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By C. D. Keith

Erie Mining Company, a pioneer in the iron ore pelletizing industry, has continued to develop methods and equipment to improve cost and quality. Under the management of Pickands Mather & Co., this property, owned by Bethlehem Steel Corporation, Youngstown Sheet and Tube Company, Steel Company of Canada, Ltd., and Interlake, Inc., has initiated a number of operating improvements for the taconite industry. One of the most noteworthy of these, which is applicable to the entire mineral industry, is the principle of fine screening with rappers (FSR). Erie's original efforts in the field of fine screening, which date back to 1961, were described in the April 1967 issue of the MINING ENGINEERING magazine. In that same month, Erie placed into operation a full scale PSR and regrind plant addition, capable of processing 10.3 million long tons of iron ore concentrates, produced by conventional taconite grinding, classification, and magnetic separation methods. Since this first successful commercial operation of the PSR principle et Erie, it has been applied in eight other iron ore beneficiation plants end is being tested by other U.S. and foreign companies. In addition to the use of PSR units at Erie Mining Company, Pickands Mather has applied PSR to other of its managed properties end to projects under development. This paper covers these applications as well as a now application at Erie Mining Company.

Jan 1, 1971

By D. W. Alexander

In 1993, CONSOL began investigating new methods of permanently filling coal mine shafts, which after ventilation is stopped, may contain a potentially hazardous atmosphere. Fill materials such as fly ash/cement can be pumped, are non-combustible and non-incendiary but tend to flow into the mine entries. A non-flowable mixture has been developed that minimizes the volume of fill used. The paper presents our recent shaft filling experience including fly ash material properties, mix designs, field problems, placement success, and gas testing techniques.

Jan 1, 1996

By A. Noble

"In coal and mineral processing, several numeric parameters are used to quantify the separation performance of unit operations. For density-based separations, the partition curve is used as the starting point for many stages of diagnostic analyses. The curve is often quantified by its midpoint slope sharpness, and this single value is subsequently used for technical evaluation, benchmarking, and comparison. While this analytical approach does depict misplacement by relative density class, it inherently prioritizes middling separation and does not consider process economics or the micro-price value of individual classes. Alternatively, the organic efficiency parameter does consider process economics; however, it does not reveal information on the root cause of lost revenue or misplacement. In this paper, a new analytical approach is introduced which reconciles the technical misplacement data derived from the partition curve with the economic data derived from micro-pricing. The result is a new analytical procedure which reflects a better use of performance data. INTRODUCTION Partition curves are commonly used in the characterization, evaluation, and simulation of various physical separators. In mineral processing, partition curve analysis is routinely applied to hydrocyclones, screens, and density separators. Graphically, the partition curve depicts the recovery of particles as a function of a physical property on which the separation is based (e.g. particle density, size, magnetic susceptibility, etc.). Given the probabilistic nature of many real separators, the partition curve often exhibits a characteristic “S” shape (Fig. 1), similar to a cumulative normal distribution. Other geometric features of the curve are also depicted in Fig. 1, including the high and low closeout (or bypass) values, the midpoint slope, and the separation cut point (property value with 50% recovery). Partition curve analysis was originally proposed to evaluate coal washability (Tromp, 1937). Given the limited computational resources at the time, the analytical methods relied heavily on graphical construction and interpretation of the curve. Owing to the simplicity of the calculation and interpretation, many of these graphical approaches are still widely used for performance analysis today. The most common calculations are based on the slope of the partition curve at the midpoint. Increased slopes correspond to enhanced separation performance, since a perfect separation exhibits a stepwise transition from 0 to 1 at the desired cut point (i.e. an infinitely large slope). One common formulation of this slope, the Ecart Probable (Ep), is derived by evaluating the slope between the 25% and 75% recovery points:"

