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By J. Brent Hiskey

INTRODUCTION Metal electrodeposition processes are of fundamental technological importance to a number of fields. Electrorefining, electrowinning, electroplating, and electrogalvanizing have all been the subject of intense study for over a century. More recently, electrochem- ical deposition has played a critical role in advances in microelectronics and lately has been an enabling technology for the production of certain nanostructured materials. Electrometallurgists have most frequently been concerned with the structure and morphology of massive deposits. For example, in metal recovery steps such as electrorefining and electrowinning, deposits demonstrating adherent coarse-grained characteristics are most desirable. In the case of electroplating, a bright fine-grained, tenacious and strongly adherent deposit is required. The fabrication of microelectronic devices and the production of nanoscale structures such as nanoparticles, nanowires, and nanorods requires a keen understanding of early stage deposition effects. The initial stages of metal deposition, usually referred to as electroclystallization, are fundamentally linked to nucleation and growth phenomena. Early stage deposits are typically very ordered. Whereas, bulk metal deposition structures are much more ran- dom. In both cases, the discharge of a metal ion at an electrified interface is represented by simple cathodic reduction as follows: [ ] Me(H2O)xn[ ] is a hydrated metal ion residing in the bulk solution and Me is the metal atom occupying a crystallographic lattice position. A similar reduction reaction can be

Jan 1, 2005

Simulation has established itself as an accepted tool for the design and optimization of complex minerals processing plants. This paper addresses the use of simulation as a tool for the design and optimization of carbon-in-pulp and carbon-in-leach (CIP/CIL) plants. The complex, interactive nature of CIP/CIL plants makes detailed experimentation an expensive and time consuming approach to CIP/CIL plant design and/or optimization. This paper discusses a simulation-based software tool that can make the process of CIP/CIL plant design and/or optimization much more cost effective. Many of the issues and problems pertaining to the use of simulation for CIP/CIL design and operation are generic. Thus, this paper also attempts to highlight generic issues that must be solved before simulation will become a more widely used design and optimization tool. Requirements for the application of simulation for CIP/CIL plant design and optimization are highlighted. Similar problems and issues can be identified for most mineral processing plants.

Jan 1, 1994

By G. E. Erdman

The total attitude of the industrial minerals producing company is a most important factor in how they regard quality control, technical support for their customers, and procedures used in mining their minerals products. This philosophy of the producing organization directs their action along certain courses. For instance, one producer might see itself as a mining company with its major goal mining efficiency to make it exceedingly price competitive in the market place. Another producer might see itself as a wide spectrum multi-mineral producer that furnishes a reputation for a complete line of products. Another producer might see itself as a specialist in one specific industrial mineral and bet its whole bankroll on providing the very best of quality with the goal of becoming the largest producer of the mineral commodity. Each perception can have a different impact upon the producer's operations and its regard for quality control. Minerals Being Produced The specific markets being served will have their own influence on how mineral product quality is regarded. Ceramic raw materials, for instance, have a very low tolerance for iron which is the cause of low fired color. Thus, industrial minerals for use in glass and ceramic markets must be won from deposits with a very low iron content. A high iron silica sand might be sold to a manufacturer of good old beer bottles. That is a solution to one particular quality facet, but eliminates selling to a significant market in clear glass, porcelain enamel, ceramics whiteware bodies and hobby glazes. Thus, there is a need for sound research in the industries expected to be served before the product is brought to market.

Jan 1, 1987

By D. L. Jones, S. Knoerr, J. Mansanti

The Buckhorn Mine in Nevada currently treats oxide ore using heap leach methods, but exploration has identified sulphide reserves which are refractory in nature. Preliminary testwork was conducted on the sulphide material to screen potential pre-cyanidation treatment methods. Processes evaluated included pressure oxidation, biological oxidation, nitric acid oxidation and roasting. An initial economic and process analysis of the results concluded that roasting was the only viable process, and only if the roaster off-gases were converted to soleable sulphuric acid. Further economic analysis indicated that roasting of the whole ore was more attractive than pre-concentrating by flotation, followed by roasting of the concentrate. These results were generalized to show that for high sulphur ore a roaster/acid plant combination is more attractive that either of the other options, ie. pressure leaching or bioleaching, provided the by-product acid is soleable.

