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By S. Slottee

The disposal of plant tailings in a safe and environmentally acceptable manner has taken on increased importance throughout the world, across all types of mineral beneficiation plants. In the U.S. plant life span, expansions and new plants in the current robust mineral markets are faced with environmental pressures to minimize the use of land for disposal by maximizing existing tailings pond capacity. The combination of many drivers from economic to environmental have brought paste thickeners into the coal industry (PasteThick 2007) Thickening tailings to a more concentrated slurry is a common step in the disposal flow sheet. Thickening to a non-settling ?paste?, also called ?thickened tails? or ?tailings stacking?, is a relatively recent development. This paper describes the paste thickener as an alternative for dewatering a fine coal refuse (tailings) stream for deposit as a paste. Initial operating results of the paste thickener are discussed.

Jan 1, 2008

By Y. C. Kim

One-quarter of a century has passed since the "theory of regionalized variables" (geostatistics) was introduced by G. Matheron (1962, 1963) in France. Yet, only during the past decade has geostatistics found broad acceptance in the mining industry. Foremost among the reasons for this time lag was ignorance. The first English treatise on geostatistics was not written until Matheron (1971), and the first published text accessible to mining professionals did not appear until David (1977). Other significant reasons for the slow acceptance of geostatistics included the conservative nature of management in the 1970s minerals industry, and the fact that conventional ore reserve estimation performs reasonably well when confined to massive deposits of base metal and iron deposits having relatively low coefficients of variation in grades. In short, mine engineers and geologists were not willing to accept a new set of tools for problems that they did not see.

Jan 1, 1989

By Herbert Pöllmann

The mineralogical and chemical compositions of various waste materials undergo different reactions when treated thermally The heavy metal contents can be bound to stable phases. These minerals are called reservoir minerals. The main property of these minerals is the stability in their geochemical surrounding containing the heavy metal cations and anions. Examples for these minerals are apatites, spinels, garnets, perovskites and also water containing minerals like ettringites, metal-metal-hydroxi salts, jarosites and zeolites. When the chemical compositions of different wastes are mixed according to the compositions of the new formed minerals, a probable reuse of these wastes can be obtained. The use of waste incineration ashes for the production of cementitious binders and the use of flue gas desulfurization products for cement additives are shown. Also the transformation of highly contaminated materials into stable reservoir mineral assemblages are shown including the study of stabilization and immobilization techniques.

Jan 1, 1998

By J. Kemeny, K. Girdner, M. A. Lowery

A strategy for proactive blast planning to improve the postblast fragmentation size has been implemented at the Phelps Dodge Morenci Mine. This strategy was developed in specific phases that include stabilization of blasting practices, systematic changes in blast design and quantification of the size distribution of blasts. Implementing this new strategy would not be possible without an accurate method for quantifying the postblast fragment size distribution. The Split image processing system is now being used to assess fragmentation size using muck pile digital imaging taken on a daily basis and an online fragmentation analysis system installed at the primary crushers. Drilling and blasting variables and fragmentation size are entered into a database, spatially evaluated in a geographic information system and subsequently utilized for mine planning purposes. Using this strategy, significant improvements have been made in postblast fragmentation and continued improvements are expected in the next several years.

Jan 1, 2002

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 Yu. A. Polozov, V. A. Lagunov, O. Yu. Lushinkova, Yu. I. Svirskiy, Eh. Ya. Kipko, Roy A. Williams

