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By Robert B. Fulton

The objective of this chapter is to discuss the interrelationship between industrial minerals and chemical manufacturing. It is intended to supplement rather than duplicate the commodity chapters. Particular emphasis is given to the pertinent chemical element and to market factors. Condensing this broad subject into a few pages of this handbook permits treating only the most important elements derived from industrial minerals. Hydrocarbons, which quantitatively dominate as raw materials for the chemical industry, are omitted, as are the metallic elements and the minerals covered in other "use" chapters such as phosphorous, potassium, and nitrogen for fertilizers, and titanium dioxide for pigments. The remaining six elements of major importance are: boron, bromine, chlorine, fluorine, sodium, and sulfur. These elements are treated individually under separate headings. [Table 1] affords an overview of the main industrial minerals, the chemical products derived from them, and end uses of the products. Salt brines have particular importance as raw material sources for the chemical industry. Table 2 is a chart of the chemical compounds derived from four types of brines: (1) Owens Lake-type brines, which are sources of boron and sodium compounds; (2) Midland-type brines, from which bromine, iodine, and chlorides of calcium, magnesium, potassium, and sodium are derived; (3) Searles Lake-type brines, yielding boron, bromine, lithium, magnesium, potassium, and sodium compounds; and (4) Silver Peak- type brines, produced mainly for lithium. MARKET ATTRIBUTES Some of the important market traits common to industrial minerals used by the chemical industry are: 1. They are international commodities, such as fluorspar and sulfur, which largely move to foreign consumers. 2. Grade, and freedom from deleterious elements are important factors affecting their usability in chemical processes. An example is salt (NaCl) used in electrolysis where ultrapure evaporated salt is required to meet rigid specifications. 3. Purified products take on the characteristics of specialty items and command a distinctly higher price than the basic commodity from which they are derived. 4. In practically all cases, chemical users require some sort of cleaning or beneficiation of the naturally-occurring mineral to bring it to specification, and individual specifications may vary from user to user for essentially the same use. 5. In some instances it is necessary to strike a balance between what the vendor can supply and what the buyer requires, with the result that specifications have to be eased to afford the needed materials in marginal cases. 6. Because they tend to be bulk commodities, low cost for handling and transportation are important and such costs may limit the area from which a chemical user can draw his supply. 7. Shipments are usually in bulk and frequently in multiple-car, full-trainload or full-shipload lots to reduce transport costs, which in turn may require large terminal investment facilities. 8. Purchases are generally by contract of one year or longer term, with spot buying playing only a minor role. 9. Contract prices are usually fixed in short term commitments, but may vary according to assay, with premiums and penalties for content above or below the norm; however, general practice is for specifications to be fixed in the contract with minimums being set for the desired material and maximums for undesired elements. In longer term contracts, prices are often escalated on labor, fuel, and other vendor processing costs. 10. Suppliers of individual commodities to the chemical industry tend to be limited in number and are generally medium- to large-size producers that supply a few major consumers. 11. The bulk of the mineral volume is for basic chemical uses, sulfur suppliers to sulfuric acid producers and fluorspar for hydrofluoric acid producers being typical examples. These basic chemical products then are used for the production of other products. 12. Shortage of a supply of adequate quality leads consumers to seek substitutes. In the case of fluorspar, much work is being done on recovery of fluorine from phosphate rock. Success in the form of fluorosilicic acid and/or hydrofluoric acid production could, in time, affect the hydrofluoric acid chemical industry. 13. Markets tend to be characterized by cycles of shortage followed by oversupply, with attendant wide price fluctuations. 14. Baniers to trade can have an adverse effect on the necessary movement of industrial minerals used by the chemical industry in international trade. Antidumping laws, quotas, and tariffs can disrupt or dislocate normal markets. 15. Chemical industry consumers may back-integrate for security of supply or for favorable economics, sometimes by joint ownership and often with experienced mining partners.

Jan 1, 1994

By Daniel H. White

Block caving, unlike most other conventional forms of mining relies principally on the natural forces within the rock mass to fragment and transport the ore. Obviously, not every orebody can be satisfactorily mined by block caving. In the early stages of mine planning an attempt should be made to assess the benefits of the block caving system relative to others, and develop a reasonable mining concept that may be used to provide preliminary information to mine planners and financial specialists. It is the intention of this paper to outline some basic geotechnical parameters that are essential to: 1) Assessing the feasibility of block caving an orebody and 2) Providing semidetailed information relative to mine design based on drill hole and other data.

