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By Norman F. Schulz

The technical excellence of separation achieved in a mineral concentration process, or any other process where two constituents of any kind are physically separated from each other, is expressed uniquely and quantitatively by the separation efficiency (E,): E. = (R - R,), where R is the percentage of the valuable constituent and R, the percentage of the waste appearing in the concentrate. The separation efficiency meets all the usual requirements of a true efficiency and is independent of the nature of the process used. It can be visualized as the percentage of the feed material that, in effect, actually undergoes complete separation while the rest of the feed is distributed randomly and unchanged into the two separation products. The problem of quantitatively assessing the results of a mineral concentration process recurs whenever one tries to decide which of two similar test results is more desirable. Although economic factors may greatly influence the eventual choice of process, they usually have very little to do with the technical excellence of a separation and are, therefore, not a consideration at this point. Concentrate grade and recovery, used simultaneously are the most widely accepted measures of performance, and if both the grade and the recovery are greater for one case than for another, the choice is simple. However, when the results of closely competitive operations are compared, it often occurs that one set of test results shows a higher grade and a lower recovery than another and the choice is no longer obvious. Laboratory investigations of a mineral concentration process applied to a given feed material can often be designed to yield successive paired values of concentrate grade and recovery over the practical range of the course of a separation process.' These results may be plotted as some combination of the cumulative values of grade, weight recovery, or unit recovery in the concentrate. The resulting correlations for two slightly different sets of conditions can then be compared qualitatively, or even quantitatively in particular cases.2 Such comparisons are not applicable, however, to individual concentration test results. The reduction of a separation test result to a single efficiency figure, preferably as a percentage of ideality, would afford the simplest and most precise means for comparing the results of competitive tests. The effective proportion of feed material that undergoes complete separation in any real concentration process, hereafter referred to as "separation efficiency," is such a figure. It is essily calculated from the usual feed and product data and can even be evaluated, in many cases, from data in publications describing various concentration processes. Mineral Concentration Processes and Their Evaluation Mineral Concentration Processes: The overall concentration process may be subdivided into a liberation process which severs the bonds between unlike mineral species, and a separation process, which sorts the resulting liberated particles into two products—a concentrate rich in mineral A and a tailing lean in mineral A. A perfect mineral concentration process is represented by the idealized scheme shown in Fig. 1 in which liberation and separation are not differentiated. The feed mixture consists of two mineral types which are completely liberated early in the process and then sorted by type. All the mineral particles of type A which respond uniquely to the selection forces acting in the ideal separator, report to the concentrate, while all the mineral particles of type non-A report to the tail-

Jan 1, 1971

By Chen Dong, Yang Wenwang, Liu Zhineng, Tan Ming

"To meet the requirement of production expanding of a certain potash ore dressing plant in Xinjiang province of China, industrial test of XCF/KYF-50 flotation machine was performed to process potash ore. The tank of XCF/KYF-50 flotation cell is in U shape, 50m3 of volume. This flotation cell is able to suck slurry by itself, and can be arranged on the same base level without high difference. In this paper, two sets of XCF/KYF-50 flotation cells were adopted to replace 8 sets of 8m3 flotation cell in original flow sheet of flotation. Aeration rate, slurry suction capacity, power consumption and slurry suspension are investigated. The measuring results show the slurry suction capacity of the flotation cell is larger than 12.80m3/min and solid particles disperse evenly in the tank without deposition. Industrial test result indicates that the final grade of concentrate is 26.69% at the recovery of 90.95%, which is up to expected performance. XCF/KYF-50 flotation cell has advantages of high flotation efficiency, significant energy saving and reasonable configuration of automatic control system, this kind of flotation cell can meet the requirement of production expanding of this potash ore dressing plant well."

