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By Mark J. Zdunczyk

"Frac sand is industrial silica sand much like glass, foundry, filtration and blast sand. The sand must meet certain specifications set forth by the industry that consumes the product. The production and consumption of frac sand has experienced record growth in the last 10 years because of new oil and gas drilling, new horizontal well drilling, multi-stage fracturing and the stimulation of older wells that have little or no production. Frac sand is needed to “prop open” the fractures in the rock reservoirs to allow oil and gas to flow out more freely.According to the U.S. Geological Survey (USGS), the estimated production of frac sand in 2015 was 71 percent of the total production of industrial silica sand or 67.4 Mt (74.3 million st). This is a decrease of about 12 percent from 2014. However, the silica sand industry and other industry sources estimate only 50 Mt (55 million st) of frac sand were produced in 2015. In recent years both the USGS and industry studies have been very close in estimating the production of frac sand but with the recent downturn in frac sand production, perhaps, reporting to the USGS was not as accurate. These discrepancies may be that the USGS statistics are based on voluntary reporting by the industry and some companies report their approximate production, others may not. It is always difficult to obtain accurate production figures of any industrial mineral or construction aggregate operation as most companies tend to keep those figures somewhat confidential. It is certainly accurate to report that the production of frac sand had decreased since the last quarter of 2014 and through 2015. The oversupply of oil and natural gas has led to this decline in frac sand usage. Oversupply has idled drilling rigs and well completion activities. World Oil Magazine reports that 2015 was the worst year for rigs in a quarter century. The only wells being completed are those that have contract agreements to do so, others have been capped. Very few new wells are being drilled. Since about 98 percent of well completion is sand and water, the sand supply has caught up with the demand. There are some bright spots in the “oil patch” as the Permian Basin in Texas and the Woodford Shale in Oklahoma have kept pace somewhat with drilling and completion. It has been reported that the frac sand producers in the Brady-Voca, TX area are producing to nearly capacity. The northern frac sand producers like those in Wisconsin, Illinois and Minnesota are feeling the downturn because of the cost of shipping sand to these moderately active basins and plays. The “rule of thumb” is that freight is 2/3 and sand is 1/3 the cost."

Jul 1, 2016

"Twin Creeks is a gold mining complex that is part of Newmont’s Nevada operations. The mining complex is composed of two openpits, Mega and Vista, external ore sources and a set of existing stockpiles, all of which provide ore for an autoclave, an oxide mill and a heap leach. Mega pit provides sulfide ore for the autoclave, whereas Vista pit provides oxide ore for the oxide mill and the heap leach. Both pits operate the same mining equipment and their extraction sequence must, therefore, be optimized simultaneously. Stringent blending requirements are associated with the operation of the autoclave for the sulfide ore. Strategic blending optimization on a large scale has brought significant value to the operation by increasing synergies. This paper presents the implementation of a stochastic optimization framework for the long-term production planning at Twin Creeks that simultaneously optimizes mining, stockpiling, blending and processing decision variables. The uncertainty and variability associated with the different sources of material are incorporated in the optimization model by means of stochastic simulations. The stochastic solution generated shows substantial benefits by increasing forecasted recoverable gold, leading to increased cash flows, while reducing the risk of not achieving forecasts by increasing the probabilities of meeting production and blending targets.IntroductionMine operations consist of multiple components such as mineral deposits, stockpiles, external sources, mills and autoclaves. These components represent a mineral value chain, also known in the literature as a mining complex (Montiel and Dimitrakopoulos 2015; Goodfellow and Dimitrakopoulos 2016). The material extracted from the mines flows through the different components and is transformed into sellable products. This flow of material in a mineral value chain involves complex, nonlinear transformations that render the use of industry-standard optimizers difficult. Furthermore, the optimization of a mining complex can be formulated as a mixed-integer, nonlinear optimization program with millions of integer variables representing mining, blending, stockpiling and processing decisions, prohibiting the use of conventional nonlinear optimization approaches. Previous methods that consider the joint optimization of multiple components of the mineral value chain are available (Hoerger, Seymour and Hoffman, 1999; Chanda, 2005; Stone et al., 2005; Wooller, 2005; Whittle, 2007, 2010; Bodon et al., 2010). Although these methods add value by increasing the synergy between the different components of the mining complex, they rely on simplifying assumptions that constrain their efficacy, while ignoring a most critical aspect. The latter aspect includes the geological uncertainty and actual variability of the materials in the mineral deposits mined and are supplied to the related mineral value chain, similarly to conventional life-of-mine planning methods used for individual mines (Dimitrakopoulos, Farrelly and Godoy, 2002; Godoy and Dimitrakopoulos, 2011; Spleit and Dimitrakopoulos, 2017). Additional simplifying assumptions may include: the consideration of a limited number of components, the combination of different methods, the aggregation of variables, fixed production schedules the definition of policies prior to optimization, such as cutoff- grade definition or destination of mining blocks, the linearization of nonlinear transformation functions and/or the disregard for the uncertainty of several critical parameters (Whittle, 2007). The simultaneous optimization of multiple components of a mining complex was introduced by Newmont. Hoerger, Seymour and Hoffman (1999) implemented a mixed-integer programming formulation to optimize Newmont’s Nevada operations. The model is based on the work of Urbaez and Dagdelen (1999) and simultaneously optimizes the extraction of materials from multiple deposits and the delivery of ore to multiple plants, as well as as"