6.1 PRINCIPLES OF PLANNING GROUTING OPERATIONS FOR SHAFTS, DRIFTS AND TUNNELS The planning of integrated grouting of vertical, inclined or horizontal underground workings in saturated, fractured rock includes the following phases: 1. Planning for the collection and analysis of geological information concerning the characteristics of the struc¬tural deformation(s) that produced the details of the frac¬ture system being studied. 2. Planning for the acquisition of initial hydrogeological information produced by the flowmetric and hydrody¬namic investigations (described in Chapters 2 and 3). 3. Computing the initial engineering calculations of the ex¬pected or planned dimensions of the isolation curtains for each water-producing stratum (fracture zone) and the expected areal spreading pattern of the grout in each of these water-producing horizons. The selection of the lo¬cations, the initial optimal number of holes and the vol¬ume of grout needed to create each isolation curtain also are included in this phase. 4. The selection or development of a grout formula for the specific hydrogeological conditions that exist at the site. 5. Identification of a resource (deposit) required to produce the grouting clay. The planning of grouting operations must be supported by the acquisition of all necessary initial data, which in¬cludes: 1. The geographic location and administrative responsibil¬ity (ownership and regulatory constraints) of the mineral deposit and any peculiar features of the area where ex¬cavation of the underground workings is planned. The surface relief, the hydrographic network of the region, and the local climatic conditions must be evaluated prior to planning for buildings and waste discharges if any. 2. The economic status of the region, the available trans¬portation, the nature of the energy base, the water and heat supply sources, the location of construction mate¬rials suitable for making the grout all must be deter¬mined. 3. The geological and hydrogeological characterization of the work site must be accomplished. 4. The technical features of the shaft(s) and underground works must be characterized. 5. The organization's principal initial design plan features and the construction sequence of all buildings and struc¬tures must be developed. These must be correlated with the organization and schedule for excavating the under¬ground works. The technical characterization of a shaft or of other un¬derground workings must contain information about the purpose of the workings, the design depth, the planned excavation procedures along with cross-sections, and the parameters of the lining, if a lining is required. The geology of the section to be penetrated must include geological data obtained from existing exploration activities at the mineral deposit and conclusions about the shaft ex¬cavation conditions obtained from drilling technical moni¬toring holes and exploration drillholes. The interpreted stratigraphic regime, including the thickness, strike and dip of each stratum, must be shown in cross-section. The tec¬tonics, including all geologic structures, must be presented by cross-sections. The bedding orientations must be used to identify anticlines, synclines, monoclines and faults. The lithologic composition and the drillability of the rock com¬prising the section must be examined. The character of the rock's fracture pattern must be presented. Finally the per¬meability, porosity and storage characteristics of each aqui¬fer must be determined by in situ hydraulic property testing (injection tests or pumping tests, as described in Chapter 3). The fracture pattern of the indurated rock is presented in reports derived from geo-exploration borehole studies and from studies of outcrops on the surface and in all nearby underground workings. The extent of each fracture zone is mapped in three dimensions. The distribution of fracture apertures, the nature of the fractures according to each litho¬logic stratum, and the relationship of bedding planes to each fracture system are all determined. Acoustic logs, downhole cameras, caliper logs, oriented core, and any other appro¬priate geophysical tools available are used to construct the data base for this purpose. The hydrogeological characterization of the geologic section to be penetrated by the workings is based on the analysis of hydrogeological data collected during the drill¬ing and testing of technical monitoring holes and from in¬formation on ground water inflow collected during the ex¬cavation of nearby underground workings, if such workings exist. The hydrogeologic characterization must contain the following information: 1. The identification of all aquifers, their thicknesses and their locations in the section, 2. The distribution of hydrostatic head in the ground water in three dimensions, 3. The coefficient of saturated hydraulic conductivity (per¬ meability) of each aquifer, 4. The porosity and storativity of each aquifer, and 5. The projected rate of water inflow into the shaft, drift or tunnel for each aquifer prior to grouting. This step is used to identify the zones to be grouted.

Jan 1, 1993

By Paul M. Keyser, Donald G. Foot, Jeffrey D. Mckay

In the past 30 years, there have been tremendous advancements in the uses and applications of column flotation. From their first use as final cleaners that could produce excellent grades at the cost of recoveries, columns are now being used in every stage of the flotation circuit as well as is SX-EW. Columns as roughers, final scavengers and even at the end of CIL circuits, are finding their way into the marketplace. Operational results of these new uses are presented. INTRODUCTION Flotation columns have been in use since the early 1950's in the U.S. (Hollingsworth, 1952) and the early 1960's in Canada (Trembley, Boutin, Wheeler, 1963). Application of column flotation has been somewhat diverse. In the early years, columns were used predominately for molybdenum cleaning in Canada and for phosphate flotation in the United States. Unfortunately, results met with skepticism and disdain as the columns were hard to operate, temperamental and although producing high grades, could not achieve acceptable recoveries. Since the inception of column flotation technology, the degree of knowledge for design and operation of columns has vastly improved. Despite improvements in the technology, there is still some reluctance by mineral producers to investigate the use of column flotation cells for processing stages other than cleaner flotation. This characterization is in part due to the proven advantage of flotation columns in reducing gangue entrainment in the froth product which results in higher grade products and/or fewer processing stages. Also, during the development of column technology, different types of spargers have been used with varying degrees of success. Furthermore, the general knowledge base of parameters affecting column flotation design and operation have advanced tremendously. Inefficient, or primitive, sparger design, coupled with the lack of column design and operating knowledge and experience, resulted in poor metallurgical and mechanical performance in many cases. Unfortunately, this lack of knowledge caused many column installations to be characterized as failures. The industry felt that columns could not achieve high recoveries, especially when dealing with coarse particles. Therefore, columns were characterized as cleaners, where low recoveries could be tolerated as recirculating loads rather than direct losses and froth cleaning advantages of the quiescent column flotation regime could be realized. Fortunately for the minerals industry, some producers have stood at the forefront of technology and allowed the column to be utilized for new applications. In the last decade, column flotation applications have expanded to virtually every mineral system and plant location throughout the world. The expanded application of columns has generated a new wave of interest for processing various streams. One of the most notable is in the use of columns as rougher cells. This is of particular interest to "green-field" plants and plants where expansions are taking place. Here, metallurgical superiority can be combined with maximum capital and operating cost advantages for a rapid return on investment. The superior results experienced to date, have generated a cohesive vision of the future in mineral processing where flotation columns function as single stage primary separation devices (roughers) with a single stage cleaner, if necessary. The advantages of column flotation go far beyond their original uses. We now have seen columns used as final tail scavengers, in SX-EW plants and even at the end of CIL circuits. Some of these cases will be reviewed. CASE STUDIES In an attempt to show the diversification of column flotation to many facets of the mineral processing plant, a variety of case studies will be discussed. Some of these were designed by the authors while others have been provided by plant sources. It is important to note that in each successful case, the columns were designed using the author's design and scale-up approach. This method assures that the columns are designed correctly for their particular application. For successful

