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By Paul G. Mahoney

The original Radum aggregate plant, built by Henry Kaiser in 1931, is the oldest of the nearly 200 individual operations established by the Kaiser companies. Since that time it has been producing aggregate products primarily for the San Francisco Bay Area. Currently, and for many years, this plant has been listed as the Nation's No. One aggregate producer. Early this year a new $10,000,000 facility went on line replacing the old plant. Construction of the facilities was performed under the direction of Kaiser Engineers construction management teams. The existing plant continued to operate without interruption during the entire construction period.

Jan 1, 1970

By Brett Schug, Caelen Anderson, Sohail Nazari, Carlos Cristoffanini

"The Haile gold mine in South Carolina is increasing the automation level of its processing plant in order to improve operational stability. One step toward this goal is the application of a digital twin concept to provide virtual instruments. Haile has engaged Andritz to implement virtual instruments at its grinding area hydrocyclones and at its tailing thickener underflow pump. These virtual instruments provide density values in a traditionally difficult location for reliable slurry density measurement. The digital twin is a first-principles integrated design engineering with advanced simulation (IDEAS) simulation model, connected in real time to the control system. Results have been promising, with the virtual instrument values matching the physical instrument under normal operating conditions and showing better prediction under upset conditions. Haile plans to use the virtual instruments as optional process control parameters.OceanaGold’s Haile gold mine is located near Kershaw, SC, about 80 km (50 miles) southeast of Charlotte, NC. This location was first mined in 1827 and has produced gold through several operating periods since then, including a heap leaching operation from 1985 through 1992. In October 2015, OceanaGold acquired Romarco Minerals, the previous owner of the Haile operation.The current operation began in 2017 as an openpit mine with additional underground resources. The nameplate throughput is 5,760 t/d (6,350 stpd) ore, and 2017 production was 3,345 kg (118,000 oz) gold, with 3,968 to 4,384 kg (140,000 to 155,000 oz) gold expected in 2018. Proven and probable reserves exceed 85 t (3 million oz) gold at a grade of 2 g/t (0.06 oz/st) gold. The process, as shown in Fig. 1, includes a primary jaw crusher, comminution with a semiautogonous grinding (SAG) mill and ball mill circuit, flash flotation, rougher flotation, regrinding, pre-aeration, carbon-inleach leaching, carbon elution and regeneration, cyanide recovery, electrowinning and refining. The Haile operation’s inaugural gold pour took place Jan. 20, 2017. Mine life is expected through the year 2030."

Dec 1, 2018

By Manuel Bernales, Aldo Leon, Alexandra Carlier, Bern Klein, Andre Xavier

Mining companies and governments at both the local and national levels recognize that Participatory Environmental Monitoring and Surveillance Committees (PEMSC) are necessary mechanisms for meaningful engagement at the community level. In many cases, PEMSCs are established as volunteer initiatives by mining companies or by the mining communities themselves. In Peru however, they can also be recommended by the government as way to address social conflict. Most PEMSCs are launched while a mine is in operation and have the objective of monitoring both water quality and quantity. Many established committees are currently evolving and adopting a more comprehensive approach, as well as expanding their initial scope from a river or micro-basin focus and watchdog agenda, to a broader regional integrated resources management view. This paper examines the origins of Participatory Environmental Monitoring and Surveillance Committees in Peru. It also discusses the typology of these committees, and the scope of their work. Furthermore, it looks at the challenges faced by these committees, as well as existing opportunities for mining companies, governments, and civil society. Finally, this study presents a governance model that could contribute to the long-term existence of these committees. This discussion is further informed by the results of a national workshop that took place in October 2016 in Peru, in which over 200 representatives from 22 monitoring committees, government and mining companies participated.

Jan 1, 2017

By D. Bahrami, W. K. Asante, G. L. Danko

It is prudent to interpret atmospheric monitoring signals in real time for checking the safe limits of the air conditions in underground mines. In gassy mines, real-time evaluation increases the safety of operations. In all mines, continuous monitoring and evaluation contributes to maintaining air conditions within healthy and safe limits. Signal interpretation for safety conditions in mines is difficult for many reasons. An increase in hazardous contaminant concentrations can be predicted by signal pattern recognition, root cause analysis of rapid changes toward deterioration, and forward prediction in time using algorithms and numerical models. The paper describes an early warning system for analyzing monitored signal patterns continuously in real time as well as forward predicting the various environmental and working conditions to recognize dangerous trends that may affect safety and health in underground mines. A dynamic, numerical ventilation model with heat and gas contaminant simulation components is used for the analysis of atmospheric data. Methods and test results are discussed with numerical examples for signal propagation prediction. Several mine examples are studied using controlled, synthetic data for malfunction simulations to evaluate time delays between the detection time of suspicious signal trends and the time of dangerous threshold crossing marking an accident scenario. Delay time is found in the order of 20 min in the examples, signifying the useful time period for preventive intervention between EWS warning and the likely breakout of a following accident.