Dec 1, 2018

By S. N. Gurulaxmi, Veerendra Singh

The abstract discusses the increasing consumption of manganese ores and the need to utilize low-grade ores and rejects. The study focuses on developing a low-cost process using a cupola furnace to recover manganese values from these resources. The process involves smelting ore blends to produce high MnO slag and pig iron. The study investigates various factors to improve iron reduction and separation from MnO-bearing slag. The results show that the process can produce slag with MnO > 35% and Fe(t) < 5% using low-grade Mn ores. The process also achieves Fe reduction between 50 and 70%. The cupola furnace offers advantages like low cost and ease of operation, making it suitable for processing low-grade ores and rejects to produce synthetic MnO-enriched products for various industries.

Apr 1, 2022

By William L. Husk

Stockpiles have always been a necessary part of coal mining except, perhaps, when a person was mining only for the needs of his family from a seam on his home place or coal mined for the use of a small hamlet and carried to each man&apos;s house as it was mined. Then it may have been stockpiled at each man&apos;s place for several days or on the village common. Mining with this limited production required waste stockpiling. Stockpiling of the products of coal mining, both coal and waste material, has always been a necessity. Very little coal has ever been moved directly or immediately from the working face to the point of consumption and burned. It has always been expedient to stockpile the coal some- where and store the waste.

Jan 1, 1981

By O. Babak, O. Leuangthong, M. A. Cuba

Integration of data from multiple sources and/or multiple scales is a common, yet challenging aspect of geostatistical resource modeling. Common approaches to data integration are based on a cokriging framework that assumes a consistency of scale in the information that leads to a requirement to composite the data prior to model construction. It is well known that the geostatistical model parameters are scale dependent. In particular, the volume variance of integrating these various scales has a direct impact on the semivariogram that should be used in model construction and/or the assessment of volume-variance relations as it affects resource estimation. This paper reviews and compares two different approaches for semivariogram upscaling. The first approach is the scaling laws. It is an empirically derived approach, involving several simplifying assumptions, one of which is a strict assumption of invariance of the semivariogram shape. The second approach is a theoretically derived direct upscaling of the semivariogram. This approach has been around for a number of years, but is seldom implemented due to software limitations. In this paper, we present a numerical integration approach to facilitate direct semivariogram upscaling. The advantage of direct upscaling over the scaling laws approach is shown by considering a synthetic example and a case study. Further, in the case of multiple codependent random variables, the extension of the direct semivariogram upscaling to the cross semivariograms is derived and an upscaled consistent linear model of coregionalization is presented.

