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By G. Caron, M. Boisclair

In 2005, CANMET-MMSL used its pool of expertise in ground control, open pit and underground mine engineering, mineral processing, information technology and applied mineralogy to launch a mine-to-mill research project. The objective of the project was to optimize the distribution of rock breakage energy among blasting, crushing and grinding activities, thereby maximizing the efficiency of energy utilization within comminution processes. Tests were designed to demonstrate that this approach could reduce the energy consumption, thus contributing to the reduction of Green House Gas (GHG) production in the Canadian mining industry. The project was accomplished in collaboration with DynoConsult and Dyno Nobel Canada Inc., a world leader in commercial explosives. Data analysis from 12 blasts (six with electronic and six with pyrotechnic detonators) in three different geological formations of a quarry (soft, medium and hard rock) shows that electronic blasting technology increases rock fragmentation by 15% (in hard rock) to 20% (in soft rock). A more uniform rock fragment size distribution is also obtained. The impact of the improved quality blast product on downstream processes of the quarry is a productivity increase of 5% in rock excavation and transportation, an energy reduction of 10% at the primary crusher and an increase of 15% of the primary crusher throughput. A soft-sensor prototype, based on primary crusher data (i.e. energy consumption, throughput, feed and product size distribution) and a simplified computerized process model, was developed for on-line measurement of the rock operating work index. Additionally, 385 rock samples and specimens were collected and prepared to determine the tensile and compressive strength of the rock material, to evaluate the aggregate crushing work index, and to examine the development of micro- and macro-fractures by means of binocular and SEM microscopy. Blast-induced rock damage was evaluated at the end of the laboratory testing program. Even though a reduction of rock hardness of around 30% was observed after blasting, the impact of the blasting method (i.e. use of electronic or pyrotechnic detonators) on the induced rock damage could not be observed. It is either absent or not perceptible with the accuracy of the measuring techniques and the number of samples analyzed.

Jan 1, 2007

By R L. Brathwaite

Previous paleodepth studies of low-sulphidation epithermal Au-Ag deposits in the Coromandel region indicated that economic gold mineralisation was generally limited to a depth zone of 100 to 400 m below the paleosurface. Notable exceptions are Waihi and Karangahake, where ore shoots extended to depths of about 750 and 900 m respectively. These studies have been extended to include Au-Ag, Hg and Sb epithermal deposits in Northland and the Taupo Volcanic Zone. The main paleodepth indicators used are sinters and hydrothermal eruption breccias, hydrostatic pressures estimated from homogenisation temperature measurements on fluid inclusions, and hydrothermal alteration mineralogy. Also the occurrence of lacustrine and fluvial sediments is an indicator of the paleosurface at their time of deposition. Selected paleodepth indicators have been compiled and mapped in a GIS environment. The distribution of the paleodepth indicators are used to define regional variations in erosion levels, and may be useful in predicting areas most likely to preserve the optimum depth window for gold deposition. In the Coromandel region, regional stream sediment geochemical data has also been used to broadly define erosion levels in terms of Zn, Pb and Cu representing deeper base metal zone mineralization and Hg and Sb representing shallower cinnabar and stibnite mineralisation. The interpretations of paleodepth and potential reconstruction of paleosurfaces are limited by the paucity of data, poor age control on the paleodepth indicators and the epithermal deposits, and marked relief and complex stratigraphy in the volcanic terranes.

Jan 1, 2003

By J. C. Cawley, G. T. Homce, M. R. Yenchek, H. K. Sacks

As in many other industries, such as construction and agriculture, overhead electric power lines are a serious hazard at mining and mining-related operations. Even when excluding injuries that occur during electrical maintenance work, over one fourth of electrical fatalities in the mining industry are due to accidental overhead line contacts, and for each fatality nearly two serious non-fatal injuries occur due to such contacts. In incidents involving high-reaching mobile equipment, many of the victims touched the equipment after the fact, unaware that the machine frame had become energized by the line contact. MSHA data for accidents involving overhead power line contacts in the mining industry between 1980 and 1997 reveal that in 57% of the cases personnel were unaware of the accidental line contact until after one or more workers touched the equipment or a hoisted load and were injured. The situation is similar in the construction industry, where according to the National Institute for Occupational Safety and Health (NIOSH) data at least 20% of such victims are unaware of the line contact. This suggests that a device that alerts workers when a power line has been contacted could help prevent many of these injuries. Such a device would not prevent power line contacts, yet if widely employed could yield a significant reduction in the number of resulting injuries. Researchers at the NIOSH Pittsburgh Research Laboratory are attempting to develop such a device. The approach being investigated is based on measuring electric current flow to ground through a machine during a line contact. The specific technique being tested involves the diversion of some part of this current through a shunt cable mounted on board the machine, to provide a point at which to install a current sensor. Experiments thus far indicate that this approach is feasible. Ongoing research is better defining electric current flow through mobile equipment, refining techniques for measuring this current, and identifying factors that could limit the effectiveness of the proposed alarm.

