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By D. Malhotra

The economic viability of a mining operation depends on continuous process improvements. Diagnostic testing and plant auditing are essential useful tools to improve performance and reduce operating costs. Case studies are discussed to illustrate benefits of these techniques to improve plant efficiency.

Jan 1, 2001

By M. Ahrens

Gearless mill drives (GMD) are a well established solution for grinding applications in the minerals and mining industries. The paper describes the functionality and technical features of such drive systems as well as the development and the progress of GMD systems over the years. With an increasing installed base and many drives operating for many years, there is an increasing need to modernize or revamp existing GMD installations. The first installations of GMD took place in the cement industry and have demonstrated that ringmotors can achieve a lifetime well above 40 years, if maintained properly. The life cycle time of many other components, especially electronic parts, is usually shorter. It is therefore necessary to replace aged or out-dated components early enough in a planned manner in order to reduce the risk of component failures and the related shutdown times. Modernization upgrades can range from minor software updates to a revamp of the cycloconverter. The paper describes typical examples of such upgrades and shows the most important aspects that need to be considered.

Jan 1, 2008

By Brenda Myers-Bohlke, Tor L. Brekke

INTRODUCTION In recent years several cities in the Eastern United States have constructed subway systems in deeply weathered igneous and metamorphic rocks. Portions of these transit tunnels and shafts have penetrated zones of saprolite. The purpose of this paper is to define saprolite and discuss saprolite behavior in terms of construction and design of tunnels and shafts. Saprolites are products of in situ weathering of rock, with properties intermediate between those of soil and rock. A well-developed weathering profile can be divided into zones of residual soil, saprolite, transition zone materials, weathered rock, and fresh rock. Saprolites are distinguished by a high degree of weathering and by retention of parent rock textures and discontinuities. These structures persist as relict features because of iso-volumetric weathering (Cleaves, 1974) and formation of intergranular bonds that give cohesion to the saprolitic material. As saprolite continues to weather, the bonds are broken, causing the saprolite to decompose and disintegrate into a true residual soil mass without relict structure. Saprolites may form from igneous, metamorphic or sedimentary rocks, but are most easily recognized when derived from igneous and metamorphic rocks because of their inherent structures. The physical characteristics and properties of residual material vary as a function of mineralogic composition, structure, and discontinuities of its parent rock.

Jan 1, 1985

By J. O. Voigt

No major changes took place in the salt industry during 2004. No new uses of salt appeared and only localized supply disruptions occurred. Many salt producers reported slightly increased salt sales and profits for the year. In the United States, about half of the salt supply is produced as brine, by solution mining, and is used by the chemicals industry. One-third of U.S. salt is produced as rock salt by 14 underground mines. The remaining two production techniques, each with less than 10 percent of the total tonnage, are vacuum-pan-evaporation for refined, food-grade salt, and solar pond crystallized salt.

Jan 1, 2005

By V. E. Chrapunov, T. V. Chnyrenkova, R. A. Isakova, V. A. Luganov

Arsenic-gold bearing ores are used as a flux in smelting or leached out to extract gold. To decrease arsenic content in processed materials and to break up the lattice to free the gold, raw materials are roasted. This article analyses the results of laboratory and pilot testing of dissociating and oxidizing roasting of gold-arsenic bearing concentrates. During the dissociation roasting under vacuum arsenic is sublimated into elemental and sulfide forms. The process allows to minimize the negative influence on the environment but requires costly engineering solutions. Roasting in a neutral medium or with limited quantity of oxygen in the gaseous phase makes it possible to sublimate arsenic in the form of oxides and sulfides and may be carried out in the autogeneous mode in fluid bed furnaces. If oxidizing roasting of the concentrates is done in the presence of soda, practically all arsenic and sulfur form water-soluble compounds and remain in cinder.

Jan 1, 2002

By Daniel W. Kappes

Testing ores for heap leach operations traditionally follows a progression of bottle roll tests, bucket and column leach tests, and very expensive large field leach tests. Enough data is now available to streamline the procedures. Data from five different operations shows that recoveries from large field leach tests can be predicted from the bucket tests. Initial recovery times in large field leaches are longer than in bucket tests- a typical response is eight days versus twenty days to the same recovery percentage; but the ultimate percent recoveries (after 60 days) are normally very close. Methods of mining and stacking can radically affect recoveries from clay-rich ores. Leaching of uncrushed ores provides special testing problems, since accurate samples smaller than several tons cannot be taken.

Jan 1, 1981

The first of this three part series examines he history and some of the properties and characteristics of explosives. Use of explosives is discussed for underground and surface coal operations—the largest consumers in the mining industry. Part two of the series will deal with explosives use in surface and underground hardrock operations. Part three will discuss explosives transportation, storage, handling, and destruction.