By D. Bahrami, W. K. Asante, G. L. Danko

It is prudent to interpret atmospheric monitoring signals in real time for checking the safe limits of the air conditions in underground mines. In gassy mines, real-time evaluation increases the safety of operations. In all mines, continuous monitoring and evaluation contributes to maintaining air conditions within healthy and safe limits. Signal interpretation for safety conditions in mines is difficult for many reasons. An increase in hazardous contaminant concentrations can be predicted by signal pattern recognition, root cause analysis of rapid changes toward deterioration, and forward prediction in time using algorithms and numerical models. The paper describes an early warning system for analyzing monitored signal patterns continuously in real time as well as forward predicting the various environmental and working conditions to recognize dangerous trends that may affect safety and health in underground mines. A dynamic, numerical ventilation model with heat and gas contaminant simulation components is used for the analysis of atmospheric data. Methods and test results are discussed with numerical examples for signal propagation prediction. Several mine examples are studied using controlled, synthetic data for malfunction simulations to evaluate time delays between the detection time of suspicious signal trends and the time of dangerous threshold crossing marking an accident scenario. Delay time is found in the order of 20 min in the examples, signifying the useful time period for preventive intervention between EWS warning and the likely breakout of a following accident.

By W. C. Hellyer

The Granduc ore body is located beneath glacial terrain on the borders of British Columbia and Alaska, some 600 miles from Vancouver and 30 miles from Tidewater at Stewart, B. C. The concentrator and attendant facilities are located in wilderness country at an elevation of 2500 feet. The average annual snowfall is 65 feet. Surface facilities and ore body are linked by a 10 mile railroad haulage tunnel. This copper property has been developed by Granduc Operating Company on behalf of Newmont Mining Corporation and American Smelting and Refining Co. First production started in November, 1970. In August, 1966, Granduc Operating Company awarded an engineering and construction management contract to McKee-Swan Wooster, a joint venture of A. G. McKee of Canada and Swan Wooster Engineering Company Limited, to design a concentrator to treat approximately 7000 tons of ore per day. The isolated location of the Granduc ore body indicated comparatively high freight rates on consumable items of concentrator supplies such as reagents, grinding media, etc. A firm flowsheet for the flotation of the Granduc ores having been developed by the Danbury laboratory of Newmont Exploration Limited, attention was devoted to means of reducing operating costs. One obvious method was to reduce or eliminate the costs of steel grinding media by employing some form of autogenous grinding. two pilot plant operations were carried out at the facilities of Lakefield Research of Canada Limited, in which autogenous grinding of Granduc ores was investigated. The results of these investigations led to the selection

Jan 1, 1972

By P. Davis

With new mineral deposits found in areas of difficult terrain, and annual production capacity increasing in mines over the last decade, the aerial ropeway is proving to be a viable, economic method of transportation from mine to processing plant. Of the more conventional designs, a bicable ropeway is more suited to difficult country than the simpler monocable. The bicable, however, does have limitations in the difference in levels it can accommodate in one section at a given capacity. This is noticeable where hilly terrain and high capacity imposes a limit on the length of each section. Increasing the number of sections for a relatively short conveying distance tends, in the case of conventional bicable, to unbalance the normally favorable economics of the ropeway. In addition to analyzing hauling rope stresses, other areas have to be considered when looking at high capacity ropeways. Bucket capacity, speed, and the wheel load on track ropes are examples. These and other factors led British Ropeway Engineering Co., of Sevenoaks, Kent, UK, to produce the twin-track system. Using twin track ropes, larger capacity buckets, and, if the height differential warrants, the installation of twin hauling ropes, BRECO produced a ropeway design for areas of hilly terrain and at higher capacities than had been considered suitable for aerial ropeways. Designs have been produced for systems handling 1.5 kt/h (1,650 stph), and the potential exists for expansion to above 2 kt/h (2,200 stph). The arrangement of ropes provides high stability of the cars and is especially suited to areas where high winds occur during normal operation. This development allows the aerial ropeway to be applied economically in difficult areas and at the increasingly high capacities demanded by engineers. Ropeway Transports Limestone to Sudan Cement Plant Maspio Cement Corp. of Atbara, Sudan, will soon use an aerial ropeway to deliver its entire limestone requirement 20 km (12 miles) from quarry to plant. The Atbara plant is located north of Khartoum, near the east bank of the Nile River. The quarry is west of the river, in hills rising from flat desert country. The original transport system was a 24-km (15-mile) railway from the quarry to the west bank and a monocable ropeway that crossed the Nile and continued to the fac¬tory, a distance of about 2.5 km (1.5 miles). This original ropeway had a capacity of 60 t/h (66 stph). With the extension of cement-making capacity in the late 1970s, 2.5 kt/d (2,755 stpd) of limestone was required and a new mono-