By David E. Albus, Ahmadreza Mortezaie, Bidjan Ghahreman

The structural evaluation of seismic performance of an existing hospital in Long Beach, California, required spring constants of foundation elements. The structure included support by deep foundation elements comprised of belled (underreamed) caissons. The available relationships in the governing building code (ASCE41-13) to compute axial stiffness is not applicable due to the belled configuration of the caissons. The large diameter of the bells required consideration of the foundation medium to the axial stiffness; a detail not clearly described in ASCE 41-13. Furthermore, prescriptive equations in ASCE 41- 13 used to estimate lateral stiffness only consider pile groups with the assumption that the only source of lateral stiffness is the axial reaction of individual piles. These assumptions were invalid for the project at hand where all caissons are configured as single foundation elements, not a pile group. In the present work, the approach taken to estimate seismic stiffness of single-belled caissons is described which accounts for the elastic behavior of the foundation medium below the bell base and lateral behavior of single-pile shafts. Results of the work provide a more satisfactory derivation of the spring constants consistent with current modeling methods. INTRODUCTION Seismic evaluation of an existing hospital in Long Beach, California, required geotechnical investigation followed by site-specific ground motion analysis. This evaluation was required by the Office of Statewide Health Planning and Development (OSHPD) in order to meet the requirements of the Structural Performance Category 4D (SPC-4D) published as a part of the 2016 California Building Code, CBC (Section 3412A). SPC-4D utilizes ASCE41-13, as modified by OSHPD, and involves two seismic performance objectives: BSE-1E (20% probability of exceedance in 50 years) and BSE-2E (5% probability of exceedance in 50 years). Spring constants and capacities of foundation elements were needed for evaluation of the structural performance of the building subjected to these two performance objectives. Our review of the as-built foundation plans indicated that both shallow footings and caissons were used for support of the structure. The plans demonstrated that all caissons are belled (under-reamed) and are individual, i.e. not part of pile groups. In this paper, the subject site condition and foundation elements are described first. This is followed by details of assessing spring constants and vertical capacities for belled caissons. The new requirements of the 2016 CBC concerning the evaluation of critical facilities will likely entail evaluation of other structures with belled caissons due to the more extensive use of these foundations in the past. This paper proposes a method to address the conditions of individual belled caissons not explicitly considered in the current code provisions.

Jan 1, 2018

By Liming Yuan

A study of the ignition of non-fire-resistant hydraulic fluid sprays was conducted by the National Institute for Occupational Safety and Health. Both an open flame and a hot steel surface were used as the external heat sources. With the open flame as the heat source, the minimum oil temperature and minimum spray nozzle pressure that resulted in an ignition were measured. The effects of the distance between the open flame and the nozzle and the nozzle orifice diameter on the ignitability of the hydraulic fluid sprays were examined. With the hot surface as the heat source, the minimum surface ignition temperature was determined. The degree of oil atomization and the relative direction of oil injection with respect to the hot surface are discussed. The ignition of oil sprays from the impingement of oil jets onto a vertical surface was also investigated. Finally, the results are compared with those obtained for fire-resistant hydraulic fluids. Keywords: Ignition; hot surface; open flame; hydraulic fluid

Jan 1, 2006

By Gungor Tuncer, Ali Kahriman, Abdulkadir Karadogan, Mehmet Aksoy, Kagan Ozdemire