Jan 1, 1990

By C. Peppin, H. McLoren, D. Bayer

Hecla Mining Company and Master Builders Inc. conducted a study to evaluate the use of admixtures in reducing backfill binder concentrations. Additionally, admixtures were evaluated to help mitigate the occurrence of cold joints in the fill. Initial results demonstrated a 20% reduction of cement was possible while maintaining critical strength and flowability criteria. Admixtures also helped to control the formation of cold joints in backfilled areas.

Jan 1, 2001

By Frank E. Kottlowski

Widespread high-calcium (HC) limestones in New Mexico and adjoining areas, are low in magnesium, but some units include shale interbeds that would be deleterious for usage in sulfur removal. In southwest New Mexico, southeast Arizona, and adjoining parts of Mexico, limestones in the thick Mississippian Escabrosa, Pennsylvanian-Permian Horquilla, and Cretaceous U-Bar units are HC as are strata in the Mississippian Lake Valley, Pennsylvanian formations, Permian Hueco, and parts of the Permian Capitan Limestone of south-central and southeast New Mexico and west Texas. In north-central and central New Mexico, many limestones in the Pennsylvanian Madera Formation are HC as are some of the Cenozoic travertines. In northwest New Mexico, where the present-day mine-mouth coal- fired power plants occur, there are no HC limestones, but to the north in southwest Colorado some beds of the Mississippian Leadville Limestone and Pennsylvanian Hermosa Formations are HC. HC limestones considered contain at least 95 percent calcium carbonate and less than 3 to 5 percent magnesium carbonate. Limits for other impurities are alumina, 1 percent; silica, 2 percent; sulfur 0.05 percent; phosphorous, 0.02 percent; and iron oxide, about 1 percent. Chemical and physical requirements differ slightly depending upon the ultimate use.

Jan 1, 1995

By Andre Vien, Frank Laroche, David Di Sandro

Back in 1994, Claude Bazin presented a novel method for linking size data from milling models to the feed input of flotation models. It was achieved with the simple addition of a metal/mineral distribution—size distribution relationship. This allows grade and recovery predictions from a varying mine plan via product size distribution predictions. This paper presents a case study where this elegant method has been used to build a very powerful forecaster at a process plant, built from historic operating data. The methodology has been used by this operation to forecast production on a quarterly, annual, and life-of-mine basis since the late 1990s. It has been upgraded several times to incorporate new drivers as the complexity of feedstocks has increased over the years.

By W. Addy Majewski, Kenneth L. Bickel

The U.S. Bureau of Mines (USBM) and Diesel Controls Limited evaluated a new diesel emission control system on an underground mine vehicle. The system was a catalyzed ceramic wall-flow diesel particulate filter (CDPF) combined with an catalytic converter, or diesel oxidation catalyst (DOC). This paper describes the design and installation of the system on a load-haul-dump (LHD). The results of screening tests conducted by the USBM are also given. The screening tests were conducted to determine if the device's particulate collection efficiency, regeneration temperature, and effect on gaseous hydrocarbon (HC) and carbon monoxide (CO) emissions changed over the period it was being used. The system was removed from the LHD and evaluated in the laboratory after operating for 308 and 1200 hours. After 308 hours of operation, laboratory testing revealed its particulate collection efficiency varied from 41.0 to 93.5 percent, depending on engine operating conditions. Its regeneration temperature was about 415° C. It reduced HC emissions by up to 97.6 percent, and CO by up to 95.0 percent. When tested in the laboratory after operating for 1200 hours on the vehicle, no significant change in performance was observed.

Jan 1, 1995

By Stefan Zanon, Ty Faechner, Clayton V. Deutsch

Secondary data are important in geostatistical simulation of continuous variables. Geophysical data and geological trends are used for modeling porosity and permeability. Multiple mineral grades must often be modeled for mining applications. Sequential Gaussian simulation (SGS) is often used because of its relative simplicity and robustness. The two most common approaches to integrate secondary data in Gaussian simulation are with (1) locally varying mean, or (2) collocated cokriging. A significant problem with both of these techniques is variance inflation, that is, the variance of the resulting simulated values is too high because of an inappropriate decision of stationarity or an artifact of choosing a single secondary data in presence of many. We introduce a self-healing procedure for dynamic correction of this problem. The dynamic correction is different for the locally varying mean approach and for collocated cokriging since there are different reasons why each of these methods causes variance inflation. The reasons for variance inflation are discussed and the self-healing is applied to a number of data sets.