Jan 7, 1981

By A. Yehia, M. I. Al-Wakeel

Flotation behavior, of magnesite and dolomite pure minerals was studied separately. Rice bran oil (a source of fatty acid ) was used as a collector for both minerals . The aim of this study is to find a separating zone in the flotation of these pure minerals to be used in the separation of their mixture. Factors affecting the flotation process, such as pH and collector, were studied. It was found that magnesite can be separated, from its mixture with dolomite, in the pH range of 5-7. At this pH range flotation recovery of dolomite reaches~98% where magnesite reaches ~20% only. Besides, the effect of collector concentration on the flotation shows that the separation of magnesite from dolomite is feasible at a collector concentration of 3x10-4 M. At such concentration, dolomite recovery reaches ~98%, where magnesite reaches 25%. The differences in the flotation behavior of dolomite and magnesite were investigated by studying the adsorption isotherms of rice bran oil on magnesite and dolomite surfaces. The adsorption study indicates that while there is an excessive adsorption on dolomite surface, the adsorption density on magnesite was restricted to be lower than monolayer capacity. The adsorption behavior of dolomite and magnesite was discussed in the light of their solubility and crystal structure. It was found that due to the higher solubility of dolomite than magnesite, Ca2+ and Mg2+ ions are available and more reactive on dolomite surface increasing collector adsorption. In addition, it was indicated that dolomite mineral has a crystal lattice structure more compatible to the geometry of the fatty acid carboxylic group than magnesite. However, the adsorption of collector on dolomite surface is more compact and more regular than on magnesite surface.

Jan 1, 2000

By S. Mishra, C. Shon, D. Saylak

Only 40% of fly ash generated by the power plants in US are recycled and used for commercial applications. Of these, the high lime, Class C ash had been preferred. Systematic laboratory and field-scale studies have shown that, by including calcium chloride in the mix design of stabilization of roadbed materials, both Class C and Class F fly ashes can be effectively utilized. Test data reveal that the addition of calcium chloride to the system accelerates its curing rate, thereby increasing early strength and long term durability of the constructed road. For road construction, a preblended Class F fly ash–CaCl2 system tends to be more forgiving than the Class C fly ash–CaCl2 system. The former system produces more durable roads. The role of calcium chloride as an accelerator in these systems is discussed along with a mathematical model developed for fly ash- CaCl2 stabilized roadbed systems.

Jan 1, 2007

By Wern-Ping Nick Chen

Durability risks for underground facilities can be underestimated during design phase as compared to well-known geological risks. However, unclear durability requirements can result in construction schedule delay and change orders. Unlike bridges or buildings, a unified underground durability code or standard does not exist. This paper will provide a durability approach for underground facilities, including degradation modes, mitigations, and compliance measures during construction. In addition, this paper will address how to clearly specify durability requirements in a contract document to reduce disputes during construction and discuss key durability tests that are time consuming and will impact construction schedule if not timely planned.

Jun 23, 2024

By L. You

Theoretical and analytical analyses of three mitigative measures- plane fitting method, trenching, and tension cable led to the development of a total protection plan to eliminate or reduce damages to the residential structures subjected to surface movements caused by underground longwall mining. The protection plan was applied to twelve residential houses and two external garages. The success rate is overwhelming. This paper describes the methods employed for protection and results of those case studies.

Jan 1, 1986

By Daniel F. Meyer

INTRODUCTION The Metropolitan Boston Transit Authority (MIA) Red Line has served greater Boston commuter needs from its Harvard Square terminus since its opening in 1912. Since then, the population of Boston's northwest area has increased substantially, and with this growth have come dramatic changes in the type and distribution of urban land uses, including the number of households, jobs, shopping and recreational opportunities; these changes have created a need for improved transportation. Extension of the Red Line to better serve these communities has been a topic of discussion for nearly 40 years. In November of 1977, the Urban Mass Transportation Administration (UMTA) granted the MBTA approval and funding for the Red Line Extension Project. With funding in place, the MBTA proceeded with final engineering and construction of the section from Harvard Square to Alewife. When completed, the Red Line Extension will add 3.2 miles of new track to the MBTA system. Estimated final cost is about $400 million. On October 3, 1978, the MBTA received bids for the construction of Project 091-105, Harvard Square to Porter Square Tunnels and Shafts, which is part of the overall Red Line Extension. The Joint Venture of Morrison-Knudsen, White, Mergentime was the low bidder at $47,478,600. Official award of the contract came on October 25, 1978, with Notice to Proceed given October 31, 1978. The contract called for construction of two independent parallel concrete-lined tunnels in rock, soft-ground and mixed-face

Jan 1, 1983

By Bruce Gellar

For the past six years, the author has made it a priority to attend the Prospectors and Developers Association of Canada’s (PDAC) annual conference. This most recent meeting took place March 10-13, 2002in Toronto, Ontario. In the three years since the author’s last PDAC report, the mining industry has undergone a severe trough. Some the industry’s woes included deeply discounted commodity prices, rampant layoffs, mergers, and overall avoidance by the investment community. However, at each of the PDAC conferences, the author has felt a heightened sense of excitement about the mining industry, more so than at other similar gatherings.