Jan 3, 1984

By H. Fayed

Two-phase (water and air) flow in a self-aspirated WEMCO flotation machine has been investigated using computational fluid dynamics (CFD). The geometric model is a replica of a 300 m3 cell. A 72-degree sector containing two blades of the ten-blade rotor has been modeled and periodic boundary conditions are applied in the circumferential direction. Simulation of a sector of the machine allows acceptable resolution of the mean flow field using 4x106 grid points. The flow is modeled by Euler-Euler approach, and transport equations are solved using a commercial software ANSYS-CFX5 [1]. Unsteady simulations have been performed. In a self-aspirated machine, airflow rate is not known a prior; it is an output from the CFD simulation. Uniform mean bubble diameter of 0.7 mm has been specified as an input for the simulation. Air flow rate and power consumption have been monitored with time, and results indicate a stable operation. Air volume fraction contours and velocity field in different regions of the machine are presented and discussed.

Feb 27, 2013

By R. Hogg, S. Chander

An overview of various physical and interfacial characterization methods for use in mineral processing is presented in this paper. The availability of a large number of characterization techniques and commercial instruments requires that the reliability and limitation of each be carefully examined. The choice of a method may depend upon the manner in which the information is to be used, for example, in development of new processes, plant and process design, plant control, problem solving, etc.

Jan 1, 1987

By William A. Vogely, John E. Tilton

INTRODUCTION Mineral commodities are normally separated into three generic classes-metals, nonmetals, and energy minerals including oil and gas as well as the solid fuels. Metals, the focus of this chapter, encompass a large number of different substances. The U.S. Bureau of Mines, for in- stance, has commodity specialists following trends in over 40 metal products of importance to the country's economy and well being. Ranging from aluminum to zirconium, the metals display an incredible degree of diversity. Some such as lead are heavy, others such as magnesium are light. Some such as copper are good conductors of electricity. Others such as silicon are semiconductors. Mercury is found in liquid form, while some metals melt only when heated to extremely high temperatures. Iron and steel, aluminum, and copper are consumed in particularly large tonnages in a multitude of end uses, while many minor metals are needed in only small amounts in a few highly specialized applications. The use of some metals can be traced back into history for millennia, indeed back to the bronze and iron ages, while the commercial consumption of aluminum and other newer metals is less than a hundred years old. Some metals are extracted from large open pits, others are dug out of deep underground mines, and still others are processed from the sea. Mining and processing can be relatively uncomplicated and inexpensive, though in most instances highly sophisticated technology is necessary and the costs are high. Some metals are produced mainly as byproducts of other metals. Some are recovered in large quantities from the scrap of obsolete equipment and demolished buildings. Some are mined in only a few locations and traded worldwide, others are produced in many different countries. Some are sold by numerous firms at fluctuating prices determined on competitive commodity exchanges, others are produced by only a handful of firms and sold at stable producer-prices. This diversity makes the metals interesting, indeed fascinating, to study. Yet, it also poses problems, for each metal in its own way is unique. There is no general model or economic analysis applicable to all metals. Rather each must be considered individually, so that the analysis or model takes explicit account of its particular features. This means that a single chapter cannot begin to cover comprehensively the economics of all metals, and no attempt to do so is made here. Instead, we will concentrate on illustrating the usefulness of relatively simple economic principles, particularly those associated with supply and demand analysis, in understanding the behavior of metal markets. The next section begins by exploring the nature of metal demand. It is followed by an investigation of metal supply- from individual product production, from by- product and coproduct production, and from secondary production. The final section then illustrates the usefulness of the concepts introduced in earlier sections by using them to analyze

Jan 1, 1985

By D. Govender

In recent years, economies of scale have continued to drive copper projects to larger throughputs to offset depleting lower grade resources. A decade ago, there were only a small number of projects that stretched beyond 100 kt/d (110,000 stpd) throughput rates. Today, and moving forward, virtually all the major copper projects are sized beyond this, with throughput rates up to 250 kt/d (275,000 stpd) now under evaluation for a number of key projects in Chile and Peru. This paper explores the development from the 160 m3 (5,650 cu ft) flotation cells, through to the 257 m3 (9,076 cu ft) cells and to the current 660 m3 (23,380 cu ft) machines. The contributions of specific copper concentrators to this growth phase are reviewed in this article. The historical basis of flotation machine scale-up is also briefly discussed. Metallurgical results as well as layout, maintenance and operational aspects are highlighted.

