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By John G. Whellock

Over the last decade new constraints have emerged in the metallurgical industry which challenge the very basis of design and construction of smelters and refineries. The hackneyed designs of the past will not now serve the revised objectives of: - minimal cost of ownership - improved productivity - reduced energy consumption - greater flexibility in feed or product - minimized recycle loops and by-products - more stringent environmental control The impact of these constraints has been channeled constructively into process intensification - exemplified at the large scale by the introduction of flash smelting technology and at the smaller scale by the application of rotary process vessels and converters for augmented heat and mass transfer. The design of successful process plants depends on the understanding of the unit operations and their interactions which is the discipline of systems engineering. With the advent of increased process intensification the importance of a systems approach to process design and implementation becomes paramount. This paper describes the systems approach with specific reference to medium scale projects in the primary and secondary metallurgical industry.

Jan 1, 1985

By J. M. Stewart

The incidence of heat stroke in the South African gold mining industry is today small (less than 1 in 10 6 shifts worked). Acclimatization and selection procedures have been developed and applied throughout the industry, underground working conditions have, and are being improved, and personnel are to-day made more aware of heat stress and its consequences than ever before. Although these actions have, over the years, brought about a steady reduction in the incidence of heat stroke (see Figure 1) the small incidence of heat stroke which persists indicates that heat stress is still a problem. This realization provides the stimulus for the work presented in this paper, which has as its primary objective the development of reliable heat stress limits for men working in South African gold mines. [ ] In keeping with recent trends3I4 the approach followed in this paper is based on the physical principles of heat transfer. Detailed studies of heat transfer from humans have been undertaken,5-l1 and certain of the results form an important aspect of this Paper -

Jan 1, 1980

By O. A. Bascur

An expert process operation advisor system can increase plant efficiency, even in a complex, natural environment where not all elements of the production process can be measured directly. This system, develaped and tested in a Frasch process sulphur mine, monitors key process variables with extended qualitative pattern processing and provides on-line advise to the operators of sulphur production wells. An expert system framework captured common sense rules generated from years of experience obtained in the operation of a sulphur well monitoring system. The existent operating procedures were enhanced by process analysis using a qualitative modeling approach which provided extended rules for on-line classification of a well operational status and an expert alarm system. The methodology for development and implementation of the process advisor is presented in this report. Qualitative process modeling, statistical process control and heuristics were incorpomted into the process advisor resulting in a more efficient use of heat, an extended well operational life and the resulting cost savings. The computer process advisor also allowed the operator to concentrate his attention on the weak wells or wells in trouble. A process management system improved plant operation by automatically storing well data into a commercial database for operator validation. The enhanced relational data base system provided valuable and timely information for planning and decision making. The synergistic combination of on-line process analysis tools, expert control systems and database technology is shown to facilitate the flow of materials, energy and infomation in a modern plant.

Jan 1, 1990

By George D. Roberts

Dams are constructed to retard the flow of water or debris; therefore natural forces are constantly at work to remove such obstructions. To circumvent nature and avoid expensive trouble with a dam requires thoughtful far-sighted planning, careful construction control and vigilant periodic inspections to detect and repair deterioration at its inception. Although the factuality of the foregoing statements is apparent, all too many have failed to consider them in the past as will many in the future. "The economic, but safe construction of dams calls for the highest order of technical knowledge, practical experience and sound judgment." (1)

Jan 1, 1967

By G. J. J. Aleva, A. H. Hilversum

The northern spur of the Bakhuis Mountains contains bauxite deposits on a dissected planation level, a region formerly indicated as the Adampada-Kabalebo area. Iron-rich laterites are ubiquitous on all more or less flat and horizontal to moderately sloping interfluves and planation levels. The known aluminous laterites and bauxites are restricted to those laterites that have relatively leucocratic and silica-poor parent rocks. The whole area is underlain by high-metamorphic Precambrian. In the northern half of the Guiana Shield at least four Cainozoic planation levels can be distinguished. The bauxite and aluminous laterite deposits are related to the oldest, Early Tertiary level. These deposits, occupying the highest positions in the present day landscape, show the destructive influence of post-laterite weathering, erosion and denud- ation; they are erosion remnants and as such are of irregular thickness, grade and shape. Consequently, exact mineable tonnages can only be determined after intensive and detailed sampling and evaluation, taking into account the latest technical and economic parameters. The bauxite potential of the region is negatively influ- enced by the complicated uplift history of the Bakhuis horst, and positively by the presence of suitable parent rock and possibly more than one phase of bauxitization.

