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By M. Fujikawa

The Kamioka Zinc Smelter was converted from the jarosite process to the goethite process in the year 2000. The reasons for the conversion of the process were that the silica content of the raw material increased and the iron content decreased. The silica easily turns to a gel in sulfuric acid solutions and this causes the solid-liquid separation characteristics to deteriorate. The basic behavior of silica in sulfuric acid solution was investigated and it was found that the goethite process is the most suitable to effectively separate and remove silica from solution. Furthermore, Fe has the capability to remove elements such as Ge that have an adverse effect on zinc electrolysis. This means that, when the Fe content of the raw material decreased, the impurity removal capability also decreased and there was a risk of a build-up of impurities in the process. Iron precipitates in many forms in sulfuric acid solutions. The capability to remove elements such as Ge differs depending on the compound precipitated. Goethite has a higher capability than jarosite to remove elements such as Ge. In this report, the results of applying the process established by investigations of the basic behavior of Fe, silica and Ge in the zinc refining plant are presented.

Jan 1, 2006

By E. Dalgaard

During linear friction welding of titanium alloy Ti-5A1-5V-5Mo-3Cr (Ti-5553), the weld zone exhibits beta (B) grain refinement and alpha (a) phase depletion that have the combined effect of deteriorating the mechanical performance of the weldment. In this work, linear friction welded Ti-5553 was subjected to pre- and post- weld heat treatments in order to determine the conditions under which a phase depletion could be mitigated in the weld zone and thermomechanically affected zone (TMAZ). The mechanical response of the welded samples to the heat treatments was determined by performing tensile testing at room temperature. While the pre-weld heat treatments had no significant effect, the post-weld heat treatments were instrumental in restoring the strength of the starting (heat-treated) material.

Jan 1, 2011

By D. C. Crothers

"What is new in air compressors? A good deal - the designers have been keeping pace with technical developments in related fields and also contributing new techniques of their own. Plant reliability no longer requires bulky slow-speed machines. Even the reciprocating machines, which still provide the most efficient method of compressing air, have been greatly reduced in size and installation cost for a given capacity rating. New materials and fabrication techniques are being used, by most manufacturers, to produce less costly plants in total. Many packaged plants are available, which generally means a more complete assembly for shipment. This type of construction offers savings in handling and erection costs at the site. A warning is in order, however - the extent of packaging in any given plant should be investigated carefully to determine what is included and just what field costs can be realized. A suggested specification has been offered for consideration when studying comparative costs. Rotating machines intrigue many because of their potential as regard fewer wearing parts, higher speeds and hence smaller units, utilizing less expensive drivers, and lack of contamination of the compressed air by lubricants. The inherent shortcomings of these machines - lower •efficiency and capacity control - have been much improved lately, and this type of plant is now becoming quite popular. Noise control, of much concern to everyone, is another development that has received considerable attention.Systems for efficient capacity control and continuous monitoring of compressor operation offer additional reliability and low-cost operation of the modern compressed air plant. Accessory equipment and its effect on over-all plant operation is also considered."

Jan 1, 1972

By H. E. Pawson

"COMMON METHODS OF ELIMINATION: The four methods most frequently used to dispose of cyanide wastes are:1. Oxidation2. Dilution with water or with cyanide free wastes3. Acidification and dilution of resulting gas with air4. Alkaline ChlorinationMost operators practice a combination of the first two methods, allowing oxidation and dilution of cyanide waste in tailings ponds. Then, pond effluent is introduced to a stream for further dilution andoxidation which is expected to take care of the cyanide. This method oftreatment does work to a certain degree. Atmospheric oxidation in tailings ponds and in receiving streams chemically breaks down the cyanide radical to form carbon dioxide and nitrogen.2(CN) + 202 2 CO2 + N2The monetary advantage to this method is obvious to the operator but too frequently though, climatic conditions are ignored. Length of winter, and reduced flow of the receiving stream in summer, adversely restricts the result of this combined method. For those of us who rely mainly on dilution it would be wise to remember that 70 million pounds of water are required to dispose of one pound of sodium cyanide (1).The third method outlined involves addition of acid in a closed vessel and venting resulting gas to atmosphere with or without air dilution by mechanical means. Cost, safety and some form of secondary treatment to complete destruction of cyanide remaining in the solution usually make this method prohibitive.The alkaline chlorination method is the one most commonly accepted for treating cyanide bearing wastes since it is felt that cyanide is completely eliminated in this manner."

