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By E. B. Fitch, D. A. Dahlstrom

Liquid-solids separation is common to practically all mineral and coal processing as the bulk of beneficiation plants employ water as the major processing vehicle. The growing usage of hydrometallurgy has increased the importance of liquid-solid separation as acidic and basic solutions result in greater amounts of colloidal solids, with their consequent greater difficulty of separation, the economic need for chemical recovery to minimize this operating cost, and the usual necessity of employing more costly construction materials. The three processing steps covered in this section have significant capital costs. Drying, particularly, has an important operating cost because of the obvious need for energy to evaporate the water or solvent. Several common factors influence all three liquid-solid separation steps. Particle Size and Size Distribution. In general, finer particles have slower settling and filtration rates. The specific surface area is increased, which means a lower solids concentration in the thickener underflow and discharged filter cake as well as a grater moisture content to be evaporated in the drying step. Therefore, overgrinding or excessive attrition should be avoided. Consideration should be given to optimum particle size consistent with entire plant operation performance and recovery. Solids Concentration. Increased feed solids concentration will generally minimize required equipment size and costs in all three liquid-solid separation steps. Most thickeners are designed on the basis of unit area required, expressed as square feet per short ton of dry solids per day (square meters per metric ton per day) which will usually decrease with increased feed solids concentration. Filtration rates also increase as the required flow through the capillaries of the filter cake decreases. Dryer capacity increases and less energy per ton of final product is required to evaporate the associated moisture. Particle Shape and Surface Characteristics. Generally, optimum shape is a spherical particle of zero porosity. As either of these factors degrade away from the desired state, difficulty increases. This is particularly true in drying, where porosity can decrease drying rate significantly if the moisture must first reach the particle surface by diffusion

Jan 1, 1985

By W. W. Stephens, W. J. Kroll, H. P. Holmes

THE only two methods for producing commercial quantities of malleable zirconium, up to now, have been using magnesium reduction of the anhydrous chloride under a neutral gas, and using purification of raw zirconium by the iodide dissociation method on a hot filament. The purity of the metal obtained by the latter process is about the same as that resulting from the chloride reduction, with the exception of the oxygen content, which may be about 0.05 pct lower in the iodide metal. Even traces of oxygen have a strong hardening effect on zirconium. Since, in the iodide process, the impurities, Si, Al, Fe, Ni, and Mg in the raw zirconium used, are carried over, it would appear uneconomical to use this method of refining solely to eliminate the traces of oxygen, unless very soft metal is desired. One important step to improve the iodide method, namely, dissociating pure iodide made from carbide and recycling the iodine, which would change this refining process into a method for extracting zirconium from the ore, has not yet been made. The Bureau of Mines, by using the chloride reduction, wanted to produce quantities of a reasonably pure and malleable metal at low cost for large-scale industrial use. This aim has been achieved, and a pilot plant permitting production of 600 lb of malleable zirconium per week will be described (fig. 1). Briefly, the Bureau of Mines process consists of reducing purified gaseous anhydrous zirconium chloride with fused magnesium under a noble-gas atmosphere. The reaction product, magnesium chloride, and any excess magnesium metal present are removed from the sponge zirconium in the next step by fusion and evaporation in a good vacuum at about 925°C. In this process, care is taken to keep air out of contact with the hot metal, which otherwise would contaminate the product with oxygen and nitrogen. Both these impurities embrittle zirconium even when present in an amount as low as 0.1 pct. A number of previous reports1-3 describe the method and the various improvements that finally led to a workable process. The major steps made were the production of large quantities of carbide, which is the raw material for producing the chloride, its chlorination with reasonable efficiencies, and the elimination of iron trichloride contained in the raw chloride, as well as that of the zirconium oxide which is always present in this product. The physical nature of the anhydrous chloride, which sublimes at 331°C at atmospheric pressure and melts at 420°C under a pressure of 25 atm, made it necessary to provide a special safety device on the purification and reduction vessels in the form of a lead-alloy seal, permitting escape of excess gases if pressure tended to build up. The main difficulties encountered in the reduction and in the following step, salt separation in a vacuum at elevated temperature, were caused by the material from which the reaction pot was constructed—iron. This metal reacts with zirconium at about 940°C with formation of a eutectic. The last step, salt separation by evaporation of the magnesium and magnesium chloride in a vacuum, is quite unconventional and has not been used before on such a scale. It is only due to the improved construction of high-vacuum pumps, especially oil-diffusion pumps, that such a method could be used. The various steps of the Bureau of Mines process, as described in the general outline above, may be summarized as follows: (1) production of the carbide, (2) chlorination of the carbide, (3) purification of the raw chloride, (4) reduction of the pure chloride with fused magnesium, (5) separation of excess magnesium and magnesium chloride in vacuum at elevated temperature, and (6) melting of the sponge obtained. Production of Carbide The arc furnace, described in a previous report,' was improved both to reduce the graphite consumption caused by the burning of the bottom plates and to concentrate the heat in order to obtain better power efficiency. This was achieved by providing the bottom with graphite plates entirely embedded in refractory bricks, the contact with the current being made with three water-cooled copper plugs. Figs. 2 and 3 show the arrangement. The crucible, made

