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By SIMON DIAZ-QUEZADA, HUMBERTO ESTAY

The heap-leaching process is widely used for recovering different metals. In Chile, copper production by heap leaching has been accounting for between 30 and 40 percent of annual copper production over the last 10 years. This level of production has been achieved through and supported by the use of a mathematical relation known as the leaching ratio (LR), which correlates operational parameters with metal extraction in a heap-leaching operation. In spite of the widespread industrial use of this relation, few scientific studies mention it. This disparity between industrial practice and scientific research could lead to operational decisions that lack substantial theoretical support and to scientific studies with limited industrial impact. This study describes the LR and its current uses and limitations.

By S. W. Cavender

The analysis of the results of metallurgical experiments is often complicated by experimental errors and uncertainty, the complexity of the system being studied, and the confusion of correlation with causation. Consequently, comparative statistics are used to determine if a difference exists between the outcomes of tests, an estimate of this difference, and the precision of the estimate. This paper reviews the use of significance tests and confidence intervals for the comparison of results from two tests, the use of reference distributions, and blocking and randomization techniques to reduce unavoidable sources of variability. These techniques are demonstrated using plant and laboratory data.

Jan 1, 1993

By H. Lyn Bourne

This marks the 15th consecutive year for this column. During 1995, readers were asked to supply royalty data for construction raw materials especially for states where none is available. The response was discouraging and royalty data are still missing for several states for either sand and gravel or crushed stone. Several readers have said that this article has merit but more new information is needed to justify its continuation. Several articles and pieces of news relative to mineral royalties appeared in the trade journals. R. Lee Aston (E&MJ, November, 1995, p. 16N) described South Australian royalties as amended by the government in1994. The royalty rate (a percentage) was lowered but the assessed value for minerals was raised and the current rate amounts to 20 cents//t (18 cents/st).

Jan 1, 1996

By C. Rutter, N. SHEA, K. KOLOBE

Henderson Mine’s primary production transitioned from the main portion of the 7700 level to the 7210 main panel in 2005. On the 7700 level, the southwest (SW) panel was brought into production in 2014 and produced through 2020. A-Panel was brought online in 2019 and took over primary production in 2020. The 7210 north panel is under development with production expected to commence in 2025. The 7700 northwest panel is expected to be the mine’s last production panel.

By Jerry R. Riding

Metallurgical process methods have seen dramatic improvement over the past fifty years. As these improvements have come about, more and more emphasis has been placed on obtaining accurate and rapid analysis of the metallurgical processes. Well-defined conventional laboratory analysis procedures which have proven to be reliable were developed early in the mineral industry's history; however, these conventional procedures, which have not changed appreciably in fifty years, have the serious drawback that they are too slow to be of appreciable value in automatic control of the processes. For example, the assay results normally become available to a mill operator from eight to twenty-four hours after a sample is taken. Since the desired mineral separation can only be made while the minerals are in the flotation circuit, conventional assay results provide information similar to postmortem reports. Consequently, using conventional procedures, the mill is operated with information from an earlier period of time, which may not reflect current conditions. In recent years there has been a steady increase in the volume of required samples. At the same time, labor, material, and overhead costs have continued to rise causing the cost per assay to reach an alarming level. This rising cost per assay, plus the increasing demand for rapid analysis necessary for control, has caused the mining and metal processing industries to look toward other techniques to solve these problems As a result, X-ray fluorescence which can provide on-stream analysis necessary for control, as well as perform numerous laboratory assays at lower cost and at a much greater speed than conventional methods, has gained wide-spread attention. In addition, multichannel X-ray fluorescent instruments are now available which have been perfected to the point where the analysis of the most important chemical constituents is available within one minute after a sample is presented to the X-ray analyzer. Because of these obvious advantages, extensive use is being made today of X-ray analysis in the mining industry to analyze slags, ores, and mineral content of rocks. The results are used to make quick decisions for both mining and beneficiation of metals. For example, X-ray systems which provide rapid on-stream analysis of the slurries at desired points Fn metallurgical processes have recently been developed. The successful application of these systems has moved the milling process a step closer to fully automatic control.

