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By Robert B. Fulton, Gill Montgomery

Fluorspar is the commercial name for fluorite, a mineral that is calcium fluoride, CaF2. The name, derived from the Latin word fluere (to flow), refers to its low melting point and its early use in metallurgy as a flux. It is the principal industrial source of the element fluorine. Two other minerals, cryolite and fluorapatite, have significant fluorine content. Cryolite, sodium aluminum fluoride, Na3AlF,, is a rare mineral that has been found in commercial quantities only in Greenland. The natural material has been supplanted by synthetic cryolite for its principal industrial use in the manufacture of aluminum. Fluorapatite, Ca5F(PO3)2, is a source of phosphate for fertilizer manufacture, containing a small percentage of fluorine. Commercially mined deposits of apatite have varying amounts of fluorine, chlorine, hydroxyl, and carbonate. HISTORY Fluorspar was used by the early Greeks and Romans for ornamental purposes as vases, drinking cups, and table tops. Various peoples, including the Chinese and the American Indians, carved ornaments and figurines from large crystals. Its usefulness as a flux was known to Agricola in 16th century Europe. Fluorspar mining began in England about 1775 and at various places in the United States between 1820 and 1840. Production grew substantially following the development of basic open hearth steelmaking, wherein it is used as a flux. Use was stimulated by growth of the steel, aluminum, chemical, and ceramic industries, particularly during World Wars I and 11. Fluorocarbons entered the picture in 1931. The use of anhydrous hydrogen fluoride (HF) as a catalyst in the manufacture of alkylate for high octane fuel began in 1942. Differential flotation for separating fluorspar from galena, sphalerite, and common gangue minerals in the 1930s and the application of heavy media concentrating methods to the treatment of low grade ores in the 1940s were outstanding technological advances that facilitated increased production. Pelletizing and briquetting of flotation concentrates for use in steel furnaces and the development of flotation schemes for beneficiating ores containing abundant dolomite and barite have been major improvements in the industry. USES OF FLUORITE Fluorspar is used to make hydrogen fluoride (HF), also called hydrofluoric acid, an intermediate for fluorocarbons, aluminum fluoride, and synthetic cryolite. It is used as a flux in the steel and ceramic industries, in iron foundry and ferroalloy practice, and has many minor specialized uses. Hydrogen fluoride is produced by reacting acid grade (97% CaF,) fluorspar with sulfuric acid in a heated kiln or retort to produce HF gas and calcium sulfate. After purification by scrubbing, condensing, and distillation; the HF is marketed as anhydrous HF, a colorless fuming liquid, or it may be absorbed in water to form the aqueous acid, usually 70% HF. Synthetic cryolite, organic and inorganic fluoride chemicals, and elemental fluorine are made from hydrofluoric acid. The acid itself is important in catalysis in the manufacture of alkylate, an ingredient in high-octane fuel for aircraft and automobiles; in steel pickling, enamel stripping, and glass etching and polishing; and in various electroplating operations. The manufacture of one ton of virgin aluminum requires about 12 to 29 kg of fluorine content in synthetic cryolite and aluminum fluoride. This quantity, through improved technology and recovery practices, is being lowered significantly in countries with the most advanced technology (i.e., Australia and Sweden), while others (i.e., Surinam and South Africa), remain at the high end. Elemental fluorine is prepared from anhydrous hydrofluoric acid by electrolysis. Gaseous at room temperature and pressure, fluorine is compressed to a liquid for shipment in cylinders or in tank trucks. Elemental fluorine is used to make uranium hexafluoride, sulfur hexafluoride, and halogen fluorides. Gaseous uranium hexafluoride is used in separating U235 from U233 by the diffusion process. Sulfur hexafluoride is a stable high dielectric gas used in coaxial cables, transformers, and radar wave guides. Halogen fluorides have important applications, mostly as substitutes for elemental fluorine, which is more difficult to handle. Emulsified perfluorochemicals, organic compounds in which all hydrogen atoms have been replaced by fluorine, are undergoing investigation as promising blood substitutes. They transport oxygen and, in conjunction with a simulated blood serum, perform many functions of whole blood. With further development, these organic compounds may ultimately, in emergencies, be useful in saving lives of animals and humans during periods of acute shortages of natural blood. Inorganic fluorides are used as insecticides, preservatives, antiseptics, ceramic additives, and fluxes and in electroplating solutions, antioxidants, and many other products. Boron trifluoride is an important catalyst. Organic fluorides are volume leaders in the fluorine chemical industry. Fluorinated chlorocarbons and fluorocarbons are prepared by the interaction of anhydrous HF with chloroform, perchlorethylene and carbon tetrachloride, and are characterized by low toxicity and notable chemical stability. They perform outstandingly as refrigerants, aerosol propellants, solvents, and cleaning agents and as intermediates for polymers such as fluorocarbon resins and elastomers. Fluorocarbon resins are inert compounds that have unusually low coefficients of friction and have found a number of applications as lubricants for parts that cannot be oiled, e.g., bearings for window raising equipment located inside of automobile doors, in small electronic equipment, for the manufacture of chem-