Feb 1, 2014

By Peter Zhang, Daniel Su, Mark Alexander Van Dyke, Heather Dougherty, Bo Hyun Kim

The National Institute for Occupational Safety and Health (NIOSH) has been evaluating longwall mining-induced strata fractures and their impacts on casing stability of Marcellus shale gas wells located in longwall pillars. To understand the extent of overburden fractures after longwall mining, NIOSH researchers drilled a post-mining corehole into the fractured strata above the Pittsburgh coal seam longwall gob. Knowing the extent of the fracture zone height will help gas operators minimize the hazards of drilling into longwall gobs. The core was retrieved from the surface down to the top of the gob void. Various fractures were encountered varying from 35 to 64°, depending on lithologic type and relative closeness to the gob. The longwall panel dimension was 457-m wide and 3657-m long, in which the total fracture zone height was found to be at 141 m and the hydraulic connected fracture zone at 87.7 m above the top of the Pittsburgh seam. In addition to core drilling through the gob, FLAC3D modeling was also used to simulate the formation of fracture zone and the orientations of longwall-induced fractures. This study provides much-needed evidence on the fracture zone of Pittsburgh seam longwall gobs to help gas operators avoid potential hazards associated with drilling through highly fractured zones in longwall gobs.

Jun 9, 2022

NIOSH is conducting research to reduce the silica dust exposure of workers at surface coal mines. One goal of this research is to evaluate the relationship between drilling parameters, rock strata and silica dust generation. This study involved measuring blast hole emission dust from a rotary drill rig which required sampling high concentration dust (>400 mg/m3) for silica content in a high velocity airstream. To measure dust initially, traditional sampling methods using personal sampling instruments were attempted in and around the shroud area of the drill with no success. Variations in the dust cloud concentrations under the shroud, the condition of the shroud and its orientation over the hole, and ambient air conditions prevented consistent and accurate dust measurements from being obtained. Amore consistent dust cloud is necessary for accurate measurements. An area of the drill’s dust collector system that consistently draws the emitted airborne dust from the hole is the collector tube. This tube connects the drill collector’s vacuum and dust filtration system to the shroud area. Assuming the collector system is working as designed, sampling from the collector tube would enable more consistent and accurate samples to be taken. However, current personal samplers are unable to sample in the concentrations and velocities experienced in the collector tube, so another method had to be devised. To achieve the desired results, an in-stack cascade cyclone was used. Preliminary field testing shows positive results.

Jan 1, 2003

By Robert L. (Original by) Llewellyn

Many of the problems that occur in the preparation plant originate from practices in the mine. Impurities in raw coal can be in the seam itself or from extraneous material taken in mining from the roof or bottom. In the case of underground mines, the choice of mining equipment will affect the size consist and the amount of extraneous material included with the coal. Also, governmental regulations concerning the degree of rock dusting, gobbing underground, and cleanup have increased the dirt in raw coal. Sulfur dioxide emission standards, on the other hand, are pressuring the coal industry to clean coal more thoroughly. Coal supplied for coking purposes is nearly all upgraded by washing, while for the largest market, electric power generation, a high proportion is shipped as a raw product with processing, in whole or in part, only necessary when excess impurities are mined with the coal. This chapter will deal primarily with plants that process or wash coal to some extent (Fig. 1) and only incidentally with mines shipping raw run-of-mine coal crushed to a top size of, usually, 51 to 102 mm (2 to 4 in.), with little, if any, other treatment.