Jan 1, 2002

By K. Hanumantha Rao, K. S. E. Forssberg, H. R. Manouchehri

The responses of calcite, feldspar and quartz minerals in a laboratory free-fall electrostatic separator after tribocharging with stainless steel, PVC and copper plates were investigated. The effects of H3BO3 and BaC12 chemical pretreatment on the electrical properties of the above minerals were examined. The changes in the electrical properties are discussed along with the determined charge, dielectric constant and electrical conductivity of the mineral samples. The electrical properties of the minerals and their responses to the electrical field during separation after tribocharging and chemical pretreatment are explored relative to the electrical behavior of the minerals.

Jan 1, 2000

By Gary A. Kordosky, R. Brantley Sudderth

The solvent extraction process as it applies to the recovery of metals from solutions on a comnercial basis is described. The four types of classes of sol vent extraction reagents are explained: 1) solvation, 2) acidic, 3) ion-pair, and 4) chelation, and examples of each type of reagent system are given. The uranium and copper extraction examples, using the ion-pair and the chelate reagent types respectively, are presented in greater detail to illustrate the more subtle aspects of reagent evaluation and selection. Practical experiences in the laboratory and at some operating plants are a1 so discussed.

Jan 1, 1986

By John D. Nelson

Unprotected uranium mill tailings impoundments can pose a significant risk to nearby inhabitants and the surrounding environment in the event of a prolonged or catastrophic release of contaminants contained in the tailings. As a result of this potential, reclamation plans for such facilities must include engineering designs to protect against disruption of the tailings and the potential release of radioactive materials. The goals for such engineering designs should be to provide overall site stability for long-term periods with no need for planned ongoing maintenance and to provide a repository for the tailings that will not place a burden on future generations. Although the goal is to provide a maintenance-free system that does not require monitoring, it must be recognized that some period of surveillance would be reasonable. The surveillance period could be relatively short and only needs to assure with reasonable confidence that the reclamation scheme that was implemented is functioning adequately. An investigation was conducted by Nelson, Volpe, Wardwell, Schumm and Staub (1983) entitled Design Considerations for Long-Term Stabilization of Uranium Mill Tailings Impoundments (NUREG/CR-3397). This report assesses the degree of confidence with which long-term reclamation plans can be expected to remain effective over specific periods of time, and to assess the additional effort required to extend the design period from one long-term period to a longer one. This paper presents a summary of that investigation and discusses some of the important conclusions.

Jan 1, 1984

By J. H. Daniel

Dust-related respiratory disease remains the major health concern in mining, and health agencies are proposing more stringent standards. The U.S. Bureau of Mines (USBM) is investigating techniques to continuously monitor respirable dust in real-time during the coal or ore extraction process. Continuous monitoring will allow mine operators to evaluate hazardous dust concentrations and adjust the operations to produce less dust. Mine instrumentation applications include machine-mounted and hand-held monitors, personal monitors, and area/environmental monitors. Six dust detection methods have been considered to meet application requirements. These are: light-scattering instruments, a smoke-particle detection technique, correlation of pressure drop across the collection filter with amount of dust deposited, the Tapered-Element Oscillating Microbalance (TEOM) instrument, a method that relates the amount of dust collected on a filter with the vibration of the filter, and beta attenuation measurement of dust. Studies to date have identified the TEOM instrument and the technique of correlating the amount of dust collected with the vibration ofthe filter as having the most promise for success. Development of the machine-mounted monitor is the highest research priority. The application options and progress to date in developing continuous monitoring instrumentation are presented.

Jan 1, 1995

By D. W. Fohlen, B. A. Filas

The International Finance Corporation (IFC), the private investment arm of the World Bank Group (WBG), requires all IFC-financed projects to comply with its environmental and social policies and guidelines. IFC's review process involves an environmental and social assessment and the implementation of an Environmental Action Plan (EAP) that will set forth the necessary actions to bring the operation into compliance. This paper provides an overview of the environmental and social policies and guidelines that apply to mining projects and examines how WBG/IFC policies and guidelines are applied to mining projects in developing countries. In addition, it includes a review of the increased emphasis IFC is giving to social issues over the past several years based on the existing WBG policies. IFC’s process for the environmental and social review of proposed investments is briefly discussed. The paper focuses on how IFC emphasis has shifted from the traditional environmental and impact mitigation analyses of a few years ago to the integrated social and environmental awareness, action (EAP), and implementation programs (social plans) required today. Today, IFC's focus is to promote sustainable development by investing in projects that directly benefit local communities and the environment. Examples of these changes will be highlighted by a review of recent investments located in West Africa. The goalposts have not moved, but the rules of the game have become tougher.

