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By D. M. Hausen

The role of applied mineralogy in mineral beneficiation begins with early prospect evaluation, and continues through stages of amenability testwork and pilot plant studies to the ultimate development of viable processes for mineable orebodies. After plant construction, mineral products from various locations, i.e., grinding circuits, flotation cells, gravity circuits, kilns, smelters, etc., require quick identification and control monitoring for optimum efficiency and recovery. Ore/gangue minerals are identified, quantified, and textural associations investigated by microscopic, spectrographic, and electron-optical instruments. Mineralogic analyses of large numbers of samples have required the development of sophisticated computer systems that merge analytical and mineralogic data into useful diagnostic data bases

Jan 1, 1991

By Mark R. Stanton, Douglas B. Yager

Integration and synthesis of mine-site topography, geophysical, and geochemical data yields both two- dimensional and three-Amensional perspective models for the May Day mine located in the Cement Creek drainage near Silverton, Colorado. Induced polarization, geophysical data are spatially registered with geochemical data acquired from drill hole cuttings that are contoured m three-dimensional space, thereby permitting determination of the most metalliferous and sulfur rich zones of a waste pile. This spatial modeling application was developed to be a visually intuitive tool to aid in mine waste reclamation.

Jan 1, 2000

By D. Royston

Curved pulp lifters have been incorporated in SAG and AG mills in Australia. The aims have been to ensure complete discharge, at high throughput, of both slurry and coarse solids, especially at high mill rotational speeds. Curved pulp lifters can overcome incomplete discharge and back-flow of solids down the pulp lifter that can occur in straight-radial pulp lifters (and is a major cause of wear). They can be designed to prevent reverse flow of pulp via grates back into the mill. Experience with curved pulp lifters now extends to three years over three mills, in one mill as an installation from new and two as retro-fitted installations. Curved pulp lifters, relative to conventional designs, offer improved discharge and wear performance and well as high impact-resistance and wear life of the curved pulp lifter grates.

Jan 1, 2000

By B. J. Arnold, F. F. Aplan, R. R. Klimpel, E. C. Jr. Dowling

Residence-time distribution techniques are useful tools in the analysis, characterization and modeling of the performance of processing equipment and circuits. This paper presents the results of both conventional and more-sophisticated residence-time distribution techniques for industrial copper-flotation-circuit data. While conventional techniques provide a description that is sufficient for macroengineering design requirements, the more sophisticated tracer-technique methods give more realistic descriptions of process flows and system effectiveness. It is demonstrated that these approaches can provide highly useful information about different equipment, as well as its configuration and performance.

Jan 1, 2000

By R. R. Klimpel

The efficiencies of plant-scale comminution processes are often evaluated by various indices calculated and/or measured somewhat independently of the performance of any associated downstream froth flotation processes. To compare specific comminution factors, such as energy utilization, media consumption and equipment utilization time, comparisons of comminution efficiency independent of flotation behavior are appropriate. However, as increasingly detailed plant-level information is gathered on the joint and highly interactive nature of comminution and froth flotation, it is becoming even more obvious that knowing and using simple efficiency indices are not enough. What is needed are more performance-related measures of the efficiencies of the combined size reduction froth flotation system for effective plant-level economic optimization to occur. The purpose of this paper is to present examples of some of the important interactions that influence the joint efficiencies of size reduction and froth flotation processes.

Jan 1, 1999

By J. M. Keane

SMEThis loaner is concerned with important criteria relative to the design of small flota¬tion concentrators. For the purpose of this discussion a small flotation concentrator is defined as a facility having a designed ore feed rate of 1,000 metric tons per day (MTPD), or less. The decision to design and construct a small flotation concentrator is the culmination of a series of logical steps relative to the ex¬ploitation of a potential ore body. The information required for a rational and timely decision regarding plant design and construction is usually contained in a feasibility report. The information required in a thorough feasibility report has been summarized (1) (2) as follows: Type of mine or plant and proposed daily, monthly, and yearly production of all intermediate and final products. Quantity of indicated ore reserves. Location of project illustrated by a map showing surroundings, trans-portation facilities, and existing utilities.

Jan 1, 1980

By George A. Snyder

The presence of moderate to high concentrations of colloidal clays in coal preparation plant waters can cause serious operating and economic problems for a coal company. Among the host of possible problems are the following: 1) Poor separation of clays in the plant thickener, resulting in: a) Increased ash in the clean coal. b) Increased specific gravity of the wash water and decreased coal recoveries at the desired quality. c) Increased thickener operating costs in trying to overcome the problem. 2) Decreased solid concentrations in the thickener underflow and increased pumping requirements to meet solids withdrawal requirements.