Jan 1, 1981

By R. A. Hevia

Florida Power and Light is the fifth largest investor-owned electric utility in the country. It has a service territory that covers 35 counties, or 28,000 square miles, 2.5 million customers, and serves 5.6 million people. The total installed capacity is 13,470 MW, generated by four nuclear units, 36 oil and/or gas fired units, and 48 gas turbine units. Traditionally, FPL has been an oil-based utility. In 1979, this dependency on oil became obvious when 42 million barrels of oil were burned during the year. At that time, it was also projected that, based on the current estimates of customer growth and available generation capacity through 1990, FPL's residual fuel oil consumption would increase from the 1979 level of 42 million barrels (6.7 million m3) per year to approximately 55 million barrels (8.7 million m3) per year by the mid-1990's. Concern over this was further aggravated by the fact that it was difficult to estimate both the price and quantity of fuel oil that would be available over the next decade since changes in the world market, decisions by oil producers and refiners, and international political developments would all affect the availability of oil. Also, at that time, the price of residual fuel oil had increased drastically, and there was no reason to think that these prices would soon stabilize. Thus, oil back-out became a primary objective of FPL and since then, FPL has been actively investigating ways to decrease fuel oil consumption.

Jan 1, 1985

It had been more than a decade since this many booths were occupied at an SME Annual Meeting, but at the 2010 meeting in Phoenix, AZ 630 booths were sold to 470 vendors from the entire spectrum of the mining and minerals industry. Exhibitors such as Metso, FLSmidth, West-Tech, ABB, NIOSH, Eriez and Resource West took their usual prominent places on the exhibit floor and were joined by newcomers such as tunnel boring machine manufacturer Herrenknecht AG, Frontier Kemper, the International Society of Explosive Engineers and more than 100 other first-time exhibitors. On the floor, one could find everything from a new pair of boots to a new career in the recruitment pavilion where some of the biggest companies in mining (Barrick Gold, Freeport-McMoRan, Newmont Mining, etc..) set up shop. The following is a look at some of the companies and products that were on display at the 2010 meeting. For information about displaying at the 2011 annual meeting in Denver, CO, Feb. 27 to March 2, contact exhibits@smenet.org.

May 1, 2010

By Andrew Hall

Many Latin American countries are facing a scarcity of water. As such, infrastructure decisions are quite different from those made in parts of the world that experience a positive water balance. In the latter case, the water treatment approach tends to be ?treat and discharge.? For Latin American regions facing the challenges that go with a negative water balance, the focus is on resource optimization and reuse. Historically, the water challenge has had a significant impact on economic development in Latin America, especially in sectors such as mining, where water usage is high. At the same time, countries such as Chile and Brazil are major development targets for mining and oil and gas operations. Given the water supply challenge, industry is increasingly turning to technologies and processes that maximize water recovery and reuse. With sulfide precipitation and ion exchange water treatment processes for example, it is possible to treat and recover more than 99 percent of water for reuse onsite. These technologies have been applied successfully in other regions of the world where water conservation practices are essential to economic survival.

Jan 1, 2012

By John A. Herbst

Flotation control systems in use around the world today owe their effectiveness to the coordinated use of appropriate sensors, control hardware, and decision-making strategies. This paper traces the development of these three main elements of the "control triangle" over time. Based on an analysis of recent developments, it is concluded that improvements occurring in instrumentation have basically been evolutionary, while advances in hardware and strategies have, in contrast, been revolutionary. An attempt is made to extrapolate developments in each of the "control triangle" elements into the future in order to make a projection concerning flotation control systems for the next millenium.

Jan 1, 1999

By J. F. Peterman, M. C. Roberts

The success of any industrial mineral project requires an accurate forecast of the demand fir the material as well as accurate projections of costs and prices. This paper develops a general method of predicting mineral requirements and applies it to the case of graphite. The basic method is to explain graphite consumption in each of its major uses by the output and manufacturing technology of the using industry. Once these underlying factors are determined, they can he projected to establish future requirements. This forecast is critical to the evaluation of a new source of supply, such as the graphite resources of Upper Michigan.

Jan 1, 1990

By D. F. Scott

Spokane Research Center personnel have been investigating the use of seismic tomography to monitor the behavior of a rock mass, detect hazardous ground conditions, and assess the mechanical integrity of a rock mass affected by mining. Seismic tomography can be a valuable tool for determining relative stress in deep (> 1220 m) underground pillars. If high-stress areas are detected, they can be destressed prior to development or avoided. High-stress areas can be monitored with successive seismic surveys to determine if stress decreases to a level where development can be initiated safely. There are several benefits to using seismic tomography to identify high stress in deep underground pillars. The technique is reliable, cost-effective, efficient, and non-invasive. Also, investigators can monitor large rock masses, as well as monitor pillars during the mining cycle. By identifying areas of high stress, engineers will be able to assure that miners are working in a safer environment.

Jan 1, 1997