With increasing environmental constraints on the levels of disturbance induced by blasting operations upon nearby residents, there is an increasing need to be able to design cautious blasting with greater precision. Therefore, determination of maximum amount of explosive per delay for a certain distance especially in large blasts is of great importance for the elimination of these environmental problems. Although too many research studies had been carried out in the past in order to eliminate environmental issues produced from blasting unfortunately a general approach or formula has not been established yet because of the complexity of the matter. In addition to the wave and ground motion characteristics, the complexity of blasting parameters and site factors restrict the developing a general criterion. So experimental site-specific studies should be still done in order to predict and control blasting effects. This paper presents the results of ground vibration measurements carried out in Espey Open-Pit Boron (Colemanite) Mine located on the west side of the central Anatolia near Kütahya province in Turkey. Within the scope of this study, ground vibration components were measured for 13 shots during bench blast optimisation studies in order to predict peak particle velocity level for this site. In blasting operations; ANFO and Powergel Magnum 600 (blasting agent), Powergel Magnum (priming) and delay electric detonators (firing) were used as explosives. Parameters of scaled distance (charge quantity per delay and the distance between the source and the station) were recorded carefully and the ground vibration components were measured for all blast events using 4 different types vibration monitors (3 White Mini-Seis and 1 Instantel Minimate Plus Models). Then, the data pairs of scaled distance and particle velocity obtained from the 38 record events were analysed statistically. At the end of statistical evaluation of the data pairs, an empirical relation which gives average line at 95% confidence level and upper bound 95% prediction line with a reasonable correlation coefficient was established between peak particle velocity and scaled distance.

Jan 1, 2005

By P. Koh

A novel approach incorporating computational fluid dynamics (CFD) and flotation modelling has been used for investigating flotation cell designs. CFD modelling has increasingly been employed to enhance understanding of the cell hydrodynamics in mineral and coal flotation. Opportunities for improving the flotation cell performance can be identify by modelling. The CFD-flotation model from CSIRO incorporates cell hydrodynamics that affect particle-bubble interactions. Information from the model includes velocities, turbulent dissipation rates, gas hold-up, particle-bubble attachment and detachment rates. The attachment and detachment rates have been found to be effective measures of cell performance for cell design.

Jan 1, 2011

By A. Pratt

Portland cement is primarily used to solidify backfill in underground mine workings and it represents a major cost in mining operations. CANMET-MMSL has invented an alternative binder technology that does not contain any amount of Portland cement and is made using waste materials, such as development rock and smelter slag. The technology has been successfully tested with many types of base metal and ferrous slag. Research conducted in collaboration with several mining operations in Canada has shown that the CANMET-MMSL binder has considerable potential as a replacement for Portland cement in mine backfill. An integral part of the overall mining operation, backfill is used for two main purposes: safety and environmental remediation. Depending on the mining method used, backfill provides a working surface, stabilizes stope and pillar walls, as well as the surrounding rock mass, and controls caving of stope backs. There are several benefits associated with the replacement of Portland cement in backfill, including reductions in (i) the footprint by placement of slag waste underground, (ii) the environmental effects and long term liability resulting from disposal and containment of slag waste on surface such as acid rock drainage, (iii) GHG as a result of reduced Portland cement usage (the production of 1 ton of Portland cement produces 1 ton of GHG), and (iv) the significant costs associated with reduced Portland cement usage.

May 1, 2010

By M. Moagabo

CO2 emissions from carbonate laden reclaimed mine spoil has been shown to pose a hazard to residents in homes built on or adjacent to such land. The objective of this project was to develop a soil CO2 flux survey protocol for assessing reclaimed mine land. The research involved CO2 chamber accumulation flux surveys; stable carbon isotope ratio analysis; statistical hypothesis testing to examine correlation between CO2 flux and soil temperature and moisture as well as spatial dependence; and geostatistics to map CO2 and delineate high flux zones. Soil temperature was observed to have a positive correlation with fluxes while soil moisture was observed to be negatively correlated. Spatial dependence of CO2 fluxes on reclaimed mine land was observed on one of the two study sites. The research suggests that macro-porosity and gas permeability may be important factors that explain CO2 migration in mine spoil. A flux survey protocol has been developed, based on these results, for reclaimed mine lands. The work demonstrates the capability of geostatistical methods to delineate high flux fields. Further research will be required to determine suitable thresholds for such analysis.

Jan 1, 2012

By Jurgen te Kook

State-of-the-art for subsidence calculation are stochastical models. Although these models were successfully used all over the world they have their limitations due to the fact that they are not based on mechanical laws. For example the models did not take the rock mass structure and the rock mass characteristics into account. Therefore in a research program the skills of geomechanical numerical models for subsidence calculation were investigated. A case study shows that numerical models which are in principle based on the elastic theory are suitable for subsidence prediction. Due to the principles of these models the results are not sufficient in the case of multiple seam extraction. More extended geomechanical numerical models like FLAC and UDEC were investigated in further steps of the research work. Up to now large area geomechanical models require unrealistic long calculation times if the level of detail is similar to that of small scale calculations. Due to this it was necessary to implement a simplified description of the rock mass structure and characteristics. Different case studies show that this approach is successfull for subsidence calculation by numerical geomechanical models even for multiple seam extraction.

