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By Z. Jin, D. DePaoli, P. Zhang

"Phosphate beneficiation in Florida generates more than one tonne of phosphatic clay, or slime, per tonne of phosphate rock produced. Since the start of the practice of large-scale washing and desliming for phosphate beneficiation, more than 2 Gt of slime has accumulated, containing approximately 600 Mt of phosphate rock, 600 kt of rare earth elements (REEs) and 80 million kilograms of uranium. The recovery of these valuable elements from the phosphatic clay is one of the most challenging endeavors in mineral processing, because the clay is extremely dilute, with an average solids concentration of 3 percent, and fine in size, with more than 50 percent having particle size smaller than 2 µm, and it contains nearly 50 percent clay minerals as well as large amounts of magnesium, iron and aluminum. With industry support and under funding from the Critical Materials Institute, the Florida Industrial and Phosphate Research Institute in conjunction with the Oak Ridge National Laboratory undertook the task to recover phosphorus, rare earths and uranium from Florida phosphatic clay. This paper presents the results from the preliminary testing of two approaches. The first approach involves three-stage cycloning using cyclones with diameters of 12.4 cm (5 in.), 5.08 cm (2 in.) and 2.54 cm (1 in.), respectively, to remove clay minerals followed by flotation and leaching. The second approach is a two-step leaching process. In the first step, selective leaching was conducted to remove magnesium, thus allowing the production of phosphoric acid suitable for the manufacture of diammonium phosphate (DAP) in the second leaching step. The results showed that multistage cycloning with small cyclones is necessary to remove clay minerals. Selective leaching at about pH 3.2 using sulfuric acid was found to be effective for removing more than 80 percent of magnesium from the feed with minimal loss of phosphorus.IntroductionFlorida phosphate ore, or “matrix,” as it is called locally, contains three different mineral groups that have to be separated from each other: (1) phosphate minerals, (2) clay minerals and (3) quartz, or sand. As mined, the phosphate and sand particles are embedded in compacted mud, or clay-balls. Before separation can begin, all of the particles must be liberated from the matrix of mud. The very first unit operation in the beneficiation process is to disaggregate the various particles. This actually starts while the matrix is flowing through the multimile pipeline from the mine to the beneficiation plant. While in the pipeline, the matrix is exposed to shear forces as it passes through the various centrifugal pumps along the pipeline. These intense shear forces cause a significant percentage of the sand and phosphate particles to be liberated from the clay-balls by the time they arrive at the plant. Once they reach the plant, the first goal is to finish disaggregating the clay, and follow that by making a size separation at 1 mm. This processing is conducted in the washer, consisting of a large rotating trammel screen and a few stages of log washer, screens and hydrocyclones. In all of the currently operating beneficiation plants, the washer is a large structure that receives the matrix, screens it and then discharges a pebble phosphate product sized larger than 1.0 mm and a slurry of liberated clay, sand and phosphate particles that are smaller than 1.0 mm."

Jan 1, 2017

By A. A. Sobek

Controlled release systems delivering the required concentration of an effective bactericide over an extended time period have been developed by The BFGoodrich Company's ProMac® Systems group. The ProMac system is site-specific and includes a four-step approach to controlling acid mine drainage (AMD): (1) Diagnosing the problem, (2) Prescribing the treatment, (3) Supervising the application of controlled release bactericides, and (4) Honitoring the success of applied treatment. The success of the ProMac system is evidenced by improved water quality, healthy vegetation, a reduction in levels of acidophilic thiobacillus, and a corresponding increase in population of beneficial microorganisms.