Jan 1, 2013

By K. K. Bhattacharyya

Vast deposits of lignite occur in the Gulf Coast states and northern plain states. Lignite resources are cited to be over 43 billion tons in the Gulf Coast states. An additional resource of 16 billion tons are reported in North Dakota (Jackson, Smith, 1981). All lignite in the U.S. is mined at present by the open pit method. Draglines and scrapers are primarily used to remove the overburden. Bucket-wheel excavators are also being considered for new mines in the planning stages. Lignite seams are mined using front-end loaders, shovels and trucks, or Easi-miners. The depositional environment of lignite is weak sedimentary soils and rock. Ground water is often encountered within the mining depth. Surface water resulting from heavy rainfall or snow melt contributes to the problems of mining. Mining depths of up to 60 m (200 ft) are under consideration. Draglines exert additional loads on the highwalls and spoil piles. The combination of any number of these factors may cause instability of the slopes. Bearing pressure, trafficability, and settlement can also be a problem for excavation and loading equipment.

Jan 1, 1982

By Drew A. Meyer

Magnetic metals are the granddaddy of products which may be recovered from municipal waste. Aside from hand-picking of newsprint and corrugated boxes, magnetic metals are usually the first items a resource recovery facility considers extracting from the solid waste stream. Magnetic metals from incinerator residues and from municipally mandated source segregation programs were first used in significant quantities by the Copper Industry. The ability of the Copper Industry to consume metals from the municipal solid waste stream raised everyone&apos;s hopes that there would be more markets for municipal scrap when more of it became available. Somehow something has gone wrong. It is widely acclaimed that scrap is an environmentally sound and economical source of iron. It is greatly in demand for Its contained energy. The prices that the steel industry has been willing to pay for the scrap during the past year are all the proof anyone should need that scrap Is desirable and sought after. But the very fact that I&apos;m speaking today on the markets for magnetic metals recovered from municipal waste indicates that something Is wrong. Clearly the problem is not that we do not need the scrap. The problem is we have not produced the kind of scrap that consumers are willing to buy - either through ignorance of what the consumers wanted or through a conviction that ferrous scrap is so obviously a good thing somebody will surely want it no matter what. Dr. Harvey Alter of the National Center for Resource Recovery has said "You can&apos;t sell garbage". In a sense that is only partly true. It really should be "You can&apos;t sell garbage for very long". The Steel Companies, in an effort to prove that steel is an environmentally desirable packaging medium, have bought some scrap that can only be described as garbage. They are to be commended for doing so. The fault lies not with the Steel Company for taking and paying for "garbage" but with the producer of that poorly prepared scrap. Far every instance where the steel industry has purchased the often undesirable product from resource recovery facility there are several magnetic installations sitting Idle because someone forgot the most essential part of producing the magnetic product - selling it to someone.

Jan 1, 1975

By S. C. Gaillard

Tailings are made of ground rock that is left over from removing valuable minerals. The tailings are usually fine particles that cause environmental issues for storage and disposal. Disposal of tailings is a growing concern, as more tailings are produced from the increasing demand for mined material (ITRC, 2008). This project proposes a way to convert the mine waste to a useful product. Tailings were selected from a South Carolina crushed stone quarry, the products of which are used for road beds, sidewalks, asphalt and driveways. These tailings were processed to generate synthetic aggregates for construction applications. The synthetic aggregate creates a product that could be used for many purposes, including aggregate for sidewalks, driveways, roads and building materials. Testing methods followed the North Carolina Department of Transportation (NCDOT) guidelines for physical testing of coarse natural aggregate, which are sieve analysis, Los Angeles abrasion, absorption, specific gravity and soundness test. The synthetic aggregate produced passed all tests for NCDOT and, in some instances, rated better than a natural aggregate. Using the tailings from the crushed stone and mining industry would convert the waste into a valuable, marketable product.