Jan 1, 2014

By Willard P. Ward

The numerous direct processes which have been patented and brought before the iron-masters of the world, differ materially from that now introduced by Mr. Wilson. After a careful examination of his process, I am convinced that Mr. Wilson has succeeded in producing good blooms from iron-ore, and I think that I am able to point out theoretically the chief reasons of the success of his method. Without going deeply into the history of the metal, I may mention the well-known fact, that wrought-iron was extensively used in almost all quarters of the globe, before pig or cast-iron was ever produced. Without entering into the details of the processes by which this wrought-iron was made, it suffices for my present purpose to say that they were crude, wasteful, and expensive, so that they can IE employed to-day only in a very few localities favored with good and cheap ore, fuel, and labor. The constructiou of larger furnaces and the employment of higher temperatures led to the production of a highly carbonized, fusible metal, without any special design on the part of the manufacturers in producing it. This pig-iron, however, could be used only for a few purposes for which metallie iron was needed; but it was produced cheaply and with little loss of metal, and the attempt to decarbonize this product and bring it into a state in which it could be hammered and welded was soon successfully made. This process of decarbonizatioa, or some modification of it, has successfully held the field against all, so-called, direct processes up to the present time. Why ? Because the old-fashioned bloomeries and Catalan forges could produce blooms only at a high cost, and because the new processes introduced failed to turn out good blooms. Those produced were invariably "red-short," that is, they contained unreduced oxide of iron, which prevented the contact of the metallic particles, and rendered the welding together of these particles to form a solid bloom impossible. The process of puddling cast-iron, and transforming it by decarhonization into wrought-iron has, as everybody knows, been in successful practical operation for many years, and the direct process referred to so closely resembles this, that a short description of the theory of puddling is not out of place here.

Jan 1, 1884

By B. C. Slocombe

A large derelict inner city site was regenerated for use as a distribution warehouse. Difficult topography and soils conditions required the adoption of a combination of specialist geotechnical processes. Particular attention was paid to the preparation of the site, programming and capabilities of each technique as additional soils information became available.

Jan 1, 1989

By R J. Holmes

An accurate knowledge of the chemical, mineralogical and physical characteristics of ores and mineral products that are mined, processed and traded is crucial to effective resource utilisation, plant design, process optimisation and finally quality control to ensure that contract specifications are met. However, all too often the responsibility for sampling is entrusted to managers and personnel who do not fully appreciate the significance and importance of collecting representative samples for analysis, and everyone seems satisfied as long as some material is collected and returned to the laboratory for analysis. Furthermore, sample stations incorporated into the design of new plants are often the first casualties when cost cutting exercises commence. This needs to change, because there is little point in accurately analysing samples if they are not representative in the first place. The resultant analyses can be next to meaningless and the effort taken to analyse such samples is to a large extent a waste of time and resources.Ultimately, a poor knowledge of the characteristics of ores and mineral products limits the ability of mining companies to optimise the life of ore resources and plant performance, and failure to meet final product specifications can have disastrous consequences, including price penalties and more seriously loss of sales contracts. It is high time that sampling is given the attention it deserves as the first critical step in the quality measurement chain.CITATION:Holmes, R J, 2013. The importance of sampling in the mineral industry, in Proceedings MetPlant 2013 , pp 34-49 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

By Osvaldo Bascur, Barun Gorain, Jaco Steyn

"The last few decades have seen some remarkable advancement in information technology, but recently various digital technologies have resulted in several synergies to deliver innovation in diverse applications. The mining industry has been relatively slow in adopting these technologies compared to the other industries, but this scenario is changing fast.Challenges. Mining companies globally are going through a series of challenges such as declining ore grades with complex metallurgy, increasing depth of ore bodies, high capital and operating costs, lower productivity, shortage of technical resources, significant pressure from stake-holders to deliver, along with growing environmental and corporate social responsibility issues. Improvement in profitability would need significant improvements in operational performance.Consequently, over the last few years, there has been a major focus among some mining companies to imbibe operational excellence. This has been only possible because of the replacement of a silos-based approach by an integrated view of the organization. Such an integrated view is now possible via the evolving digital technologies. Even so, such a transformation calls for a change in culture, which, for most organizations is not trivial. Attempts in the past to integrate functions, such as through mine-to-mill initiatives in the mining industry, have demonstrated significant benefits to many operations (McKee, 2013). Still, sustaining these benefits has clearly been a challenge due to manpower turnover and lack of proper systems and structures that integrate information between business functions within an operation and between operations and the corporate level.Opportunities. The advent of digital technology has opened up opportunities to integrate interdepartmental information for a unified understanding across an entire organization. The advances in instrumentation, equipment control systems, supervisory control systems (SCADA/ Historian) and industrial networks have helped in the direction of enterprise- wide integration. The availability of real time information across an enterprise has given rise to numerous possibilities to improve organization performance. As suggested by Seshan and Gorain (2016), some of the potential opportunities are as follows:"