Jan 1, 1951

By J. E. Lamar, J. S. Machin

INSULATING materials include a wide variety of nonmetallic mineral products such as exfoliated vermiculite, expanded gypsum, 85 pct magnesia, diatomite, asbestos, perlite, cellular glass, pumice, silica aerogel, expanded aggregates and mineral wool. Except mineral wool, most of these products, or the materials from which they are manufactured, are described in other chapters of this book. PROPERTIES OF INSULATING MATERIALS The insulating properties of the materials considered in this chapter result in general from entrapping extremely small pockets of air in such a manner that heat is not transferred by convection. The minimum heat conductivities of such insulating materials are slightly greater therefore than the conductivity of still air. In addition, conductivity varies with the overall density of the material, the temperature range in which the measurements are made, and the form into which the material is fabricated. However, the numerical value of heat conductivity should not be the sole criterion of an insulating material; for a particular application it may be advantageous to use a material of somewhat higher conductivity in order to secure other desirable engineering properties. This is especially true with certain materials that are used because of their refractoriness. Comparative insulating values of some commonly used insulating materials are shown in Table 1. In comparing the values presented in this table it should be borne in mind that heat conductivity varies with the mean temperature, with the overall density, and with the amount of moisture present. With fibrous or granular materials it varies with fiber or grain size and with the amount and kind of binder, if any is used. Under some circumstances it may vary with the arrangement of

Jan 1, 1949

By Alder KF

Nuclear power stations to be installed in Australia will be fuelled from Australian resources of raw materials. This will require the establishment of new manufacturing industries and the eventual expansion of established activities, especially in uranium mining and the preparation of precision metal products. This paper presents some predictions of the possible growth of nuclear power installations in Australia. These might amount to 4000 MWE by 1985 and 11,500 MWE by 1990 and towards the end of the century, about 50% of new generating plant might be nuclear. Predictions are given of the demands for materials (uranium and zirconium) and fuel manufacturing services for four reactor systems which might be considered in the programme. - The availability of raw materials and technical capability place Australia in a particularly good position to undertake the manufacture of nuclear fuel'; in addition to satisfying the domestic demand we should actively seek export markets for these products.

Jan 1, 1970

By Q. Chen, J. H. Zhang, M. Zhang, F. M. Zheng, Y. J. Zhang

The characteristics of air bubbles and gas dispersion in KYF flotation cell are studied using the method of the point conductivity probe and CFD simulation. With increasing of speed, the velocities of air bubbles increase slowly and the distribution of diameters exhibits little change. With increasing of aeration rate, the gas holdup is increased. However, the velocities and diameters of bubbles have no great change. The CFD predictions on gas holdup have good agreement with the experiment results. The gas holdup distribution in the center section is revealed. The gas dispersion in the middle and upper part of flotation cell is uniform. It would be helpful for bubbles and solid particles collision. The gas holdup of the lower part of flotation cell is scarce, and it agrees with the observation in experiment. The gas would accumulate at the suction side of impeller blades, and it would decrease the power consumption. The rotating speed and aeration rate have great effect on gas dispersion. With increasing of aeration rate, the gas holdup of flotation cell will increase. The increasing of speed would improve gas dispersion. The results are expected to help to optimize the performances of KYF flotation cell.