Jan 1, 2013

By B. Samanta, S. Bandopadhyay

Ore grade modeling of a placer gold deposit is considered a challenging problem even today. Typically, gold-bearing deposits show extremely erratic and unpredictable grade variation. This is principally because of isolated occurrences of gold metal within a few high-grade pockets. Because of sporadic fluctuation of high-gold-grade distribution, the overall spatial continuity of the deposit becomes poor. This type of variation is often described by a lognormal or highly skewed frequency distribution, and the spatial continuity of the deposit is characteristically represented by a variogram model that exhibits a high nugget component. Further complicating the matter is the sparse availability of drillholes to capture such erratic variation. Due to the prohibitive cost of drilling, gold grade and reserve estimations are typically carried out using insufficient exploratory data. Use of a traditional estimation technique on limited data often produces an unreliable ore grade model. Kriging and its nonlinear variation, lognormal kriging, are frequently used in gold deposit modeling (Rendu, 1979; Journel, 1980); however, kriging is flawed by the smoothing effect. Moreover, though kriging is known to be globally unbiased, it is not free from conditional bias. As a result, if a deposit is modeled using the traditional kriging technique, a high-grade zone can be predicted to be a low-grade zone and vice versa. Predicting high grade as low grade results in a missed opportunity to exploit profitable ore. On the other hand, prediction of low-grade ore as high-grade ore might result in financial loss for a mining operation. Thus, the use of kriging for ore grade mapping of a gold deposit may not be recommended. Estimation techniques (including kriging) can produce an estimate with minimum error in a minimum-error variance sense. However, no matter which estimation technique is used for grade modeling of a highly erratic deposit like gold, the error margin is bound to be high. Therefore, any grade prediction made for an unknown location is associated with high uncertainty. Since various mine-planning operations, including derivation of grade tonnage curve, pit design and economic analysis of the deposit, are based on estimated grade rather than true grade, a mining project evaluation that depends upon estimation will be subject to considerable risk. Thus, the successful design of a mining project not only depends upon accurate grade estimates, but also upon accurate assessment of uncertainty, for predictive grade is equally important. Although the kriging standard deviation is used as an indicator of uncertainty for prediction, it is flawed by characteristics related to a data-independence property. This study, therefore, investigates the stochastic simulation technique of conditional simulation for ore grade modeling of a placer gold deposit at Nome, Alaska. It is expected that the research will provide a better solution to ore-grade deposit modeling than the kriging technique because (1) conditional simulation preserves spatial continuity as well as reproduces the data histogram, thus avoiding the smoothing problem; and (2) generation of multiple realizations helps to accurately quantify the uncertainty about grade values in the deposit.

Jan 1, 2009

By J. S. Rapp

This report is based on existing reports and recently gathered field data. It discusses mineral resource potential of Tertiary playas in the Fort Irwin region. An estimated 1.3 million tons of measured salt "reserves", and 20 million tons of indicated salt resources, have been identified north of the fort. Other indicated resources include 300,000 tons of celestite, 800,000 tons of gypsum, and 10 million tons of selenite. Zeolitic tuff was mined south of Fort Irwin from 1978 to 1984, and unexplored occurrences are widespread. Calcium-bentonite is mined near Barstow, and more may exist, including valuable sodium-and lithium-based bentonites.

Jan 1, 1992

By G. J. Joy

Although rates of pneumoconiosis in coal miners have declined substantially in the United States since the passage of the Federal Coal Mine Health and Safety Act of 1969, new cases continue to occur, including cases of rapidly progressive disease. In contrast, Australia&apos;s underground coal mining industry has reported few new cases of pneumoconiosis for more than 20 years. Mortality from coal workers&apos; pneumoconiosis in official health statistics and the prevalence of pneumoconiosis among miners screened in X-ray surveillance programs are also lower in Australia. The U.S. National Institute for Occupational Safety and Health (NIOSH) was requested by both industry and labor stakeholders to examine this issue, with the ultimate aim of reducing the rate of pneumoconiosis among U.S. coal miners. A number of factors, including coal dust exposure, silica exposure and coal rank were examined as potential contributors to the above noted differences. Comparison of coal rank data from each country did not illuminate the issue. Air sample data from the coal mining industries in both countries show that coal dust levels in Australian mines are somewhat higher than those reported in similar U.S. mines; however, quartz exposure for Australian miners is lower than for many U.S. miners. If quartz is contributing to the greater number of cases of pneumoconiosis in the United States, more effective dust control measures, as well as an independent exposure standard for respirable quartz in coal mining, should be implemented to reduce this potentially disabling condition.