Jan 9, 2018

By M. Sturzenegger

This paper documents a field survey using long-range terrestrial digital photogrammetry at the Palabora open-pit mine, South Africa, for multi-scale characterization of rock mass discontinuities. Stereomodels covering the entire mine were generated based on photographs taken from a distance of 1600m across the pit, using a series of f=20-400mm lenses. Details on the methodology used and its accuracy are discussed. Preliminary results on discontinuity orientation, persistence and intensity are presented, highlighting the effect of observation scale. The potential uses of long-range terrestrial digital photogrammetry in open-pit mine and large natural rock slope environments is emphasized. The use of an f=400mm lens from distances larger than 1.5km may represent an important step forward in the geotechnical characterization of inaccessible remote rock faces.

May 1, 2009

By Madgwick J. C

A novel, microaerobic, heterotrophic microbial leaching system for manganese dioxide is described. Mixed natural microflora were enriched by addition of sugars and crude plant nutrItIOnal supplements. Between 84 and 104 mg MnH was solubilized per gram sugar at I per cent (w/v) concentrations for fructose and galactose in the presence of 0.03 per cent w/v dried microalgae (a Chlamydomonas species). Some 42 per cent soluble manganese was dissolved by microbial action on MnO, (3 per cent (w/v) pulp density) using a 10 per cent (w/v) molasses growth substrate.

Jan 1, 1983

By M Dickie

During the 1980s and early 1990s low cost gold treatment plants were at the forefront of the Australian engineering and mineral processing business. This opportunity was the result of a high gold price and innovative design by emerging engineering companies in an expanding market. The low cost approach to gold plant design and project execution resulted in smaller and shorter life projects becoming viable and the multiplicity and fast track approach of the projects resulted in sharp learning curves. From the mid 1990s to the early 2000s the relatively low commodity prices and resultant reduction in minerals opportunities also resulted in innovative design in both small and large plants, albeit on a reduced scale. The innovation was associated with alleviating capital cost pressures for large capacity low-grade (eg NewcrestÆs Cadia) or small-scale (eg JubileeÆs Cosmos) projects to either improve NPV or to enable the project to be won and profitable in the competitive lump sum environment. Between 2004 and 2008 the engineering market became less competitive from an engineerÆs perspective due to the high demand for engineering services in a high price commodity market. The need for innovation remained but was driven overtly by shortages in water, power and personnel and long equipment lead times. This paper discusses some of the factors that contribute to the capital cost of a project and the scope for improving the likelihood of financing and increasing the project net present value (NPV). Case studies with recent large copper concentrator projects will be used to demonstrate how a value driven approach to project and plant layout can result in significant improvement in NPV.

Jan 1, 2009

The Research on Refined Gold Bullions Surface Upgrading

Sep 13, 2010

By M. A. Reyes, L. Yan

Heat and humidity buildup withn refuge alternatives (RAs) may expose occupants to physiological hazards such as heat stress. The Mine Safety and Health Administration (MSHA) regulations require RAs in underground coal mines to provide a lifesustaining environment for miners trapped underground when escape is impossible. RAs are required to sustain life for 96 h while maintaining an apparent temperature (AT) below 95 °F (35 °C). The National Institute for Occupational Safety and Health (NIOSH) tested a 10-person tent-type RA, a 23-person tent-type RA, and a 6-person metal-type RA in its underground coal mine facilities to investigate the thermal environment over a 96-h period. The test results showed that mine air and mine strata temperatures surrounding an RA occupied by simulated miners (SMs) increased over the 96-h test period. The test results suggest that RA manufacturers should consider this increase in temperatures when calculating and evaluating RA components during surface and laboratory tests. The findings can equip stakeholders with additional considerations for calculating the interior heat and humidity temperature profiles for occupied RAs not tested in situ.

By P. Mbele

Iron ore concentrate is not easily transported to, or processed in, ironmaking plants, therefore it is necessary to agglomerate. This paper will determine the possibility of agglomerating Sishen concentrate into suitable ironmaking feedstock. Pelletizing is one of the conventional and preferred agglomeration processes for iron ore concentrate investigated at Kumba Value-In-Use Laboratories. Sishen concentrate was mixed with binder, and then pelletized using a laboratory pelletizing disc; afterwards the green pellets were indurated at high temperatures to give strength high enough to survive handling and lessen disintegration in the shaft during ironmaking. Sishen pellets have satisfactory physical and metallurgical properties which make them suitable feedstock for the direct reduction processes. These were tested under Midrex shaft operational conditions and performed well, with a metallization of 94.47% being attained.