Jan 1, 2015

By Clair Murdock, David Heath

The 1,280 MW Sir Adam Beck II Hydroelectric Project was constructed in the1950s, at Niagara Falls, Ontario, Canada. The twin intake tunnels total over 17 kilometers in length and pass deep below the City of Niagara Falls. The tunnels were excavated using drill and blast methods, with a top heading and bench approach. The shot rock was loaded with electric shovels and transported to the five shafts with off-highway trucks. The tunnel muck was hoisted to the surface by skip and transported by truck to disposal areas. The volume of underground excavation for the 15.55 meter diameter tunnels and the shafts exceeds 3,500,000 cubic meters, then and now the largest underground civil works excavation by drill and blast in the Western Hemisphere. The lining required over 900,000 cubic meters of concrete. All of this work was completed in three years, remarkable progress, considering the technology of the day, comparing very well with the rapid excavation and tunneling methods of the twenty-first century. Big, fast, and deadly—at least 20 lives were lost in construction accidents.

Jan 1, 2007

By Daniel T. Eyde

The U.S. Geological Survey (USGS) estimates world production of natural zeolites to be 2.7 Mt (3 million st) in 2013. China ranked ?rst with 2 Mt (2.2 million st), followed by the Republic of Korea at 230 kt (253,000 st) and Turkey at 50 kt (55,000 st). Japan?s production is reported to have increased as a result of zeolites, reportedly low grade local mordenites, being used to treat the low-level radioactive contaminants in the areas surrounding the damaged reactors at the Fukushima Daiichi power plant. China and other countries? high-volume, low-value construction applications, which include dimension stone, pozzolans and lightweight aggregate, are also included in production. This means the production data does not accurately indicate the quantities used in high-value added specialty applications. Consumption in the United States, according to USGS estimates, increased slightly, to an estimated 71.3 kt (78,400 st). Domestic uses for natural zeolites were, in decreasing order by tonnage, animal feed, pet litter, cement (primarily down-hole cement applications by the drilling industry), water purification, odor control, waste water cleanup, fungicide or pesticide carrier, gas absorbent, fertilizer carrier, oil absorbent, desiccant, catalyst and aquaculture. The six leading uses accounted for more than 70 percent of the domestic natural zeolite sales tonnage.

By C. H. Riggs

This petroleum-engineering study of the Healdton oil field in Carter County, Okla., describes the geology and production history of that field and estimates the oil reserves that could be produced by efficient secondary-recovery methods. The Healdton field, in western Carter County approximately 20 miles west of Ardmore, Okla., was discovered in 1913 and was one of the early important oil-producing areas in the State. Although the volume of oil recovered from the Healdton sands has been comparatively high, studies show that a large reserve remains in the pressure-depleted sand, which can be recovered by efficient water-flood operations. In making this study of the Healdton-sand reservoir, the writers utilized many data already available in company and Government offices. Most of the fluid samples were collected by Bureau of Mines personnel and analyzed in the Bureau's laboratories at Bartlesville, Okla.; but other data, including logs, core analyses, and production records, were obtained from outside sources. These data were examined critically but were not verified, and possible errors in the original data may be reflected in the conclusions. In this study, attempts were made to consider only those aspects of the available information that would contribute to a clear and concise engineering report on the Healdton-sand reservoir. Other phases of the data, as well as those concerning associated reservoirs, were eliminated from consideration as being irrelevant to the particular problem. Cores and drill cuttings of the Healdton sands were analyzed and studied to determine the nature of the reservoir rocks. Analyses of samples of produced oil, water, and gas were studied to fix the different types, the limits of their occurrence, and the suitability of different waters for injection into the Healdton sands. Records of oil, gas, and water produced and of gas and water injected were studied to interpret the production behavior of the field and of certain individual leases. Theoretical calculations were made to predict the probable water-flood behavior and oil recovery, at constant water-injection rates, for individual sands on two leases.