Jan 1, 1979

By James M. Stauffer

There are many types of filters designed to separate a solid from a liquid, including plate and frame presses, pressure leaf filters, gravity filters and vacuum filters. This discussion will be limited to continuous vacuum filtration and, specifically, to continuous rotary vacuum disc filters, drum filters and horizontal belt filters. The use of vacuum filtration can be advantageous in that: 1. The feed slurry can be delivered to the filter either by gravity or by a simple, inexpensive low pressure pump that only has to overcome the resistance of the feed piping system. 2. The filter equipment does not have to withstand high pressures. Consequently, a wide range of materials of construction, including plastic and fiberglas reinforced polyester (FRP), can be used in the fabrication. 3. After the form time, the filter cake is exposed to the atmosphere and the cake is accessible for further operations such as mechanical or physical dewatering, washing, and sampling on a continuous basis. 4. The discharge of the dewatered solids is continuous for directly feeding to the next operation; for example, a dryer. 5. Various methods of discharge can be fitted to the filter to effect optimum discharge of the dewatered cake solids. The principal of operation of a vacuum filter, regardless of type, is basically the same. The filter incorporates a filter medium supported on a drainage system and arranged so that the mixture to be separated (feed slurry) can be introduced to one side of the filter medium on which the solids are trapped and through which the liquid (filtrate) flows due to the applied vacuum.

Jan 1, 1979

By Robert G. Woolery

Union Carbide_ began looking seriously at heap leaching in 1971. At that time some 1.6 million tons of mineral averaging 0.040% U308 were stockpiled at various sites around the Gas Hills, Wyoming, uranium facility. Several alternatives for economically exploiting these reserves were considered and heap leaching seemed the most attractive. At the time, Western Nuclear Inc. was operating a heap leach project nearby in which the low-grade ore was leached with sulfuric acid, the product liquor treated in an on-site solvent extraction circuit, and the stripped product liquor re-acidified and recycled. They were most generous in allowing us to visit their site, answering our questions, and were helpful in discussing the problems associated with heap leaching. They confirmed our belief that, it was possible to operate a heap leach profitably on material too low grade for. conventional milling. Based largely on what we had learned from Western Nuclear's experience, a program was set up involving a laboratory study to determine the characteristics of the mineral stockpiles as related to heap leaching and to conduct a pilot heap leach adjoining our Gas Hills mill. Basically, the pilot heap construction and leach procedure were similar to those described in the literature(1,2) with certain modifications to permit detailed monitoring of the operation. In May, '1972, the decision was made to construct a test heap. The UCC plant at Gas Hills, Wyoming was selected as the most appropriate site for the follow¬ing reasons:

Jan 1, 1977

By E. V. Bowman

This paper is intended to deal with the material handling aspects of fine coal cleaning as applied to a recently built plaint in: southern West Virginia. This plant is processing 160 tons per hour of 1/4" x.0 coal on a two shift basis. Past experience with this very friable low volatile metallurgical coal indicated that its plastometer readings, varied directly with the size and length of time elapsing between mining' and ultimate consumption. Due to the mines location with, respect to its consumers, little could be done to decrease the time element. Studies indicated that the plastometer readings are considerably less in the minus 60 mesh range than that experienced in the plus 60 mesh sizes. Therefore, handling the coal in such a manner as to have the least amount of degradation became extremely important.

Jan 1, 1961

By Thomas A. Wilson

Mountain Pass, California is located 96 km southwest of Las Vegas, Nevada, and has an exposed surface orebody within view of Interstate Highway 15. Mineral prospecting in this region dates back to about 1860 followed by the discovery and subsequent mining (1870-1895) of silver bearing veins on the north slope of nearby Clark Mountain. In contrast to the four lane divided interstate highway of today, all supplies needed for mining during this early history were transported by wagons from San Bernardino which is 320 km west. Many small lead mines were active in the area during 1917-20, and a small gold mine operated in 1941-42 within 100 m of the orebody presently being worked. In 1949 two prospectors searching for uranium with a Geiger counter discovered a radioactive vein outcrop at Mountain Pass. Further investigation revealed the presence of a large amount of a light-brown, heavy mineral to a depth of about 2 m. A sample of this unidentified mineral was submitted to the Boulder City, Nevada, U.S. Bureau of Mines where a spectroscope examination shoved high level rare earth oxides, carbon dioxide, and fluorine. These results indicated the mineral was bastnasite.