Jan 1, 2012

By Mario E. Rossi

The full economic evaluation of a mining project requires a block model that provides an estimate of the tons and grades of available resources. The model must be representative of the mineralization to be found at the time of mining for specified extraction periods and within acceptable error margins. In an operating mine, there may be a reasonable understanding and estimates of actual dilution and ore loss. This paper discusses the issue from the perspective of a project at a feasibility or preproduction level of development. Three types of dilution are discussed. Internal dilution (or change of support) is function of the spatial distribution of the mineralization and its relation to the operation?s selectivity. Geologic contact dilution is the unavoidable mixture at contacts or boundaries of material with different geologic characteristics, grades, or metallurgical performance. Operational planned and unplanned dilution should also be considered, sometimes incorporated by factoring the resource model, but more accurately by mimicking the grade control process. The resource estimation process always carries uncertainty, which is sometimes significant, and usually caused by several factors. These include quantity and quality of drill hole information; quantity and quality of geologic data; grade estimation methodology; dilution and mining recovery factors applied; etc. A key decision is to whether estimate as accurately as possible the in-situ geologic resource or to estimate the tons and grade of the material to be fed to the processing plant. The geologic modeling and grade estimation methods used are conditioned by this decision.

May 1, 2009

By Dominic Fragomeni

"The mineral processing industry has had a long history of innovation that is recognized but not often celebrated. These include significant advances in mineral measurement, testing, comminution, mineral separation and process control technologies that have transformed mineral assemblages into ore.This presentation presents some of the major mineral processing innovations and the impact they have had on our industry. As we look to the future, it is critical that we innovate and change. We will explore some examples of the next developments and how they can be catalyzed in the face of risk management, lower metal price cycles, resource constraints, inertia and the challenge of short term value delivery."

Jan 1, 2017

By W. W. Scott

Measurements of the absolute value of electromagnetic noise and attenuation along a hoist rope were made in an operating hard-rock mine, Lucky Friday Mine, located near Wallace, Idaho. Spectra of electromagnetic noise generated by various pieces of equipment, spectra of specific noise signals at various depths, and noise and attenuation on the 4250 foot (1295 meter) hoist, were measured. Three techniques were used to make the measurements. First, noise was measured over the entire electromagnetic spectrum of interest for brief time periods. Data were recorded using broadband analog magnetic tape for later transformation to spectral plots. Second, noise amplitudes were recorded at several discrete frequencies for a sufficient amount of time to provide data for amplitude probability distributions. A third technique gave attenuation data through the direct measurement of field strength at various depths. The specific measured results are given in a number of spectral plots, amplitude probability distribution plots and amplitude curves as a function of depth.

Jan 1, 1974

By Srisharan Shreedharan, Gang Huang, Hongqing Song, Sijing Cai, Pinnaduwa H. S. W. Kulatilake

"Subsidence prediction due to ore extraction and backfilling during open stoping operations for an underground iron mine in China is reported in this paper. Geologic complexities including faults and interfaces between different lithologies, and the stoping and backfilling sequence adopted from the mine plans are incorporated in building a 3-D discontinuum numerical model. The stoping was simulated in two vertically stacked horizontal layers (Fig. 6), with a total of 16 stopes. Large displacements of up to 50 cm were predicted by the model along the roof of the stopes, and a maximum surface subsidence of 22.5 cm was predicted by the model . Backfilling was found to control subsequent deformation and subsidence. The extraction of the upper orebody led to relatively higher deformations in extracting the lower orebody. Finally, the predicted subsidences at all locations along a subsidence profile on the surface are shown. INTRODUCTIONThe Luohe iron (pyrite) mine, located in Hefei city, Anhui, is an underground mine in China, being mined through the open stoping and backfilling method. The orebody lies at a depth of about 400 m and has an average thickness of 250 m (Magang Steel Company, 2012a). Discovered in the 1960s, the location has a reserve estimate of 300 million tonnes, which have been mined since 2007. The orebody has been divided by the mining company into an east and a west section to facilitate planning for ore extraction.Figure 1 shows the surface above the underground mine, which is seen to contain many human settlements including villages, pastures and other infrastructure. These locations are sensitive in that they need to be protected from potential adversities due to the underground mining, such as surface subsidence. While it may be near impossible to completely eliminate the subsidence due to ore extraction, operations such as backfilling have been adopted by the mine in an effort to substantially reduce it. Hence, this paper focuses on describing the stability of stopes in the mine and estimates future subsidence in a part of the mining region through numerical modeling."

