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By William A. Vogely, John E. Tilton

INTRODUCTION Mineral commodities are normally separated into three generic classes-metals, nonmetals, and energy minerals including oil and gas as well as the solid fuels. Metals, the focus of this chapter, encompass a large number of different substances. The U.S. Bureau of Mines, for in- stance, has commodity specialists following trends in over 40 metal products of importance to the country's economy and well being. Ranging from aluminum to zirconium, the metals display an incredible degree of diversity. Some such as lead are heavy, others such as magnesium are light. Some such as copper are good conductors of electricity. Others such as silicon are semiconductors. Mercury is found in liquid form, while some metals melt only when heated to extremely high temperatures. Iron and steel, aluminum, and copper are consumed in particularly large tonnages in a multitude of end uses, while many minor metals are needed in only small amounts in a few highly specialized applications. The use of some metals can be traced back into history for millennia, indeed back to the bronze and iron ages, while the commercial consumption of aluminum and other newer metals is less than a hundred years old. Some metals are extracted from large open pits, others are dug out of deep underground mines, and still others are processed from the sea. Mining and processing can be relatively uncomplicated and inexpensive, though in most instances highly sophisticated technology is necessary and the costs are high. Some metals are produced mainly as byproducts of other metals. Some are recovered in large quantities from the scrap of obsolete equipment and demolished buildings. Some are mined in only a few locations and traded worldwide, others are produced in many different countries. Some are sold by numerous firms at fluctuating prices determined on competitive commodity exchanges, others are produced by only a handful of firms and sold at stable producer-prices. This diversity makes the metals interesting, indeed fascinating, to study. Yet, it also poses problems, for each metal in its own way is unique. There is no general model or economic analysis applicable to all metals. Rather each must be considered individually, so that the analysis or model takes explicit account of its particular features. This means that a single chapter cannot begin to cover comprehensively the economics of all metals, and no attempt to do so is made here. Instead, we will concentrate on illustrating the usefulness of relatively simple economic principles, particularly those associated with supply and demand analysis, in understanding the behavior of metal markets. The next section begins by exploring the nature of metal demand. It is followed by an investigation of metal supply- from individual product production, from by- product and coproduct production, and from secondary production. The final section then illustrates the usefulness of the concepts introduced in earlier sections by using them to analyze

Jan 1, 1985

By J. Espí

The mineral price assigned in mining project design is critical to determining the economic feasibility of a project. Nevertheless, although it is not difficult to find literature about market metal prices, it is much more complicated to achieve a specific methodology for calculating the value or which justifications are appropriate to include. This study presents an analysis of various methods for selecting metal prices and investigates the mechanisms and motives underlying price selections. The results describe various attitudes adopted by the designers of mining investment projects, and how the price can be determined not just by means of forecasting but also by consideration of other relevant parameters.

Aug 1, 2013

By Alan Bauer

In recent years there has been increasing interest in employing the technique of explosive casting in strip mines. Explosive casting, applied to dragline mining, describes the procedure whereby the overburden is horizontally displaced by blasting causing a portion of the material to be thrown into the previously mined cut. Therefore, it is not necessary to subsequently excavate this waste with the stripping equipment. In addition, allowing the overburden unrestricted movement during the blast most often results in improved fragmentation and enhanced machine productivity. The method is receiving attention because the capital and maintenance costs of stripping equipment has risen rapidly in relation to explosives costs. Improved productivity is necessary to maintain unit costs at an acceptable level.

Jan 1, 1983

An incremental-analysis-based stope design and cutoff grade calculation method was developed for an underground metal mine project. Traditional stope design methods are typically very time consuming and lack consistency and accuracy by manually drawing stope shapes. For quick reserve calculation and economic analysis, a new method named "3D incremental analysis based stope design" was created for mine-wide stope designs. The key idea of this method is to replace engineers' manual checking of each incremental ring with one calculation of all the rings, and to build the final stope shape with the maximum values. This process was realized through a 3D ring grid setup and proper naming conventions for rapid calculations. With this unique but practical method, multiple options for a mine design were completed within a short time before the final selection of optimal cutoff grade and best stope designs for the project.

