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By G. M. Wilemon

The U.S. Bureau of Mines has conducted preliminary investigations on the leaching of phosphate ores obtained from deposits in the western United States using sulfuric acid (H2SO4) in the presence of methanol. Phosphate extractions in excess of 80 pct were obtained on an ore sample from Pocatello, ID. Initial leaching studies using the ore as received yielded extraction levels of approximately 35 pct. However, when the sample was ground for as little as 5 min in a rod mill, in methanol, then treated with HzS04, 82 pct extraction was achieved. The R2O3-P2O5 (R2O3 = Al2O3 + Fe2O3) ratio of the starting material was 0.11. Solubilized products after leaching exhibited an R2O3-P2O5 ratio of 0.02, which is well within desired limits. These results illustrate the potential of acid-alcohol leaching for recovering phosphate values from marginal-grade ores and as an alternative to methods involving current beneficiation techniques that yield lower phosphate recoveries.

Jan 1, 1992

Because of its many advantages, roof bolting has been widely used in hard-rock underground mines. In this paper, the applicability of roof bolts to mine openings in frozen ground, and the affects of bolts on the stability of the openings are presented. A comprehensive finite-element program, ABAQUS, was used to analyze the temperature distribution, the stress field and the displacement, field around a mine opening. Openings that were supported by roof bolts and openings that were unsupported were both analyzed. The thermal and mechanical processes were treated as a quasi-coupled problem, with the thermal analyses being conducted first, followed by the mechanical analyses in each case. For the opening under consideration, i.e., a roof area of 15 m2, five to seven roof bolts are appropriate. When the number of bolts is less than five, the displacement within the ground can be improved only locally.

Jan 1, 1997

By J. A. Herbst, Z. Rogovin

In order to develop more accurate procedures for scale-up and design of semi-autogenous grinding mills through detailed mathematical models, a better understanding of the charge motion and rocklball segregation is needed. To achieve this a 0.61 m (2.0 ft) diam by 0.305m (1 .0ft) length plexiglas mill was constructed as a scale model of a commercial SAG mill. Rock motion in the rotating mill was simulated using various sizes of ceramic balls. Quantitative measurements of dynamic angle of repose, water and slurry motion, holdup and size segregation of the charge were taken. In addition, a video presentation (available to the public) was prepared to elucidate charge and water motion at various mill speeds, charge volumes, rocksize distribution, and flow rates.

Jan 1, 1990

By J. W. Merks

Spreadsheet software is an effective tool for simulating dynamic stochastic systems such as mineral processing plants. The two-product formula is used to show how to set up a Monte Carlo simulation in a spreadsheet template and how to calculate variances of dependent variables. The key to a reliable and realistic simulation model is to obtain unbiased estimates for all independent variables and variances in the set that defines the stochastic system. Monte Carlo simulation is also a powerful tool for optimizing sampling procedures, for applying sensitivity analysis and for designing and evaluating experiments.

Jan 1, 2000

By A. K. Bakshi

An on-line rheometer, suitable for use with slurries, has been developed at Michigan Technological University. This rheometer can be used with both Newtonian and non-Newtonian slurries, and produces complete shear-rate/shear stress curves which characterize the time-independent rheology of the slurry. The sensor utilizes the Hagen-Poiseuille equation and Boyle's Law to calculate the shear rate, slurry flowrate, and shear stress from a series of pressure measurements. The design of the unit allows the measurement sample to be continuously collected from operating process streams in the often-hostile on-line environment. The shear rate/shear stress curves can be used to conveniently calculate the apparent viscosity at any given shear rate, and also to measure any yield stress or other deviations from Newtonian behavior.

Jan 1, 1999

By Carl (Original by) Hrovatic

Land is a precious resource and should be treated as such by all members of our society. The soil covering this earth is only a very thin outer layer, varying in thickness from a few inches to a few feet and covering the rocks and minerals lying beneath the surface. The wise use of this valuable commodity is the responsibility of everyone. Many everyday activities disturb e earth's surface. Examples are highway construction, housing and commercial developments, agriculture, and various types of mining. This chapter discusses the relationships of the environment to land as it applies to surface operations in the coal industry. Mining by surface methods disturbs, for a brief period of time, thousands of acres of land annually. In addition, refuse piles, slurry ponds, abandoned mine structures, unprotected mine openings, and unsightly cleaning plants can also adversely affect land unless properly handled.

Jan 1, 1981

By H. H. Murray

Tactical R & D is research and development for a specific application or applications. The mineral scientist has to define and understand the physical and chemical parameters required for a specific or potential application. Then the researcher must know the structure and composition of the mineral and its physical and chemical properties. Can these properties be changed by processing particle size and shape modification, and surface chemical treatment? Examples of tactical R & D in the industrial minerals area will be described.