Jan 1, 1993

By Karl Ingmarsson

Larger mines spend millions of dollars annually on rock drilling tools, but often purchase based on historic consumption. The results vary from excess inventory to acute tools shortages. These lead to emergency sourcing, sometimes mixing products that don’t perform optimally. Boart Longyear analyzed the usage pattern of 96 thousand drill bits at thirteen different underground mining contracts, showing very high variability. The monthly standard deviation on a product level was 42%, with the highest for development and low volume bits. A new rule of thumb is suggested to carry only one month of safety stock for high volume bits, but increase to three months for low volume bits. This balance will reduce the risk of outages with less inventory. The accuracy can be improved by considering the specific conditions at each mine and reclassifying individual bits for a different safety stock level. Root cause analysis and collaborative forecasting between mines and suppliers can lead to further optimization of availability and inventory levels.

Feb 1, 2024

By Simon D. Strauss

This paper discusses the ways in which the metals industries dealt with surplus capacity in the past, primarily the twenty years, 1950 - 1970. During this period, the bulk of metals production in the market-economy countries was controlled by private sector companies. Since then, public sector companies have played an increasingly important role in the metals industries of the market-economy countries. Of course, the change was not overnight. It occurred gradually over a period of many years. Indeed, by 1965, several developing nations had adopted policies of government control of metal operations previously in private hands. The metals industries are so many, so large and so diverse that the constraints of time make it impossible to deal with all segments. To illustrate the problems of surplus capacity in the metals industries during the period, this paper focusses primarily on three metals. One experienced rapid market expansion between 1950 and 1970; one had a growth more or less in line with the expansion of the world economy; and one lagged well behind the pace of industrial expansion. No one will be surprised if aluminum is identified as the metal with rapid growth; copper is identified as the metal that kept pace with the world economy; and tin is identified as the laggard. Individual computations of the rate of growth for these metals show some variations, but most estimates place the increase in aluminum consumption in the market economy countries between 1950 and 1970 at a compound annual rate of about 8%. The corresponding figure for copper is a compound rate of 4%. Tin consumption showed no growth. A widely accepted point of view is that sharply rising demand will force the price of a commodity to increase substantially in order to attract a necessary expansion of supply. The corollary to this is that stagnant demand will hold prices down, as there is no need to stimulate new supply and it may be necessary to force marginal producers out of the market. The experience with aluminum, copper and tin in the years 1950-1970 does not support this theory. In 1950, the average prices in the United States market as reported by the American Bureau of Metal Statistics were 17.74 a pound for aluminum, 21.24 a pound for copper, and 95.54 a pound for tin. The corresponding figures in 1970 were 28.74 a pound for aluminum, 57.74 a pound for copper and 174.24 a pound for tin. Aluminum, with the greatest market growth, rose by 60%, whereas tin rose 82% and copper by 172%. Clearly, other factors were a more important influence on price than was the trend of demand To revert now to the capacity issue, during the period under review aluminum demand was rising so sharply that that industry had no sustained problem with surplus capacity. Instead, if anything, capacity may at times have been a constraint on demand. The industry succeeded in attaining explosive market growth through imaginative research and promotion programs. Some of this growth was the result of substitution of aluminum for other commodities – steel, copper, wood and glass as examples. But much of the growth was the consequence of developing entirely new products through technological innovation. Prior to World War 11, the number of aluminum producers was extremely limited. Alcoa and Alcan in North American and Pechiney and Alusuisse in Europe were the dominant firms. The developing countries had virtually no production and in Japan and Germany production was only a small fraction of the North American output. During the War years the United States had financed the construction of many new facilities. After the war these plants were sold by the government to Reynolds and Kaiser in order to foster more competition in the market. Subsequently many other concerns became aluminum producers, both in the United States and elsewhere and competition for markets intensified.

