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By Hugh Douglas

This paper discusses the financial health of the U.S. mining industry and its ability to meet the future raw material requirements of this country in the context of resource independence. The title of this paper begs several questions, and three will be raised here. The answers to them will form the basis for discussion. The three questions are: What does one mean by resource independence. How is the U.S. mining industry defined. How is financial health measured.

Jan 1, 1977

By W. H. A. Timm

Lake Dufault Mines, Limited, is located ten miles north of Noranda, Quebec. Following discovery of a copper-zinc orebody late in 1961, metallurgical investigations of diamond drill core were conducted by Lakefield Research Limited during 1962 and 1963. These were followed by pilot-plant tests in May and June of 1964, utilizing underground development ore. Milling operations commenced on August 16, 1964, and reached rated capacity of 1,300 tons per day by October 1, 1964 (Figure 1). Since that time, tonnage was gradually increased to a maximum of 1,400 tons per day and since January 1, 1968, gradually decreased to the present rate of 1,100 tons per day due to an increase in the hardness of the ore. The ore milled from start-up until January, 1968, was mainly massive sulphides, consisting of a complex mixture of iron, copper, zinc and minor amounts of lead sulphides with important associated values in gold, silver and cadmium (aver- age specific gravity 3.8). From January, 1968, until the present, the ore being processed is described geologically as a boxwork of sulphide stringers of chalcopyrite, pyrite and pyrrhotite and some local dissemination in siliceous rhyolite (average specific gravity 2.9) supplemented by the massive copper-zinc ore. The limited size of the orebody and the mining method employed (open stoping by blasthole and slash and bench methods) would have made grade control from the mine difficult and expensive. It was decided to try to cope with grade variations in the mill. The resulting rapid and wide swings in mill heads, hardness and specific gravity have presented many and varied challenges for the mill personnel.

Jan 1, 1970

By Zengwu Zhao, Peng Xu, Jieliang Wang, Qingwei Bai, Xinyang Liu, Xiao Lei

The paper investigates the capture and recovery of rare earth minerals from Bayan Obo ore using superconducting magnetic separation. A finite element model (FEM) was established to study the influence of various factors on the capture of rare earth minerals under a high-gradient superconducting magnetic field. The study aims to improve the efficiency of rare earth mineral separation and recovery.

Oct 1, 2023

By Hal McVey

The logic and importance of marketing in the industrial minerals industry is generally recognized by those of us intimately involved in this industry. The illogical instances where marketing is ignored in evaluating projects or poorly implemented in operations are also well known. The interplay between these two extremes is interesting territory and is explored commencing with a logical progression of a metal mine that became an industrial minerals mine and ending with the most illogical and failure-prone decision common to the minerals industry today. This paper will demonstrate how: 1. A logical progression of marketing expertise can result in previously unseen benefits to a minerals venture. 2. Logic can turn to illogic due to market conditions and price fluctuations. 3. How operations can turn marketing logic into illogical results. 4. Short term "logic" is often illogical.