Jan 1, 1986

By James R. Dunn

The nature of water and clay in carbonate rocks is currently being investigated at Rensselaer Polytechnic Institute by various thermal and sorption techniques. Two basic concepts 'led to the present research. (1) To explain the expansion and contraction on wetting and drying of some unsound argillaceous carbonate rocks, it was postulated that the pore space around each clay particle is such that when water is sorbed by the clay, force is exerted against the pore walls. (2) The clays in expansive rocks are rejected from the growing dolomite crystals during their growth, and form a more or less connected network, thereby becoming "wettable," or available to water. New quantitative cold differential-thermal-analysis (electrocalorimetric) equipment was designed and constructed to check the "limited space" and "wettable clay" concepts and to determine the thermal nature of the transition of water to ice in rocks. This DTA equipment can detect the release of heat in freezing of less than 0.001 per cent water in a rock. Twenty-three rock cores (nine sound and fourteen unsound) and 4 procelain cylinders for standards were studied. In the nine sound rocks and in all the procelain cylinders, the rapid freezing of from 50 to 100 per cent of the water was readily detectable after 7 to 10° C of supercooling. No further freezing could be detected to -20° C. However, in eleven of the fourteen unsound rocks, no freezing was detected to as low as -40° C; in the other three, less than 50 per cent of the water froze. As a check of the DTA measurements, adsorption isotherms were determined for all materials. Calculations of theoretical freezing points for sorbed water again demonstrated that the least sound rocks had the most nonfreezable water. "Frost" sensitivity in these carbonate rocks is, therefore, probably not the result of the force of expansion of water to ice. The disruptive force is believed to result from expansion of sorbed, ordered water on clay surfaces. The relationship between the unfilled rock pores after 24-hour water saturation and the water sorbed at 85 per cent humidity at 30° C (i.e., the theoretical nonfreezable water delineates the sound and unsound carbonate rocks.

Jan 1, 1966

By Frank W. Bowdish

Studies of sulfidization and flotation of chrysocolla involving the use of pH and sulfide ion instruments, a Zeta meter, microflotation techniques, and sensitive determinations of adsorbed sulfur have given new insight into the mechanism of the process. Factors that affect the recovery of sulfidized chrysocolla by flotation appear to be the pH at which it is sulfidized, and certain alterations of the surface that occur during aging after sulfidization. Such aging results in increased recoveries. The surface charge, as measured by electrophoretic mobility, of chrysocolla shows an unexpected negative increase as pH values are changed from 6.0 to about 4.5, and this appears to be correlated with increasing sulfur adsorption and flotation recovery over the same or even wider pH ranges.

Jan 1, 1970

By E. W. Geist, W. J. Bronkala

PRINCIPLES OF MAGNETIC SEPARATION The application of magnetic separators relies on the different behavior of individual mineral particles under the influence of magnetic forces. When exposed to a magnetic field, all materials are affected in some way. According to whether materials are attracted or repelled by the magnetic field, they are designated paramagnetic or diamagnetic, respectively. Paramagnetic materials are attracted along lines of magnetic force from points of lower magnetic field intensity to points of higher magnetic field intensity. The very strong response of some materials to a magnetic field is sometimes designated ferromagnetic and the particles attracted frequently retain magnetic properties after the applied magnetic field is removed. Diamagnetic materials are repelled along the lines of magnetic force from points of high magnetic intensity to points of lower field intensity. Only limited commercial use of diamagnetic effects has been made. For practical applications, the paramagnetic groupings are: 1. Strongly magnetic (ferromagnetic) 2. Magnetic 3. Weakly Magnetic 4. Non-magnetic The limits of these groupings are not well defined and will vary in some mineral species. Only a few minerals are ferromagnetic (magnetite is an example) and arbitrarily some investigators have selected 10,000 gauss, or 1 Telsa, as the dividing line between low and high intensity magnetic fields. I. S. Wells has developed a table indicating the magnetic intensity required to separate a selected grouping of minerals which is shown in Table 1 on page 2. A similar table has been developed by Carpco Inc. of Jacksonville, Florida in conjunction with the use of its high tension separators. This table, Table 2 on page 3 shows other minerals grouped in the broader categories cited above. Magnetic separation methods are used either to separate valuable minerals from nonmagnetic waste or magnetic impurities or other valuable magnetic minerals from bulk nonmagnetic values. Magnetically susceptible mineral particles occur as either individually discrete particles,