Jan 1, 1994

By D. W. Fuerstenau, P. C. Kapur

A model equation is presented for breakage of single particles as a function of the impact energy. The model takes explicit cognizance of the distribution of feed particles in their resistance to breakage as well as of the weakening of particles under repeated impacts. With the proposed formulation, it is possible to simulate the size spectra of progeny particles, interrelate quantitatively the so-called ‘t’ family of curves, derive an energy-size reduction relationship, compute the primary, energy-free breakage distribution function, and predict the optimum level of impact energy for a given size reduction task. Published data on single-particle impact grinding are in agreement with the model.

Jan 1, 1995

Laboratory techniques have been developed at the Julius Kruttschnitt Mineral Research Centre which relate comminution energy to size reduction. These relationships have been applied in the mathematical modelling of autogenous and semi-autogenous mills. Since their development in 1987 these models have been successfully used in many wide ranging design and optimization studies. A description of the basic structure of the models is presented with particular reference to ore characterization. Two case studies are presented which illustrate their effectiveness in evaluating and predicting the effects of circuit changes.

Jan 1, 1992

By D. Yeager

Researchers at the U.S. Bureau of Mines have successfully used a genetic algorithm to tune computer models of three column flotation units simulating a separation circuit. The computer models rely on empirical constants that are selected so that the models accurately predict the performance characteristics of individual column flotation units. Unfortunately, these empirical constants have traditionally been selected using a time consuming trial and error process. A new and more efficient approach to selecting empirical constants for computer models has been developed. A genetic algorithm has been used to select the empirical constants for column flotation models used to simulate a three column circuit. Genetic algorithms are search algorithms based on the mechanics of natural genetics. They rapidly locate near optimum solutions in difficult search spaces. Bureau researchers have used these innovative search algorithms to dramatically reduce the time needed to select empirical constants for column flotation models. The approach is applicable to the selection of empirical constants for numerous other computer models.

Jan 1, 1995

By Corby G. Anderson

Since 1985, the Sunshine Mining Company has used a patented nitric-sulfuric acid pressure leaching system for production of silver and copper from a refractory sulfide ore body. To better understand this novel process, a program of lab scale testing was undertaken to quantify the effect of system variables on silver recovery. Some of the factors studied include temperature, agitation, acidity, vessel pressure, particle size, percent solids and oxidizer amount. In turn, this knowledge will be applied in actual plant practice to upgrade reaction time, increase concentrate throughput, raise silver recovery and lower reagent costs. A discussion of plant process changes resulting from lab scale testing is included.

Jan 1, 1991

By J. Mark Richardson

Modern mining operations are increasingly affected by complex economic factors. Broad and rapid fluctuations in metal prices, rising operating costs, socio-political trends and the inherent technical difficulties encountered in most operations, all can combine to quickly change once-profitable ventures into money-losing propositions. Accurate knowledge of metal inventories during all phases of an operation has become essential to wise management decision-making. This paper reviews key elements of metallurgical accounting: sampling theory, measurement technology and computerized data adjustment. Application of current technology to the reconciliation of a hypothetical operation is discussed.

Jan 1, 1991

By D. M. Muir

Thiosulfate offers a nontoxic alternative to cyanide for processing gold ores. The mechanism of leaching gold using ammoniacal thiosulfate solution is driven by the Cu(II)-Cu(I) redox couple and is complicated by competing ligands such as NH3 and S2O32; It is shown that an understanding of the copper speciation and sulfur speciation is required to optimize this system. This paper presents Eh-pH and speciation diagrams for varying concentrations of Cu(II), S2O32- and NH3 and discusses the conditions under which various copper and sulfur species are stable.