Jan 1, 1979

By William G. Davenport, Eric H. Partelpoeg

Direct smelting of copper in a single vessel has long been the extractive metallurgist's dream. Such a process offers the important advantages of (i) maximum use of the energy available from oxidizing the sulphur and iron of the concentrate; (ii) restriction of SO2 emissions to a single constant-strength source; (iii) minimum materials handling and (iv) elimination of at least one process step. Extensive developmental work was carried out in the 1960's and 1970's to implement such single-step processes. Some of the processes reached the prototype stage and it appeared that copper smelting technology was on the threshold of a new, efficient, minimum-pollution era. Since that time, however, the forward thrust has slowed and single-step smelting is still a process of the future. The paper describes in detail the potential advantages of single-step smelting; its history and current status; and the reasons why it has not been adopted industrially. It concludes that the potential benefits of single-step smelting are powerful and that many of the difficulties encountered in the 1970's will be overcome in the 1980's.

Jan 1, 1985

By J. L. Gent

Compressed air distribution networks are essential for powering equipment in many mines even though some mines are replacing them with electrical power for hydraulic drills. Compressed air can be costly especially if the system is poorly designed and maintained. This paper outlines a technique for proper compressed air system design that will help mine managers reduce compressed air power costs; an important topic in today's highly competitive international minerals market. Compressed air system design is complex. It requires specifying: 1) air quantity and pressure in all branches of a large network, 2) proper location and types of valves and fittings, 3) the network solution that determines compressor requirements, 4) optimal hose and pipe, diameters, 5) receiver and compressor accessories, and 6) required capital and operating costs.

Jan 1, 1989

By Samara Ali-Ahmad, Keith Hanks, Cindy Pham

The City of Los Angeles will rehabilitate approximately 9 miles of its North Outfall Sewer. This sewer was constructed in the 1920s as an unreinforced concrete semi-elliptical sewer. One of the methods for rehabilitation is to approach the sewer as a pre-excavated tunnel and install pre-cast segmental liners to provide a single pass corrosion resistant, structurally self sufficient project. The estimated cost for this project is $46 million. The project has completed the pre-design study, and the design is now underway.

Jan 1, 2003

By Sundar S. Saluja

Efficient and re1iable methods of fragmentation through blasting have been sought ever since the introduction of black powder in mining operations, but the pace of investigation became faster with the discovery of nitroglycerine. The development of modern measuring instruments and the need to blast more rock with the least damage has made the study of blasting mechanics and its application more important, particularly since the oil embargo. Investigations into the practical approach evolved by Daws (1909) and the work done to make it more useful is discussed. The work of several investigators is touched upon with particular reference to the development of computer programs to simulate and optimize blasting operations.

Jan 1, 1986

By K. V. S. Sastry, A. J. Hunt, K. D. Lofftus

Sol-gel processing is rapidly becoming an important process for producing such advanced materials as high activity catalysts, fiber optics and ceramic precursors. These materials can be tailor made with properties unique to sol particles as well as the gel aggregates by controlling production of the sol, the formation of the gel, and the removal of the interstitial fluids. This paper presents colloidal and kinetic principles of sol generation and gel formation. Hydrolysis of alkoxides provides the best means of controlling sol production and electrostatic stabilization enables the formation of the most homogeneous gels. Gelation occurs by hierarchial aggregation which produces inhomogeneities much larger than the sol particles. Colloidal and kinetic principles can be applied to reduce the size of the inhomogeneities and obtain high performance transparent insulation and new ceramic composites.

Jan 1, 1990

By V. W. Skema, M. W. Smith

Pennsylvania has 4,000 km (2,500 miles) of streams that do not meet water-quality standards due to acid mine drainage (AMD), making AMD the greatest cause of water pollution in the state. The problem is mainly caused by abandoned coal mines. To abate AMD, Pennsylvania is using a watershed-based approach that includes remining as a key component of a comprehensive restoration strategy. The Tangascootack Creek Water-shed was targeted for AMD restoration through remining. Geologic mapping and overburden data were analyzed using Earth Vision software to identify areas of coal reserves that could be remined to improve water quality. Incentives are offered to encourage mining in these designated areas.

Jan 1, 2002

By Y. C. Kim, F. Szidarovsky

The technique of linear kriging as a grade estimation method of mining blocks is reason¬ably established in the mining industry. During the kriging process, negative kriging weights ([]i) are sometimes encountered. Due to negative kriging weights, negative block grades may be obtained in some extreme situations, which makes no practical sense. To guarantee nonnegative weights, an additional constraint is required in the kriging system of equations. Unfortunately, the nonnegative weight constraint results in a set of nonlinear system of equations. In this paper, a derivation of the resulting set of nonlinear equations is presented and a numerical algorithm is developed for the solution of the equations. Because the algorithm developed does not remove negative weights arbitrarily, optimal nonnegative weights are always guaranteed. Results obtained using the developed algorithm were compared with those using the standard linear kriging, in terms of computer, time and the estimation results. Both the computer time and the kriging variance were found to be higher with nonnegative constraint, as expected. However, some systematic pattern was observed in the kriged values (i.e., over-or underestimation) with or without the nonnegative constraint. The study also demonstrated when one should generally expect negative kriging weights in practice, and what practical impact the negative weights can have on the kriging estimates.