Jan 1, 2001

By George M. McArthur

General Statement In Montana, as in most states, the requirements for water quality control are becoming more restrictive. What was once accepted practice is now obsolete. The planning and construction of water quality control facilities has taken on new importance. Past practices and new ideas must be examined to meet the challenge. By this paper we hope to encourage the exchange of ideas for the improvement of water quality control techniques. Both the mining industry and governmental agencies should benefit from such an exchange. The following is a summary of the work done and in progress by The Anaconda Company in Butte to provide an improved water quality related to production processes. We invite your comments. Acknowledgements This paper would not have been possible without the efforts of many individuals and departments in The Anaconda Company, including the Environmental Engineering Department, Mr. Frank J. Laird, Director; Montana Operations, Mr. M. K. Hannifan, General Manager, and their assistants.

Jan 1, 1972

By Ernest Koenigsberg

In 1961 Lerchs and Grossman presented a method, based on graph theory, to determine the optimum ultimate pit limits for an open-cast mine. At the same time they demonstrated a dynamic programming algorithm for the optimum pit limits for a two-dimensional open-cast mine. Since then many methods for determining optimum limits for three-dimensional mines have been programed, and even more have been reported in the literature. The methods include computer "simulation" of the manual methods used by engineers, the development of sets of conic sections and fitting to exclude overlap, integer linear programming (and its equivalent network flow model), and dynamic programming. Many of the methods do not guarantee optimal solutions but seem to satisfy the user. Other reported methods have never been applied, partly because they did not yield optimal solutions. We have developed a three-dimensional dynamic programming algorithm which requires a single pass through the data. Large problems can be solved on a small computer because only a small part of the data is required at any time. In this paper we will review the state of the art and to demonstrate the connection between linear programming (and network flow) models and the dynamic programming method.

Jan 1, 1982

By R. A. Jankowski

Although the number of operating longwall mining systems has remained relatively constant, longwall production levels during the last five years have increased significantly. In the United States, longwall mining now accounts for approximately 50% of all underground coal production. While longwalls are highly productive and offer other advantages, operations employing this method of mining continue to experience dust-compliance problems. This increased longwall productivity has meant that far more dust is being produced. An improved understanding of the longwall face-ventilation system and the advancement of face-ventilation technologies are necessary to ensure all face personnel are allowed to work in an environment that is free of excessive levels of airborne respirable coal mine dust. The Dust and Toxic Substances Control Branch, National Institute for Occupational Safety and Health, Pittsburgh Research Laboratory, examined several basic principles of the long wall face-ventilation system and has evaluated the effectiveness of numerous improved face-ventilation techniques for longwall mining systems. These include identifying improved techniques for measuring face-ventilation parameters on longwall mining sections and investigating the fundamental relationship between face airflow and the entrainment and dilution of respirable coal mine dust. Studies have been completed to determine the impact on face dust levels of using belt entry air to ventilate the longwall. Novel methods have been identified to increase the face air¬flow and to manage face airflow to effectively minimize dust exposure to face workers. Unique systems of auxiliary face ventilation have been developed and evaluated at full-scale, simulated longwall test facilities. The theoretical and applied aspects of each of these principles and technologies are discussed. Application of these results throughout the longwall mining industry, as documented from surveys conducted in the early 1980s and 1990s, have reduced the health hazard associated with excessive exposure to respirable coal mine dust.

Jan 1, 2000

By Lawrence A. Ph. D. Hansen, J. David Deatherage

Laboratory testing programs were conducted to investigate the performance under compression loading of several types of geomembranes and geotextiles proposed for use in heap and dump leach projects. Synthetic liners of several thicknesses were sandwiched between representative subgrade soils and cover materials, thus modeling in the laboratory the actual installation conditions expected. Performance was evaluated by visual inspection and vacuum testing. Several testing procedures and equipment were used to investigate the effect of these testing parameters on the predicted performance.