Jan 1, 1973

By A. K. Debnath

The water resource is key to survival of the mankind and this resource is now becoming critical in many parts of globe including India. As per an assessment of Central Ground Water Board (CGWB) of India, a huge shortfall of about 58 billion m3 of water is anticipated by the year 2050. In order to counter this shortfall, there is thrust from Government of India to adopt water conservation measures. National Environment Policy, 2006 of Government of India also stresses upon the need to take up water conservation measures for water security of the country. The coal mines in India provide an excellent opportunity to take up water conservations measures therein. The mine water is not acidic unlike western countries and it conforms to the prescribed regulatory standards. This nature?s gift is utilized in Coal India Limited by allowing mine voids to get filled with mine water. The net recharge potential of the opencast mining area is found to be about 5% in comparison to 2% in non-mining area offering good prospects for ground water recharge. The seasonal rainwater is also diverted into mine voids left at the end of mining operations which act as huge reservoirs/ pit lakes for storage of the water. They also serve as surface water bodies for recharging of water table in the surrounding areas. The area and space left from where coal has been extracted completely in underground mines and will not be entered by any man or machinery after the extraction, called goaf, are also potential source of water conservation. These additional water resources created are being utilized for meeting the industrial, domestic, irrigation and other requirements of the projects and local communities eliminating the need to tap other fresh water resources including ground water. Presently, 75% of the water demand of the coal mining project is being met from the water stored in the mine pits. In future, CIL is likely to create about 3.3 billion m3 of water resource, on an average, in its opencast mines alone. In the mine closure plan of opencast mines, the last cut is proposed to be developed into water body for recharge of ground water and creating additional water resources. A clean potential source of potable water is thus developed after mine closure. This will ensure water security of the country.

Aug 1, 2013

By B. D. Sparks, I. E. Puddington, F. W. Meadus

The continuous separation of bitumen from Athabasca tar sands, with a high clay content, has been demonstrated. Recoveries of 95 per cent or higher have been obtained. Further processing of this product, to produce an accept-able type of crude oil, would require less heat than currently used in the hot-water process. Also, by comparison, substantial savings in equipment and operating costs are indicated.

Jan 1, 1971

By Terry Braden

"Meeting probable world mineral demand in the years ahead will almost certainly require an ability to economically treat lower grade and more complex ores. Achieving this will require extensive research and technical development across the full spectrum of mineral processing.For mid-sized or smaller companies the most effective way to participate in such extensive programs - and gain access to the technology required to stay competitive - may be through collaborative research.This paper explores the recent history of collaborative research in mineral processing and in particular its ability to attract world-class multi-institutional research teams with sufficient resources to make step-change advances. It chronicles the advances achieved, but also explores the research architecture and administrative structures required to deliver research outcomes and technology transfer mechanisms to a range of often disparate sponsoring companies.INTRODUCTIONIn medieval times the dream of alchemists was to turn base metals into gold. We modern alchemists, of course, don’t waste our time on that sort of foolishness: we turn base metals into dollars. When I see the profit reports filed by some companies recently, I can only conclude that a lot of those present today must be pretty good at this.But the fact that we are here at this conference reminds us that an alchemist’s work is never done; turning base metals into dollars is not a one-trick wonder but an art that we must extensively refine year after year if we are to survive in a competitive marketplace.It is not that demand for metals is likely to slow; most people seem to think that China, India, Brazil and other emerging economies are still at the lower end of their demand curve. They will need significantly larger volumes of metals in the years ahead. The challenge for us as processors is that to supply increasing tonnages of those metals profitably we will almost certainly need to process more complex or lower grade ores and probably to do so with reduced energy inputs."