Jan 1, 1986

By Rainer Kahrger, Guenter Ewald

The topic of this paper is to demonstrate the development of mobile crushing installations from throughput capacities of 200 tons per hour, to mobile and semi-mobile large- scale crushing installations with throughput capacities of 3,500 up to 10,000 tons per hour. Basis are approximately 140 mobile and semi-mobile crushing installations which have been built since 1956 or were on order in 1987. [FIGURE 1. Total Number of Mobile or Semi-mobile Crushing Plants] Sixteen of these approximate 140 mobile and semi-mobile crushing installations have a throughput higher than 3,500 metric tons per hour. Mobile crushers were developed more than 25 years ago in Europe for the quarry industry, which had special requirements - fairly low capacity, mostly softer and less abrasive material (limestone) and full mobility. So the majority of the units up to about 1980 were fully mobile, having a fairly small capacity and utilizing mainly hammermills, double roll and impact crushers. It was only when the mining industry and large quarries picked up the concept in the early 1980's that a drastic increase in capacity took place. Even though the first mobile crusher in a true mining application went into service in 1971, it took another 10 years before it proceeded in a larger scale. This trend was obviously supported by the drastic fuel price and energy cost increase in the mid 70's. Since the cost of conveying material is substantially cheaper than trucking it, the increase in energy cost, combined with increasing haulage distances provided a strong incentive. Figure 1 shows clearly the throughput distribution of all crushing installations and it also shows the sharp increase in the throughput capacities within the last few years.

Jan 1, 1989

By S. C. Schmelter

The destabilizing effect of water pressure on rock mass stability is examined quantitatively by the finite element method. A coupled code that accounts for the simultaneous effects of rock mass deformation and transient fluid flow is used for this purpose. The traditional soil mechanics assumption of an incompressible fluid is shown to be untenable for the analysis of porous, fractured rock slopes. A Mandel-Cryer effect, a transitory but elevated and potentially destabilizing water pressure following a cut, was not observed.

Jan 1, 1997

By Robert A. Jankowski, Charles A. Babbitt, Natesa I. Jayaraman

Today, approximately 31% of underground coal mining operations have designated occupations or areas with more stringent (below 2.0 mg/m3) respirable dust standards in place. Many U.S. coal mines have been able to maintain compliance with very low dust levels, and the Bureau of Mines, in an effort to identify those factors contributing to low dust levels, completed a survey of twelve continuous miner sections which were able to maintain their dust levels at or below 0.5 mg/m3. The quantity and quality of face ventilation appeared to be the most important factor in controlling dust exposure. The results directed Bureau research towards identifying improved face ventilation techniques for reducing quartz dust levels on continuous mining operations. This research has involved the evaluation of a half-curtain face ventilation technique which reduces the cross-sectional area of the entry, thus increasing the air velocity over the operator. The Bureau has also conducted extensive laboratory studies to compare tubing versus brattice, including an evaluation of both systems in a crosscut turn. In an effort to improve ventilation and reduce dust exposures of roof bolter operators working downwind of the continuous mining machine, the Bureau has evaluated two novel face ventilation systems. The first system consists of a fan discharge tubing technique which routes dusty air away from the return entry being bolted. In a technique similar to the fan/tubing concept, exhaust air from the upwind continuous miner face can be scrubbed using a dust collector to capture a portion of the dusty air, clean it, and supply it to the bolter operators as a split of clean intake air. A better understanding of face ventilation techniques should lead to solutions to the problem of more stringent dust standards due to quartz.

Jan 1, 1989

By James R. Norris, Thomas A. Conto, Gary R. Walter

For at least five decades, a plume containing acidic metal-bearing water has been moving through the shallow alluvial aquifer along Pinal Creek in the Globe-Miami area. Two chemical facies of water are distinguished in the alluvial aquifer: (1) a metal-rich acidic plume with gram per liter concentrations of metals (primarily iron) and pH values between 3 and 5 and (2) neutralized water with a pH greater than 5, low concentrations of metals, and high concentrations of sulfate and manganese. Historically, the acid plume has moved through the aquifer at an average velocity of 0.6 m/day, ten times slower than the average pore velocity of groundwater in the aquifer calculated using the Darcy equation. The rate of migration of the metal-rich plume is retarded by pH-dependent chemical reactions between acid water and the aquifer matrix. As acid water is neutralized by reaction with calcite, rising pH conditions in- crease the oxidation rate of iron and decrease its solubility resulting in the precipitation of ferric hydroxides. The formation of ferric hydroxides is a proton releasing reaction which main- tains acidic conditions. The acidit of the plume and the neutralization capacity of tKe aquifer are best assessed in terms of the iron content of the water and not the hydrogen ion activity computed from pH measurements. The parameters controlling plume migration are: (1) the calcite content of the aquifer (2) the iron acidity of plume water, and (3) the rates of acid neutralization and ferrous iron oxidation. A numerical solute transport and reaction model based on the concept of iron acidity effectively simulates the historical development of acidic conditions, predicts the behavior of the plume, and was used as a management tool to identify the most efficient and cost effective remedial strategy.

