole world heard about that disaster--it and the 452 people who died in it. In that same year, nearly five times as many people died in coal mines, but no one particularly noticed.

Jan 1, 1986