Jan 1, 1982

By Edward J. Adams

In recent years, there has been a shortage of individuals trained in the technical skills entering the mining industry. The university and industry, both indicating their concern, have joined efforts in an attempt to do something about this situation. An example of such an effort is the Pennsylvania State University's Student-Trainee Program in Mining Engineering, now in Its third year. The program is a five-year plan in which six months of schooling and six months of on-the-job training are alternated, climaxed by the student trainee earning a Bachelor of Science Degree in Mining Engineering plus two years of practical experience. The student trainee accepts the work-study plan as a satisfactory method of receiving a thorough education and preparing fog a career in the mining industry. Inasmuch as the work and study-periods are alternated, the trainee has an opportunity' to integrate his practical experience with his academic knowledge. He receives a chance to observe others perform she duties of the profession he is preparing to pursue, and he regards this as an essential part of any such cooperative effort. Even though there are some disadvantages, the trainee feels that the advantages of the program are definitely more decisive.

Jan 1, 1963

By W. L. O?Connell

[Patent Issue No. Date Issued To Subject 386,504 July 24, G. Sweanor The separation of quartz from a 1588 metal with a liquid such as CS2 or CHC13 under water by introducing mixture into water layer. Quartz will stay in water layer while metal sinks through organic.]

Jan 1, 1963

By Ulf B. Andersson, Christina Dahnér-Lindkvist, Bruno Figueiredo, Jessa Vatcher, Jonny Sjöberg, Joel Andersson

Hydraulic fracturing to precondition the rock mass in high seismic risk environments has great potential. Unfortunately, there are many unanswered questions about how to best implement a hydraulic fracturing program at individual mine sites, and even how to best use our engineering tools to evaluate these plans. To give the hydraulic fracturing field tests at LKAB’s Kiirunavaara Mine the best chance of success, fully-coupled, discontinuum numerical modelling Itasca’s 3DEC code was used together with statistical simulations of the fracture network. For modelling purposes, it was assumed that hydraulic fracturing successfully reduces seismic risk through 1) the creation of hydraulic fractures along a plane at each injection site, and 2) activation of existing discontinuities. A variety of scenarios for the mine were evaluated, which focused on site specific uncertainties (such as the spacing of the pre-existing discontinuities) and practical solutions (such as the hydraulic fracture spacing, selection of injection medium, and hydraulic fracture site location relative to production). The discrete fracture network (DFN) realizations were developed using available statistical data for discontinuities near where hydraulic fracturing was planned.

Apr 26, 2022

By Matthew Grzelak, Gulsah Erinc, David R. Chapman

"The third phase of the Bagram Drainage System project at Bagram Air Force Base in Afghanistan included construction of a shallow, 540-m long, 1.8-m inside diameter drainage tunnel. The tunnel penetrated mostly stiff to hard clayey and silty soils. The contractor’s Value Engineering Change Proposal (VECP) to use pipe-jacking with a microtunnel boring machine (MTBM) instead of the specified two-pass Earth Pressure Balance method was evaluated and supported using hand calculations. Contractor support was provided throughout the project by providing design reviews and instrumentation monitoring during construction. This paper compares the value-engineering proposal to the specified method and describes the construction conditions encountered. INTRODUCTION As part of a larger improvement project at the Bagram Air Force Base in Afghanistan, a shallow, 540-m long, 1.8-m inside diameter drainage tunnel was constructed to provide additional capacity for Coyote Creek to pass below several critical structures, including taxiways and the main runway, for mitigation of recurring flooding (see Figures 1 and 2). Overburden over the tunnel crown ranged from about 3 m to 5.5 m. An existing cast-in-place twin barrel concrete culvert runs approximately parallel to the new tunnel and is within about 8 m at its closest point. The contractor’s Value Engineering Change Proposal (VECP) to the specified two-pass Earth Pressure Balance (EPB) method (steel ribs and lagging or steel liner plate with a carrier pipe later grouted in-place) called for installation of the required drainage pipe by pipe-jacking (one-pass installation) using a slurry microtunnel boring machine (MTBM). The critical nature of the operations at the air base resulted in significant construction coordination challenges and a greater than usual need to avoid excessive settlements. Substantial restrictions were placed on drilling of investigative borings and installing instrumentation near runways and taxiways due to drill mast height. The prime contractor was SERKA TAAHHUT INSAAT A. S. (SERKA), the microtunneling subcontractor was Ludwig Pfeiffer Microtunnel GmbH & Co.KG (Pfeiffer), the jacking pipe designer was Gollwitzer Pipe and Shaft Technology GmbH (Gollwitzer), and the contractor’s tunnel engineer was Lachel & Associates, Inc. (Lachel). Lachel provided contractor support throughout the project including preparation of a VECP/Design Summary (including interpretation of existing and new geotechnical information), design reviews for jacking pipe, estimating settlement of an existing drainage structure above the new tunnel, and instrumentation planning, monitoring, and analysis during construction."