Jan 1, 1953

By T. Wasson

Midland and Isabella counties have been the centers of activities for the year 1932. The major part of the 6,967,000 bbl. produced during the year was obtained from the old Mt. Pleasant field and the Eastern Extension field. The total production to the end of 1932 for Michigan, from all fields since discovery, is 20,679,600 bbl. Production in the Eastern Extension field was obtained from Dundee limestone of Devonian age, at a depth of about 3600 ft. As a result of the year's activity in this area, the limits of the Eastern Extension have been defined. No new fields have been discovered. A number of prospective areas have been drilled and condemned by dry holes. Probably the most outstanding development of the year was the discovery of oil on the Yost farm, in sec. 35 of Greendale Township, Midland County, by the Pure Oil Co., in the early part of December. Production is from the Dundee limestone similar to that in the Eastern Extension but is 4 miles south of that area. The first well has averaged about 500 bbl. per day since completion. It is near the center of a solid block held by the Pure Oil Co., so that rapid development due to competitive drilling is not expected. During the early part of the year the Midland-Isabella area was under proration, but on May 17 proration restrictions were discontinued and remained so until the end of the year. While the Eastern Extension saw the principal activity, some work was done in other fields of Midland and Isabella counties, but very little new production was added. The Vernon field on the north showed a slight increase in production over 1931. The Leaton field decreased. The well in Porter Township, Midland County, is still kept in the production ranks but very little drilling was done in that area. The old Saginaw field, Saginaw County, still remains the only spot in the state where commercial production is obtained from the Berea sand. It showed a slight decline over 1931 with no new producers for the year. The Muskegon field on the west side of the state showed a considerable decline over 1931, but owing to the rejuvenation of some wells by the use of acid this drop was not as great as might have been expected. Only two new producers were drilled in that area.

Jan 1, 1933

By B. Fitch, E. J. Roberts

Definitions and Terminology Classification is defined within this section as the separation of solid particles into size or weight fractions or classes by differential settling through a fluid. It is usually thought of as a size separation, but is actually made on the basis of particle settling rate, and so is affected by any variations in particle density and shape. The fluid may be liquid (wet classification) or gas (dry or air classification). This section will treat only wet classification. There are two basic types of classification; pool and hydraulic. In pool classification a suspension of feed particles is fed into and out of a pool of some kind at such a rate that only part of them¬ the coarser and faster-settling part-has time to settle out. The remain¬der overflows as fines. In hydraulic classification the feed suspension is introduced into or above one or more columns or pockets through which water is rising at a controlled velocity. Coarse particles subside through the pockets and are removed through spigots. Those which settle slower than the rising velocity in any column or pocket are (at least ideally) prevented from subsiding and so must overflow. Hydraulic classifiers or sizers are capable of making far sharper sepa¬rations than pool classifiers. The force causing settling may be gravity, or alternatively may be from centrifugal acceleration as developed in a centrifuge or hydra cyclone. Two things are needed to characterize the separation produced by classification: first, the size, D„ or equivalently the screen mesh at which it is made; second the sharpness of separation. Separation size may be defined in various ways. In closed-circuit grinding it is commonly specified by some point in the overflow screen analysis: For example, 5% on 65 mesh. In other applications, notably

Jan 1, 1985

By Dennis Dolinar, Russell Frith, David Oyler, Christopher Mark

Unusual circumstances may require that a longwall retreat into or through a previously driven room. The operation can be completed successfully, but there have been a number of spectacular failures which exposed miners to serious roof fall hazards. To help determine what factors contribute to such failures. the National Institute for Occupational Safety and Health (NIOSH) compiled a comprehensive international database of 130 case histories. The cases include five failures where major rock falls occurred in front of the shields, and six even more serious failures involving major overburden weighting. This suggests two room failure mechanisms The first is a roof fall type failure caused by loading of the immediate roof at the face as the fender narrows. The second is a weighting type failure caused by the inability of the roof to bridge the recovery room and face area, and affecting rock well above the immediate roof The data indicate that the roof fall type of failure is less likely when intensive roof reinforcement (bolts, cables, and trusses) is employed together with higher-capacity shields The overburden weighting failures, in contrast, occurred when the roof was weak and little standing support was used