Jan 1, 2002

By G. Vijaya Kumar, B. Srinivasa Rao, G. V. Krishna Rao

The paper outlines the ventilation practices prevailing in coal mines of Singareni Collieries Company (South India). The high annual average surface temperature and relatively steep geothermic gradient results in virgin strata temperatures in the region of 38- 42°C creating environmental problems in the working places. Expensive methods of air cooling can not be employed as the mines are small, and production and productivity do not justify the costs of artificial cooling of mine air. Controlled recirculation of mine air -- the unconventional technique being tried with success in some coal mines in U.K. has been analysed for improving the environmental conditions. The analysis shows that the method is safe, cost effective and can be applied with very little extra equipment.

Jan 1, 1991

By Bruce D. Hanson

A computer model capable of simulating the basic production system in a variety of underground mining methods has been developed at the Twin Cities Mining Research Center. This Bureau of Mines paper describes the simulation of the basic production system at the working face, which includes drilling, blasting, mucking, and roof bolting. The model is event-oriented; that is, the status of the system is updated at the occurrence of an event. All event or activity times, including failure and repair of equipment, are treated as stochastic variables. A location dimension, in addition to the time dimension, is used, allowing the simulation of multiple location systems. To aid the user in determining the efficiency of his system, the model provides several reports. An event or activity report gives the frequency of occurrence total active time, and cumulative delay statistics for each event. An equipment report delineates the availability and utilization of all equipment. A production report provides information on various performance measures such as tons produced and holes drilled. The cost report gives the cost of various elements in the system. Operating data from an actual mining situation were used in validating the model. In addition to the description of the model, examples of simulation experiments which were performed on a room-and-pillar mine system are given. Use of the model to determine methods for improving the efficiency of the system is discussed.

Jan 1, 1974

By Stig Premfors

Lamco Joint Venture is operating a Dravo Pelletizing machine to produce pellets from the natural slimes of an earthy hematite ore. The grate area of the machine 3.3 x 106 m equal to 350 m2 (3800 sq. ft.) and the installed fan capacity is 8200 HP. The limiting factor for production is normally fan capacity. This means that the processing fans can not pull the additional air (i.e the additional calories or BTUs) through the bed which would be required for increased production. A way to increase production without major modifications is to supply the additional calories needed for increase production by adding coal to the pellet feed. After successful laboratory tests following method of coal addition has been chosen and the following results have been obtained. 1. The ground coal is added to the slurry prior to the filters and the rotary dryer. 2. By adding 0.6% coal, an increase of about 15% in production rate has been obtained. 3. No significant changes of metallurgical properties have been observed (i.e. tumbler index, compressive strength, ferrous iron content, reducibility, Linder degradation and swelling). 4. No unexpected operation problems have been experienced. The pellet discharge temperature increases and is the limit for how much production can be increased by coal addition without making plant modifications.

Jan 1, 1971

By H. K. Pelzer

Belt conveyor systems for long-distance haulage are nowadays in a competitive position with conventional methods of transportation such as railways, truck haulage, and also pipelines for solid materials. In a number of cases, the economical use of conveyors is obvious. This is in all those cases where typical features of a conveyor system are showing the outstanding economical position in the very first approach for a certain project. Regarding downhill conveyors, with today's level of belt conveyor techniques nobody would reasonably doubt the justified application of a conveyor system, - as for instance at the Marcona Mining Installation, or at the iron ore mine of Lamco in Liberia.

Jan 1, 1968

By R. Addison

Boom, boom, boom, boom. The staccato beat rings out across the bush; the stamps are at work - slowly pulverizing gold-bearing ore for a patient, grizzled prospector. This is the State Battery near Marvel Loch - a tiny (capacity: 25 ton/day) gold plant operated by the Western Australian government. It is one of many such plants located in remote corners of Western Australia and the Northern Territory - miniature custom mills operated for the benefit of prospectors and small mine operators. These State Batteries, so called because they are operated by state governments and because the principal item of machinery in the plants are stamp batteries, are fascinating anachronisms: throwbacks to times long past, to a century ago, to the hard and heady existence of gold rush days.