Jan 1, 2012

By J. Fuchs

This paper describes the mechanized narrow vein cut-and-fill approach used for the Deep Copper orebody at Falconbridge Limited's Strathcona Mine. Strategies for achieving high productivity while maintaining ground stability at depth and controlling dilution are discussed, including the use of mini-electrohydraulic drilling equipment, containerized truck haulage, consolidated rockfill placement techniques, and a miners' incentive system.

Jan 1, 1992

By J. B. Davis

Isotope analyses distinguish biogenic sulfur ores from non-biogenic ores, but do not distinguish bioepigenetic from biosyngenetic ores. Sulfur deposits of salt dome caprocks and of bedded Permian evaporites of west Texas, however, are clearly bioepigenetic. Anhydrite, introduced by salt diapirs into geologically younger sediments, is converted biogenically to sulfur and calcite in the presence of petroleum; for example, in Challenger Knoll, a salt dome at a water depth of 3600 m in the Gulf of Mexico. Bedded evaporites of west Texas in association with petroleum show an obvious epigenetic replacement of the anhydrite layers by biogenic sulfur and calcite

Jan 1, 1978

By Edward Holloway

The basis for the selection of the ultimate pit for an open pit mining operation is generally opaque. Some form of value-based analysis will generally guide the final decision; however, the value will often gradually plateau whilst the ultimate pit size continues to increase. There is no established framework to guide specialists in the selection of the ultimate pit, with such decisions regularly made on a somewhat arbitrary basis. The key component that is missing from the analyses typically used to select the size of the ultimate pit is risk. Once risk is quantified within the analysis framework, the decision-making range is significantly reduced, and the process for selecting the ultimate pit becomes more consistent, replicable, and defensible. This paper provides an approach to including risk in the process used to select the ultimate pit.

Feb 21, 2024

By K. L. Boyd

"Can the ever-increasing tonnages of ore and waste being mined today be accommodated simply by using bigger and better crushers? This paper reviews the latest primary crushing and large cone crusher designs. It highlights how—in addition to using the larger crushers now available—maximizing the utilization percentages in each of the four stages of the rock size reduction circuit will assist in meeting the larger production requirements of existing and new mining operations. Its goal is to help consultants and operators select the optimal equipment and custom-designed items in the material handling flowsheet from the mine to the mill, maximizing operating hours per year. INTRODUCTION Are larger crushers the answer to meeting the demands of existing or new mining projects for increased tonnage? Boyd (2002) predicted that larger crushers for primary and fine crushing would be beneficial and contribute to the further development of mineral processing. Larger crushers for primary and fine crushing applications are now available. The rock size reduction process from the mine to the selected milling process facility has not changed since man first broke a rock to get at the interesting mineralization within. The rock size reduction process circuit from the mine to the mill can be summarized in four stages: • Stage 1: Mining (rock breakage and fragmentation) • Stage 2: Pre-screening (scalping) • Stage 3: Primary crushing • Stage 4: Fine crushing (secondary, tertiary and quaternary) Plant throughput and ore delivery schedule will form the basis for flowsheet design and equipment selection. Once the project design criteria and the mine plan have been established, the circuit’s utilization percentage (percentage of hours when the circuit is being utilized) can be optimized for each of the four stages. The mining and process departments are the key stakeholders in the selection of the final comminution circuit, and both departments should be familiar with and contribute to the design of the circuit. This paper focuses on the four stages of a rock size reduction circuit from the mine to the mill, equipment selection, various ore and waste handling flowsheets, and improvements in crusher station design, all with the purpose of maximizing availability and plant utilization percentages. What is a large tonnage? From 1907 to 1914, the American Panama Canal excavated 300 million tonnes of material in 7 years (History of the Panama Canal, Wikipedia). Today’s large mining operations can move the same material in 10 months, using large crushers or multiple crushers for ore processing and large crushers and a mixture of truck haulage and conveyors for handling the large waste tonnages. Some examples include:"

Jan 1, 2017

By M. R. Paterson

Operational and economic factors tend to favor the application of continuous processes in preference to batch processes in the majority of mineral processing applications. In this paper, the requirement for a Continuous Elution Process is established and the development of a large-scale pilot plant is described. It is based on a Continuous Elution apparatus which has a number of special features. These are the subject of various patent applications. The apparatus is suitable for adaptation to the AARL, Zadra and other methods of elution. The performance of the Atmospheric Continuous Elution System (ACE) is concluded to have significant advantages over the batch process.