Jan 1, 1991

By William E. Lamont

As a part of the Department of the Interior's rutile and titaniferous materials development program conducted under the Defense Production Act, the Bureau of Mines investigated the potential for producing national stockpile grade rutile from plant products of phosphate beneficiation plants operating in the central Florida pebble phosphate district. The potential for producing ilmenite, zircon, and monazite concentrates from the plant products was also investigated. Results of these studies indicated that 3,000 to 6,000 tons of rutile, 28,000 to 55,000 tons of ilmenite, 9,000 to 19,000 tons of zircon, and 400 to 800 tons of monazite passed through the plant circuits annually. All of these minerals are presently being sent to waste ponds. Beneficiation of a bulk heavy mineral concentrate separated from the amine flotation tailing (froth product) of numerous plants in the district showed that it was possible to produce a rutile concentrate containing over 94 percent Ti02. Additional studies showed that over 70 percent of the Ti02 in the rutile concentrate could be isolated in a product containing 98.0 percent Ti02. The studies also showed that it was possible to produce ilmenite concentrates containing 63 percent Ti02, zircon concen¬trates containing 65 percent Zr02, monazite concentrates containing over 85 percent monazite [(Ce,La,Y,Th) (P04)], and xenotime concentrates containing over 35 percent xenotime (YPO4).

Jan 1, 1969

By Z. Hladysz

It is common to nine a coal seam affected by previous extraction of a coal seam below. As a result of that severe problems may occur during the extraction process. This paper presents the analysis of undermining effects based on field observations. A simplified method for the evaluation of risk in undermining operations is presented and predictions of the degree of possible damages to the undermined coal seam is given.