Jan 1, 2003

By P. Brooks, W. LaRochelle, J. M. Tranquilla

EMR's recently commissioned Pilot Plant in Fredericton, N.B. Canada, the latest and largest in the company's sequence of prototype and demonstration systems, is being used as a process development facility for mining clients worldwide. Fitted with two microwave reactors and 75 kW generators, this plant is designed as a two-stage continuous processor with a throughput in the 5-10 tpd range depending upon the material feedstream. This facility has been used principally to calcine pyrite and arsenopyrite gold concentrates although it can readily accommo­date carbonaceous materials as well as a wide range of other ore types. Engineering details of the plant and the results of the first nine months of operation are presented. The plant has proven very successful as an advanced process development facility as well as a basic production unit module.

Jan 1, 1998

By D. Dolinar, T. P. Mucho

Horizontal stresses are caused by global platetectonic forces. During 1995 alone they were largely responsible for the closing of two longwall mines in the United States. This paper presents six case histories from Pennsylvania, West Virginia, Kentucky and Alabama. In each case, a mine encountered roof falls or difficult ground conditions at the headgate caused by horizontal-stress concentrations. The problems are detailed, and the control measures adopted are described. In most cases, nearby longwall panels without stress concentrations were trouble free. The paper also discusses detailed measurements that were made at two adjacent Pennsylvania longwalls. One headgate was oriented to avoid a horizontal-stress concentration, and the other was not. Eliminating the stress concentration dramatically reduced roof support loads and roof deformation. The paper concludes that proper panel orientation and sequence is the key to maintaining headgate ground control. The optimum orientation is not parallel to the maximum horizontal stress, as previously thought, but rather it is 20o in the stress shadow of the gob. Other stress-control techniques, including artificial support, are briefly discussed

Jan 1, 1999

By Suresh K. Bhatt

A mathematically simulated modeling technique is used in this U.S. Bureau of Mines paper to represent a hypothetical mining operation with existing mining technology and prevalent mining costs. Mining scenarios are prepared and evaluated for potential benefits and costs available through computer-assisted mining. Base criteria, parameters, and methodology are described.

Jan 1, 1991

By M. R. Yalamanchili, C. A. Young, J. J. Kellar, W. M. Cross, J. D. Miller

Introduction Researchers have long speculated regarding the adsorption state of collectors on mineral surfaces. Only recently have analytical techniques become available that allow direct in situ analysis of adsorbed layers. With reactive internal reflection elements (IREs), Fourier transform infrared spectroscopy coupled with internal reflection spectroscopy (FT-IR/IRS) allows for unobtrusive investigation of the adsorbed layer (Harrick, 1979). This technique has been used both for the in situ identification of adsorbed species and for the direct calculation of collector adsorption density in real time from infrared spectral data (Miller and Kellar. 1988). The reactive mineral IRE serves both to internally reflect the infrared light and to act as a substrate at which collector adsorption can be monitored. Shown in Fig. I is a schematic of light being internally reflected in an IRE. As the light is totally reflected at the interface, an evanescent wave propagates a short distance (typically a few microns) away from the IRE, and sampling of the interfacial region occurs. Because of multiple internal reflections, great sensitivity can be obtained. Flotation systems for which this method has been demonstrated include CaF2/oleate, Al2O3/dodecylsulfate, CaCO3/oleate, ZnS/xanthate and KCI/octylamine (Miller and Kellar, 1988; Kellar et al., 1989, 1990; Miller et al., 1990). Of particular interest to flotation chemists is the conformational behavior of the alkyl chain of adsorbed collector molecules. In the simplest sense, conformation can bethought of as the relative flexibility of the hydrocarbon chain caused by rotations about carbon-carbon single bonds. The flexibility is described by the amount of gauche/trans conformations in the alkyl chain. Figure 2 shows examples of gauche and trans conformations (rotational isomers or rotamers) in a hydrocarbon chain. These two conformations are observed when the terminal methylene groups in any four-carbon subchain are on the same side (gauche) or opposites sides (trans) of the plane of the middle carbon-carbon bond. A gauche conformer (rotamer) is thus a state of maximum potential energy, whereas a trans conformer is a state with minimum potential energy. The difference between these states has been found to be approximately 0.5 to 0.8 kcal/mole (Mead et al., 1986). The relative number of butane molecules present as gauche conformers with respect to trans conformers can be calculated from the Boltzmann equation (Mead et al., 1986). At 25° C approximately 66% of the butane molecules are trans rotamers. [ ] However at 100° C, only 33% of butane molecules are trans rotamers. Exposing the hydrocarbon chain to a polar, rather than an a polar, medium should also cause an increase in the number of gauche butylene groups in a hydrocarbon chain, although this effect has been difficult to observe experimentally (Mead et al., 1986). Forming a crystalline hydrocarbon is equivalent to decreasing the temperature, which greatly increases the amount of trans butylene groups present in the chain. From the preceding discussion, a picture of the solution species of concern can be developed. The collector monomer should exhibit the greatest number of gauche rotamers and most likely will look crumpled or balled-up to reduce the surface area in contact with water. The micellar form is expected to be aggregated, with the hydrocarbon chain existing in a less polar environment. These characteristic conformational features have been examined by FT-IR spectroscopy for various liquid phases of alkanoic acids (Umemura et al., 1981; Cameron et al., 1982a; Yang et al., 1986; Wong, 1987; Wong and Mantsch, 1983; Cross et al., 1992), phospholipid membranes (Fringe Ii, 1980; Casal and Mantsch, 1985: Wong et al.. 1988;