Jan 1, 2008

By Geir Martin Haarberg

Modern electrolysis technologies can provide possibilities for developing sustainable processes in terms of energy and environment. Laboratory experiments were carried out to study electrodeposition of iron from molten salts and aqueous solutions using an inert oxygen evolving anode to eliminate the emissions of CO2. The possibilities of molten salt electrorefining of metallurgical grade silicon to produce solar grade silicon were also investigated. Electrochemical techniques were used to study the electrochemical behaviour of dissolved iron, silicon, and titanium species. Bulk electrolysis was carried out to deposit pure iron, silicon, and titanium. The quality of the deposits was studied by SEM/EDS and XRD analyses. Calculations based on laboratory studies indicate that great improvements in terms of reduced energy consum

Jan 1, 2010

By Thomas Fraser, M. G. Driessen

This report is one of a series written by members of the Solid Fuels Mission to Germany describing wartime developments in the mining , preparation, and utilization of coal . The mission was organized early in 1945 under the auspices of the Technical Industrial Intelligence Committee , which cooperated with a counterpart British Committee . Engineers from other allied countries cooperated in some of the investigations . The Solid Fuels Mission operated under the direction of a steering committee headed by Dr. C. J. Potter , deputy solid fuels administrator . The personnel of the mission consisted of H. F. Yancey , in charge , J. W. Buch , Thomas Fraser , L. L. Newman , and L. D. Schmidt , of the Bureau of Mines ; H. H. Lowry , Director of the Coal Research Laboratory , Carnegie Institute of Technology ; H. J. Rose , vice president and director of research , Bituminous Coal Research, Inc .; and F. H. Reed , chief chemist , Illinois Geological Survey . Over 50 reports were written by the members of the Solid Fuels Mission . These and microfilms of supporting data obtained in the course of the investigations are on file at the Bureau of Mines , Washington , D. C. where they are available for public examination . The Office of the Publication Board in the Department of Commerce is prepared to furnish photolith copies , photostats , or microfilm reproductions of all declassified reports . A Bibliography of Scientific and Industrial Reports is issued weekly by the Department of Commerce , Office of the Publication Board , and is sold by the Superintendent of Documents , Government Printing Office , Washington 25 , D. C. , on a subscription basis . An initial payment of 10 dollars will provide for approximately 9 months , and subscribers will be notified when additional remittance is necessary . All subscriptions will begin with volume 1 , No. 1 , unless ordered otherwise . The Bibliography covers all materials and subjects and gives instructions for obtaining the desired items . The reports of the Solid Fuels Mission relate to the following general subjects : Mining methods in the Ruhr district of Germany , with special reference to mechanical cutting and loading equipment , pneumatic packing , and Diesel mine locomotives ; activities of industrial research laboratories supported by the German coal and coke industry ; coal preparation in western Europe ; low-temperature carbonization processes ; metallurgical coke from weakly coking coals ; low- ash electrode carbon from coal ; new developments in the production of metallurgical coke and the utilization of gas and byproducts ; briquetting brown coal and bituminous coal without the use of binders ; recent engineering developments in gas turbines and steam generators , with special reference to use of coal ; German coal-fired heating and cooking stoves; and the commercial extraction of coal with solvents for production of synthetic liquid fuels or chemical products . Numerous reports on the activities of German synthetic - liquid -fuels plants and the plants for the production of synthesis gas from solid fuels are available in the same office as the Solid Fuels Reports . It is planned to publish in this series of Information Circulars the more important reports or combinations of reports prepared by the members of the Solid Fuels Mission . A similar series on synthetic - fuel activities is being prepared .

Nov 1, 1946

By Debbie Laney

DOUG HALBE: Second in our quick run-through on "Operating Ideas That Have Saved Me Some Bucks," was Debbie Laney of Rayrock Mines. Debbie apologizes. She can't be here. But she said, "Doug, don't worry. I've asked Mary Korpi to present the paper. We're both short, blond, and wear glasses. Nobody will know." [laughter] Mary, I caught it right away. You ladies can't fool us. Debbie, who wrote the paper, has spent almost her entire career in operations. She is currently metallurgical manager of Rayrock Mines in Valmy, Nevada. Mary Korpi is also a real operator (that doesn't sound right). She has been responsible for a number of operating areas at Newmont's Nevada operations, and she is currently taking a break from operations as manager of public relations/employee communications for Newmont Gold in Carlin. MARY KORPI: They told us this year at Newmont that we were going to have to work twice as hard. I had no idea it meant I would have to work for another company, too. Over the years, and many times in association with work for mid- to small-size mining companies, there have been two areas that seem to have been the focus of cost savings when looking at new facilities or new processes.