Jan 1, 2002

By T. S. Golosinski

Introduction Typical dragline rigging includes several sets of ropes: hoist ropes, drag ropes, dump ropes and boom suspension ropes. The drag and hoist ropes contribute most to the dragline operating cost. Both work in very difficult conditions and wear out rapidly. As a result, frequent rope changes are required resulting in substantial cost and productive time loss. Although performance of rigging has a profound impact on dragline efficiency, there are no common, industry accepted standards related to its selection, operation and maintenance. Little information on the subject is available and the practice differs widely throughout the industry. The performance of drag and hoist ropes depends on: •rope construction that should closely match requirements of the specific application, rope operating conditions and its maintenance and • correct definition and application of the rope discard criteria so that full advantage of the rope can be taken without endangering safety of its operation. This paper reviews the present practice related to all these factors. Its findings are based on the wide survey of the present industrial practice. Field survey In total, 33 North American dragline applications were surveyed of which 17 were Bucyrus-Erie machines, 10 were Marion and six were Page (now P&H). Most of the draglines were stripping overburden in coal mines, but the survey also included some unique applications such as phosphate mining in Florida and oil sand mining in Alberta. Hoist drive power of the surveyed machines varied from 300 to 7775 kW (400 to 10,400 hp). Drag drives varied from 300 to 5815 kW (400 to 7800 hp). Boom lengths varied from 37 to 110 m (120 to 360 ft). Bucket sizes varied from 5 to 96 m3 (6 to 115 cu yd). The hoist and drag ropes installed on the surveyed machines were supplied by 10 rope manufacturers and differed widely in type and construction. Most common rope strand constructions included standard strands, Seale, Warrington, Warrington-Seale and Filler-Seale. Results of the survey [ ] Working conditions Working conditions of hoist and drag ropes are quite different. The first cope primarily with bending on rope drums, point sheaves and deflection sheaves, and with tension force imposed by the bucket and its load. The drag ropes are exposed to severe abrasion at the pit crest, and to severe bending and crushing at fairleads, all while coping with tension forces imposed by resistance of the bucket to dragging. Bending of drag ropes at house rollers and at rope drums is of minor importance for their performance. Differences in working conditions result in different wear patterns, which make it feasible to install discarded hoist ropes to further serve as drag ropes. The hoist ropes wear primarily due to fatigue breaks of wires, while the drag ropes are subject to severe abrasion of outside wires, rope deformation and internal wire-strand breaking. The last is often indicated by the reduction of rope diameter. The summary of working conditions for the surveyed draglines is shown in Table 1. For simplicity, Table 1 does not include the data on rope bending at the fairleads, nor at the deflection rollers and house rollers. Similarly, Table 1 does not include the data on drag rope bending (other than that on the rope drum), as its influence on rope life is insignificant in view of severe abrasion and internal wear taking place elsewhere. The following abbreviations are used in Table 1: [D - diameter of rope drum. DP - diameter of boom point sheaves. d - rope diameter x - mean value of the measured parameter. s - standard deviation of x B/d - average bending ratio of ropes B/d =(D+ DP)/2d n - operational safety factor of the rope (rope stength) x (number of ropes) n(bucket load + bucket weight)] In terms of D/d ratio, the working conditions of hoist and drag ropes are similar to that in other related industrial applications. However, the safety factors of the dragline ropes are lower, which requires them to carry relatively large tension forces. The last explains the fact that the life of dragline ropes is low when compared to other industrial rope

Jan 1, 1995

By C. Chamberlain

The mining industry continues to underpin the regional economy. Australia, benefiting from a weak currency, receives 27% of the total goods export value from non-energy mining lead by aluminium, iron ore, gold and nickel. Consolidation has eliminated CRA, Comalco, North, Savage, Acacia, Ashton, Great Central, Aberfoyle, Placer Pacific, Plutonic, Normandy and RGC leaving Rio Tinto, BHP-Billiton, WMC, MIM and, increasingly, the South African companies Anglo, Gold Fields and Harmony as dominant players. Exploration stagnates with expenditure dropping 40% in Australia and 80% in PNG from peak levels. Major new regional developments include Rio’s West Angles iron ore project, Newcrest’s Ridgeway gold-copper mine and Inco’s Goro nickel-cobalt project in New Caledonia.