Jan 1, 1984

By S. Siewierski, L. Wojno

INTRODUCTION Bumps are among the most dangerous hazards in the Polish copper ore mines. Their occurrence is the result of the dynamic processes in the rock mass caused by natural factors connected with the deposition of strata and, to some extent, by technological factors resulting from the process of exploitation. In this connection, in order to ensure worker safety and choose such a technology that allows an achievement of high technological and economical parameters, a detailed knowledge of the phenomena occurring in the rock mass is required. In copper mines the basis for forecasting and control of bumps is obtained by continuous measurements and observations of the symptoms of rock mass pressure, the analysis of which ensures the accuracy of forecasting and points toward preventive means that must be applied to prevent bumps. The methods most often used for preventing bumps in copper mining are discussed in this paper.

Jan 1, 1982

By S. Zendejas-Mendivil, E. Pérez-Segura

The Cananea porphyry copper-deposit is the site of the second largest mining operation in Mexico. Mineralization is related to quartz-monzonite Laramide stocks that intrude volcanic and volcaniclastic Mesozoic rocks. The ore deposit is a stockwork and breccia-pipes system with Cu-Mo sulfides and pervasive quartz-sericite hydrothermal alteration. A study was made of the arsenic distribution in the mine and the ore-dressing plants. The arsenic (As) in the mine is related to a feldspathic quartz-porphyry type rock associated mainly with the breccia pipe structures (100-700 ppm As in the Veta 7 Breccia). There is vertical zoning, with As decreasing in the deepest part of the breccias. This As mineralization corresponds to a later sulfide hydrothermal stage. The concentrates are made of Cu, Fe and Mo sulfides and some minor quantities of As minerals. The most important copper minerals are chalcocite-covellite, bornite and chalcopyrite. Some of these minerals have 390-880 ppm As. The main As mineral is enargite[ [Cu2.97Fe0.06(As0.90 Sb0.01Pb0 01 )0.92 S4 051 and there are traces of stibioluzonite-luzonite I Cu, .95(Aso.4vSbu.49)0.9rfS4.07-Cu2 93(Aso.H4Sba.10)0.94S4.13] and of another stibioluzonite mineral type with substitution of As by Bi[Cu,96(Ascr,,'Sb0ccrB'OJ3jI~6S] These minerals contribute 80% of the As in the concentrates.

Jan 1, 1992

By Douglas J. Cork

Biohydrometallurgica1 processes in the areas of coal desulfurization (Hoffman, M.R., et al., 1981) and recovery of metals from metal sulfide ores (Lundgren, D.G. and Malouf E.E., 1983) are well known. In addition other areas of potential interest to the mining industries have been outlined (Spisak, J.F., 1979). For instance, scientists involved in this interdisciplinary field have endeavored to apply microorganisms to the problem of effluent sulfate disposal. This chapter assesses the feasibility of utilizing a particular two stage anaerobic microbial process to convert effluent sulfate to orthorhombic sulfur. Strong emphasis is given to the possibility of substituting this bioprocess for alternative gypsum synthesis and disposal methodologies commonly practiced by companies which emphasize sulfuric acid or ammonium sulfate leaching processes.

Jan 1, 1985

By D. E. Munson, H. J. Sutherland

Empirical methods for describing the shape of the subsidence trough over coal mines in Europe are tested against field measurements of subsidence over longwall panels in the United States. The graphical methods developed by the National Coal Board in the United Kingdom do not correlate well with the U.S. measurements; however, the profile functions typically used on the Continent give quite acceptable fits to the data. In the case of two longwall panels mined at Old Ben No. 24 in Illinois, a trigonometric profile function appears the best choice; in the case of two longwall panels mined at York Canyon in New Mexico, an error integral function is somewhat superior. Analyses of subsidence development curves show that rate effects occur. A comparison of fitting parameters establish influence functions as an important methodology for future analysis. In conjunction with the evaluation of empirical methods, an analytic model based on material failure and bulking was developed. A key element of the model is the void-volume distribution function which establishes a mechanism for transfer of significant amounts of the mined volume to the surface. Preliminary calculations demonstrate the features of the model and illustrate close correlation to physical observations in the field. Moreover, centrifuge models simulating the subsidence process have been used successfully to demonstrate the dominant or key failure modes necessary to the analytic model. General features of the centrifuge simulations and model calculations correlate well.