Jan 1, 1981

By R. Venugopal, V. K. Saxena, A. K. Mukherjee

"Coal, iron and manganese ore samples were exposed to different ultrasonic intensities of 250, 300 and 350 W/L for five minutes and to an ultrosonic intensity of 270 W/L for different time durations of 3, 5 and 7 minutes. The ultrasonically treated samples showed reductions in D80 particle diameters of 6 percent for the coal samples, 5.95 percent for the iron ore samples and 35.63 percent for the manganese ore samples during grinding. The ultrasonic treatment was also observed to assist in reducing ash content in the coal product by 8 percent and to reduce manganese losses in rejects by about 5 percent. Ultrasonic treatment was concluded to be capable of assisting in the comminution of friable ores more prominently than the hard and porous materials.IntroductionComminution is an important unit operation in the mineral-processing, cement-making, powergeneration and pharmaceutical industries. But most of the milling technologies are considered to be energy inefficient, with less energy consumed in real size reduction and most of the energy consumed in the machine. This is more critical for the mineralprocessing industry because of the growing need to exploit lower-grade ore bodies and process rejects (Blazy et al., 1994; U.S. Department of Energy, 2005). Low-grade ores require crushing and grinding to liberate the valuable minerals, which are further separated from gangues by various beneficiation methods such as gravity separation, flotation and leaching. Various studies have been carried out to minimize energy consumption during milling by developing pretreatment methods that can initiate new fractures or improve the fracture density in materials before comminution. These studies were mainly focused on chemical additives; thermal, ultrasonic and microwave treatments; and electric disintegration (Klimpel and Austin, 1982; Norgate and Weller, 1994; Bearman, Briggs and Kojovic, 1997; Gaete-Garreton, Vargas-Hermandez and Velasquez-Lambert, 2000; Kumar et al., 2010; Wang, Shi and Manlapig., 2011, Singh et al., 2012).The fragmentation effect of ultrasonic fields in solids has been investigated since the 1950s, and Gärtner was probably the first researcher who attempted it (Gaete-Garreton, Vargas- Hermandez and Velasquez-Lambert, 2000). Sound waves can propagate in solids in the form of longitudinal waves, shear waves and surface waves, and in thin materials as plate waves.In surfaces, fractures and interfaces, various types of elliptical or complex vibrations of the particles make other waves possible. During ultrasonic-vibration treatment, cavitation bubbles nucleate, grow and collapse, generating microjets, whose impacts on the particles initiate microcracks. The ultrasonic waves can enhance the nucleation, growth and coalescence of flaws, caused by tensile or shear stress. The mechanisms operating in the materials and inducing these stresses have been identified as spall and compression-induced tensile microcracks, nucleating at preexisting flaws. These mechanisms are driven by the shock wave and cavitation effects in the surrounding fluid (Chen, Huang and Shih, 2003)"

Jan 1, 2016

By Jacob Carr, Rebecca Knuth, Emily J. Haas, Marvin Cheng, Bob Bissonette

Many industries, including mining, are experiencing an increase in the use of robotic and other artificial intelligence (AI) systems to improve efficiency, productivity and precision. For example, a 2023 survey showed that mining industry executives wanted to integrate more autonomous equipment to improve productivity and alleviate workforce shortages (Haas, 2024). This feedback was coupled with an increased appetite to advance the types and uses of automation and AI in the workplace. However, there is also an increasing concern about the ways that robotic applications may unintentionally affect worker safety. Humanmachine interaction poses potential risks, especially when industrial robots operate near workers in specific environments (such as drilling, handling and transporting materials, equipment inspection and lifting heavy loads). Research has explored the unintended consequences of introducing new technologies or processes in the workplace to include incidents such as being struck by equipment and challenges around data privacy (Lööw et al., 2019; Khurram et al., 2025; Haas and DuCarme, 2015; Almeaibed et al., 2021; Zio and Miqueles, 2024). More recently, the use of digital twin technologies and simulations (hereafter referred to as digital twin systems) has been boasted as a tool that can help prevent unintended consequences around worker safety by identifying and mitigating risks before a worker completes a task in tandem with a robot or other new technology. Digital twin systems produce a virtual replica of a physical environment or process (Almeaibed et al., 2021; Zio and Miqueles, 2024; Saes, 2024). To this end, this article explores the potential role of digital twin systems in enhancing safety within mining and other similar environments. It will primarily focus on environments where robots and human workers may interact, although digital twin systems can be useful with other technology applications. First, we define digital twins and digital simulation as components of a system. Then, we highlight possible applications of digital twin systems in mining to replicate real-world processes, followed by potential benefits of their use and where more research may be needed.