Jan 1, 2012

By Steven P. Oman

Large room and pillar mines are characterized by numerous and widespread working places. Ventilation requirements are high since each panel employs men and equipment that work simultaneously in multiple headings. Also, it usually is not feasible to redirect airflow from idle to active panels as the demands of each shift vary so every panel in the mine is fully ventilated at all times. Ventilation requirements will be even higher for mines that are classified as gassy. As a result of these considerations, ventilation systems for room and pillar mines are generally designed to handle large quantities of air. But as mining progresses and the mine be- comes larger, greater demands will be placed on the ventilation system. To insure that adequate ventilation is maintained at these times, ventilation engineers must anticipate problems and plan how best to deal with them.

Jan 1, 1983

By Brian H. Kaye

Efficient design of grinding circuits for efficient production of ultrafine material requires rapid feedback of information concerning the fineness of material leaving the grinding device. Generating this information requires efficient sampling and adequate rapid characterization of the material leaving the grinding machinery. Recent developments-in electrooptic inspection of dry end wet material leaving a grinding device are critically reviewed. New methods for characterizing ultrafines are discussed. A rapid operating automated cybernetic (intelligent) permeability device for automatic control of grinding circuits using Blaine index and other fineness indices is described.

Jan 1, 1983

By JIACHENG XIE, Juanli Li, Wenyong Du, Tao Cui, Mengyao Dong, Pengfei Huo

The operation of intelligent coal mining in complex geological environment is still unable to realize automation. In order to realize the autonomous cutting of fully mechanized mining equipment and improve coal production, a mining and transportation equipment dynamic advancement path planning method based on spatial kinematics coordinate deduction prediction and real-time correction prediction of coal-rock state identification of equipment cutting current index are proposed. Firstly, the spatial motion law of the mining and transportation equipment is analyzed, and the mathematical model of the spatial motion of the mining and transportation equipment is established. The relationship between the adjustment of the shearer rocker arm and the pose change of the scraper conveyor is determined, and the coordinate deduction model of the spatial advancement position of the equipment is determined, which provides a theoretical basis for the advancement path planning of the mining and transportation equipment. Then, on the basis of the mathematical model construction, combined with real geological data and equipment information, the three-dimensional dynamic planning of the advancement path of the mining and transportation equipment is carried out from the two dimensions of the horizontal advancement direction and the shearer walking direction. At the same time, the relationship between the cutting current index of shearer and the state recognition of coal-rock mass is analyzed, and the coal-rock mass state identification of cutting current and the adjustment of rocker arm model is constructed, and the real-time dynamic correction of three-dimensional path is carried out, so that the planned path can better adapt to the sudden change of real geological environment. Then, using the unity3d virtual reality technology, a simulation system for the horizontal advancement path planning of the virtual mining and transportation equipment is constructed, which simulates the real advancement operation process of the mining and transportation equipment and conducts advancement training. Finally, the dynamic advancement scheme update prediction based on the existing actual cutting but ahead of the actual cutting is realized in the virtual scene, and the optimal scheme is transmitted into the existing prediction cutting system to guide the actual physical equipment mining. The path planning method can control the coordinate position error of the advancing cutting path within 15 mm, which provides ideas for the research on the advancing path planning of fully mechanized equipment.