Jan 1, 2015

By D. Wenstrup, K. Perry, J. Hatfield, P. Sainato, B. Lusk

Concrete-infused cloth is used in several civil and mining surface applications whose circumstances are similar to some of those in underground mining. A feature of this material is that it cannot be overhydrated. In underground conditions, however, the excess supply of water to the cloth for hydration could lead to muddy and potentially unsafe working conditions, as well as resource wastage by supplying more water to the construction site than is needed. The objective of this study is to verify the water-to-cloth ratio and study the effect of hydration level on the strength of the Concrete Cloth product. We found that the strength increases with increased hydration up to a 1:2 water-to-cloth ratio by weight, after which the strength holds steady regardless of additional hydration. This confirms the 1:2 water-tocloth ratio by weight for hydration and confirms that strength is retained even if the cloth is excessively hydrated.

Jan 1, 2014

By James J. Fallon

I'm glad this meeting is being held in New York. First, because the city is close to my home in New Jersey, only 35 minutes from Times Square ..... if I were to come to Times Square between two and three in the morning. Otherwise it takes two hours. But even more important is the fact that all of you good people from around the country and around the world will enjoy the unique experience of that warm friendly atmosphere in the greater metropolitan area, something that you won't see any place else on the face of the earth. Seriously, the greater metropolitan area has been a large part of my industrial, cultural and spiritual experience. There are many aspects of it which I find disagreeable but on net I would rather live in this area, at least for the time being, than any other area of the United States. As a consultant I find contact with financial institutions, corporate headquarters, information sources and a great many production and research facilities a valuable asset to my activity.

Jan 1, 1985

By W. K. Pincock

Accident prevention can be portrayed as a science that deals with facts and natural phenomena and must be dealt with in the same manner as any other operating problem. Safety at the Copper Queen Branch dates back to 1913 when a Safety Organization was started and rules formulated for underground mining. Since then the mining industry has made substantial progress in the elimination of accidents and when the Lavender Pit was started in 1951, it adopted the general plan in use at all Phelps Dodge properties. Following is a brief description of the Pit Operations:

Jan 1, 1959

Electronic detonators have been in commercial use for a decade, with an excellent safety record. This paper lists known incidents involving electronic detonators. Typical standards required by regulatory bodies for static electricity and electromagnetic fields are reviewed. The performance of some detonators is compared to these standards; in general the minimum standards are easily exceeded. The general resistance of electronic detonators to extraneous electrical energy that can be derived from the body of test results is compared to danger levels for exposure of humans to these energies; it is shown that electronic detonators can safely tolerate higher electrical energies than people can. This comparison includes comparable data for electric detonators, which are shown to be more vulnerable to extraneous electrical energy than people are. Electronic detonators also bring significant safety benefits in blasting due to their testability, two-way communications, reliability, programmability and precision. The links between these attributes and enhanced safety are discussed with examples from actual blasting. Although electronic detonators are usually more vulnerable to extraneous electricity than non-electric initiation systems, the paper shows that the net safety benefit in handling and blasting is in favor of electronic detonators, which are the safest initiation system that has ever been offered to the mining industry.

Jan 1, 2010

By J. A. Organiscak

Longwall mining technological improvements have provided significant increases in productivity over the last 15 years. Longwall productivity is anticipated to continue to escalate with expanded application of automated equipment. Automation technology that will likely be adopted over the next 5 years is memory cut with shearer initiation of shield movement supervised by a couple of face workers. Operations using this technology will most likely relocate many production workers from the face to the outby gate entries and position several face workers outby the shearer, exposing workers to different health and safety risks. These changing risks are primarily related to worker relocation and expected increased production levels. Workers outby the face will most likely have less dust and noise exposure, but will be exposed to other safety hazards associated with outby equipment movement, materials handling, and gate entry ground movements. The face workers will most likely be exposed to higher respirable dust and noise levels generated by the equipment at elevated production rates. Methane gas emission is also expected to increase with faster mining rates. These operational changes and the control technologies needed to reduce redefined longwall worker hazards at semiautonomous longwall operations require examination to maintain the health and safety of mine workers.