Jan 1, 1969

By Chen-Luh Lin, Jan D. Miller, Sindhoora Puvvada

The depletion of good-quality phosphate resources, coupled by a need to supply acceptable products at a rapid rate, while meeting the specifications of fertilizer chemical plants, is of significant concern to the phosphate industry, particularly the production of concentrates with tolerable dolomite content. Tremendous efforts have been made in the past to develop an efficient and economical process that can effectively reject dolomite. However, dolomite removal continues to plague the phosphate industry due to several process-specific challenges being encountered with various beneficiation technologies. In this regard, detailed characterization of phosphate reserves is crucial to understand textural limitations and help design appropriate strategies to achieve quality products. In this paper, the development of procedures to establish dolomite rejection/francolite recovery curves for gravity preconcentration of pebble phosphate from Central Florida is described using high-speed X-ray computed tomography (HSXCT). The developed procedure is illustrated with the analysis of high MgO pebble phosphate samples (10.39 mm × 1 mm) received from South Pasture and Four Corners locations operated by the Mosaic company. The rejection/recovery curves were calculated for each sample for five different particle size classes to observe the trend in rejection/recovery with variation in particle size. In order to evaluate the reliability of the HSXCT data, analysis using the high-resolution X-ray computed tomography (HRXCT) technique was performed on one particular sample (FC-3-1). Finally, to assess the separation efficiency, the HSXCT and HRXCT rejection/recovery curves obtained were compared to experimental gravity preconcentration results reported in the literature. In this way, liberation limitations for gravity preconcentration in the processing of pebble phosphate have been established based on X-ray computed tomography analysis.

By Leon Y. Sadler

Equations which predict the unsteady-state response of the continuous froth flotation cell to changes in operating conditions are necessary for the rational design of an automatic flotation cell control system. Unfortunately application of automatic control to froth flotation separation equipment has lagged behind application to other types of separation equipment (for example distillation columns, absorbers, liquid-liquid extractors, etc). This may be due partly to the unavailability of suitable mathematical models for predicting the dynamics of continuous mechanical froth flotation cell. This paper presents the results of a comparison of four dynamic flotation models (in transfer function form) using the same set of unsteady-state continuous flotation data. One of the transfer functions tested has been presented previously in the literature (1), another (2) has been accepted for publication, and two are given here for the first time. In addition, data are presented which confirm earlier findings that the mixing in the rotor-stator type cell is nearly perfect. The specific purposes of this paper are to: (1) provide the automatic control systems designer with several alternative dynamic mathematical models of the continuous mechanical froth flotation cell (2) give some idea of the relative a¬bility of each model to predict unsteady-state behavior by fitting each model to the same set of experimental stimulus-response flotation data and (3) provide more insight into the macro-mechanisms prevailing in the continuous mechanical flotation cell. The dynamic models which are presented and tested here all relate the time variation of the concentration of a given floatable mineral in the tailings to a time-dependent disturbance in the same floatable mineral concentration in the feed to the flotation cell.

Jan 1, 1972

By J. Mark Richardson

The use of an integrated software package to simulate and optimize the performance of mineral processing circuits is illustrated by three examples. Each represents application of the software and associated techniques to optimization of an existing plant. In the first example, a South-western U. S. copper company employs the method to simulate and improve performance in crushing, screening and SAG milling. A second copper producer evaluates equipment changes and flowsheet alternatives in a closed-circuit ball mill-cyclone operation. A Southeastern U. S. aluminum refinery optimizes performance of a dry milling and classification circuit for production of carbon particles used in anode casting. Graphical and tabular data describe the circuits simulated and the results achieved in each example.

Jan 1, 1990

By Jacob L. Brinkman, Catherine E. Johnson

Researchers are exploring the use of unmanned aerial vehicles (UAV) to measure concentrations of gas emissions in situations where such measurements are otherwise extremely difficult to obtain, such as NO and NO2 (NOx) emissions from surface mine blasting. Recently, countries have imposed or are planning to impose surface blasting gas pollution regulations, which creates a need for an improved understanding of UAV-based gas measuring systems. The experiments detailed in this paper were performed to determine if airflow generated by the rotors, also known as downwash, unnaturally alters concentration measurements. Downwash turbulence could create locations of varying pressure, which could affect density-based concentrations as measured by some governing entities, including the Occupational Safety and Health Administration (OSHA). 