Jan 1, 2009

By P. Chryssanthakis

"The aim of this study is to give a better understanding for the behaviour of the composite material RRS and the synergy effect of its components while an excavation face advances during tunneling. The lower part of the Q-system scale (i.e. Q-values of 0.4 or less for a tunnel span of 10 m) is commonly used for tunnel applications in softer rock formations. This is implied in the updated Q-chart, where the dimensioning of rock support by using Reinforced Ribs of Shotcrete (RRS) comprises the use of fiber reinforced shotcrete, S(fr), rock bolts and shotcreted beams reinforced with steel rebars. The newest part of the lower part of the Q-chart gives more information on required support compared to older Q-system versions. The RRS can be described as a three part composite material with the 3rd component being the reinforced concrete beam (with no fibers) and with steel rebars that are placed in groups and sprayed with pneumatically applied shotcrete in layers. The RRS usually have a total thickness varying between 0.20 and 0.50 m and a width between 0.25 and 0.60 m respectively. They are placed at different distances along the tunnel axis depending on the rock mass quality.In this study, an effort has been made to simulate RRS in a numerical code and to study its behaviour in a real case study. A double tube, triple lane tunnel in weathered tuff has been chosen as reference material for testing RRS under changing load. This was done by writing a FISH subroutine which is implemented in the discontinuous numerical code Universal Distinct Element Code (UDEC) that takes into account the characteristics of the reinforced beam (height, width, number of steel rebars, and spacing) in the calculation process. A rather extensive parametric study has been run by using the same key input rock mass parameters and in situ stresses (?H/?v = 0.5), and changing only the RRS key input parameters in order to simulate the changing loads during the face excavation process in tunneling. The critical part of this numerical modelling work that is under investigation in this study, is the period just after the excavation: i.e 4 hours; 16 hours after excavation; and finally after the complete curing (28 days) of the cement based components. The RRS are installed in three consecutive steps as follows: a) the application of S(fr) on the rock surface in order to even it up for the RRS application; b) radial bolting; and c) installation of the reinforcing steel rebars, that form the reinforced beam.The results show that: a) the S(fr) is almost overloaded in the first 4 hours after application in both tunnels; b) on the S(fr) and steel rebars, the stresses, axial and shear loads, as well as moments are decreasing after 16 hours and 28 days; and c) the bolts loads are increasing with time. The observed reduction in stresses and loads in both the S(fr) and reinforced beam is surprising. A possible explanation is that tunnel arches are self-supported to a lesser extent as time progresses due to redistribution of stresses in the nearby rock mass through the radial bolts. The loads in radial bolts are increasing by almost 25%. This can be seen from the overall results as we observe an increase in maximum principal stresses, displacements, shear displacements along joints and hydraulic apertures compared to tunnel baseline that has no support of any kind."

Jan 1, 2015

By Elbasher M. E. Ahmed, Indresan Govender

"A mechanistic model of axial charge segregation in rotating drums is presented. We show that granular material composed of different frictional properties diffuse into axial bands as a consequence of concentration fluctuations in the free surface layer that is caused by friction-limited mobility. A Bagnoldian stress assumption ensures an asymmetric free surface profile thereby providing the essential ingredients for the evolution of axial bands and the subsequent band coarsening observed in the literature. The formulation is sensitive to the boundary conditions of tumbling mills, including particle size and density, mill speed, inter-particle bulk friction, end wall friction and drum geometry (length and diameter).INTRODUCTIONA mechanism to fully describe the axial segregation of charge in a rotating drum remains elusive to the mineral processing industry. With regard to low aspect ratio mills (like ball mills), current thinking favours the use of closed circuit mills with correspondingly low residence times to offset the completely random contact probabilities between particles and balls (Wills & Napier-Munn, 2006). Conical end caps are argued to exploit the centrifugal force to achieve a regular gradation of ball size along the mill with larger sizes at the feed end and smaller ones closer to the discharge. However; segregation along the length has been observed in the absence of conical end caps (Oyama, 1939; Levine, 1999): In these investigations, sufficient differences in the particle’s mechanical properties (particle size, density, shape, surface roughness) was enough to successfully achieve axial segregation. Figure 1 shows the segregation of a bimodal distribution (by size) into bands of larger (darker colour) and smaller (lighter colour) particles."

Jan 1, 2016

By A. P. Schissler

Mining has several characteristics, uncommon in other business sectors, which pose additional challenges to the implementation or design of IT and management systems that use the information. Understanding these characteristics would improve the chances of successfully importing new information technology and management techniques to mineral producers. The most important characteristics that should be understood are workplace issues, the industry’s dual nature of being a continuous construction project using cyclical factory processes, labour challenges, workplace culture, information availability, integrative data elements, and the current technical education of mining engineers. These characteristics were taken into account in two applications of information technology and systems design at operating companies. The research and consulting projects focused on the development of an IT-enabled performance management system at several underground metal mines in Canada and an integrated data warehouse for surface mines spread throughout the United States and Latin America.