Jan 1, 1982

By Anshumali Gangwar

This paper outlines the chance constrained binary integer program developed by the author in his doctoral dissertation at Columbia University, New York, 1973. The optimum planning of a mining program involves the determination of a production schedule which maximizes the net present value of the mining property. The actual mining process has an inherent stochastic and discrete nature. In particular, the demand for the mined product and the grade of the mineralized material in the ore are the two most important stochastic mining variables. The decision to mine or not to mine any block of a mining property is a binary integer variable. This paper outlines the formulation of pit production scheduling problem as a chance constrained binary integer program. The deterministic equivalents of these chance constraints are nonlinear in binary variables which have subsequently been linearized. The planned objective is to meet with a stipulated high degree of reliability, all the random demands as they materialize with a random supply of the commodity being marketed as determined by the eventuating random grade values of the exposed ore blocks and the mining system's production constraints such that the discounted total production costs over the entire planning horizon are minimized or the profits maximized. The emerging surface of the mine in each scheduling period is determined by the values taken by the binary decision variable associated with each block of material in each scheduling period.

Jan 1, 1982

By David V. Fitterman, David L. Campbell

We've used direct current resistivity (DC), electromagnetic (EM), induced polarization (IP), and ground-penetrating radar (GPR) geoelectrical methods to study mine dumps. The results reflect lithology, pore water saturation, and dissolved solids in the pore water. If the pore water has a pH less than 5, conductivity maps can indicate acid generating potential. IP measurements can help distinguish mineralogy in mine dumps, especially concentrations of sulfide minerals. EM and DC can help locate acidic/high TDS groundwater associated with mine dumps. GPR methods failed at the sites we studied in the West. Our own conclusions are augmented by those from the recent literature.

Jan 1, 2000

By J. Mark Richardson

Steady-state flowsheet simulators for mineral processing plants have evolved to a current high level of utility and accuracy. Reliable, general-purpose, semi-empirical models now exist in nearly all unit operations categories particularly in the areas of comminution and classification. .These models, installed as user-selectable functions within the integrated frame- work of flowsheet balance-solver software systems, can be strung together to represent any plant configuration. In addition, CAD-like graphics, data reconciliation and model parameterization functions have become standard features of the current generation of integrated plant simulators. These advances have given engineers the capability to investigate many different plant scenarios while requiring a minimum of actual plant testwork. This paper describes a methodology and an integrated software package which are being successfully applied in a number of operating plants worldwide to predict plant performance under changing conditions. Those conditions which can be changed include effect-of ore type, feed size, water addition rates, equipment geometries and flowsheet modifications. By using data from actual plant optimization exercises in real mills, the paper illustrates and out- lines a technique which includes plant data collection, ore breakage testing, flowsheet simulation, model-fitting (parameterization), data adjustment and model experimentation. Brief descriptions of some unit operations models, such as autogenous mills and cyclones, are provided as examples of the current state of such models. Ore breakage testing and its relation to certain models is also discussed. Computer- generated size-distribution graphs, along with tabular data generated by the simulator, round out the presentation and serve to demonstrate the real- ism and accuracy of the models. The paper concludes with a partial list of cases where this technology has been successfully applied.

Jan 1, 1992

By Harold A. Taylor

The first use of graphite is lost in the mists of time. It was used by primitive man to make drawings on the walls of caves and by the Egyptians to decorate pottery. As early as 1400 AD graphite crucibles were being made in the Haffnerzell District of Bavaria. Through the Middle Ages graphite was confused with other minerals, especially galena and molybdenite. Two common names that are still being used for the mineral are plumbago, meaning lead-silver, and black lead. The latter name implied that graphite is either composed of lead or at least contains a large percentage of it. Gessner is credited with having recognized it as a separate mineral in 1565, but its composition was not determined until 1779, when Scheele demonstrated that graphite oxidized to carbon dioxide, thus proving its carbon constitution. In 1789, Werner named it graphite from the Greek word graphein, meaning to write. The United States has long relied on foreign countries for its graphite supplies. This reliance has been due more to the lack of suitable domestic graphites than to any particular preference for buying minerals overseas. Sri Lankan graphites were imported as early as 1820, and Madagascar graphites have been imported since the properties on that island were opened up about a hundred years later. Mexico has long supplied the United States with most of its requirements for amorphous graphite.