Jan 1, 2016

By Crystal Poon, Paul Matlashewski, John Morkeh, Kathryn Dorfschmidt, Jose Carvalho, Chad Williams

Rockfall hazards are ubiquitous in mining environments making their control critical for safe mining operations. The complex processes involved in rockfall events necessitate a probabilistic modeling approach with well-calibrated material properties. The controls designed to mitigate rockfall hazards need to be reliable, efficient, and safe to deploy to meet the constraints present at an active mine. This paper presents an innovative solution to rockfall at Rio Tinto’s Bingham Canyon Mine. The solution incorporates the site-specific calibration and creation of a predictive rockfall model with the design, field testing, implementation, and monitoring of the rockfall controls.

By Crystal Poon, Paul Matlashewski, John Morkeh, Kathryn Dorfschmidt, Jose Carvalho, Chad Williams

Rockfall hazards are ubiquitous in mining environments making their control critical for safe mining operations. The complex processes involved in rockfall events necessitate a probabilistic modeling approach with well-calibrated material properties. The controls designed to mitigate rockfall hazards need to be reliable, efficient, and safe to deploy to meet the constraints present at an active mine. This paper presents an innovative solution to rockfall at Rio Tinto’s Bingham Canyon Mine. The solution incorporates the site-specific calibration and creation of a predictive rockfall model with the design, field testing, implementation, and monitoring of the rockfall controls.

By P. G. Semple

For the last four years, the Kilborn Group of Companies (Kilborn) has been involved in several major projects in the CIS. These projects include the Kumtor Project, the Kubaka Gold Project, the Kazgold Project, the Aginskoe Project and the Jerooy Project. These projects are all in various stages of detailed engineering and construction. In this paper, Kilborn will discuss our experience in the CIS and share some insight into project development in this geographic region.

Jan 1, 1996

By LeRoy Kienitz

There may be someone here who is not required to run his equipment at its maximum capacity. There may be some fortunate enough to have more crushers than needed, wider conveyor belts than required, and other mill equipment equally oversize. If so, then this paper will have no interest for him; but if most of you are in the situation we in the aggregate producing industry are in, then you probably wish to crowd your mill equipment to its limit. When you do this you must watch for block-up and overloads of all sorts. You need more eyes than you have to guard the critical points. The human eyes that now do nothing much, but watch should be freed for more productive work.

Jan 1, 1961

By V. L. Magnus

The text of this chapter was not received in time for printing.

Jan 1, 1979

By K. A. McDonald

This paper will describe the experiences of Hibernia Holdings, Inc. in constructing a mineral processing facility in Mexico. It will attempt to set forth a guideline on what companies attempting to operate in Mexico can expect and what actions they can take. Ownership laws, import/export laws, labor laws, security, transportation and operating experiences will be discussed.

Jan 1, 1994

By B. Caines

Much of the mining industry in North America is in a crisis state. Host producers are operating at production levels well below capacity, some have been merged or sold, while others have been mothballed or closed permanently. For many of us still operating, the future is uncertain. Despite the many cutbacks and closures, there is still an abundant supply of minerals in the world market and there is almost no hope for any relief on price pressures on most mineral commodities in the near future. The Iron Ore Company of Canada (IOC)operates an iron ore mine, a concentrator and a pellet plant known as the Carol Project located in Labrador City, Newfoundland. This concentrator and the pellet plant have the annual capacity to produce 20 million and 10 million tons respectfully. A company owned and operated railway links this operation with the dock terminal facilities in Sept Iles, Quebec.