Jan 1, 1994

By Joe Keane

DOUG HALBE: The kickoff speaker, and my unanimous choice, is Joe Keane. Joe was born in Butte, Montana, and began his association with the mining industry as an under- ground miner at age 16. Currently he is president of KD Engineering and Metcon Research. He had it lucky when he went to school because there were only 44 elements in the periodic table, I understand. [laughter] Here's Joe. JOE KEANE: I'm doing this under protest. Maybe we can start the slides. Mr. Halbe gave me this topic, but I don't like it. I don't like Mr. Halbe either [laughter] because of the way he shanghaied me into this. He called me up on the phone and said this is what you're going to speak about: "Five Things I Never Want to See Again in Plant Design," and I said, "Huh!" Then I started getting stuff from SME about how to make a presentation. I have decided to change the title to "More Than Five Things I Never Want to See in Plant Design," since you can't have a completely negative speech; you have to have other topics. So we will have some other, not completely nonrelated, topics to sort of break the tension. I tried to find a joke to open with. I talked to Omar Mutati. All of his jokes were either about Bill Clinton, our beloved President, or they were too filthy to say in a mixed group. [laughter] So I decided to start this out with a profound statement. The pro- found statement is, "The meek shall inherit the earth, but not the mineral rights," [laughter] by J. Paul Getty. J. Paul Getty was one of my favorite guys because when a real obnoxious reporter asked him one day, "How can I become wealthy?" he said, "Drill for oil and find it."

Jan 1, 1998

By Bruce B. Hanshaw

The Tertiary carbonate aquifer of central Florida is composed of about 2/3 calcite and 1/3 dolomite with minor amounts of quartz and apatite. The Mg content of the calcite is lower in the recharge areas than in the deeper confined parts of the aquifer system. Various geochemical lines of evidence indicate that much of the dolomite is of penecontemporaneous origin but that some may have been formed much later, possibly by ground water. Theoretical studies indicate that the Mg/Ca ratio in solutions is about unity for the three-phase equilibrium, calcite-dolomite-water. Solutions, such as ocean water and some subsurface brines, have Mg/Ca ratios higher than one and should represent dolomitizing solutions. In the areas of principal recharge to the Floridan aquifer, ground water is undersaturated with respect to both calcite and dolomite, and the Mg/Ca ratiois as low as 0.05. As the water moves downgradient, the Mg/Ca ratio systematically increases and approaches unity; saturation of the solution with respect to both calcite and dolomite also increases with length of travel in the system. Thus, in the zone of active potable-water circulation, the chemical process is one of dissolution of minerals until saturation is reached or exceeded. However, in the deeper brackish-water zones that underlie peninsular Florida, dolomite may be forming where the Mg/Ca ratio is greater than one. The necessary Mg may be derived from ocean water or brines recycled through the system as the hydrologic regimen is changed. The driving force may be simple mixing, relative fluctuations of sea level, or a combination of mechanisms.

Jan 1, 1972

By Angus Campbell, Michael J. Gobla

Numerous techniques for treating, controlling, and preventing acid rock drainage have been applied at the Summitville Mine Superfund Site. Challenging aspects of the remote mine site include the wide-spread occurrence of acid-generating soils and rocks, extensive surface and underground mine workings, and a cold and wet climate. Water treatment was an immediate necessity when the Government took control of the abandoned site in December of 1992. Subsequent reclamation activities have emphasized prevention and control of ARD to minimize future water treatment requirements. A combination of conventional, innovative, and experimental methods are being applied to successfully mitigate ARD at Summitville.