Jan 1, 1994

By R. S. Rickard, B. Ball

INTRODUCTION Pyrite responds to the flotation reagents normally used in sulfide flotation systems. For example, it is well known that xanthates are good collectors for pyrite, and cyanide, sulfide and hydroxides are depressants. The particular response of pyrite to these and other reagents is used to advantage in several areas. By careful control of depressant and collector additions, pyrite can be separated from other sulfides by flotation. This is of obvious importance in base metal sulfide flotation where pyrite depression is often required to produce a marketable grade concentrate. Flotation of pyrite has long been employed in gold ore processing, and it appears that pyrite flotation from coal may become important in the future (1). It is probably a direct consequence of this relative ease of separation, plus the low economic value of pyrite, that detailed investigations on the chemistry of its flotation and depression are relatively limited. Gaudin (2,3,4) and others, in the mid-1950's published data on the flotation of pyrite, but detailed or consistent mechanisms were lacking. In 1955, Sutherland and Wark's book (5) was published, in which a large amount of empirical information, especially earlier work of Wark and Cox, was presented. More recently, in 1968, significant contributions have been made by Fuerstenau et al. (6,7) and Majima and Takeda (El. These papers introduced electrochemical explanations of the effects observed with xanthate and cyanide ions.

Jan 1, 1976

By R. Q. Honaker, D. Tao, D. Taulbee, B. K. Parekh

A significant amount of energy exists in the waste generated by the coal and timber industries. In the coal industry, the energy loss is mainly due to the discharge of fine coal to the waste impoundment. Despite the fact that the fine coal has the greatest cleaning potential, dewatering, handling and transportation concerns prevent its use as product in many cases. Likewise, the sawdust generated from wood production has energy value and is used as industrial boiler fuel when the transportation distance is relative short. However, wood waste is often discarded into cumbersome landfills due to uneconomical transportation alternatives. Recent research found that these two waste materials can be combined to provide a high energy fuel of around 13000 btu/lb that can be easily handled and transported to end users.

Jan 1, 2004

By J. F. T. Agapito

Energy West Mining operates the Deer Creek and Cottonwood/Trail Mountain coal mines in the Wasatch Plateau about 40 km (25 miles) southwest of Price, UT. The Deer Creek Mine extracts the Upper Blind Canyon seam and the Cottonwood/Trail Mountain Mine extracts the Hiawatha seam 12 to 36 m (40 to 120 ft) below. Both seams average about 2.8 m (9 ft) in thickness. Cover depths exceed 550 m (1,800 ft) in a large portion of the unmined reserve. Stability problems at Deer Creek are mostly due to coal bursts caused by high stresses associated with deep cover and sandstone channels. Most of the bursts have occurred in gate pillars and, to a lesser extent, at the longwall face and during development. The introduction of a two-entry gateroad system with 9-m- (30-ft-) wide yield pillars has been a major factor in controlling and minimizing gate pillar [ ] bursts (Agapito et al., 1988). However, some bursting began to occur in the 9-m- (30-ft-) wide pillars as cover depths reached 550 to 610 m (1,800 to 2,000 ft). This was due to more rapid and higher abutment loading in areas with very strong roof and stiff floor.