Jan 1, 2006

By Karim El-Ouassiti, Marc Minville, Stéphane Chabot, Claude Bazin, Valérie Ouellet

"Alumina is the main source of aluminium and it is extracted almost exclusively from bauxite ores found in the Southern hemisphere. Clays are abundant minerals that contain from 15 to 40% w/w of alumina from which it can be extracted by various processes. This paper reviews the processes used for the extraction of alumina from clays and discusses results obtained with a clay sample from the Murdochville area in the Quebec Province. The application of a conventional process to this clay did not yield an acceptable recovery although smelter grade alumina was produced. A modification to the process allows increasing alumina recovery from 85% to more than 92%. The application of the improved flow sheet to other alumina carriers failed to yield comparable recovery, showing that an optimum processing path for the recovery of alumina should be found for individual clay materials.INTRODUCTIONMost of the aluminium smelters are fed with alumina extracted from bauxite found in the Southern hemisphere. Bauxite is processed by the Bayer process that uses a caustic leach of the ore. In the middle of the century, the US Bureau of mines, motivated by the fear of an alumina delivery disruption, conducted several research projects aiming at producing alumina from non bauxitic ores. These projects led to the development of various acid leaching processes (Habashi, 1993). The sulphuric and hydrochloric acid leaching processes were brought to pilot plant evaluation (Bengtson, 1979), while nitric and other leach liquors were tested in the laboratory (Phillips and Wills, 1982; Habashi, 1983). Although clays are abundant and inexpensive minerals, the studied processes remained uncompetitive with the alumina extraction from bauxite (Hudson, 1987 page 42; Peters et al., 1962) for which reserves are estimated to support alumina production for the next 50 years (Oye et al., 1999). On the other hand, the local extraction of alumina from clays could significantly reduce the transportation costs of alumina to smelters and provide an alternative source of alumina supply from the Southern hemisphere countries. Also, the extraction of secondary products for some types of clay (Nasyrov et al., 1999) containing significant amounts of potassium and sodium could provide an additional return that may improve the economics of alumina production from clays."

Jan 1, 2005

By K. V. Konigsmann

"Mattagami Lake Mines Ltd operate a zinc-copper mine with an annual output of about 200,000 tons of zinc and 30,000 tons of copper concentrates. Zinc concentrates arc shipped to a company owned smelter in Valleyfield (a distance of 690 miles), for Export to Quebec City and also to Josephtown, Pennsylvania (1,060 miles, Figure 1.)The protection of concentrates in open gondola rail shipments has been a matter of concern since operations commenced. Considerable financial losses did occur at times because of wind erosion. Operating difficulties were also encountered by customers because of excessive moisture accummulation in the concentrates. Test shipments made in 1969 established the magnitude of losses in open cars. The results and subsequent investigations at our mines and elsewhere confirmed that load protection is an economic necessity.Many types of covers were experimented with, more or less successfully. In 1972 we agreed on a joint program with Dupont of Canada Limited. A new type of cover was developed by early 1973. It has been in use since, undergoing several improvements as experience accumulates."

Jan 1, 1975

By William Pitman

Ground instability and subsequent rock falls are a major concern in underground mines. As a result, several mining companies are conducting risk assessments of the ground support installed in their mines. Risk assessment is now commonly used to provide mine operators with a systematic process to assess the strategic risks that could lead to injury to personnel or loss of production, and evaluate possible risk control measures. Risk assessments can be carried out to identify major hazards, assess the likelihood of occurrence and consequences of each hazard and estimate the level of risk. This process allows assessment of possible remediation actions to minimize the risk and likelihood of occurrence or mitigation of the consequences to a level that is reasonable and practical. This paper presents two practical mine applications of qualitative risk assessment of ground support to highlight the benefits of this process. Yearly or bi-yearly risk assessment of mine excavations can assist mine operators in prioritizing resources and areas that require support remediation. In addition, it provides a mechanism for proactive response to reduce potential risks associated with personnel safety, equipment safety and environmental impact. It also provides a baseline against which changes in ground condition can be compared and quantified.