Jan 1, 1987

By Peter N. Loncar

Most miners dream of finding a gold mine sometime during their mining careers, but not very often do such dreams come true. On the tenth day of September, 1962, our dream of finding gold came true when the results of the third drill hole were received. This was undoubtedly one of the most exciting days of our lives. Little did we realize then that this was the beginning of a major discovery destined to became one of the largest gold mines in the country. Discovering and mining gold is not entirely new, however, to Eureka. County a old Lynn Mining District in northeastern Nevada. Since 1900 there has been sporadic activity, mostly consisting of small lode mines and placers. These have produced totally about $300,000; and existence of our orebody would probably have remained unknown had it not been for the United States Geological Survey. The USGS extensively mapped the Roberts Mountain Thrust and published a paper indicating that mineral occurred along this fault and in some places was gold bearing. Utilizing this information, our Newmont Exploration geologists located an area in which: drills were brought in to test their theories. By keeping flexible in our thinning and working, we were able to bring a raw prospect to a producing mine with ore reserves of eleven million tons in a short three-year period.

Jan 1, 1965

By J. Groppo, W. Zhang, R. Honaker

"Rare earth elements (REEs) found in coal are in the form of minerals, ion-substitution with clays and organically bound. Rare earth minerals (REMs) such as monazite exist in coal and have a grain size less than 5 microns. Froth flotation was successful in concentrating REMs existing in a thickener underflow material derived from Fire Clay seam coal which contained around 300 ppm of rare earth elements (REEs). Conditioning with fatty acid followed by processing using multiple stages of conventional flotation produced a final concentrate containing 2300 ppm REEs. Using a laboratory flotation column, a concentrate containing around 4700 ppm of total REEs was produced equating to an enrichment ratio of 10:1. INTRODUCTION Rare earth elements (REEs) are becoming increasingly important and have been widely used as raw materials for the production of phosphor, metal catalysts, magnets, and batteries [1, 2]. REE recovery from alternative sources such as coal and coal by-products has the potential to stabilize the economic viability of coal mining operations while providing a dependable supply of critical materials. The average REE content of the world coal is around 60-70 ppm [2]. There are many well-known coal beds with high contents of REEs such as those in the Far East coalfields in Russia (300-1000 ppm), the Fire Clay coal seam in eastern Kentucky (500 ppm), and the Sydney Basin in Nova Scotia, Canada (72-483 ppm) [3-6]. The occurrence of REEs in coal and coal by-products can be classified into three types, i.e., rare earth minerals such as monazite and xenotime, ion exchangeable REEs in clays, and REEs associated with organic matrix. The particle size of the rare earth (RE) minerals in coal and coal by-products is very small and normally in the micron and/or nanometer scales. The flotation technique, which is based on the surface chemistry difference, has been widely used to treat fine rare earth industrial minerals such as monazite, xenotime, and bastnaesite [7-11]. As such, flotation is a promising method for the concentration of REEs from coal and coal by-products. In the current study, rare earth flotation was conducted using the fine coal refuse generated at an operating coal preparation plant treating coal from the Fire Clay seam. REE concentration by flotation required an appropriate amount of grinding and control of the pH value while using typical collectors. Prior to RE concentration, release tests were conducted to evaluate the floatability of the recoverable coal and the REE distribution in the flotation fractions in the fine refuse. Mineralogy of the REE was studied using SEM-EDX."

Jan 1, 2017

By M. A. Pipke, C. M. Brown

The semiautogemus grinding circuit at the Utah Mines Ltd., Island Copper operation, located on Vancouver Island, British Columbia, is described. Since startup of the operation in 1971, grinding circuit throughput has been progressively increased from the initial design rate of 90 000 (99,000) to the current average 45 000 t/d (49,600 stpd) of porphyry copper ore. Key developments ad modifications in operating and maintenance practice that have contributed to this increase are reviewed.

Jan 1, 1987