Jan 1, 1989

By Donald T. Delicate

Since the discovery of uranium in the Ambrosia Lake Area in 1955, a new mining district has developed which promises to be the greatest uranium producing area in the United States. Exploration and development work is proceeding rapidly in mines operated by Kermac Nuclear Fuels Corporation, Phillips Petroleum Company, Rio De Oro Uranium Mines, Inc., Calumet & Hecla, Inc., Rare. Metals Corporation, Homestake-Sapin Partners, Homestake-New Mexico Partners, and Centennial Development Company. Individual mining operations vary in size from 200 tons to more than 1200 tons per day with production from wet and dry ore bodies ranging in depth from 300 to 1500 feet. Many problems have been encountered during the development period in the district mines. Within this paper the author will review some of these problems and mining practices being used. In order to understand better the developments to date, a brief description of the area and its geologic setting will be presented.

Jan 1, 1959

By Robert C. Bacon

The first commercial installation of the Dashaveyor has recently been completed at the White Pine Mine in Northern Michigan. After four years of development work, including prototype testing, and pilot plant operation, this new and unique system is being tested under operational conditions. Many of you may be familiar with the concept through numerous articles which have appeared in the technical press. But this discussion of the system will be simplified and less time consuming with the presentation of a portion of a film showing the Dashaveyor in actual operation. After the movie, I will show some slides which will supplement and clarify it and hopefully lay the basis for questions you will undoubtedly wish to ask.

Jan 1, 1968

By D. A. Norrgran

The recent development of rare earth permanent magnets has revolutionized the field of magnetic separation. The advent of rare earth permanent magnets in the 1980's provided a magnetic energy product an order of magnitude greater than that of conventional ferrite magnets. This has allowed the design of high-intensity magnetic circuits operating energy free and surpassing the strength and effectiveness of electromagnets. New applications and design concepts focused on the mineral and metal processing industries have evolved. This technology also led to the development of various magnetic separators specifically designed for mineral processing applications. Applications which were not previously considered are now being applied to primary mineral upgrading and recycling and secondary recovery.

Jan 1, 1993

By K. T. Cunningham

The Oakfield, New York Hine of the United States Gypsum Company is a shallow, room and pillar mine developed in the Camillus Formation of Silurian Age on the up-dip edge of the northern Appalachian Basin. The gypsum comes to subcrop beneath a variety of glacial materials and is subject to solution activity by groundwater. A geologic environment unfavorable to mining activity is thus created. Since 1978 seismic studies have been used to supplement core drilling to determine a conservative boundary between normal and questionable mining environments. A single channel seismograph, originally in use, is now replaced by a twelve-channel unit and is used to determine bulk material velocity which is the basis for defining the mining limit.

Jan 1, 1987

By W. Hu

Traditionally, coarse wolframite ore processing has been done almost exclusively by gravity concentration methods. However, there has been a depletion of rich and coarse ore reserves and a proportional increase in the mining of low-grade, fine-grained complex ore feeds. This change has resulted in the need for better slime-processing technology. Research and development activities in this area have gained momentum, and recent innovations appear promising. This paper covers the recent innovations that have been made in dealing with tungsten ore slime processing. The new techniques include the application of a centrifugal cone separator, high-intensity wet magnetic separator, the use of phosphonic and arsonic acids as collectors in ultrafine wolframite flotation, and combined processes.