By Peter Amelunxen, Brandon Akerstrom

Since its introduction 40 years ago, the compartmental model of flotation has been used to predict the performance of mechanical flotation cells. However, it has found limited success for modeling dual-chamber machines and, as a result, engineers have adopted empirical correction factors usually derived from field audits of industrial cells to predict the performance of dual-chamber flotation cells. This paper introduces an extension of the compartmental model that applies to both single- and dual-chamber cells. The model is tested against pilot test work performed at Capstone’s Pinto Valley concentrator, and then used to evaluate the key operating and design parameters of dual chamber flotation cells. The results suggest that the design of the mixing chamber — for example, whether it is pneumatic or mechanically agitated — is not a significant contributor to overall machine performance. The work also suggests that the highest recoveries are achieved when the froth recovery is high, and longer separation chamber residence times and/or higher internal circulating loads are only beneficial when the froth recovery is low. Lastly, the results show that the single most important driver of the machine performance is the froth recovery of the separation chamber.

Mar 1, 2025

By Snehamoy Chatterjee, Dharmasai Eshwar, Aref Majdara, Rennie Kaunda, HUGH MILLER

The U.S. mining industry has made progress in reducing accidents and injuries, but interpreting safety data remains difficult due to changes in workforce size and productivity. The Mine Safety and Health Administration (MSHA) uses tools like the pattern of violation (POV) and significant & substantial (S&S) calculator to monitor safety, though these have limitations. To address this, we developed an information entropybased risk (IER) index that combines various safety metrics, including citations, penalties and injuries. Using data from 2011 to 2020, the IER index was validated with statistical methods and clustering algorithms to ensure it accurately reflects risk levels. The analysis showed clear differences in risk across mining sites, proving the index’s usefulness. The IER index was then applied to a coal mine to demonstrate its effectiveness. This new tool can help mining companies better assess their safety risks and take action to improve workplace safety.

Nov 1, 2024

By Georgios Bartzas, Vasiliki Karmali, Konstantinos Komnitsas, Anna Kritikaki, Dimitra Vathi, Stylianos Tampouris, Arne Peys

Large volumes of slags, with varying mineralogical and geochemical characteristics, are produced annually by the ferrous and nonferrous metallurgical industry. Most of them are considered as potential secondary resources and may be valorized, following the principles of circular economy, for the recovery of critical elements, including energy transition metals. Apart from the economic benefits, valorization of slags may contribute to the competitiveness of the metal industry and the conservation of natural resources. Valorization also results in minimization of environmental impacts on soils and waters in slag disposal areas, due to the prevention of solubilization and subsequent migration of potentially hazardous elements. The present study utilizes ferronickel (FeNi) slag for the production of alkali-activated materials. The effects of the main experimental parameters, including sodium hydroxide (NaOH) molarity, silica/sodium oxide (SiO2 /Na2O) molar ratio in the activating solution, precuring and curing time, curing temperature and aging period on several properties of the final products, are assessed.

Apr 1, 2025

By Steve Kral

Americans are taking a more critical view of various environmental laws because the effects of those laws are becoming more pervasive and intrusive, according to William Perry Pendley. And Secretary of the Interior Bruce Babbitt is seemingly so unpopular in the West, he no longer campaigns there for Clinton Administration policies. Pendley is president and chief legal officer of the Mountain States Legal Foundation, a public service, non-profit law association that takes on property rights cases for people who cannot afford representation. He was one of the luncheon speakers at the 101st Northwest Mining Association meeting, held in Spokane, WA in early December.