Jan 1, 1985

By Neil J. Dahmen, Howard J. Handewith

INTRODUCTION Tunneling machines were introduced into civil con¬struction in the 1800s, but their practical applications were not realized fully until the 1950s. As of 1977, tunneling machines were being used on most tunneling projects of substantial size. As in civil construction, the mining applications of tunneling machines have included long drives such as tunneling for long ore-body develop¬ment drifts, long haulage tunnels, longwall access drifts, and long crosscut developments. Tunneling machines ranging from 1.75-m (5.7-ft) to more than I1.0-m (36-ft) diam are available from several manufacturers; machines for mining applications generally have ranged between 1.75 and 6.0-m (5.7¬and 20.0-ft) diam. Tunneling machines usually operate at or near horizontal grades and are supported by a rail-haulage backup system. However, declines and inclines have been made using alternative backup equip¬ment. Either circular or shaped tunnels may be bored, depending upon the particular equipment used. Using tunneling machines to bore openings through rock offers several advantages over the use of the drilling and blasting technique. These advantages include a rapid advance, continuous operation, uniformity of the opening size, smooth walls, and safe working conditions. Compared to drilling and blasting, boring reduces the disturbance of adjacent rock, thereby reducing the ground-support requirements and the exposure to water inflows. The smooth walls provide natural arching and present minimum resistance to the flow of air. A tunneling machine should be considered a spe¬cialized mining tool that is well-suited to certain mining applications. Properly applied and sustained, a tunnel¬ing machine contributes to realizing substantial econo¬mies in the development of underground mines. All costs herein are expressed in 1977 US dollars, unless otherwise noted. The mention of trade names and manufacturers is not intended to imply an endorse¬ment of any specific equipment. TYPES OF TUNNELING MACHINES As listed in Table 1, five principal types of tunneling machines were being manufactured in 1977. Each type of machine offers a special solution to a specific mining problem. Although each of these types of machines is described herein, most of this chapter is devoted to the full-face rotary rock-tunneling machine that has demon¬strated the greatest production in both civil construction and mining applications. Full-Face Rotary Rock-Tunneling Machines As shown in Fig. 1, a full-face rotary rock-tunneling machine consists of a rotating head that is fitted with rock-cutting tools and is forced into the tunnel face. This head is supported by a bearing on a structural support member that, in turn, is held in place by a hydraulically positioned wall-gripping mechanism. Both torque and thrust are reacted from the cutterhead, through the structural support and gripper mechanism, and to the tunnel wall. The rock cuttings fall to the invert at the tunnel face, and they are removed by means of cutterhead buckets or scoops that transfer the cuttings to a conveyor belt. After advancing the cutter¬head through a preset boring stroke, the tunneling machine is advanced by hydraulically pulling the gripper mechanism in from the tunnel walls, stroking forward, and resetting the gripper to the new forward position on the wall; the machine then is set for the next advance stroke. Full-face machines cut only circular openings. Ma¬chines with diameters as small as 1.8 m (6 ft) and as large as 6.1 m (20 ft) have been used in mining applica¬tions, excavating rock with unconfined compressive strengths in excess of 276 000 kPa (40,000 psi). Although special machines have been designed to turn on a radius of 30 m (100 ft) in both horizontal and vertical directions, the conveyors and backup sup¬port equipment generally limit tunneling machines to turns with a radius of more than 60 m (200 ft). The full-face rotary rock-tunneling machines have provided the fastest and most reliable production of any mining method or machine. These machines can be equipped to place any of a variety of ground-support systems, and they can be provided as "open" machines, as shown in Fig. 1, or as "shielded" machines, as shown in Fig. 2. The open machines have the advantage of allowing the ground to be supported as near to the tunnel face as possible. The shielded machines have been designed principally to allow placing precast con¬crete segments. The shielded machines completely pro¬tect the equipment and personnel at the heading, but they are economically limited to permanent long-life haulageways where full lining is required. Partial-Face Rotary Rock-Tunneling Machines As shown in Fig. 3, the partial-face rotary tunneling machine is equipped with a cutterhead that rotates slowly at about 0.21 rad/s (2.0 rpm). The single-disk cutterhead produces the tunnel section shown in Fig. 4 by means of an oscillating motion. These machines work on the undercutting principle, and they are avail¬able in spring-line dimensional increments of 0.1 m (0.32 ft) from 1.5 to 2.1 m (5.0 to 7.0 ft); the vertical dimensions are 2.4 to 3.2 m (8.0 to 10.5 ft), respec¬tively. Depending upon the tunnel width, the cutterhead disk may be fitted with from 8 to 16 drag-bit cutters. Penetration is achieved by means of hydraulic rams that force the tungsten-carbide bits into the rock mass. The operation is cyclic, with cutting occurring only on the upstroke. On the downstroke, the rotating cutter¬head draws the fallen muck from the invert into the panzer-type conveyor for rearward transfer. This feature allows time to either reposition ore cars or to exit the tunnel with muck trains while the machine is cutting, as shown in Fig. 5. Boom-Type Rotary Excavators The boom-type rotary-excavator tunneling machines commonly are known as boom-type continuous miners

Jan 1, 1982

By V. W. Smith

For the past 50 years, the primary crushing of stone at the Dolase Bros. Co. Richards Spur Quarry. 13 miles north of Lawton, Oklahoma, has been accomplished by a Traylor 42-inch gyratory crusher. The production capacity of the primary system, consisting of a feeder, grizzly, and the gyratory crusher, was approximately 2100 tons per hour. Shot-down scone was hauled from the working face about one mile to the feeder by a fleet of Caterpillar Model 773's and WABCO 60- and 65-ton trucks. In order to maintain production, nine to ten trucks and four Caterpillar Model 992 front-end loaders were required to be operational at all times.

Jan 1, 1986

By Robert C. Salak

The era of low-seam mining with continuous haulage has been here for quite some time. Typical tonnages in companies such as Terry Glenn Coal are currently averaging 405 tonnes per shift in .8m coal. JoAnn Coal has averaged 453.6 tonnes per shift in .775m to .825m coal for the past four years. John Chaney of Chaney Coal has averaged 297 tonnes per shift in .6m to .65m coal. There are many other mines that are experiencing similar success and with maintenance costs that are averaging $.10 to $.40 per tonne. These figures have been documented and can be verified by the operators.