Jan 1, 1998

Effects of DA as a Grinding Aid on Selective Grinding of Low-Grade Bauxite Effects of DA (a copolymer of acrylic acid and acrylamide) as a grinding aid on selective grinding of low-grade bauxite were investigated in this study. The addition of DA into the grinding system enhanced the selectivity of grinding and increased the A/S ratio in the coarse fraction of ground product, leading to improved throughput of grinding mills and alumina recovery. The results showed that DA decreased the viscosity of slurry significantly and hence improved grinding efficiency due to low viscosity at a high slurry concentration. Both the hydrogen bond formation and chemical adsorption existed between DA and the surface of bauxite particles. The adsorption of DA on the surface of bauxite could decrease stress needed for crack initiation and extending during grinding, prevent new-born crack surfaces from rejoining, and promote the expansion of the cracks.

Sep 13, 2010

By James McKelvey, Larry Drolet, Jason Swartz

INTRODUCTION When divers discovered that sections of a tunnel housing the pipeline that conveys wastewater from the Charleston Peninsula to the Plum Island Wastewater Treatment Facility had caved in, the Charleston Commissioners of Public Works(CPW) moved quickly to determine a long term solution for the city’s collection system, immediately focusing on the Ashley River sewer tunnel along the western boundary of the peninsula. Working with the Charleston community, as well as federal, state, and local officials, CPW developed a fast track yet long life design that can be used as a model for underground construction of tunnels in urban areas. The paper that follows summarizes key aspects of the Ashley River sewer tunnel project. HISTORICAL CHARLESTON Charleston, South Carolina is a culturally significant and historic city that was originally settled in 1670. There are over 100 buildings on the National Register of Historic Places within the Charleston area. Additionally, the first shots of the American Civil War were fired at Fort Sumter in the Charleston Harbor in 1861. As one can imagine, tourism generates significant business for the area with over 1.5 million people visiting Charleston each year. No project, especially one that requires digging, is done within the old city on the Charleston peninsula without careful planning. Many precautions are necessary to prevent damage or disruption to the historical properties. The Ashley River sewer tunnel project is exclusively in the old city. A lot of work was done during the design phase to minimize the impact to historical properties. Some of this work included: an archeological study (where pre-digs were monitored at all shaft sites by an archeologist); a building/structure assessment study (where structures near a shaft site were completely surveyed and cataloged); and an environmental study.

Jan 1, 2005

By Harry W. Campbell

A Bureau of Mines investigation identified no mineral deposits in the Lost Creek RARE II area. Sand and gravel has been mined from alluvial flood plain deposits just outside the RARE II boundary. An oil and gas lease application which includes the eastern portion of the RARE II area is pending. Abundant basalt in the area can be crushed and used as aggregate; but it could not compete with similar deposits in more favorable locations, or with cheaper substitutes such as volcanic cinders or sand and gravel which are available outside the study area closer to major markets. No indication of coal or geothermal energy resources was found. INTRODUCTION Location and Access The Lost Creek RARE II area encompasses 8,300 acres (3,400 ha) of Lassen National Forest in north-central California, about 20 mi (30 km) north of Lassen Peak. The closest city is Redding, California, 50 air mi (80 km) southwest. Peripheral access is provided by State Highway 89 passing near the western RARE II boundary (fig. 1). The Pacific Crest Trail traverses the western margin of Hat Creek Rim adjacent to the eastern boundary of the area.

Jan 1, 1983

By Steve Collinsworth, Nils Heinke

In 1989, I realized the definite need for change in the Blast Hole Drilling Industry. With over 25 years of experience in dealing with the industry, I am well inGormed and educated concerning the problems that occur in Blast Hole Drilling. After continues interaction with the Drill & Blast Superintendents, Drillers, Purchasing Agents, Mechanics, and others in the field, a basic understanding was developed as to the origins of the main problems that the industry f&s with their drillings programs.