Jan 1, 1996

By T. R. Hughes

How do you fit a processing plant underground with minimal change to mine infrastructure and yet maintain economic recovery, operability and maintainability? By combining fine crushing, continuous-gravity recovery and flotation. A modular, transportable processing plant has been designed that is capable of being installed in underground drives/drifts or on the surface. The Python processing plants have been designed to treat 20 or 50 tons per hour of ore to a particle size of approximately 500 µm and recover gold and sulfides into the concentrate. The plant is only three meters wide (including bolt-on platforms) and can be installed on a 1:50 slope, making for very simple installation. Test work carried out by Gekko Systems Pty. Ltd. has indicated that up to 50% of ores tested to date would achieve gold recovery rates of over 90% using this method. The projected benefits of this strategy are numerous and include low overall capital and operating cost, significantly less power consumption compared with traditional milling circuits and low environmental footprint.

Jan 1, 2010

By Henry P. Ehrlinger III, Latif Khan, John M. Lytle

The primary purpose of this project was to produce and test coal concentrates made from coal preparation plant waste fines for use in a slurry-fed gasifier. Concentrates from several individual waste streams were examined to determine their amenability as feedstock for a slurry-fed, slagging, entrained-flow gasifier. The tests included analyses of the plant feed and product, material balances, and estimates of gasification reactivity and of pumpability. The following preparation plant fines were examined: • fresh rejects produced in a plant processing underground- mined Springfield Coal • fresh rejects produced in a plant processing underground- mined Herrin Coal • fresh rejects produced in a plant processing surface-mined Springfield Coal and Herrin Coal • Five-year old impounded fines rejected during processing of underground mined Herrin Coal. At high coal recoveries the Btu content of the concentrates was greater than the Btu content of the utility product from the plant. The coal recovered from fines was found to be entirely acceptable for gasification and pumping without additives.

Jan 1, 1995

By Glenn Boyce, Paul Gribbon, Gary Irwin, Greg Colzani, Jim McDonald

This paper discusses the process utilized by the City of Portland Oregon’s Bureau of Environmental Services (BES) to procure and compensate Impregilo-SA Healy (I/H)for the West Side Willamette River Combined Sewer Over?ow (CSO) Project. The contract method is a three-phase process consisting of qualifications based contractor procurement, pre-construction phase design assistance/construction planning, and facility construction where the contractor is compensated on a cost reimbursable-fixed fee basis. The paper focuses on pre-construction phase lessons learned from the development of the contract general conditions, establishment of a construction budget and cost control program, incorporation of contractor recommended design changes, and development of a subcontractor procurement program for construction.

Jan 1, 2003

By John R. Buzek

Thickeners are simply large tanks, usually circular in shape, which are designed to allow settling of solids and to operate with continuous overflow of clear water and underflow of thick pulp. The dimensions of the thickener are usually such that dewatering of very fine pulps may be accomplished while still 1 overflowing clear water. Some thickeners such as the Genter, Hardinge and Hydrotator types combine thickening with filtering2 while others such as the Dorr type are pure thickenersl,2,3. A schematic diagram of the traction type Dorr thickener is shown in Figure 1. This type is appropriate for tanks over 15 m (50 ft) in diameter. This tank employs a rotating raking mechanism which moves the settled material toward the central discharge. For this and other thickeners, it is common to have a shallow conical tank bottom in order to conform to the geometry of the raking mechanism, and it is often desirable to elevate the tank for ease of access to the product. When the tank does not rest on the ground, the forces resisted by the cone are large, and thick plates must be employed. The fabrication of these tanks requires temporary supports in order to erect the cone. A flat-bottomed tank could also be used because the settled material would soon form a hardened conical surface. However, because of the presence of large bending forces, even larger plate thicknesses are required than for the conical bottom. Significant cost savings often can be realized by the use of a scalloped-bottomed tank such as the one partially shown in Figure 2. The particular scalloped bottom discussed in this paper (and shown in the Figure) employs radial beams forming the outline of the cone-shaped bottom. These beams are supported directly by columns. Cone segments are hung between adjacent beams. The exact geometry of these segments depends upon the cone angle and radius, the number of radial beams, and their inclination. The geometry is chosen to satisfy certain clearance restraints and to utilize the material as efficiently as possible. The resulting thickness of these segments is significantly less than that of the