[ ] John M. Davis has left Western Machinery Co. to take a job as project engineer with Baroid Sales Div., National Lead Co., and is now located at Houston, Texas. C. W. Allen, general manager of the mining dept. of the Cleveland Cliffs Iron Co., visited the firm's iron mines on the Mesabi iron range of Minnesota recently. Thomas P. Anderson, mining engineer and geologist, has resigned from the Raw Materials Div. of the U. S. Atomic Energy Commission where he was assistant chief of the Denver Exploration Branch. He will enter private practice in Golden, Colo. James E. Atkinson, consulting mining engineer and geologist, left New York for Colombia, S. A., as general manager for Cia Minera Choco-Pacifico, S. A., operating five dredges in gold and platinum on the Pacific coast of Colombia. Russell H. Bennett has been elected a director of Placer Development, Ltd. with head office in Vancouver, B. C., and is also a director of its subsidiary, Canadian Exploration, Ltd., which mines and mills lead, zinc, and tungsten ores at a property near Salmo, B. C.

Jan 1, 1952

By William D. Mayercheck

The U.S. Bureau of Mines is conducting research aimed at providing technology for a low-cost, high-recovery, environmentally acceptable mining system to recover the vast thin-seam coal reserves existing in the mountainous areas of the Appalachian region in the Eastern United States. As part of this research, the Bureau is evaluating new techniques to address these coal resources. This report summarizes the results of a worldwide technical search on thin-seam coal mining, the formulation of various methodologies for mining mountaintop thin seams, and the implementation and status of a physical model test program to validate and further develop the most promising concept-the "roof-fall-tolerant" mining system.

Jan 1, 1990

By Gary L. Hundley

The Bureau of Mines has devised and demonstrated an ammoniacal sulfate leach process for recovering nickel and cobalt from low-grade domestic laterites. Solvent extraction of cobalt, one of the process steps, requires the reduction of hexammine complexes of C03+ to C02+ in an ammo-niacal leach solution. Previously, reduction was accomplished using cobalt metal shot in a column. This report presents experimental results and an economic evaluation comparing two alternate techniques with the shot column: (1) an electrolytic reduction cell with an extended surface area cathode and (2) direct electrowinning from purified leach solution using a cell with a fluid bed cathode. The second alternative eliminates the conventional solvent extraction-electrowinning steps. The costs of the three methods, based on the requirements of a pro-posed commercial-sized plant, including all unit operations, were deter-mined by the Bureau's process evaluation group. The operating costs for the shot column, $1.19/kg Co, and for electrolytic reduction, $1.20/kg, are essentially the same, but the cost of direct electrowinning, $3.77/ kg Co, would eliminate this method as a practical alternative. The cap-ital cost of approximately $14.4 million for reduction in a shot column is much higher than the approximately $4.4 million for electroreduction.

Jan 1, 1985

By Todd M. Ruff

Researchers at the National Institute for Occupational Safety and Health (NIOSH), Spokane Research Laboratory, are investigating technology and methods to monitor the blind areas around large haulage equipment used in surface mines. On average, six fatalities a year can be attributed to equipment colliding with other vehicles or pedestrian workers, or backing over the edge of a dump point. Several off-the-shelf technologies exist for monitoring areas that an equipment operator cannot see from the cab, including radar, video cameras, and radio signal detection systems. NIOSH researchers have tested many of these systems on large dump trucks both at their test facility and at surface mines. This article discusses the technologies available for this application and their effectiveness in detecting objects near an off-highway dump truck. Also, guidance is presented for mine safety personnel who are planning to evaluate collision warning systems or cameras on their haulage equipment. Available Technology Over the past few years, the number and types of systems available for monitoring the blind areas around heavy equipment have increased. Systems marketed for the automotive and recreational vehicle industries have been around for a while. Small video cameras can be found