Jan 1, 2016

By N. D. L. Burger

A low noise blast hole drilling system was developed to limit the risk of noise-induced hearing impairment in mining operations. Noise- induced hearing loss has been identified as a major occupational health risk in SA mines. The noise generated by pneumatic percussion drills is a major contributor to such noise-induced hearing loss. This motivated the South African Safety in Mines Research Advisory Committee (SIMRAC) to commission the development of a low noise rock drill system. The system had to be designed, manufactured, tested and demonstrated in a simulated underground mining environment. The specification required noise levels below 90 dBA. Other important design considerations were ease of manual transport, setting up and operation. The primary design concept was to encapsulate a standard SecoS215 pneumatic rock drill in a composite material tube. The tube is pushed onto the rock face by a pneumatic cylinder and is sealed at the rock face by an elastic seal. The drill is pulled towards the rock face by a rope and pulley mechanism fitted inside the tube. This mechanism is powered by a second pneumatic cylinder. The actions of moving and setting the drill require two persons. However, the team can carry out the drilling function itself on several drills simultaneously because of the self-thrusting design. The drill is supported by two camlocks. The exhaust (air containing dust, water, rock debris, oil and grease) is removed from the encapsulating tubes via an exhaust tube to the end of the stope. In this way exhaust noise and air pollutants are disposed of away from personnel. Tests were conducted in a test stope. Noise levels of under 90 dBA were achieved, thereby attaining the primary design specification. This was achieved without materially compromising ease of handling. Penetration rate was somewhat improved compared to that of the standard drill, so that productivity could be maintained. Keywords: Drill, rock drill, quiet, noise, mine, underground.

Jan 1, 2004

By Michael Amick, G. Swan, R. Hill, C. Pritchard

Falconbridge, a major base metal producer in the Sudbury Basin of Ontario, identified a need to find a safe and cost effective replacement for welded-wire mesh used to support loose ground during underground nickel mining. Falconbridge took a methodical approach to the concept of a spray-on liner as a screen replacement proving the strength characteristics of the liner as a safe, cost effective, and suitable method of supporting ground. Compact, hydraulic mixing and spraying equipment have been developed and are in use at the Fraser mine. The Tekflex material has been approved as a wire-mesh replacement and has been in use since November1998.

Jan 1, 2000

By Belcher C. B

The Groote Eylandt manganese ore deposits contain mainly pyrolusite and cryptomelane with lesser amounts of the manganese minerals lithiophorite, todorokite, psilomelane, and nsutite. The major non-manganese minerals which occur are quartz, kaolinite, and goethite.Determination of the mineralogy relies mainly on x-ray diffraction analysis. Quantitative methods for the determination of pymlusite and cryptomelane in Groote Eylandt manganese ores have been developed, A large amount of isomorphous substitution may occur in the manganese minerals and a number of minor and trace element associations have been noted. A correlation has been established between the potassium and cryptomelane contents for a wide range of ore types. Anomalous calcium, magnesium, and sodium values occur in samples containing todorokite, and barium is associated with psilomelane. Groote Eylandt lithiophorite appears to contain negligible amounts of lithium (<O· 05 per cent).A relationship between the H20+ and the Al203, K20, and Fe203 contents has been estahlished indicating that much of the combined water content is due to the presence of kaolinite and goethite, and cap be removed by beneficiation of the ore.

Jan 1, 1975

By M. Dobbins

The advent of the more efficient and effective rare-earth roll (RER) separator in the early 1980s began a new era of dry magnetic separation. The RER units quickly became the separator of choice within the materials processing industry. Though RER separators are now commonplace throughout the world, only modest advancements have been made to the original design. This paper details recent, more significant, rare-earth magnetic separation developments. These developments maintain the best features of existing technology while minimizing shortcomings. The discussion includes discerning features that aid in better metallurgical performance. Also discussed are improved mechanical aspects that allow for both easier operation and maintenance. Performance details from various test programs are included.

Jan 1, 2010