Oct 1, 2025

By Gerd L. Klinkenborg

Throughout the history of the development of mechanical conveyor systems, it has always been an established condition that loads are received at one end of a single-belt conveyor and discharged at the other end, in a point-to-point, manner. In systems designed for the continuous transport of granular materials, vertical or horizontal changes in; direction have always necessitated two or mope single-belt conveyor units, with a corresponding number of motors, assemblies and attendant mechanical and human or electronic controls. Besides these high-cost factors, every change in the system's direction also calls for a transfer point that involves a drop-back of the material from one level to another with some loss of the material and, in many cases, unwanted additional granulation. Where changes in the location of the discharge point are wanted, the conventional single-belt conveyor must either be replaced by a shorter or longer unit or additional units purchased and installed, or existing units rearranged. This can take days or weeks, and involve special expenditures as well as loss of valuable production time.

Jan 1, 1962

Introduction One hundred years ago, a recent college graduate created the US aluminum industry. He found an economic way to crack the primeval bond that makes the metal so special. Aluminum doesn't "rust" - oxidize progressively. Rather, when exposed to air, it instantly forms a gem-hard but microscopic oxide coating. This seals off oxygen from the metal underneath. Scratch it and the seal reforms instantly. That tight chemical bond is the reason the metal is not found in nature; it exists only as a compound. The bond had to be broken to free the shiny metal. But once it is free, that self-sealing protection, alongside a remarkable strength-to-weight ratio, offers a marvelous material. Until 100 years ago, finding a way to do that economically was a challenge that defied science. Then it was solved, in a remarkable coincidence, on both sides of the Atlantic. And the way was paved for a material that would become the second most widely used metal in the world. Until that time, aluminum was a rare and precious metal. But then two young scientists independently invented the process that took aluminum outside the laboratory and into applications ranging from pots and pans to spacecraft. Discovery of aluminum Other major metals - copper, iron, lead, gold, and silver - had been used for thousands of years. But aluminum was entirely unknown until 1782, when French chemist Antoine Lavoisier suspected its presence. It was not actually discovered until Sir Humphry Davy, in England, detected it in clay in 1807. It was first isolated as a free metal only in 1825, by Denmark's Hans Christian Oersted. For years, laboratory methods yielded aluminum only in tiny amounts costing about $1200/kg ($545 per lb) - $13,333/kg ($6000 per lb) in today's dollars. Methods developed by French scientist Henri Sainte-Claire Deville in 1854 cut the cost to about $200/kg ($90 per lb). King Frederick VII of Denmark had a helmet of aluminum and gold. And Emperor Napoleon III of France reportedly served his most exalted guests at a state dinner with aluminum plates. He left the lower ranks to dine from pure gold. Deville and others continued to reduce production costs. But the price of aluminum still rivaled silver - $31/kg ($14 per lb) versus about $35/kg ($16 per lb) for silver. Then in 1884, a 2.8-kg (6.25-1b), 230-mm-tall (9-in.-tall) aluminum pyramid was cast as the tip of the Washington Monument. It was probably the first architectural use of aluminum. And it is still there after more than a century. The attractive properties of aluminum were obvious: it is lightweight but strong, conducts heat and electricity, reflects light and other electromagnetic radiation, and resists corrosion. But its commercial promise was blocked by its cost. In 1885, the price of aluminum was $17.70/kg ($8 per lb). It stayed there for the next couple of years until the Hall-Heroult process brought it down sharply. Hall-Heroult process lowers aluminum costs The characteristic that kept aluminum hidden so long continued to thwart chemists. Aluminum clings to oxygen so tightly that it is never found as a free metal in nature, and it is hard to break that bond chemically. The best chemical methods of the 1880s required sodium, and sodium itself was expensive. At Oberlin College in Ohio, chemistry professor Frank Fanning Jewett advised his students that anyone who could make aluminum inexpensive would do humanity a favor and get rich as well.