Jan 1, 1986

By T. G. Rozgonyi

The basic goal of this investigation was to determine the degree of drying of high moisture lignite through the use of high temperature and pressure steam autoclaves. Specific items studied were: a) the effect of lignite particle size, b) steam temperature and pressure required, and c) the time of ahydration. Although removal of sodium, ash, sulfur and other ash-forming minerals was not the goal of this study, basic analysis of effluent water showed organic material and alkalai metal content. Removal of inherent moisture from run-of-mine lignite was tested by lock-feeding the lignite, which was previously sized by screening into 25 kg autoclaves. High pressure, up to 4.053 MPa (588 psi), saturated steam was then introduced into the pressure reactor. Reaction time, pressure, temperature, and depressurization rates were strictly controlled for each reactor test run. Results indicate that about 80% of lignite total moisture was removed, including some of the inherent moisture, yielding a non-oxidized, and thus stable, lignite product. As stated, a side benefit occurred as some reduction of non-combustible portions of the lignite also took place. The conclusion reached as a result of the tests is that the steam-drying process can be successfully applied to reducing moisture in lignite, and may be considered for additional studies on acceleration of the coalification process. On the basis of the data presented, the author believes that lignite can be economically upgraded in steam autoclaves by simultaneously reducing the moisture content by 80 percent and the sulfur content by at least 50 percent. Upgrading the lignite by this method will result in large energy and financial savings.

Jan 1, 1984

By Niles E. Grosvenor

One of the most important considerations in the efficient operation of an under¬ground mine is the haulage system. Often the determining factor between profit or loss is the quick removal of ore and waste from the working places to secondary and main-line haulage areas, and so on to the outside. Important, too, is moving supplies from the surface to the working faces so that the loading process can continue with little interruption. Men must he transported in a rapid but safe manner. It has been through the efficient use and generally the combination of mine cars, track, belt conveyors and rubber-tired haulage equipment that underground operations have been able to compete with the more popular strip or surface mining. As near-surface ore bodies are exhausted, underground haulage will play an expanding part in economically furnishing the world's needs for all types of minerals. The choice of underground haulage equipment, wherever possible, should be one that will give the smallest overall cost of ore removal during the life of the mine while meeting necessary safety requirements. The reader is referred to Sec. 12 for equipment such as scrapers and load-dump-¬haul units that perform loading as well as haulage duties. 14.1-MINE CARS AND TRACK NILES E. GROSVENOR Main-Line and Secondary Haulage-Many mines today use a combination of belt and rail haulage. Even if a- belt system is used to carry the product from the face to the surface, track is used to transport workmen and supplies. A track system, when properly installed, will provide interruption-free and safe haulage. Schrecengost 2 lists the following as major advantages of track haulage: 1. Safety in transporting men in and out of the mine in personnel cars. 2. Easy and rapid transportation of supervisory personnel. 3. A temporary shutdown occasioned by a roof fall or power failure along the haulage system will not shut down the production areas. 4. Quick availability of repair parts and supplies. 5. Large pieces of coal or rock can be handled without damage to the haulage equipment. 6. In areas where quality fluctuates noticeably, different cars may be separated out for special preparation. 7. Rock or equipment may be loaded and moved out of the mine without interference with the production or preparation of the coal. 14.1.1-MINE CARS Mine cars with steel bodies are used in all types of present-day mining. Wooden cars usually are more bulky and less resistant to wear and damage, but are more easily repaired. Regardless of the type of mine car selected, it is most practical to standardize on one type or make to simplify repairs and limit the amount of spare parts necessary to stock. Rigid-body flat-bottomed cars are simpler and usually lower than others of equal capacity. Advantages are: ease of loading because of the low sides, simplicity, cheapness and high ratio of capacity to weight. The disadvantages include the