May 1, 2004

By J. A. Finch

For base metal sulphides, iron rejection starts in mineral processing. This review focuses on the changes in plant practice specifically to improve iron sulphide rejection by controlling contaminant ion effects and discusses selected innovations in mineral processing that can be expected to play a role in iron control. One change to control contaminant ions is size reduction (the use of stage grinding and inert stirred milling) and another is system chemistry (order of reagent addition and exploitation of the flexibility of sulphoxy species). Plant examples illustrate the successes, and indicate that there are several options available. The general innovations consider the new tools for measuring gas dispersion properties and quantifying froth characteristics from images. Examples of their application to improve concentrate quality illustrate the potential. Other innovations adapt geostatistics to model variations in ore flotation response to provide feed forward control and rigorously apply the statistical experimental methodology in plant test work. An example from one concentrator shows that significant improvements to reduce the iron content of concentrates can be achieved by applying these basic principles.

Jan 1, 2006

By J. R. Giegerich

THE problem of dust control in metal mines has, of late years, received considerable attention. In 1932, a detailed study of dust conditions at the Sullivan mine was undertaken and, while there are no actual data available regarding conditions prior to that date, there has unquestionably been a great improvement as a result of the investigation and of the preventive methods adopted. In attacking the problem, three main factors were considered: first, and most important, how to prevent dust from being formed; second, how to depress or collect it if formed; and third-if unable to accomplish these-what precautionary measures must be adopted to prevent inhalation of this dust. Seven distinct methods of dust control are now practised at the Sullivan. Six of these are employed underground; they are tabulated below in the order of their relative importance. The seventh method is used in the crushing plants on the surface. (1) Improved ventilation (2) General use of water sprays and atomizers (3) Curtailment of secondary blasting during shift hours ( 4) 100 percent wet drilling-primary and secondary (5) Wearing of protective equipment (6) Change from carbide to electric lamps (7) Installation of dust collectors

Jan 1, 1936

By Dirige. A. P. E.

A study was conducted for an operating mine to determine the appropriateness of its tailings material to be used for the preparation of a low modulus, high density backfill. The research was initiated due to issues arising from increased observations of compressive failure of backfill placed in stopes and inconsistent backfill behaviour (i.e. increased backfill brittleness and modulus). Backfill materials investigated were classified tailings and de-slimed tailings. Characterization of the physical properties of the classified and de-slimed tailings materials was conducted to assess the effect that these material properties would have on the strength and deformation behaviour of high density backfill products made using them. Such behaviour was investigated to determine whether differences in tailings physical properties would influence the strength and modulus character of the backfill materials. Uniaxial (UCS) and consolidated-undrained triaxial compression strength tests were conducted to determine strength performance and deformation behaviour of backfill. This paper presents the results of the backfill material characterization study and how different particle size distributions affected the strength performance and deformation behaviour of the different backfill mixes. It also demonstrates how stress-strain curves generated from material strength tests were used to evaluate variation in high density backfill mix response when such materials were subjected to unconfined and confined (triaxial) compression loading.

Aug 1, 2013

By P. Kostuik

"Recent interest in the pipeline transport of solid mate-als has been sparked by the idea that, in an inflationary onomy, pipeline costs are more stable than the costs of any other transport systems. Pipelines have proved over 1e years to be dependable, records indicate that main-•nance and operating costs are comparatively low, and 1eir amenability to automation is of considerable im->rtance.The concept of hydraulic hoisting of solids from under-round, or cross-country hydraulic transportation of con-~ntrates and ores, is currently of prime interest to the ining industry. In general, this paper deals with a preliminary investi-ation of energy losses incurred while transporting a rela-vely heavy, crushed mine product, namely magnetite, oth vertically and horizontally. The basis and validity of everal equations derived by other experimenters to com-ute these losses is discussed. A theoretical analysis of ydraulic hoi:,,ting is made, and, based upon test results, calculation of horsepower requirements for hoisting an re under a given set of conditions is presented. Results indicate that:n vertical transport, the friction head losses are identical to those of clear water, and the total energy requirement for hydraulic hoisting then becomes a function of height of lift, concentration and specific gravity of the solids being hoisted. .-In horizontal transport, friction head losses can be calculated with reasonable accuracy using Bonning-ton's correlation curve. Losses computed utilizing Durand's correlation (K = 85) result in estimates which are too low by 10 to 30 per cent, an<l those calculated using Newitt's correlation (K = 1,100, K = 66) give friction loss values which are too high by 10 to 30 per cent . . -The theoretical horsepower (RMS-hp.) required for hoisting hydraulically is approximately half of that required for conventional double-drum skip hoisting."