Jan 1, 1986

By T. BACHMANN, G. SHAPLAND, E. Amini, N. BEATON, M. BECERRA

Process plant modeling in the computer environment has been developed over the past 40 years by implementing the comminution models formed by the Julius Kruttschnitt Mineral Research Centre, University of Queensland, in the early 1970s. The models for the other processes in a mine value chain, such as blast fragmentation and flotation, were continuously developed and improved in parallel as well. Other research and commercial entities have also developed process modeling methodologies in the computer environment, which evolved as specialized commercial software or through equations set up in Excel spreadsheets. These were performed on a local computer, in thousands of simulations over a long period of time due to hardware limitations and the lack of a fully automated process. This limits the application of detailed process simulations for scale-up and strategic planning analysis, as they require many simulations to cover all possible scenarios which would take a lifetime when using local computers. The Integrated Extraction Simulator (IES), as the next generation of cloud-based software package, has made it possible to run simulations on the entire operation value chain in the same platform, including drilling and blasting, crushing, grinding, flotation, and other downstream process and material-handling units. This capability has allowed IES to handle multivariable simulations across the mine value chain, including pre-concentration and in-pit size reduction, and modify the process simultaneously.

By D. Veigel, J. D. McKay

Model enhanced Expert control has been implemented at the Newmont Lone Tree mill grinding plant as well as rule based Expert control for flotation and thickening circuits. The project has been successful in producing benefits but more importantly has contributed to an ongoing effort for continuous process improvement. This paper discusses how the control at Lone Tree has evolved and the part that Expert control has played in the overall improvements made. Specific examples of how the advanced control has integrated with instrumentation and stabilizing control are given and illustrations of how it has been effective in defining limitations and bottlenecks in the process or process control areas are provided.

Jan 1, 2002

By W. G. Pariseau

Recent advances in rock mass mechanics and computational technology now allow for stability analysis of excavations in "wet" mines where mining-induced changes in rock mass deformation and fluid flow are coupled and time-dependent. All the usual dry mine parameters including the premining stress state and rock mass properties are taken into account, in addition to water pressure and flow in jointed, possibly porous, rock masses. Finite element analyses of shafts and tunnels as circular, elliptical, rectangular and arched-rectangular hole shapes excavated in an initially stressed and pressurized rock mass indicate that the usual guidelines for optimum shape and orientation of single openings apply. Here, optimum means maximizing the minimum wall safety factor, or equivalently, minimizing the peak stress concentration. The results also show that failure originates in elements at the wall and that the minimum safety factor at the wall in the wet case is always less than the dry case regardless of drainage time allowed.

Jan 1, 1995

By Robert Walker

The win theme of this session is Unique Material Handing Systems. The theme was selected because of two major factors. 1. Accomplishments of unique character manage to attract interest regardless of their age. 2. There is much to be learned from pioneering efforts of the past as they are the stepping stones to technological development. Thus, 2-1/2 years after completion, the engineering feat of Oroville Dam still looms large let us take a close look at this project to see what made it unique. To begin with, it established a number of firsts: At 770 feet it was the highest earth fill dam in the world. At $121 million dollars, it was the largest ever United States construction project (Civil). At 80 million cubic yards it had the largest earth volume of any dam in the world. The extensive use of belt conveyors for this application had never before been tried. The use of a high capacity bucket wheel-excavator with shiftable belt conveyors had never before been utilized as a con¬tractor's tool. The principal of the "integral train" was applied most effectively whereby up to 220,000 tons of material-was transported daily some 14 miles. To achieve optimum economics a number of technical breakthroughs were necessary. The suppliers of major commercial components worked hand-in-hand with system engineers to develop new machinery necessary for the highly mobile characteristics of the systems, viz., single pulley drives delivering 2000 horsepower, 1000 horsepower right-angle shaft-mounted reducers, across the line starting of 1000 horsepower squirrel cage motors, 10 miles of steel chord conveyor belts with belt tensions up to 150,000 pounds, aircraft-type disc brakes, hydraulic take-ups, train loading at a rate of 25,000 tons per hour, automatic train indexing for rotary dumping at 10,000 tons per hour, roll-over car dumping without uncoupling cars, shifting 7500 ft. long conveyors up to 300 feet laterally without disassembly. These are some of the superlatives that have made the Oroville Dam project unique. The measure of its success is demonstrated by the results.

Jan 1, 1970

By Jack S. McPartland, Gene E. McClelland

It is advisable, for any heap leach project, to develop an historical metallurgical data base to predict production heap performance before ore is mined and placed onto the heap. A data base would include results from: interval assays, cyanide solubility tests, and bottle roll tests on exploration drill cuttings samples; and those results plus column leach test data on diamond drill core or bulk ore composites. Subsequent larger scale heap leach test data can then be compared to the historical data base, to blast hole composite data during mining, and eventually to production data. This paper does not discuss metallurgical comparisons between assays, cyanide solubility tests, and bottle roll tests on exploration drill cuttings samples, but does discuss metallurgical comparisons from bottle roll tests, laboratory scale column leach tests, and pilot scale heap leach tests on core and bulk ore samples with operating data for three U.S. commercially producing heap leach operations. Provided that representative core or bulk samples are used for evaluation, heap leach test results accurately predict or understate the success of the commercial operation and remove most of the uncertainty from the investment decision.