Jan 1, 1981

By G. Pierson

Explanations of commodity price levels, or movements, commonly focus on the supply and demand fundamentals of the particular commodity, or else are assigned to speculative activity. Comparisons of metal price histories with monetary and other economic data support the argument that the supply of and demand for money are no less important in price determination than are the supply and demand of the commodity itself. That these relationships should exist is evident in the price identity and are consistent with monetary theory. The patterns developed have limited usefulness as predictors, but their recognition is essential for the construction of price scenarios for planning purposes.

Jan 1, 1996

By R. J. Sweigard

One of the foremost problems in reclaiming prime farmland is compaction of the subsoil which is caused by the reclamation equipment. Wheel tractor-scrapers are most commonly used to replace subsoil and have been blamed for the majority of the compaction problems. Two methods of alleviating this problem that are presently being considered are mechanical subsoil loosening machines and truck- shovel combinations for subsoil handling. A field study was conducted in which dry bulk density measurements were taken in an effort to determine the effectiveness of truck-shovel combinations and subsoil loosening equipment in reducing bulk density in comparison to typical scraper replacement.

Jan 1, 1987

Modern coal cleaning technologies have allowed coal preparation facilities to become quite efficient at removing sulfur compounds, waste rock and low grade coals from run of mine coal. Up to 50% of the raw mined coal stream may end up as refuse, particularly when the coal originates from longwall mining operations, or is high in partings, rock and impurities. The refuse materials vary from coarse materials removed by physical screening to very fine materials removed by floatation and density separation processes. Coal refuse piles are also known by a variety of other names including "waste dumps", "gob piles" and "slate dumps". The potential hazards of improperly reclaimed refuse include contamination of surface and groundwaters by acidic leachates and runoff, erosion and sedimentation into nearby watersheds, spontaneous combustion, disturbance of topsoil borrow areas, and damage from landslides should large slope failures occur. Many of these problems have been particularly acute for abandoned refuse piles, and modern regulations attempt to minimize the environmental impact of coal refuse disposal operations.

Jan 1, 1993

By Trevor R. Ellis

In this paper a method is presented for estimating the specifications of sandstone-type uranium deposits which will be the minimum that can meet a company's economic requirements for investment. The method interpolates and extrapolates from available cost data for typical mines to provide the costs for a wide range of possible deposits. The range of deposits achieving the company's required discounted cash flow rate of return on investment at an estimated uranium oxide selling price is then calculated, thus giving the complete range of deposits which meet the minimum required specifications. Prospects are then evaluated by comparison with these minimum requirements.

Jan 1, 1979

By D. Suarez

The work of engineers responsible for the design and performance of mine facilities is often challenged by economic and practical constraints in the field. Problems have developed in implementing design criteria dictated by persons or agencies not familiar with the dynamic nature of mine engineering. Regional and site-specific conditions frequently require changes to standard designs, or the use of a completely innovative approach, which is not provided for in the regulations. The implementation of engineering design, therefore, usually requires a hard-sell approach to management and regulatory agencies that allows for a happy-medium to all parties concerned. Flexibility on the part of the regulatory agencies is needed to solve operational and environmental problems with sound engineering. Typical hydrologic issues which will be discussed fall in the following general categories: ? Design criteria for sizing water control structures (i.e., culverts, diversion and sedimentation ponds, ditches, etc.) ? Implementation (construction and operation) difficulties ? Regulatory compliance ? Reclamation planning with hydrologic considerations ? Protection of groundwater resources

Jan 1, 1986

By Don C. White

Santa Rosa is a mid-Tertiary, volcanic-hosted, bulk-mineable, open-pitable, heap-leachable, gold-silver deposit. It is the product of hydrothermal mineralization along an arcuate segment of a caldera collapse ring fault in a probable maar volcanic setting. This segment was later broken by radial faults. Gold occurs principally as electrum finely disseminated through intermediate tuffs, and associated with pyrite, at Santa Rosa. The nearby Alto de la Mina deposit displays stockwork silica-pyrite-gold in a tectonically and hydrothermally shattered andesite flow. Miocene epithermal mineralization was accompanied by central silicification and pyritization and more distal argillization. An andesite flow cap rock at Santa Rosa played a pivotal role as an upward permeability barrier. Highest gold grades and most intense alteration occur closest to the ring faults and immediately beneath the andesite flow. Supergene alteration effects on the gold distribution are minimal.

Jan 1, 1993