Jan 1, 1966

By Margarete Kalin

"Difficulties arise in implementing environmental technologies in the mining sector because important fundamental processes, which lead to the environmental degradation, are ignored. Weathering rates, the role of bacteria in the process and the incomplete application of the matching principle of accounting at the time the mining disturbance take place. Mining is a multi-stakeholder activity and the environmental problems have multivariate dimensions also effecting process.The limiting factors in the contaminant generation process are the transport of oxygen by advection, convection or diffusion in air or water and the associated microbial activity. Weathering products are transported from the mineral surface by atmospheric precipitation to surface and groundwater. This contamination takes place at different rates, requiring a long time to evaluate technological choices.Restoration efforts have to focus on slow reaction rates in the contaminant generating processes. Technology, which does not address the reaction rates and is selected based on inappropriate time scales, will not provide long-term solutions. Natural approaches to reduce acid generation, based on Ecological Engineering principles have required decades of research and field testing, but now show promise in addressing the cause of AMD and ameliorating its effects."

Jan 1, 2005

By Martin Stoklossa

Surface mining operations typically require run-of-mine material to be sized for further processing. In-pit crushing facilities serve this need, as stationary, semi-mobile or fully mobile units. Although in particular fully mobile crushing facilities have been in use for over half of a century, other surface mining techniques have typically been implemented. However, with increasing operating costs in truck and shovel operations, and other economic considerations, mobile crushing plants are increasingly a viable option. The operational and economical parameters in relation to the optimal surface mining equipment selection will be reviewed. The role of the mobile crushing technology within the continuous vs. noncontinuous surface mining operation and basis for mine planning are also discussed. Current applications and respective case studies will be reviewed. Key performance indicators will be presented. These performance parameters can be viewed as a tool to aid in the equipment selection process. The future direction for further research and development in mobile crushing facilities will also be presented.

May 1, 2008

By James A. Finch, Robert E. McIvor

"This paper presents the development of a new grinding circuit steady-state modeling system. It is fundamentally based on the “functional performance equation”, which has now been used to improve the performance of numerous grinding circuits. This equation characterizes the two distinct efficiencies that are at work in a ball milling circuit, and how these relate to overall circuit productivity. It does so based on the particle size chosen to distinguish between coarse and fine (product size) material. Now, by applying it to all the material size classes, a simple yet reliable ball mill model was created. Combined with cyclone recoveries, the complete, detailed grinding circuit performance can be exactly reproduced mathematically by the computer program. It can then be used with separate process equipment application engineering methods to systematically engineer grinding circuit improvements. The development, features, uses and limitations of the system are described.INITIAL DEVELOPMENT OF THE CIRCUIT MODELThe Functional Performance Equation for Closed Circuit Ball (or Pebble) MillingIt has been shown that closed grinding circuit performance can be effectively characterized by the “functional performance equation” for closed ball or pebble milling circuits (McIvor, 2006a). One method of its derivation is summarized here for convenient reference.First select a cut-off size to define “coarse” versus “fine” or product size material for the grinding circuit. Any particle mesh size can be used to differentiate between coarse material and fines, but the circuit target P80 is often an effective choice for these purposes.Any energy expended on “fines” is wasted. It also generates “extreme fines” often detrimental to downstream processing (McIvor and Finch, 1991). Only the portion of the mill power draw that is expended on coarse material is effectively used. This portion can be estimated from the mill feed and discharge size distributions (McIvor, 1988a) by taking the average of the percentage of “coarse” material in the mill feed and discharge. We can define the thusly calculated percentage of the mill power that is expended on coarse material in the mill as the ball mill circuit “classification system efficiency” (CSEff). The “effective mill power” (EMP) can be calculated from the total mill power (TMP) as follows."

Jan 1, 2007