Nov 22, 2022

By Robert J. Brison

The intent of this paper is to try to answer the complex question: "How much grinding capacity should be designed into a new mining - milling project?" Much work has been devoted to the technical aspects of grinding, the "how" of grinding. But, in the writers&apos; opinion, the economically important subject of optimizing grinding capacity in mill design has not received the attention it deserves, at least not in published literature. For the purpose of this paper it is necessary to distinguish clearly between optimizing operation and optimizing design. Optimizing operation involves making the best use of the available plant and equipment. Much excellent work has been done and is being done in this area. In operation, one can make tradeoffs of production rate and recovery, or recovery and grade, to maximize profits. However, this must be done within the limitations imposed in the design stage. Flexibility is limited by the existing plant. In project design, on the other hand., there are no preexisting physical limitations except as imposed by nature itself; the planners and designers have considerable latitude in their efforts to optimize the overall project. They have complete control over a large number of important design variables from the mine to the finished product. The grinding process design is one of these variables. It not only determines the capital cost charges for grinding and the maximum grinding capacity that operating management will have to work with, but also determines the range of capability of the auxiliary equipment, which fixes the degree of flexibility possible in operation. This paper is concerned with optimizing design rather than operation. The terms "optimum" and "optimize" are sometimes used in a technical sense in connection with grinding, recovery or grade. In this paper, these terms are used only in the economic sense. In this age of working large deposits of ever lower grade ores, it is in¬creasingly essential to design projects and plants for optimum economics, based on the most applicable economic. criteria. Since grinding represents a large part of both capital and operating cost of the project, and largely determines percentage recovery of metal, it should be included as one of the factors in optimizing the project design. This paper is written primarily with reference to medium to large copper concentrators employing conventional wet grinding. However, the principles involved should be applicable to other ores and other methods of grinding.

Jan 1, 1972

By A. M. El Shafey, Ahmed W. Hussein, Ibrahim M. Gaafar, Mona M. Fawzy, Mohamed Diab, Mohamed S. Abu El Ghar

The Quaternary stream sediments of the Diit area, southern Red Sea coast, Egypt, were mineralogically studied for their content of economic heavy minerals. The study area covered approximately 450 km2 and included three main parts: Wadi and Delta Diit, as well as Diit lens. The mineralogical investigation revealed that these sediments contain considerable amounts of placer ilmenite, magnetite, zircon, sphene, apatite, garnet, and rutile. Also present, in minor or trace amounts, are uranothorite, monazite, xenotime, fergusonite, khatyrkite, and gold. The magnetic fractionation tests, supplemented with the XRD and SEM mineral analyses, indicated the presence of Fe-oxide minerals as wuestite, hematite, and maghemite accompanied with magnetite as products for hand magnet separation. Ilmenite separation was carried out using a high intensity magnetic separator at a current of 1 A, while the paramagnetic minerals (e.g., garnet, pyroxene, amphibole, epidote, monazite, xenotime, and fergusonite) were separated as magnetic fraction at a current of 3 A. The non-magnetic minerals (e.g., zircon, apatite and rutile, uranophane, uranothorite, gold, and khatyrkite) were obtained at 3 A current. On a mineralogical and geochemical basis, the present work suggests that Diit stream sediments should be considered as a potential source for Ti, Fe, Zr, Zn, and Cu after the physical upgrading processes for concentrating the minerals carrying the aforementioned economic elements.

Jan 21, 2022

By Sunfangze Liu, Xumeng Chen, Yongjun Peng

Efficient separation of naturally hydrophobic gangue, such as talc and carbonaceous materials, from sulphide minerals in flotation is becoming a significant challenge in many processing plants due to the need to process lower grade and more complex ores. Considering the hydrophobic nature of these gangue minerals, prefloating them at the beginning of the flotation circuit in the absence of collectors and rejecting the concentrate is a common practice to remove these gangue minerals. However, sulphide minerals, such as chalcopyrite, can become naturally floatable due to surface oxidation and therefore may float together with naturally hydrophobic gangue. In this study, a new approach was developed to maximize the prefloat of hydrophobic gangue while minimizing the loss of sulphide minerals. The new approach introduced a prefloat cleaner stage where sulphide minerals recovered to the prefloat concentrate was depressed and separated from other hydrophobic gangue minerals at a low pulp potential with the prefloat cleaner tailing fed back to the main sulphide flotation circuit. Flotation tests were conducted using chalcopyrite and organic carbon. The results show that the proposed approach can significantly reduce the loss of valuable minerals in the prefloat flotation without affecting the reject of naturally hydrophobic gangue. Applying pulp potential control at the prefloat cleaner flotation stage also reduces the consumption of reducing agents while minimizing the effect of reducing agents on downstream rougher flotation.