Jan 1, 1987

By A. W. Scaroni, C. Y. Tsai

The effect of particle size and composition on the pyrolysis and combustion of a pulverized bituminous coal in an entrained-flow reactor has been investigated. Predicted time-temperature histories of the coal particles and experimental weight loss data indicate a strong coupling of heat and mass transfer to the pyrolysis and combustion rates. A higher combustion rate following ignition was observed as particle size was increased to 112 µm (about 140 mesh). This is related to a higher particle temperature after ignition for the larger particles. Although the heating rate before ignition decreases with increasing particle size, higher slip velocities and surrounding gas temperatures for the larger particles promote early ignition. The presence of liptinite in the coal increases the weight loss rate before and immediately after ignition. Similar behavior was observed for pyrolysis. Fractions of an HVA bituminous coal that were rich in mineral matter or semi-fusinite were found to have a higher heterogeneous char combustion rate than vitrinite-rich samples.

Jan 1, 1987

By Peter Fordham

A Norbridge review of 25 top mining companies highlighted financial problems for many firms. To better understand these results, Norbridge benchmarked 17 mining companies to understand the problems that companies face, the methods being used to improve performance, and the results that have been achieved. The study indicates that many mining companies in three sectors-coal metals, and non- metallic minerals-have implemented new strategies to improve performance. Many of these strategies supplement traditional initiatives with two types of process improvement efforts, facility-specific and company-wide, to help generate performance gains. The study compares the results of these strategies in each sector. INTRODUCTION imes are tough in the mining industry. Norbridge reviewed financial results of 25 top mining companies for the past 2 years-seven coal companies, twelve metals companies, and six non-metallic minerals firms.*The study found that 40% lost money in 2002, and * Coal companies include Alliance Resource Partners, Arch Coal, Consol Energy, Massey Energy, North American Coal, Peabody Energy and Westmoreland. Metals producers include Barrick Gold, Cleveland-Cliffs, Coeur d'Alene, Falconbridge, Freeport McMoran, Grupo Mexico, Inco, Newmont Mining, Noranda, Phelps Dodge, Placer Dome, and Teck Corninco. Non-metallic firms include Florida Rock, IMC Global, Martin Marietta Materials, Oglebay Norton, PotashCorp and Vulcan Materials. Information is from public sources, e.g., annual reports, company Web sites.

Jan 1, 2004

By N. Finkelstein, D. A. Hinckfuss

The large and compact but simple Bougainville Copper Limited flotation circuit has been in operation for 3-1/2 years. Discussion of problem areas encountered since start-up and remedies that have been implemented or proposed, form the main basis of this paper. Full cur- rent operational data is also provided.

Jan 1, 1976

By J. Herbst, K. Fallenius, G. Poling

Since 1970 a new series of pneumo-mechanical flotation machines has been developed by Outokumpu Oy. The cells have a completely new type of mechanism based on a recently-developed theory of conditions necessary for dispersion of large amounts of air. The mechanism was developed in 3 cu m cells and scaled to 16 cu m cells. Rotor and stator description, scale-up theory, and practical experience with the 16 cu m cell are presented.

Jan 1, 1976

By Richard R. Klimpel, Basil F. Fee

This paper summarizes the status of a series of new chemical reagents developed with the explicit goal of expanding the capabilities of existing froth flotation processes as well as allowing for new solid/solid separations to be undertaken that are not now feasible with flotation. The first portion of the paper briefly outlines the theory and motivation behind the development of each new reagent family. 'The second portion of the paper deals with specific laboratory examples of some separation systems studied to date.

Jan 1, 1993

By Takashi Sakaguchi, Akira Nakajima

Some attempts were made to recover and remove heavy metal elements, such as uranium, copper and chromium, from aqueous systems by using several phosphate compounds. The phosphorylated derivatives of polysaccharides, chitin phosphate, chitosan phosphate and cellulose phosphate, have high abilities to accumulate heavy metals, such as uranium, copper, manganese, cobalt, cadmium, zinc, nickel and chromium, compared with non-phosphorylated polysaccharides. In order to obtain basic information on the recovery and removal of uranium that may be present in industrial effluents, mine waste water and seawater, the adsorption of uranium by chitin phosphate and chitosan phosphate was investigated in details. The adsorption of uranium by chitin phosphate and chitosan phosphate was much greater than copper, cadmium, manganese, zinc, cobalt, nickel, magnesium and calcium. The adsorption of uranium was very rapid and was affected by pH of the solution, temperature. granule radius and co-existence of carbonate ion. The amounts of uranium adsorbed on the adsorbents increased linearly as the external uranium concentration increased. Uranium adsorbed on chitin phosphate easily desorbed with diluted sodium carbonate solution. On the other hand, uranyl and cobalt ions were separated from each other by using chitin phosphate. Along with these fundamental research, some attempts were made to recover uranium from seawater.

Jan 1, 1993