Jan 1, 1996

By Cory Dippold, Michael Mett, Jérôme Steinkühler, Kristi Latimer

For decades, tunnels of all types have been a significant part of our infrastructure. In particular, water tunnels carry millions of gallons of fresh water every day to major metropolitan areas and surrounding communities. As a critical piece of public health infrastructure, it is important to inspect the condition of these tunnels regularly to ensure reliable and continuous operation. A specific challenge with water infrastructure is that it’s often difficult or impossible to shut down the system for long periods of time to perform the needed inspections. The latest method of tunnel condition assessment is the use of hybrid reality 3-D scan data. Photogrammetric and LiDAR based 3-D data ensure a reliable and objective view of tunnel conditions. The data can be used to support a detailed digital inspection including the compilation of databases that consist of a wide variety of deficiencies such as cracks and spalls within the structure. Mott MacDonald, a design engineer company worked closely with Dibit, used a 360-degree scanning system to collect high-resolution photogrammetric and LiDAR data on a recent project involving a water tunnel. The allows for full 360-degree coverage of the tunnel surface including a water covered invert. It operates at walking speed and ensures a fast and reliable data acquisition which can reduce the time of tunnel shutdowns. Several allocated inspection weeks can reduce to few days, with the final work product being a higher quality and more complete deliverable than traditional inspection methods would have provided. The true-color 3D-model has a photo resolution of 1 × 1 mm (0.039 × 0.039 inches) which makes cracks visible with a width of down to 0.3 mm (0.011 inches). The assessment of water tunnels, its technical challenges and the results of the 3D-tunnel inspection case study are illustrated and described in this publication.

Dec 1, 2022

By Chaoxun Zhao, TAIYOU LI, JIAQI JIN, Chen-Luh Lin, Jan D. Miller

A large portion of the energy consumed in copper concentrators is used to reduce the particle size of the feed by crushing and grinding. The cost of metal production could be reduced if low-grade particles of centimeter size were removed prior to further processing. Two copper sulfide ore samples (3 × 1 cm) from Arizona were analyzed by micro X-ray computed tomography (Micro-XCT) to determine the grade of copper sulfide in each particle. For copper ore sample A, a significant number of particles contained very low amounts of copper, while some particles had copper sulfide grains of millimeter size. Based on Micro-XCT, it was expected that 85 percent of copper for sample A could be recovered at 65 percent of mass rejection during preconcentration by sorting. However, in sample B (a different copper ore), distribution of copper sulfide was dispersed primarily in each ore particle, so for the particle size class of 3 × 1 cm, liberation of copper sulfide and gangue minerals was not significant. In view of the XCT results, dual-energy X-ray radiography was used as a basis for sorting. Pilot-scale X-ray sorting of sample A (10 × 1 cm) showed 31 percent rejection of a 0.08 percent Cu gangue product with a corresponding recovery of 90 percent copper.