Jan 1, 1989

By F. W. DeVries, J. Brent Hiskey

The search for noncyanide lixiviants for treating gold and silver ores and concentrates is not a new endeavor. However, in recent years, the overall activity to seek a less environmentally controversial reagent than cyanide has occasioned considerable developmental work. While the elegant economy and simplicity of cyanide, because of its selectivity and the ease of recovering gold and silver from the cyanide complexes, is well recognized, two failings have justified the search for alternates: increasing concerns and costs to assure avoidance of environmental damage from cyaniferous liquids and solids, and the need to simplify recovery of gold and silver from refractory ores. Generally, process development work to date on the alternate reagents has lacl<::ed environmental focus ( Hiskey and Devries, 1992). This paper covers briefly the chemistry of various alternates to cyanide and reviews their environmental implications. In each case, environmental overtones are reviewed following the chemistry. For ease of follow-up, the authors have listed sources of information in detail. Alternates examined include:

Jan 1, 1992

By Randy Fulton, Ignacy Puszkiewicz, George H. K. Schenck

Stuart Olson Construction, Inc. excavated 385m (1263 ft.) long twin tunnels with 6.25m (20.5 ft.) O.D., a portal and a cross-over for the Edmonton, "Metro". The work for Contract No. 76458, SLRT South Tunnel and Portal, in Edmonton, Alberta, Canada was performed in 1989 and 1990. NATM was specified because of the instability of glacial deposits. The contractor decided to use "two firsts" on this project: Fully mechanized NATM and a novel excavator¬mounted tunneling machine. An excavator was equipped with a cutter boom, and a loading and conveying system. This novel machine cost only about one-third of the price of a special NATM roadheader. This new combination of NATM and an excavator-mounted cutter boom offered a cost-effective alternative to shields, slurry TBMs and roadheaders for short tunnels in unstable ground. For NATM tunneling in hard rock or in mixed faces, the roadheader-type cutter boom can be replaced with an impact hammer (hydraulic breaker).

Jan 1, 1993

By Maurice Jackson et a1

Golder Moffitt and Associates (GMA)", were commissioned to reassess a large metallic low grade orebody. One of the aims of the study was to estimate recoverable reserves. Recoverable reserves are here defined as ore reserves for a specific mining block size. The mining block is that block on which the decision that the material is ore or waste is made. Recoverable reserves take into consideration mining methods. New methods for solving this type of problem were recently developed in Geostatistics and so for this reason GMA called for the technical assistance of the Centre de Geostatistique (C.G). The complete estimation was done using the geostatistical techniques and programs of the C.G together with some of the programs of GMA. As the mine was in production at the time the study commenced it was-possible to make frequent checks on the estimated values using blast-hole data. The ore reserves were also estimated using the more conventional interpolation method of inverse square of distance weighting.

Jan 1, 1979

By Robert Snow, Yingxue Yu, Patrick Zhang

The FIPR/SAPR process is FIPR&apos;s third approach to develop a viable alternative to the Crago "Double Float" process for phosphate flotation. SAPR stands for Single-collector, All-anionic Phosphate Recovery. The FIPR/SAPR process - offers a universal flowsheet for any anionic reagent system and flotation feed of varying sizes. For an unsized or fine flotation feed, the FIPR/SAPR process consists of the following steps: 1) high-solids conditioning with an anionic collector; 2) anionic rougher flotation, with the rougher concentrate sized at 48 (or 65) mesh and the +48 mesh recovered as a final product; and 3) cleaning flotation of the -48 mesh fraction from step 2. In a variation of step 2, the rougher concentrate from the first two cells may be collected as a final product, and the rougher concentrate from the last two cells sized at 48 or 65 mesh. The new process was tested with a blend of anionic collectors, achieving single-digit Insol at 85 + % recoveries.

Jan 1, 2002

By B. V. Cooper

The word "research" has been used in the title of my presentation somewhat against my better judgement. There are many definitions of the word. But the one I like best comes from Webster&apos;s New World Dictionary. It reads: "Careful, systematic, patient study and investigation in some field of knowledge, undertaken to discover or establish facts or principles. ..." I like that. In only 9 words, the definition conveys to me the very essence of what should be going on either in or for the coal industry. Unfortunately, not enough coal-related research is going on. And much of what is being done is, in my view, not really as effective as it might be.

Jan 1, 1983

By L. S. Gourevitch, E. B. Kremer, A. Y. Fidlin, Y. M. Katsman, I. I. Blekhman

A new kinetic approach to simulation of fracture is given. The main object of the simulation is forecasting transformation of ore lumps size distribution in squeezing of ore layer between two planes. The approach rests on fundamental principles of energy and mass conservation and on new ideas about fracture physics connected with fractal geometry. On this base an integro-differen tial equation of layer crushing kinetics is formulated. This equation is similar to well-known kinetic equation of grinding, but here we use elastic energy density in place of time as an independent variable while selection function is considered by us to be dependent on this variable. Properties of the equation have been investigated by us and its analytical solution has been found. It allows to compute simultaneously both the evolution of the size distribution process of squeezing and force-displacement diagram. Results of theoretical calculations provide a good fit with experimental data.

Jan 1, 1995