Nov 23, 2020

By James Addis, Zoheir Khademian, Marcia L. Harris, Charlie Matthews, Y Zheng

Shale gas wells can sometimes drill through coal reserves. Hypothetically, the caving of the gob from longwall coal mines may deform the shale gas well casing and potentially result in a breach. NIOSH researchers studied the permeability of the surrounding ground strata that may affect the potential for an inflow of gas into an underground mine environment. An overview and comparison of measured permeability values under differing cover depths (147 m and 353 m to the Pittsburgh coal seam) and mining cycle phase will be presented and discussed in this report. The findings highlight data-driven experimental evidence that affect the interaction between gas wells extraction and mining operations that may lead to potentially hazardous environments.

Feb 1, 2025

By Hongwei Wang, PEIPEI CAO, Yongping Wu, JIANQIANG JIAO

In the fully mechanized top caving mining of steeply inclined, extra-thick seams with variable angles, the mechanisms of roof rock movement, failure, caving and filling are highly complex. This is due to the varying angle of coal seam in different areas, which makes rock–equipment stability control challenging. In this paper, the surrounding rock deformation and failure mechanisms, bearing structure of the overburden, and working characteristics of the supports are elucidated. The principle and key technologies of rock–equipment stability control are presented and applied to control the overburden of the regional failure and realize safe and efficient mining of the working face.

By R. Casagrande, L. R. Moore, J. Sessoms, P. Macy

"A South American nickel mine has been producing a nickel concentrate that also contains copper and iron (15 percent nickel, 5 percent copper, 28 percent iron) for the end use of stainless steel production. A critical specification for the quality of the steel is the iron to magnesium oxide ratio (Fe:MgO), with a ratio of below 3.5:1 having a substantial impact on the nickel value. This nickel concentrate producer historically mined the sulfur-rich mineral pyroxenite but had been forced to move to a magnesium oxide/silicate (MgO/SiO4)-rich mineral harzburgite, resulting in nickel recovery being reduced to around 50 percent to maintain the required Fe:MgO ratio. In this study, ore mineralogy, water chemistry and the chemistries associated with the flotation process were evaluated in an effort to increase nickel recovery while maintaining the Fe:MgO ratio according to specification. New chemistry was introduced with the specific goal of complexing with the MgO and retarding its interaction with the bubble flow in the flotation process.IntroductionGlobal nickel production in 2011 totalled to 1,770,000 tons, according to the Raw Materials Group (2013). From 1950 to 2005 there was an aggregate 4.4 percent increase in nickel production, with a market-value high of $1,000/ton nickel reached in 1998 (Mudd, 2010). Approximately 65 percent of nickel production is consumed by the stainless steel industry, with 12 percent of the remainder used in super alloys or nonferrous alloys. Nickel imparts corrosion resistance, temperature resistance and other benefits to its alloys (Table 1) (Oberg, 1996; Cáceres, 2003). The dominant types of nickel-bearing ores are classified as either laterites (limonite: nickel-iron oxide; and garnierite: nickel hydrosilicate) or magmatic sulfide deposits (pentlandite: iron-nickel sulfide) (U.S. Geological Survey, 2013a, 2013b). In 2012, about 40 percent of the nickel ore mined was sulfidic-type ores and about 60 percent was laterite. The processing of laterite ore is expected to continue to increase as the availability of sulfidic ores continues to decline."

Jan 1, 2015