CARNEGIE INSTITUTE OF TECHNOLOGY On May 27, twenty-five of the leading representatives of the coal mining industry of Western Pennsylvania met with President A. A. Hamerschlag, of the Carnegie Institute of Technology, with a view to bringing about closer relations between the Institute and the mining interests. It was felt that the advice of the men in the field was necessary for the proper training of young men for mining work. A resolution adopted at this conference, among other things, called for a board of mine operators and engineers to serve in an advisory capacity with the Carnegie Institute of Technology. As a result of the counsel and recommendations of the Advisory Board, the Carnegie Institute of Technology, in cooperation with the U. S. Bureau of Mines, has recast its four year course in Mining Engineering and has also established a two-year course in Coal Mining. To carry out this new program, there has been organized the "Cooperative Department of Mining Engineering" in the Division of Science and Engineering of the Carnegie Institute of Technology.

Jan 8, 1919

Dr. Rausch, from your vantage point as educator, engineer, and corporate executive, what would you say is the most fundamental need that must be satisfied for the continuing welfare of our society, our industry and our profession?

Jan 3, 1977

By M. J. Lawrence

Independent natural resource Valuers are an essential link between miners and mineral explorers on the one hand and the finance industry on the other. Investors (and regulators) expect the mining and financial industries to be vigilant against the use of inappropriate methodology or use of illogical steps within the chosen valuation method. The Australian Corporations Law generally requires an Independent Expert Report to support mergers and takeovers (as well as for capital raising activities). The introduction of the VALMIN Code (1998) by The Australasian Institute of Mining as Metallurgy, has meant that such Reports, when prepared in compliance with it, are now much more comprehensible and reliable than before. This is because the key requirements of the Code are for transparency and materiality in the Technical Assessment and Valuation Reports prepared in connection with the transaction involved. Transparency is particularly important because it allows the reader to identify and understand the assumptions made to derive a value and to then form a view as to the reasonableness of the result. Even though many elements of resource asset valuation practice are undeniably subjective, there must be some basis of objective rationality to it. Where the reasoning is patently illogical or the inputs are chosen to achieve a particular result, the estimated value must be viewed as virtually worthless. Experience, qualifications, competence and repute are the hallmarks of a professional technical auditor and valuer.

Jan 1, 2000

By D. W. Fuerstenau, S. Raghavan

This paper presents a brief summary of some of the thermo- dynamic aspects of flotation processes. Thermodynamic considerations that control interfacial and wetting behavior in mineral/water/air systems are discussed. Particular attention is given to the thermodynamics of collector adsorption.

Jan 1, 1976

By Paul E. Rosten

This paper describes some of the latest improvements that have been incorporated or planned by the Cleveland-Cliffs Iron Company to reduce operating costs and improve pellet quality. The Cleveland-Cliffs Iron Company operates and manages mining, beneficiation, and pelletizing operations in Michigan, Canada, and Western Australia. This paper deals with the grate-kiln pelletizing operations at Republic, Humboldt, Tilden, Empire, and Pioneer in Michigan, and the Adams and Sherman in Ontario, Canada. Table I characterizes .each operation in regard to location, ore type, pellet capacity and date that pellets were first produced. All of the operations with the exception of Pioneer and Tilden, utilize downdraft-two-pass grate cycles of drying followed by preheating. Pioneer utilizes an all-downdraft, three-pass grate cycle which consists of three drying zones followed by the preheat zone. The Pioneer and Tilden cycles have been described previously. (1) (2)(3) Tilden utilizes a three-pass grate cycle with a stage of updraft drying, followed by two downdraft drying stages. Recuperation systems which supply hot gases to a drying zone from second stage cooling were designed and furnished for Tilden I. Tilden II will be identical. Empire IV will also be furnished with a recuperation system. The Adams grate-kiln system was retrofitted with a recuperation system. This paper will summarize some of the efforts that are in effect or planned for grate-kiln pelletizing systems to (1) reduce operating and maintenance costs, (2) reduce energy requirements, (3) improve product quality, and (4) meet environmental standards.

Jan 1, 1977