Jan 1, 2000

By Sergio Estebanez, Martha Gross, Ruben Rubal, Yvonnick Rescamps, Alexandre Cochennec

The Hampton Roads Bridge-Tunnel (HRBT) Expansion project in coastal Virginia, USA will add two 1.5-mile (2.4 km) TBM bored tunnels alongside two existing immersed-tube tunnels between artificial islands. The site’s unusual constraints and the requirements of a large-diameter variable-density TBM shaped the design-builder’s decisions for handling TBM inputs and outputs, siting the TBM plant and supporting equipment, and sequencing tunnel-construction operations. This paper addresses the logistics necessary to enable key functions of the 46-ft (14-m) TBM and its ancillary equipment, including transport of most materials by barge, U-turn of the TBM on an artificial island, and delivery of materials for the second tunnel through the first one while interior structures are under construction.

Jun 13, 2021

By Thomas H. Koenning

The number of spontaneous combustion incidents in the U.S. is expected to increase as the consumption of lower rank coals and the use of longwall mining becomes more prevalent. A spontaneous combustion incident holds the potential for substantial loss of life from a mine fire or explosion if not prevented or controlled at an early stage. Laboratory tests have been developed which are useful in ranking the susceptibility of various coals to spontaneous combustion. Ventilation circuits and mining methods can be designed to minimize the risk of spontaneous combustion. Early detection of spontaneous combustion is possible with the combined use of continuous monitoring, periodic gas sampling, and inspection.

Jan 1, 1989

By R. D. Begley, A. W. Khair

This paper presents an assessment of modeling techniques in predicting subsidence over longwall areas. Extensive instrumentation has been made, both at the surface and subsurface, at three longwall mines in northern West Virginia. Ground movements were monitored during a three- year period until subsidence ceased in these areas. A comparative analysis of empirical subsidence prediction techniques including graphical (NCB), profile function, influence functions (USBM, Bals', Knothe's, and zone area) will he presented. A brief geologic and topographic description of each site, along with the instrumentation and monitoring program, will also he presented.

Jan 1, 1990

By John A. Herbst

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

Jan 1, 1999

By S. Khoshjavan

Separation of refractory rock phosphate (P2O5 = 11.5%) from the Dalir area, Iran, containing quartz, calcite and other impurities, by calcination and flotation processes has been successfully used to upgrade the phosphate values. Petrographic studies of this ore showed that collophanite was the major phosphate mineral and the main gangue minerals were calcite, dolomite and quartz. The results of characterization studies showed that the liberation degree of apatite occurred below the average grain size of 140 µm. Preliminary flotation tests were used to process the phosphate samples. Results of preliminary flotation tests showed that they don?t contain any desirable efficiency (grade or recovery) of P2O5. Calcination was the best process for preconcentration of this ore. In the desliming stage, about 14.4% of total P2O5 was removed. Encouraging concentrate grades were obtained after flotation with anionic and cationic flotation, successively. The reagent schemes that have been used in this study consisted of COCO-amine acetate and fatty acid as silicate and apatite collectors, respectively, as well as fuel oil and anionic poly acryl amid as promoter collectors. The optimum pH values for direct and reverse flotations of phosphate were 11 and 6, respectively. Experiments conducted using d80=140 µm deslimed fractions has yielded an acceptable grade of more than 30% P2O5 with a recovery of more than 62%. Finally, a laboratory flowsheet for the processing of Dalir refractory phosphate ore has been proposed.

Jan 1, 2011

By R. J. Roman

Several research groups have spent considerable time investigating coarse ore leaching. Coarse ore leaching includes both heap and dump leaching. The term "heap leaching" will be used in this paper to mean any type of coarse ore leaching. The results of their work are generally in agreement: the progress of leaching can be described by the shrinking core model and its associated mathematics. The shrinking core model is schematically represented in Figure 1. The particle is contacted by the leach solution on its outside surface and the solution migrates inward by filling the pores on the particle. As the solution filling the pores comes in contact with grains of ore mineral the reagent chemically reacts with the ore mineral to solubilize the contained metal. The solubilized metal diffuses outward to the particle surface and is washed away by the leach solution flowing past the particle. The leaching reagent in the particle interior is replenished by the diffusion of reagent from the surface of the particle to the interior of the particle. If the chemical reaction between the leaching reagent and the ore mineral is relatively fast compared to the diffusion rate of the reagent in the solution in the pores of the particle then leaching proceeds from the outside of the particle inward resulting in a "shrinking core" of unreacted ore surrounded by a "leached shell". The rate controlling step in the reaction can initially be a chemical reaction between the reagent and the ore mineral grain, however, once the reaction has proceeded a short period of time diffusion of the leaching reagent through the leached shell will be the slow step and hence the rate controlling step in the production of metal from an ore particle.

Jan 1, 1992