Jan 1, 1973

By James G. Mock

The choice of equipment to be applied to a given installation by the Application Engineer begins with the data as presented to him by the user. This point in the relationship establishes a communication link, which will decide whether or not the correct piece of Overhead Equipment is applied at the most economic advantage to the user. The role played by the user cannot be minimized. No one knows better than he, just what work he expects to accomplish with this piece of machinery. However, all too often, he oversimplifies the requirements, and along with minimal crane and building parameters, merely refers to one of the following crane classifications as defined by The Crane Manufacturing Association of America, as shown in Figures 1, 2, 3, 4, 5, 6 and 7. This approach places the ultimate user in an unfair position, since he has then assumed the status of the machinery designer and must, therefore, assume the responsibility of the success or failure of the operation of that piece of machinery. If the user selects a Class "C" crane for his job requirement, when actually a Class "B" crane can adequately handle the work load, he is not offering the most economic solution to his company and added little to the cranes service capabilities.

Jan 1, 1973

By J. D. Noll, J. A. Organiscak, A. B. Cecala

Significant strides have been made in optimizing the design of filtration and pressurization systems used on the enclosed cabs of mobile mining equipment to reduce respirable dust and provide the best air quality to the equipment operators. Considering all of the advances made in this area, one aspect that still needed to be evaluated was a comparison of the efficiencies of the different filters used in these systems. As high-efficiency particulate arrestance (HEPA) filters provide the highest filtering efficiency, the general assumption would be that they would also provide the greatest level of protection to workers. Researchers for the U.S. National Institute for Occupational Safety and Health (NIOSH) speculated, based upon a previous laboratory study, that filters with minimum efficiency reporting value, or MERV rating, of 16 may be a more appropriate choice than HEPA filters in most cases for the mining industry. A study was therefore performed comparing HEPA and MERV 16 filters on two kinds of underground limestone mining equipment, a roof bolter and a face drill, to evaluate this theory. Testing showed that, at the 95-percent confidence level, there was no statistical difference between the efficiencies of the two types of filters on the two kinds of mining equipment. As the MERV 16 filters were less restrictive, provided greater airflow and cab pressurization, cost less and required less-frequent replacement than the HEPA filters, the MERV 16 filters were concluded to be the optimal choice for both the roof bolter and the face drill in this comparative analysis case study. Another key finding of this study is the substantial improvement in the effectiveness of filtration and pressurization systems when using a final filter design.

Aug 1, 2016

The Longwall Strata Control and Maintenance System (LoSCoMS) is designed to monitor shield pressures in real-time from longwall faces and to provide on-line information related to underground strata behavior and longwall mining operation. The information includes shield pressure data with statistical analysis of setting, developing and final pressures, prediction of shield pressures for the following shift or day, etc. and maintenance data on the shields. The LoSCoMS has been installed and tested at Shoal Creek Mine operated by Drummond Company, Inc. The system is providing valuable information to mine operators for better understanding of underground behaviors. As a result, it has become an effective tool for minimizing ground control hazards and reducing out of seam material.

Jan 1, 1997

By Fathi Habashi

THE MINERAL monazite (µ?v??e?? = to be alone) is a rare earth phosphate containing some thorium and small amounts of uranium. It is widely distributed in the earth's crust. It occurs in small proportions in granites. Table 7-1. Mineralogical analysis of Rosetta black sands, U.A.R. (Nakhla, 1958). [Black sands Concentrate Augite 10.8 - Calcite 1.1 - Felspar 0.1 - Garnet 1.8 - Hornblende 2.4 - Ilmenite 50.7 8.0 Magnetite 15.3 Monazite 1.1 84.3 Quarz 7.3 - Rutile 1.0 0.5 Titanite 0.2 - Zircon 7.3 7.1 Others 1.0 0.1 100.0 100.0]

Jan 1, 1970

By B. Cavender

Mining managers trying to rapidly reduce production costs tend to implement a traditional set of topdown managerial practices: reductions in production volume, employee layoffs, renegotiation of supplier contracts, cancellation of employee training, restrictions on travel, reductions in office supplies, and so forth. While these practices do reduce costs, the benefits are often limited in both magnitude and duration, and the workforce is usually left demoralized. Successful cost-cutters take a different approach. They make the continuous reduction of costs a priority for all members of the organization, whether managers or workers. The culture of these firms emphasizes the commitment, voluntarily given, of individuals and work groups to this goal. Cost-cutting practices often reject all of the traditional methods mentioned above, but are far more numerous, innovative and successful. This culture of cost reduction is the result of a set of leadership competencies that establish direction for the organization, align the organization's various constituencies with this direction, and motivate and inspire the organization. Cost reduction then becomes a routine task rather than a heroic achievement.