Jan 1, 1997

By D. E. Calisaya, É. Poulin, A. Desbiens, R. del Villar, A. Riquelme

"A 15 cm diameter by 732 cm height, fully automated pilot column was installed in the Agnico-Eagle’s Laronde concentrator (Québec), for evaluating the performance of newly developed sensors and advanced process control algorithms. For eventual comparison purposes, the pilot column is continuously fed with the same slurry feeding the copper-circuit third cleaner column. It is equipped with electrical conductivity-based sensors for estimating the three variables used in the multi-variable control algorithm under evaluation: froth depth, fraction of wash water underneath the interface and gas hold-up. Froth depth is regulated using a PI controller while a predictive controller is formulated as the minimization of the tracking errors of gas hold-up and bias rate, keeping several operating constraints between their practical upper and lower limits. In particular, an unreachable high set point of gas hold-up can be selected in order to maximize the bubble surface area available for particle collection, while maintaining bias rate above a minimum value required for froth cleaning. The proposed strategy may indirectly help optimizing flotation column operation by using these secondary variables, without the implementation of a real-time optimization layer.INTRODUCTION Flotation columns have already been used for more than 30 years, mainly in cleaning stages, as a result of their froth washing capabilities. Despite their widespread usage, the measurement of some pertaining variables and their use for automatic control is rather scarce. Among the most important variables directly related to the process metallurgy (concentrate grade and recovery), froth depth (hf) is the only one normally monitored and controlled. Even though commercial sensors are available, gas hold-up (eg), a variable directly related to concentrate recovery, is seldom measured and never controlled. Another important variable, bias rate (Jb) responsible for concentrate cleaning, is simply not measured at all, as there is no commercial sensor available. Therefore, besides froth depth, continuous monitoring of process variables is limited to flow rates (gas, feed, tailings, wash water), i.e. to manipulated variables. Some new available sensors have been industrially tested, e.g. the Sonar-TracTM for eg (O'Keefe, Viega & Fernald, 2007) and the McGill hold-up sensor (Tavera & Escudero, 2002). Others, for bias rate and frother concentration, have been successfully validated at laboratory scale by Laval’s LOOP researchers (Maldonado, Desbiens, del Villar & Chirinos, 2008b; Maldonado, Desbiens, del Villar & Aguilera, 2010a). Some devices have been extensively used for monitoring bubble size and space distri-bution, e.g. McGill bubble viewer (Gomez & Finch, 2007) and others."

Jan 1, 2012

By Peter Swanson

A seismic monitoring network has been installed in western Colorado (USA) in the vicinity of three underground coal mines to (i) distinguish and characterize seismic activity as either mining related or naturally occurring, (ii) implement a real-time event monitoring and notification tool, and (iii) collect data for use in research studies aimed at quantifying impacts from mining-related and natural seismicity. These potential impacts include dynamic rock mass failures such as coal bumps as well as strong shaking in the vicinity of critical structures such as impoundment dams, reservoirs, mine seals, mine openings, and steep slopes. Examples of two damaging seismic events are presented and the mining and geologic factors attending these dynamic failures are described.

Jan 1, 2008

By A. Noble, R. Q. Honaker, J. Werner

Recovery of rare earth elements (REE) from coal-related resources has recently received significant interest due to supply concerns and their key roles in critical industries and defense-related technologies. An integrated flowsheet consisting of sorting, crushing/grinding, physical separation, acid leaching, solvent extraction, and selective precipitation was designed to achieve continuous production of rare earth products from various coal-related resources such as coarse refuse and acid mine drainage. A pilot plant was constructed that enabled continuous testing of the circuitry on a range of different coal-based feedstocks. Despite achieving significant success in producing high-grade rare earth oxide products, low REE recovery values and high operational costs necessitated a re-evaluation of the process flowsheet. This article describes the circuitry improvements that were based on both laboratory and pilot plant test results. Roasting as a pre-leach treatment was found to significantly improve the leaching rate and overall REE recovery values. After roasting West Kentucky No. 13 and Fire Clay coal refuse materials at 600 °C, REE recovery increased by 60 and 40 absolute percentage points, respectively. Rare earth concentration in the pregnant leachate solution (PLS) was increased to around 700 ppm prior to solvent extraction using a staged precipitation method. REEs in the precipitate were re-dissolved, purified, and extracted from the PLS using solvent extraction and selective precipitation to values of around 80%. As a result of the improvements, chemical consumption in the acid leaching and solvent extraction processes was significantly reduced. A techno-economical assessment of the improved flowsheet indicated significant commercialization potential.