Jan 1, 2002

By Will Foreman, Douglas D. McLearie, Edwin K. H. Tong, William H. Hansmire

Hong Kong’s Strategic Sewage Disposal Scheme (SSDS) Stage I involves the provision of a system of deep tunnels for transporting to a central treatment works wastewater collected from a number of catchments around Victoria Harbour. For the SSDS Stage I works, about 24 km of tunnels have been excavated in hard rock at depths ranging from about 80 to 150 m below Victoria Harbour and the surrounding heavily developed areas of Kowloon and Hong Kong. Five tunnel boring machines(TBMs) with diameters ranging from 3.2 m to 4.3 m were used to excavate the tunnels. Tunnel excavation has been completed and tunnel linings are in progress. Major tunnelling issues such as ground stabilisation and water control encountered in the project are summarised. An overview of one of the possible future tunnel systems that might be adopted in subsequent stages of SSDS is also presented.

Jan 1, 2001

By B. Cousins

Flotation reagents are critical to the optimum performance of flotation circuits. How a flotation reagent performs within the first few cells of a flotation train is a key indicator of how well it will perform throughout the entire circuit. A method to compare reagent performance was recently developed by Ashland Water Technologies. The procedure involves collecting a timed sample of concentrate from each cell and then measuring the volume of the settled solids. An estimate of the percentage of concentrate collected from each cell can then be mathematically determined, providing an understanding of the recovery changes in each cell. Data from trials at a coal flotation circuit are used to demonstrate the method's validity.

Feb 27, 2013

By C. S. Kucukkaragoz

An ilmenite concentrate was reduced in the solid state with carbon under argon atmosphere at temperatures between 1000oC and 1400oC. The ilmenite concentrate and 50% excess carbon were reacted to achieve the highest attainable degree of reduction at each temperature and the reaction products were subjected to a series of analytical work by optical microscopy, X-ray diffraction analysis and SEM ( EDS) analysis. The ilmenite remained unaltered at 1000oC and had a slight change in its composition at 1050oC. A secondary oxide phase containing metallic nuclei was detectable at 12% reduction at 1100oC. The reduction of TixOy took place in a sequence changing the y/x ratio from 2.0 to a value less than 1.0 at 84% reduction at 1400oC. Metallic phase consisted of Fe and C initially and started to include Ti at the later stages. Complete reduction of TixOy to metallic Ti was not possible at these temperatures.

Jan 1, 2005

By F. B. Henderson

1.0 PROLOG Since the "end" of the Cold War, revolutionary new research and commercial remote sensing capabilities are being developed that will dramatically change the way we map the earth and address its environmental problems. The technology challenge is not the growth of new environmental remote sensing technologies themselves. It is, rather, how these new innovative observing systems can be accepted and used to the benefit of both the regulatory and the mining communities in the light of present concerns about unknown risks of discovery and liability. The basis for this paper is an unpublished technology primer prepared for the industry-government Workshop on Advanced Measurement and Site Characterization for Mining Impacts held at Colorado School of Mines, Golden, Colorado, July 14-17, 1997

Jan 1, 1999

By Russell Barr

Strategic alignment throughout a mining organization is critical to effective strategic execution and good business performance. The alignment of strategic goals and objectives in the different operations and functions in a large global operation is a challenge facing executive management in light of legacy organizational structure and processes. An additional confounding factor in strategic alignment of acquisition and new project expansion is that mining projects and operations are frequently multi-cultural in terms of country origin as well as organizational culture. This brings together many cultures to accomplish the project or complete an acquisition (Financial Times, 2006). The mining industry presents numerous challenges to executives and mine management by the nature of the operation and organizational processes used in running it. For example, there seems to be an inherent conflict between the individual goals of the components that constitute a mineral processing operation (the mine, the mill, the smelter and the refinery), and lowest cost production of the final product. Managers of these component operations have specific objectives passed down from the corporate executives. Those site managers tend to be compensated based on throughput and perform to this main metric. This tendency to maximize throughput for an individual operation can contradict the general process flow of a best-fit solution to producing the final product at the lowest cost. In an effort to become more aligned, firms are increasingly using balanced scorecard derivatives at great cost and effort (whether internally or externally sourced) in an attempt to help with strategic alignment. Balanced score-cards have been effective in providing a good strategic scorecard to companies with some measure of strategic alignment. Many firms make this effort of using balanced scorecards. However, most firms are not strategically aligned or, at best, are sub-optimized, in terms of strategic alignment (Kaplan and Norton, 2006). The tendency in mining operations is to focus on operating individual components as optimally as possible and stretching existing assets to the best possible production rates. ?Making tons? is the common operational focus. Numerous factors underpin this focus and can affect the ability of the operation?s ability to align properly with the corporate strategy and strategic goals. Critical factors are legacy organizational structure, culture, processes and performance measurement systems. Changing anyone of these factors to affect better strategic alignment requires significant attention to managing change.

Jan 1, 2008