Jan 1, 2002

It had been more than a decade since this many booths were occupied at an SME Annual Meeting, but at the 2010 meeting in Phoenix, AZ 630 booths were sold to 470 vendors from the entire spectrum of the mining and minerals industry. Exhibitors such as Metso, FLSmidth, West-Tech, ABB, NIOSH, Eriez and Resource West took their usual prominent places on the exhibit floor and were joined by newcomers such as tunnel boring machine manufacturer Herrenknecht AG, Frontier Kemper, the International Society of Explosive Engineers and more than 100 other first-time exhibitors. On the floor, one could find everything from a new pair of boots to a new career in the recruitment pavilion where some of the biggest companies in mining (Barrick Gold, Freeport-McMoRan, Newmont Mining, etc..) set up shop. The following is a look at some of the companies and products that were on display at the 2010 meeting. For information about displaying at the 2011 annual meeting in Denver, CO, Feb. 27 to March 2, contact exhibits@smenet.org.

May 1, 2010

By R. K. Clifford

The formation of elemental sulfur on the surface of sphalerite in aqueous systems was investigated. Hallimond tube flotation tests showed that unoxidized sphalerite did not float well without a collector. Flotation recoveries of greater than 95 percent were obtained without the use of a collector or frother after the sphalerite had been reacted with oxygen under pressure and water at pH 2.8 at room temperature. High flotation recoveries also resulted when sphalerite was reacted in acidic solutions in the presence of platinum sponge, titanium sponge, 316 stainless steel, copper turnings, or [10-5M++]. Conditions which produced high flotation recoveries of sphalerite yielded contact angles of 37° to 40° and also produced elemental sulfur. The increase in elemental sulfur on the surface of sphalerite was detected by elemental sulfur extraction with petroleum ether, electron spectroscopy for chemical analysis (ESCA), and the electron beam microprobe. The quantity of elemental sulfur formed was insufficient to be detected by infrared or Raman spectroscopy, or by the optical microscope or by the scanning electron microscope. An electrochemical type reaction for the production of elemental sulfur in acidic solutions was proposed. The cathodic reduction of oxygen was the slow step which needed to be catalyzed. A chemical type reaction which produced H2S rather than elemental sulfur was evident in non-oxidizing conditions.

Jan 1, 1974

By J. T. Winkelmann

The Mineral Park Mine is an open pit copper-molybdenum mine located in northwestern Arizona, approximately twenty miles northwest of Kingman, Arizona. The concentrating facility has been regarded, with the expansion in 2011, as a plant capable of treating fifty thousand short tons of feed per day for the mixture of supergene and hypogene ores available. The grinding circuit consists of two 32? x 14? SAG mills and four 20? x 28? ball mills. As ores became harder with greater depth in the adjacent pit areas, however, the SAG mills became severely throughput limited. The traditional treatment for similar properties is the installation of a recycle pebble crushing circuit. Because the cost of such an installation is quite elevated, and preliminary testing and research was inconclusive regarding the predicted throughput increases, management and technical personnel set out to find another solution to the problem. The result entailed a redesign of SAG lifters/liners and a nearly unique circuit change which was, at best, a difficult step that defied current grinding logic. This paper describes these changes, events leading up to them, and the results.

Feb 23, 2014

By Allan R. Ide

It is a great pleasure for me to speak-before such a prestigious group as the American Institute of Mining, Metallurgical and Petroleum Engineers. The substance of my talk today is the handling of coal and petroleum coke: their characteristics and environmental problems, and how we were able to correct the problems, prescribe the cure and enjoy the benefits. When coke first became a by-product derived from the oil refineries everyone would have been very happy if someone had offered to take this pro- duct off their hands. Unfortunately, there was no market at that time, and no one seemed interested. Soon thereafter, it became a sellable product and began to be shipped to many countries in the world. This was when all of the pollution problems began. I will be talking briefly about some of these problems and showing a short film on this subject afterwards.

Jan 1, 1984