Jan 1, 1987

By M. J. Howes, C. A. Nixon

INTRODUCTION A safe heat stress control strategy for an underground mine has three elements: Application of an environmental measure which reflects physiological strain with sufficient accuracy for the range of conditions encountered underground. Acceptance of a functional relationship between the environ- mental measure and human performance which is used to optimise the environmental conditions achievable with either ventilation or ventilation and refrigeration. A management control strategy based on the environmental measure which is designed to ensure that work in environments where excessive physiological strain may occur is prevented and corrective action is initiated. The environmental measure that reflects physiological strain is the link between the three elements and, since the turn of the century, the discussion of the merits of various indices has been prolific. One problem in selecting a suitable measure or index is the ease with which it can be physically obtained relative to accurately reflecting the physiological strain. For example, wet bulb temperature is simple to measure and, for a particular mining sys- tem, it may adequately represent physiological strain, however, it would not necessarily provide the same relatively safe measure in a different mining system. The acceptance of a measure which can be universally applied has been confounded by both development and predisposition. That is not to say that there is only one "correct" measure and all others are unsuitable. It is self evident that if the application of a particular index has resulted in adequate control, then that mea- sure is correct for that situation. However, an understanding of the limitations is necessary to ensure that adequate control is maintained as mining conditions change. Almost 100 years after the question of heat stress in mines started to be dealt with in a collective manner, an analysis of the available information is leading towards a general strategy to control this problem. In the paper, the developments in heat stress assessment are briefly examined and followed since the earliest published observations on the effect of heat in mines (Haldane, 1905), efforts to determine a relationship between an environmental measure and human performance are reviewed and summarised and the benefits of control strategies such as acclimatisation and shortened shifts are discussed as they relate to Mount Isa Mines. The results of testing the prototype air cooling power instrument are discussed and a heat stress control strategy outlined. HEAT STRESS AND AIR COOLING POWER The operation of the human engine is analogous to other engines where the conversion of chemical energy from the oxidation of fuel to useful mechanical energy is not 100% efficient. In a diesel engine it is about 33% and in a human engine less than 20% resulting in at least five times as much heat produced by the meta- bolic process as useful work done. Metabolic energy production is related to the rate at which oxygen is consumed and is about 340 W for each litre of oxygen per minute. Using measured oxygen consumption and an average body surface area of 2.0 m2, the approximate metabolic energy production associated with different mining tasks is (Morrison et al. 1968):- • Rest, 50 W/m2 • Light work, 75 to 125 W/m2 (machine, LHD or drill jumbo operators) • Medium work, 125 to 175 W/m2 (airleg drilling, light construction work) • Hard work, 175 to 275 W/m2 (barring down, building bulkheads and timbering) • Very hard work, over 275 W/m2 (shovelling rock) Heat balance is achieved when the rate of producing heat (the metabolic heat production rate) is equal to the rate at which the body can reject heat mainly through radiation, convection and evaporation. Heat exchange between the lungs and the air in- haled and exhaled is normally less than 5% of the total and there- fore usually ignored. Any heat not rejected to the surroundings will cause an increase in body core temperature. Since heat stress is related to the balance between the body and the surrounding thermal environment, the main parameters required to be known when determining acceptable conditions are those associated with the heat production and transfer mechanisms. These can be summarised as follows: Metabolic heat production rates (M - W) Skin surface area (A3) (and effects of clothing) Dry bulb temperature (t[ ]) Radiant temperature (t[ ]) Air velocity (V) Air pressure (P) Air vapour pressure (e [ ]) The rate of heat transfer to or from the environment depends on the equilibrium skin temperature t, and the sweat rate S,. These in turn depend on the response of the body to the imposed heat stress and the effect of thermoregulation (Stewart, 1981). Thermoregulation The body contains temperature sensitive structures which send impulses to the brain at a rate depending on the temperature. Both hot and cold signals can be differentiated and the thermoregulatory response ahivated according to which signal pre- dominates. If "cold" signals are dominant, body heat loss is re-

Jan 1, 1997

By Jozef Szymanski, Julian Partyka, Jerzy Krynicki

In order to study blast-induced dust in a hard rock metal mine experimentally and analytically, a part of a stope mined by Vertical Retreat Mining (VRM) was monitored throughout its lifetime. Dust measurements were used to describe the dust source, to study the dynamics of removal of airborne dust from the blasting area, and to examine a variation in dust production with a stope's progress. An analysis based on graphical and analytical comparisons of blasts taking place in a single stope is presented and discussed. Also, some transient phenomena of dust flow in the stope vicinity, caused by the blasts only, are examined.

Jan 1, 1997