Jan 1, 1977

By Stanislaw Wasolewski

Computerized systems for ventilation parameters monitoring which are used in Polish coal mines provide the ventilation staff with a great number of measuring data. These data can be used to get knowledge about dynamic properties of ventilation process and disturbances affecting its state. This is necessary to create a reasonable concept of mine ventilation control system and make a practical application of such system. In the paper a method of ventilation process identification with the use of measuring data from monitoring system is described. Computer analysis of time series including statistical, correlation and frequency methods are applied to estimate dynamic properties of ventilation process and its disturbances. Using the Fast Fourier Transformation (FFT) algorithm the parameters of the process have been obtained which can be efectively used in a system for mine ventilation control.

Jan 1, 1991

By J. E. Hoffman, Massimo Maccagni, T. J. Keefe, Marco Olper, O&apos

The research laboratory of B.U.S Engitec has identified and patented a new process for electrolytic production of lead from lead sulphide concentrates with simultaneous production of elementary sulphur. The process occurs in an aqueous solution, at atmospheric pressure, utilizing a solution of ferric fluoroborate in fluoroboric acid as the oxidizing and solubilizing medium for lead sulphide. After the filtration and separation of a residue composed of elementary sulphur and the gangue which accompanied the concentrate, the solution containing lead as fluoroborate and iron reduced to a ferrous state is sent to a diaphragm electrolytic cell where, in the cathode compartment, the lead is deposited in a compact form on the stainless steel permanent blank. The exhaust solution stripped of lead is sent to the anode compartment where the oxidation of ferrous fluoroborate into ferric fluoroboratetakes place, reproducing the oxidizing solution for new leaching. Depending on operating conditions, it is possible to selectively solubilize the lead from the other metal values present in the concentrate. The sulphur produced from the reaction may be separated from the gangue by extraction with solvent or by flotation.

Jan 1, 1993

By Alireza Ayoubian, Richard Finno

The network of freight tunnels in Chicago consists of about 62 miles of horseshoeshaped tunnels constructed typically less than 50 feet below ground surface. These tunnels serve as repositories of much infrastructure and should remain serviceable. The tunnels are often impacted by adjacent excavations and the question arises as to the existing state of stress in the final liner. This paper discusses construction of these tunnels and presents the results of finite element analyses which were used to obtain ranges for axial forces and bending moments that have developed in the final liner of the freight tunnels since their construction.

Jun 13, 2023

By Enrique Rubio Esquivel, Matías Fuentes Bustamante

The transition from open pit to underground mining represents a key strategic challenge in modern mine planning. This paper presents a multicriteria and multivariable methodology to plan such a transition, integrating technical, economic, environmental, and social considerations. The proposed framework focuses on risk reduction (de-risking) through the identification of alternative development paths, the use of stochastic simulation to model geological and technical uncertainty, and different mining strategies such as methods, production rates, sequence, etc. for ultimate underground implementation. The study summarizes the limitations of traditional planning methods—which usually treat the open pit and underground mine designs as independent processes—, also often it considers a single mining method and production rate for the underground option. Instead it is proposed an integrated approach that leverages synergies between both mining methods and scalable production rates. Also the proposed methodology incorporates the definition of critical variables (geotechnical, economic, and social, among others), the construction of multiple operational and technological transition paths, and the evaluation of each path under criteria of economic attractiveness and practical do-ability (capacity to be executed). Using simulation tools (SIMPLAN for operational performance and SIMVAL for economic evaluation), probabilistic distributions of the different path are obtained, enabling the quantification of the project’s Value at Risk (VaR). A subsequent multicriteria analysis weights the expected profitability against the feasibility of execution of each alternative, producing a decision matrix that provides a framework for evaluating the different project path. As a result, the proposed approach identifies OP→UG transition strategies that maximize business value by capturing remaining resources while minimizing financial and operational risks. Finally, strategic conclusions and recommendations for the industry are provided, emphasizing the importance of early transition planning even challenging the open pit sequencing of the latest push backs by introducing early underground operations. Future work includes strengthening the methodology—such as integrating real-time analysis and adaptive decision-making—and providing recommendations for its application in various mining operations. In summary, this paper delivers a technical and professional framework to guide mining companies on when and how to carry out a successful transition from open pit to underground mining, balancing resource recovery with financial, operational, and social security.