By Joseph W. Murray

GENERAL DESCRIPTION The undercut-and-fill method of mining was devel¬oped by Inco Ltd. in the Sudbury district of Ontario, Canada, to deal with abnormal ground conditions en¬countered in pillar recovery. Although it is now some¬times utilized as a primary stoping method, the main application continues to be in pillar recovery. In any mining method in which fill is employed, pillar systems tend to fail gradually as stoping pro¬gresses. As a result, most pillars are completely destressed and broken by the time pillar recovery com¬mences. Control of the back in such ground becomes a major problem and is contingent on local conditions as they exist in the workplace. In most mining methods, operations such as drilling, blasting, slushing, and tim¬bering can be readily assessed and the mining cycle pre¬dicted. However, in the mining of pillars with overhand methods, the time and effort required to maintain a safe back varies to a quite unpredictable extent. For years the square-set method was the most effective means available for pillar recovery. However, in areas where bad ground was encountered, square setting was a costly and sometimes hazardous method. As the tonnage mined from pillars increased, it was apparent that a safer and less expensive approach was required. Past experience indicated that the best way to deal with broken ground was to mine from the top down. Top slicing systems were examined but were rejected due to the major sub¬sidence which resulted. However, ideas generated from studying top slicing finally developed into the present method of undercut-and-fill. This method, which has almost completely replaced square-set mining, exhibits reduced costs, has improved safety and efficiency, elimi¬nates the factor of bad ground overhead, and allows a closer prediction of the actual mining cycle. The result is more accurate scheduling of pillar production. This factor is of increasing importance as the tonnage from pillar recovery increases in relation to total mine pro¬duction. Undercut-and-fill is a method of extracting a block of ore by mining successive cuts, working from the top down. After a cut of ore is completely mined out, lami¬nated timber stringers are constructed along the sides for the full length of the cut. Round logs covered by a wire screen are laid across the stringers to form a mat. The cut is then tightly filled with hydraulically placed cemented sand fill. Mining is then resumed on the cut immediately below the mat. As the cut advances, the timber stringers are supported by round timber posts seated on the solid bottom of the cut. Drilling, blasting, muck removal, and timbering operations are repeated until all the ore in the cut has been removed. At this time, another log mat is laid and the cut is filled. This sequence is continued until the block has been mined from level to level. The basic principles of undercut-and-fill can be adapted to a variety of mining situations. It can be applied transversely or longitudinally in ore bodies of varying width, that dip from vertical to flat lying. The method can be applied using conventional equipment or it can be mechanized through the introduction of small diesel or air-powered units for muck removal. Undercut¬and-fill is a selective method, ore recovery is high, and dilution can be controlled to an acceptable level. How¬ever, it is a high-cost, labor-intensive method and as such its use is restricted to areas where the less costly meth¬ods of ground support are not successful or where bulk mining methods are not adaptable. One basic require¬ment for undercut-and-fill is an adequate source of hydraulically placed cemented sand fill and a dependable sand plant and distribution system. The success of the undercut method is to a large degree dependent on the competence of the fill placed in each of the successive cuts. In theory, the weight of the fill on each cut is supported in part by the cemented sand itself as it binds to the rough sides of the mined¬out areas next to the pillar walls, and in part by the tim¬ber support. As mining progresses beneath the mat, a downward pressure is exerted within the cemented fill and a voussoir arch develops above the mat, across the full width of the cut. This supports the major portion of the load. The log mat and posts have a double func¬tion in that they carry the remaining weight not sup¬ported by the voussoir arch and in addition prevent any pronounced settling of the fill mass. Excessive settling breaks the bond between the cemented fill and the pillar walls, eliminating the arch effect and transferring the entire load to the mat and posts. The theory of a voussoir arch forming within the cemented sand fill mass is substantiated in practice by the fact that pillars have been mined from level to level with no more significant weight on the bottom cuts than was experienced on the top cuts. In effect, as mining progresses downward, there is no additional transfer of weight from previous cuts to the cut being mined. APPLICATION OF UNDERCUT-AND-FILL Because of their size, the Sudbury ore bodies are, for the most part, mined transversely and, to a considerable extent, by filling methods. Transverse stoping blocks are designed with 9-m (30-ft) crown pillars established be¬low each level and with stopes separated by vertical rib pillars. In past years, floor pillars were left above the level as well, but present practice favors the silling of primary stopes at the base of the rail. Rib pillars are designed to meet the ground control requirements of the primary stoping methods. Local conditions and past experience generally dictate their size. Historically, since the square-set method was to be used for recovery, rib pillars were designed to accommo¬date standard 1.7-m (5'h-ft) sets. A typical rib pillar is four sets wide [6.7 m (22 ft)] when located between two square-set or cut-and-fill stopes having a width of 8.4 m (27.5 ft). When the undercut-and-fill method was de¬veloped, a mat width of two sets was adopted. This di¬vided each cut of the common four-set pillar into two

Jan 1, 1982

By K. K. Kohli

Since the adoption of the Surface Mining Reclamation and Control Act of 1977, which mandates that surface subsidence be an intergral part of the underground coal mine design, there has been a sudden rise of demand on guidelines for minimizing surface subsidence and its associated structural damages. Unfortunately there is no sufficient amount of systematic subsidence data to fill such a gap, although considerable research has been devoted to the subsidence-induced damages of surface structures in the past. However, it was said that many surface subsidence surveys have been performed and monitored by coal companies during the past twenty years, and that it will be a great source of information for subsidence engineering design if they can be collected and assembled together. An effort was therefore initiated in the Department of Mining Engineering, West Virginia University, under contract with the U. S. Bureau of Mines in December 1978 to contact each individual coal company in the Northern Appalachian Coal Field for any surface subsidence survey data. After 10 months' survey, the data collected include 17 longwall panels and 2 room and pillar sections. The data in-each panel and section cover the complete set of subsidence survey raw data, underground mine layout maps, surface topo maps, geological loggings showing the stratigraphic sequences and thickness of the overburden, and if available, locations and types of surface structures. On-site visits were followed to study the surface terraines and structures. Interviews were conducted with the owners of the surface structures in most cases about, if any, the history and characteristics of damages.