Jan 3, 1987

By Colleen A. M. Gibbs

On July 30, 1979 New Council on Environmental Quality (CEQ) regulations for implementing the procedural provisions of the decade-old National Environmental Policy Act went into effect. These new regulations replace approximately seventy different sets of agency regulations, providing some uniformity throughout the Federal government in the conduct of environmental reviews and preparation of environmental impact statements (EIS). This attempt by the Federal government at a general improvement in the preparation and quality of EIS's presents an opportunity for the mining industry to evaluate how the EIS process for mining proposals can be expedited. The environmental impact statement is often a key element on the critical path of a major mining project. Preparation of the EIS is ordinarily the responsibility of the Federal agency with primary decision-making authority over the project. Still, the proponent, i.e. the mining company, can play a major role in the process and have a major impact on the timeliness and adequacy of the effort. Typically, the Proponent will conduct (or will hire consultants to conduct) environmental baseline studies of, for example, air quality, wildlife, geology, water quality, vegetation and archaeology. These studies are then compiled into an environmental report and submitted to the agency. The agency verifies the data and incorporates them into the environmental impact statement.

Jan 1, 1979

By S. Rajan

Familiarity with NEMA standards and the influence of the power supply on the motor-load system permits the user to make the necessary decision as to whether a standard or special motor is needed for his particular application. This paper highlights the more important aspects of NEMA standards for ac induction motors from the application engineer's standpoint and the effect of the power supply on motor characteristics.

Jan 1, 1975

By Douglas J. Lacke

1974 marked the start of a new era for Climax Molybdenum Co., a division of AMAX, with the initiation of an open pit operation above the existing successful underground block panel caving mine. A number of problems posed a challenge to the Climax open pit. Highly fractured rock, old mine workings, permafrost, and more than 7.6 m/a (300") of snowfall forced changes in normal operations. Final pit wall design was altered. Production bench heights were lessened due to old workings. These and other modifications contribute to a highly successful open pit operation.

Jan 1, 1981

By Rick A. Croote

The objective of the Cerrejon Coal Project is to mine and export a minimum of 15 million metric tons per year of bituminous coal from the Guajira Pennisula in Colombia, South America. Major components of the project will include an open pit mine, 150 km railroad, marine terminal for storage and shipping, and accommodations for the support personnel. This paper primarily reviews the coal handling facilities at the mine and port which will include crushers, conveyors, silos, stacker/reclaimers, and a shiploader. Of special interest is the design concept for unloading bottom-dump railcars, a programmable controller control system with automatic stacking and reclaiming, a linear-type shiploader, and 2.4m wide conveyors running at 5 m/sec.

Jan 1, 1983

By Y. Luo

Surface subsidence process due to underground coal mining often has the potential to cause problems to buried pipelines. In this paper, a technique for assessing the stress level on a subsidence-affected pipeline is introduced. The main contributors for the stresses on the pipelines are identified. Mitigation techniques for reducing the stress on the pipeline have been proposed and successfully tested.

Jan 1, 1997

By K. V. K. Prasad

Forecasting mined grade variability from exploration information is a challenging task in mine planning. For effective planning of activities such as workplace scheduling, ore grade quality control etc. development of realistic numerical/simulation models of in-situ variability from exploration information is an essential first step. Geostatistical conditional simulation (GCS) is one of the well known methods to develop these simulations. Recently, stochastic fractal models based on the assumptions of scale-in variance and self-similarity have been used for developing simulations of several natural phenomena. It has been suggested that these models might permit generation of short-scale variability information from exploration data with greater fidelity when the data satisfies the attendant assumptions. In this paper the stochastic fractal models are reviewed and their relationship to geostatistical variogram models is examined. A comparison of the two simulation techniques has been per-formed using coal sulfur data from a mined out coal property. The results of this comparative analysis are also presented in the paper.

Jan 1, 1992

By H. P. Hatch

Ash is a material that many people leave to nature to handle. Others sometimes sweep it under the rug to be disposed of by someone else. In our business we cannot do either. In fact the American Electric Power System spends many millions of dollars in plant investment costs to collect the material, and then many more millions to dispose it. In 1965 alone the coal fired steam generating plants in., the AEP System produced approximately 2,400,000 tons of ash, enough to fill 40,000 coal cars which would extend as a single train across the entire states of Ohio and Indiana. Even though our present ash production is large, this is only the beginning when we forecast the future growth of our system. By 1980 it is estimated that our generating capacity will expand to about three times its present size, and with coal as our primary source of fuel our ash production will increase proportionately to about 7 million tons a year.