Jan 1, 1997

By J. Moreno, P. Sinton, R. Vogwill

Groundwater models are often used to estimate and optimize dewatering volumes, locations, and rates, as well as water supply production for mines. Projections of future dewatering rates are highly dependent on the conceptual model used as a basis for the numerical model. This paper presents an audit of modeled dewatering rates versus actual data and an examination of the reasons for discrepancies. The setting is a gold mine, in a collapsed volcanic crater breached by the ocean. Mining will occur to about 200m below sea level within a remnant geothermal system. A detailed hydrogeologic investigation was conducted to support dewatering and geothermal depressurization design for future mining operations. These studies included development of a three-dimensional model to simulate heat and density-coupled groundwater flow, using software developed by URS/Dames & Moore. In this paper, the groundwater modeling results prepared 5 years previously by others was audited using operational dewatering data. This model was then extended using the new mine schedule and actual locations for dewatering wells to predict future dewatering requirements. In addition, a comparison between “hot” and “cold” model results was used to assess the need to use a heat-coupled versus a standard groundwater model for dewatering predictions.

Jan 1, 2003

By Phillip O. Tyree, R. A. Metz, Joseph W. Mussey

Bio-epigenetic sulphur deposits occur in Pecos, Reeves and Culberson counties of far West Texas. Sulfate reducing bacteria, utilizing hydrocarbons as energy, transformed gypsum into replacement limestone and hydrogen sulfide. Hydrogen sulfide, retained in the pores of the replacement limestone, was subsequently oxidized by highly oxygenated groundwaters, and native sulphur precipitated. West Texas sulphur was first recognized at surface exposures by William P. Blake, a geologist attached to the Captain Pope Military/ Scientific Expedition of 1854. Attempts were made in the early 1900's to mine these sulphur vent exposures by a retort method, but the ventures met with little success. In 1967, Duval discovered a large sulphur deposit near some of the old sulphur works in Culberson County. Duval also expanded reserves in a small sulphur deposit in Pecos County. The Frasch process, developed for producing sulphur from Gulf Coast salt domes, proved successful in West Texas type sulphur deposits also. However, modifications of the process were necessary to provide economical and efficient sulphur recovery from the varied ore occurrences. West Texas conditions and logistics require the ultimate in productivity to be competitive in the domestic and foreign sulphur markets. Several companies, in addition to Duval, are producing or have produced sulphur in West Texas. As of June 1, 1984, a total of 29.87 million mt (29.4 million long tons) of sulphur had been produced west of the Pecos River. Duval corporation has produced more than 88 percent of that total.

Jan 1, 1992

By M. J. Friedel

The scale-dependent hydraulic properties in a fractured porphyry copper oxide deposit are investigated for relevance to In Situ Leach Mining (ISLM) design. In most well field designs, mine operators assume that hydraulic properties represent a continuous spatial function, or continuum. The problem, however, is that the representative elemental volume, the volume over which hydraulic properties are described as a continuum, is a domain (if it exists) that occurs between end members representing varying degrees of heterogeneity. At the Cyprus Casa Grande mine, transmissivity fluctuations are spatially correlated. This suggests that, at the scale of ISLM, the hydraulic process is heterogeneous, and a typical continuum representation is inappropriate for design. Alternatively, a conditional stochastic approach using the Simulated Annealing (SA) technique is deemed useful for the imaging of heterogeneous hydraulic properties. Specifically, SA preserves transmissivity extremes and spatial complexity, both necessary for accurate conditioning of a flow simulator. Also, the stochastic continuum approach provides an avenue whereby uncertainty (or risk) may be addressed. Currently, the SA weaknesses are that it is computationally time consuming and that uncertainty may increase when simulating under conditions of statistical isotropy. Recognizing that ISLM exerts a dynamic influence on hydraulic properties with time, the mine design should be re-evaluated at intervals throughout the evolution of the leaching process.

Jan 1, 1994

By R. E. J. Putman

The past ten years have witnessed substantial development of electronic equipment for execution of process control functions. The methodology of giving instructions to the data-handling system and the organization of the system, both the equipment and instruction coding taken together, have developed simultaneously. Examples of the technology specific to the mineral processing industry can be cited. Approaches to system design developed for the Pinto Valley concentrator incorporating slave and master data processing have been described by Arney, and his associates (1974). Madge (1970) has described the hierarchical systems employed at the operations of Cominco Ltd. The Kennecott Garfield smelter is controlled by a system of microprocessors linked to a general purpose data processor (Marchant, et al., 1977). These systems provide innovative approaches to couple advancing technical capability in electronic data processing to the objectives of process management. The current state of the art described in this chapter is certain to require updating in the 1980's with the advances in technology anticipated.

Jan 1, 1979