Jan 1, 1990

By J. Wiebmer

The two most important influencers of cost-per-ton in an underground mining machine are its productivity (tons/hour) and its availability-utilization (hours/year). Operating cost and initial price have far less impact. This paper reviews a cost-per-ton sensitivity analysis for underground mining equipment and discusses benchmarks for measuring its performance. The conclusion is that miner-supplier partnerships and the Information Age are the two most significant trends in cost-per-ton reduction.

Jan 1, 1997

By B. Gorain

"INTRODUCTION The last few decades have seen some remarkable advancement in information technology, but recently various digital technologies have resulted in several synergies to deliver innovation in diverse applications. The mining industry has been relatively slow in adopting these technologies compared to the other industries, but this scenario is changing fast. Keywords: Digital Transformation, Operational Intelligence, Gold Recovery, Mine to Mill integration, Planning and Execution strategy, Theory of Constraints. Challenges Mining companies globally are going through a series of challenges such as declining ore grades with complex metallurgy, increasing depth of ore bodies, high capital and operating costs, lower productivity, shortage of technical resources, significant pressure from stake-holders to deliver, along with growing environmental and corporate social responsibility issues. Improvement in profitability would need significant improvements in operational performance. Consequently, over the last few years, there has been a major focus amongst some mining companies to imbibe Operational Excellence. This has been only possible because of the replacement of a silos based approach by an integrated view of the organization. Such an integrated view is now possible via the evolving digital technologies. Even so, such a transformation calls for a change in culture, which, for most organization is not trivial. Attempts in the past to integrate functions such as through Mine-to-Mill initiatives in the mining industry have demonstrated significant benefits to many operations (McKee, 2013). Still, sustaining these benefits has clearly been a challenge due to manpower turn over and lack of proper systems and structures that integrate information between business functions within an operation and between operations and the corporate.Opportunities The advent of digital technology has opened-up opportunities to integrate inter-departmental information for a unified understanding of, and across, an entire organization. The advances in instrumentation, equipment control systems, supervisory control systems (SCADA/Historian) and industrial networks have helped in the direction of enterprise wide integration. The availability of real time information across an enterprise has given rise to numerous possibilities to improve organization performance. As suggested by Seshan & Gorain (2016), some of the potential opportunities are as follows:"

Jan 1, 2018

By D. Tepavac, S. Simmonds

"The high virgin horizontal in situ stress field in the Sydney Basin and its impact on civil engineering projects is a well-known and accepted phenomenon found in significant literature (e.g., Pells, 2013). The prevailing high-stress effects depend on many factors — rock quality, tunnel orientation, proximity of geological features to tunnel crown, size and shape of opening, depth of excavation and stress magnitude. The behavior of the rock mass under high in situ stress conditions can cause stress fracturing and consequent dilation of the tunnel periphery, resulting in rock spalling at the tunnel crown/ invert or raveling of rock blocks on the tunnel sidewall. This type of failure is of a brittle nature and may create construction and safety risks during tunnel excavation, if it occurs behind the excavation face where ground support has already been installed. Therefore, the associated risks need to be managed during construction. This paper presents the design strategy adopted to mitigate these adverse tunneling conditions for the WestConnex Project to-date. Overview of the WestConnex M4 East and new M5 tunnel projectsWestConnex is one of the New South Wales government’s key infrastructure projects. This 33 km (20.5 mile) project aims to ease congestion and connect communities and is the largest integrated transport and urban revitalization project in Australia. It was a key recommendation of the State Infrastructure Strategy released in October 2012. It brings together a number of important road projects, which, together, form a vital link in Sydney’s Orbital Network. These road projects include a widening of the M4 east of Parramatta, a duplication of the M5 East, and new sections of motorway to provide a connection between these two key corridors. The WestConnex project includes a number of stages: Stage 1a: M4 Widening; Stage 1b: M4 East; Stage 2: New M5; and Stage 3: M4–M5 Link. The tunnel design referenced in this paper relates to Stage 1b and Stage 2 of the WestConnex Project (Fig. 1)."

Dec 1, 2018