Jan 1, 1980

By Philani Larrance Ngwenyama, Ronald CW Webber-Youngman

The survival chances of trapped miners in underground mines depend on how quickly they can be located and rescued post-accident. During entrapments, emergency rescue is highly desired but can be hindered by the lack of positioning information when a fit-for-purpose missing-person locator system is not available. Various types of missing-person locator systems are available to aid search-and-rescue operations. From the wide range of the available systems, selecting the most suitable one becomes the next challenge. The available systems have not been measured if they are fit-for-purpose or not, and to what situation. This study proposes user requirements that can be used as a guideline to facilitate the system selection process. These user requirements provide a framework for the design and development of a fit-for-purpose missing-person locator system. The user requirements can also be used for evaluating the performances of a particular system, predict its success, and also drive future research toward developing new technology to enhance the capabilities of the current systems.

Apr 1, 2024

By Rongjie Kong, Shiwei Wang, Dongjiao Gui

Metal cations have significant effects on the flotation of coal and minerals. In this study, the effects of monovalent cations ( Na+ and K+) on the flotation of low-rank coal (LRC) were investigated using flotation and particle–bubble attachment experiments and through X-ray photoelectron spectroscopy (XPS) and molecular dynamics simulations. Oleic acid (OA), methyl linoleate (ML), hexadecyltrimethylammonium chloride (CTAC), ricinoleic acid (RA), and kerosene were used as flotation collectors. The flotation experiments revealed that the flotation yields of LRC improved when OA, ML, RA, CTAC, and kerosene were used in pure deionized water. However, flotation was suppressed for these collectors in the presence of K+ and Na+ ions. In contrast, when using CTAC, the flotation yield increased in the presence of these ions. Specifically, the flotation yield increased from 41.24 to 87.03% when 2.0 kg/t CTAC was used in 10 mmol/L NaCl solution. Particle–bubble adhesion experiments and XPS revealed that the hydrophilic groups of CTAC were adsorbed on the LRC surfaces by electrostatic forces, whereas the oxygen-containing functional groups of OA, ML, and RA formed hydrogen bonds with the LRC surface in pure water. Finally, the simulating result revealed that the hydrophobic ends of the OA, ML, and RA collectors hinder the flotation of LRC by adsorbing monovalent cations, whereas the adsorption of monovalent cations on the hydrophobic end of the cationic surfactant (CTAC) promotes flotation via strong electrostatic interactions.

Jan 31, 2024

By Charles T. Holland

INTRODUCTION Insofar as I am aware, the term rock mechanics was not in the English dictionary in 1930 when I started my graduate program at West Virginia University. Hence, I never thought that I was undertaking studies in rock mechanics when I undertook to write a thesis on the physical properties of West Virginia coal. In this case, the subject was primarily concerned with the compressive strength of coal, the elasticity of the coal, the physical weathering properties of the coal and its friability. These days investigations of rocks pertaining to such properties are included in the term "rock mechanics". Other than this aspect, the principle interest in this part of my program was that I became interested in the strength of coal from the standpoint of structural purposes, and also became cognizant of its elastic properties as well as its energy storing properties. This research also tied in with a remark that Professor Lawall made in a Mining Methods class in 1928 when he remarked that a peculiar thing was happening in the southern part of West Virginia, namely, in the Pocahontas coal field. His remarks were to the effect that pillars were blowing up in the mines and when asked why he replied the cause was not known. The failure of three-inch coal specimens, especially those in stronger coal, in non-hydraulic actuated testing machines was reminiscent of his description of those pillar bursts or bumps.

Jan 1, 1971