Jan 1, 1966

By Ralbern H. Murray

Typical First Year Selling Price Strip Mined Western Sub-Bituminous Coal Based [Fixed Capital (1) $600 MM Construction Loan Interest $100 Working Capital $ 30 Start-up Costs $ 30 Total Capital Requirement $760 MM Annual Costs (First Year) $M/Year Coal (2) 443,550 Operating Costs(3) 53,000 Depreciation(4) 36,500 Interest(5) 45,220 After Tax Profit(6) 34, 200 Federal Income Tax (48% Rate) 31, 570 Gross Revenue Required 245,040 (Less) By-Product Sales (18, 000) Net Revenue Required 227, 040]

Jan 1, 1975

By V. J. Hucka

Coal, which was discovered in Utah in 1849, covers about 18% of the total area. Production in 1981 vas more than 14 million tons. However, some Utah coal mines are quite gassy. If longwall face technology is applied, then a release of a high volume of methane may be expected during the mining process. Investigations on methane content have been made by use of an isothermic bubble desorbometer. The desorbable methane content of 5 m3 to 16 m3 of methane per ton of coal mined has been determined.

Jan 1, 1983

By J. C. Gathje

The Robinson copper ores were mined for many years from pits containing varying ore grades, sulfide and oxide ore types, and differing mineralogy. The ores also contain gold and molybdenum values, and their recoveries are an integral part of the flowsheet development. Metallurgical responses were characterized using a standard flotation procedure. Further studies investigated primary and regrind particle sizes, reagents, and other variables. The metallurgical testing was supported by mineralogical studies. Results demonstrated a high degree of metallurgical success for flotation. Final copper concentrates ranged in grade from approximately 28 to 30% copper and copper recoveries were 89 to 95% based on laboratory and pilot plant data.

Jan 1, 1992

By Juan Andres Jarufe, Carlos Cifuentes

Numerical modelling has been extensively used to estimate plastic displacement in faults and rock mass surrounding mine excavations. Particularly, for fault slip seismicity, modelled plastic displacement is usually utilized to estimate seismic potential, however these methods assume that all the displacement caused during an specific simulated excavation step, is released as a single event at each step. This representation corresponds to a conservative estimation since rock mass displacement does not occur as one single event but as an exponential distribution of many small displacements and a few large ones. When displacement is expressed as seismic magnitude, this exponential distribution is addressed as the Gutenberg Richter (GR) relationship. This paper present a method to decompose the results from numerical models into a distribution of seismic events The reconstruction of the GR relationship from modelling displacement permits not only a more realistic approximation of the expected maximum magnitudes but also provides a tool to develop a probabilistic estimation of the maximum possible magnitudes.

Apr 26, 2022

By Raj K. Rajamani, Samira Rashidi

High pressure grinding rolls have been utilized in various operations during the past four decades, simply due to their inherent mode of breakage that offers metallurgical benefits with pronounced energy reduction. For every new application, wear and in particular roll surface wear protection has always been the focal point of HPGR trade-off studies. Wear remains an important issue throughout a mine’s life given inevitable variations in the ore deposits properties. Hence, the capability of continuous scanning of rolls provides ample information about any deviations in the design values as well as their effect on the wear pattern. In part I of this manuscript, we present the feasibility of in-line scanning of roll surface in a 200 × 100 mm lab-scale HPGR. First, the in-line scanning was developed in a mock-up roll and then the scanner was moved to the laboratory-scale HPGR. We present the choice of scanners and the methods adopted to achieve high-level accuracy of determining wear. Even though we planned for micron-level precision of scanning, the inherent variability in shaft rotation was higher than the variability in the roll diameter due to wear. The hundred-kilogram mass processed in the HPGR was not sufficient to create enough wear that is discernible to the in-line scanner. Yet, the method tested is a promising avenue for inline scanning of HPGR rolls.