Feb 22, 2026

By Qingming Feng, Bo Huang, Dongbo An, Jinhong Zhang

A study of the application of mine tailings as precast construction materials through alkali activation has been carried out, focusing on efficiently activating mine tailings, reducing alkali consumption, decreasing curing time and improving compressive strength. Firstly, the effect of temperature on the alkali activation of mine tailings was studied. Secondly, the impact of additives, i.e., calcium hydroxide and aluminum oxide, on the compressive strength of samples was investigated. Thirdly, the impact of forming pressure on sample strength was studied. Test results showed that unconfined compressive strength (UCS) of 40 MPa was achieved with the geopolymerization products through optimization. Finally, to elucidate the geopolymerization mechanism of mine tailings, microscopic and spectroscopic techniques including SEM/EDX, XRD, and FTIR spectroscopy were used to investigate the microstructure and the elemental and phase composition of the geopolymerization products. The findings of the present work provide a practical method for applying mine tailings as precast construction materials through alkali activation.

By Peter W. Lipman

In the Rocky Mountain region, variations in Tertiary mineralization correlate with changes in tectonic setting and associated igneous activity that can largely be related to tectonics along the west boundary of the American plate. Successive settings include compressional tectonics and associated continental-arc igneous activity; transitional igneous types associated with intra- and back-arc extension; and basaltic or bimodal basalt-rhyolite assemblages associated with Basin and Range extension in- ward of a growing transform boundary between Pacific and American plates.

Jan 1, 2013

By Robert E. Mclvor

Classification system efficiency (CSE) is a simple metric that can be used to measure and increase ball milling circuit efficiency. It is defined as the percentage of the ball mill energy being used to grind target (oversize) particles. This paper describes CSE analysis conducted for a variety of operations with related improvements in circuit efficiency ranging from 3 to 30 percent. The achievable CSE for any given ball milling circuit is described, providing the means to determine the extent to which every plant can benefit from increasing grinding circuit CSE.

By Joshua Cole, Joshua Sovechles, Christian Cardoso, Guillermo Bermudez, Martta Hirsi, Joshua Dettamanti, Rabia Abbasi

The implementation of technological advancements in flotation is key to optimize performance in mining operations. Consequently, flotation cell’s performance is highly dependent on the effectiveness of the mixing mechanism. A more efficient flotation mixing mechanism is likely to improve metallurgical performance and optimize energy consumption, which is the motivation for Metso’s journey to develop the latest iteration of FloatForce®. Looking to test the new design at plant scale, Metso approached the Kennecott Copperton concentrator, which is continuously looking for different venues to improve metallurgical performance. In this context, a test campaign was conducted to implement this new flotation mixing mechanism in their rougher circuit during 2024. The industrial trial consisted of several sampling campaigns assessing different operational parameters for comparison purposes around a 300m3 flotation cell. The effect of the new flotation mixing mechanism on the cell’s power draw was also studied. The results of this trial at Kennecott are presented in this paper. Overall new flotation mixing mechanism, FloatForce+ was seen to perform as well as the original FloatForce.

Feb 1, 2025