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By Clay Haynes

While the Kansas River Tunnel is a relatively short, small diameter tunnel, the shaft excavation methods implemented were long and large on innovation and use of reverse circulation drilling equipment. ATS Drilling, L.P. used mechanical excavation techniques for both soil and rock segments of the 42.7 m (140 feet) and 38.1 m (125 feet) deep shafts that were 2.9 m (9.5 feet) and 4.1m (13.5 feet) diameter, respectively.

Engineering Experiment Station, Kansas State College, Manhattan, Kansas. For publications or a list of publications, address the above Of the 29 Bulletins issued by the Engineering Experiment Station, a few on cement and road-building materials may well be listed here: Bulletin 12, Road materials of Kansas; 15, Tests of Kansas road materials, 17, Some strength characteristics of portland cement; 25, Volume change of concrete, 26, A study of fourteen brands of standard portland cement and four early-strength concretes, 28, The durability of concrete, 29, The effect of aggregate and other variables on the elastic properties of concrete

Jan 1, 1933

By Haydn H. Murray

Since the advent of machine coated paper in the mid 1930's, the kaolin industry has had a remarkable growth, In 1935 the domestic production of kaolin was 500, 000 tons and in 1970 the estimated production was in excess of 3. 5 million tons. The process industries which use kaolin most extensively are paper, rubber, paint, ceramics, plastics, catalyst manufacturers, ink, and pharmaceutical. The paper industry is by far the largest consumer of kaolin using approximately 70 per cent of the total tonnage mined and beneficiated. Up until 1970 the major kaolin producers were able to expand rapidly enough to supply the demand but for the first time in thirty years the demand is expected to be in excess of mining and beneficiation capacity through at least 1975. The major reason for this is the expansion of coated paper production in Europe and Japan. Two areas supply the lion's share of kaolin for the world markets. These are the Cornwall area in extreme southwestern England and a limited area of Georgia and South Carolina in the southeastern U. S. The English kaolins are primary - (found in decomposed granite) whereas the Georgia-South Carolina kaolins are secondary - (found in lenticular, continuous beds in the Tuscaloosa formation of Cretaceous age. ) The English kaolins are mined by hydraulic methods whereas the Georgia-South Carolina kaolins are mined by dragline or shovel and benefidated by using a wet process for the majority of the production and/or a dry

Jan 1, 1971

By Kenneth J. Hartman

Introduction The term kaolin is derived from kauling, a Chinese word meaning high ridge. This was the name of a hill in China where kaolin was first mined several hundred years ago (Murray, 1976). Other common names used for kaolin include clay and China Clay. Clay technically has a broader meaning and could refer to bentonite and ball clay as well as kaolin. China clay, as a descriptive term, apparently results from kaolin's origin. But it could also be due to a significant historical use in ceramic applications. The terms kaolin and clay will be used interchangeably in this analysis because of the common practice of using these terms in the paper industry. Major reasons for kaolin's wide-spread industrial usages center on kaolinite's physical features of good color, low viscosity, and inertness. Kaolin is described as a hydrous aluminum silicate with an approximate composition of 2H2O • A12O3 . 2SiO2. A new version of the product is calcined clay with modified hydration content. It is gaining widespread use. Components of any particular kaolin, in addition to alumina and silica, are viewed as impurities. The more values deposits and, hence, higher priced kaolin products are those of the highest purity. Kaolin is the most widely used mineral in paper manufacturing throughout the world. Key production centers are located in England and the US. Most of the Tatter's production is located in Georgia. The key markets for Georgia kaolin are paper markets - both paper coating and paper filling. These paper markets extend throughout the world, not just to domestic markets. In fact, export markets are second in size only to domestic paper markets for Georgia's producers of kaolin. Just as the paper markets are important for kaolin producers, kaolin is an important raw material for papermakers. Compared to the other three major pigments - titanium dioxide, calcium carbonate, and talc - kaolin's 1984 tonnage for papermaking represented 85% of the total. Even though titanium dioxide's unit value is much higher, kaolin's estimated total 1984 value still represented 51% of total dollars spent by papermakers for the four pigments. Kaolin grades- are briefly defined using particle size and brightness as principal means of classification. Likewise, grades of papers using kaolin are defined using the American Paper Institute's guidelines. From these definitions, associated kaolin grades used in particular grades of paper are reviewed. Special emphasis is placed on how qualities desired in certain papers are achieved through the use of specialized kaolin grades. World kaolin production World production statistics (Coope, 1979; Table 1) demonstrate that kaolin is produced in many areas of the world. About 60% of production is centered in the US and England (Fig. 1). Deleting Eastern Europe's produc-

Jan 4, 1987

By Tim B. Vander Wood

Standard methods of determining clay mineral powder aspect ratios involve manual scanning electron microscopy analyses of shadowed particles in order to measure both platelet thickness and diameter. We present a method whereby the diameters of platelets are quickly determined by automated scanning electron microscopy and their images are recorded and digitally transferred to a transmission electron microscope equipped for parallel electron energy loss spectroscopy. Thickness' of platelets whose diameters are known from the previous analyses are determined by measurement of the ratio of scattered and unscattered electrons in the beam after it has been transmitted through the platelet.

Jan 1, 1995

By K. J. Hartman

The term kaolin is derived from "kauling". a Chinese word meaning high ridge, which was the name of a hill in China where kaolin was first mined several hundred years ago.(1) Other common names used today for kaolin include "clay" and "China Clay". The former word technically has a broader meaning and could refer to various types of clays such as bentonite and ball clay as well as kaolin. China clay, as a descriptive term, apparently results from kaolin's origin as described above but could also be due to a significant historical use in ceramic applications. The terms "kaolin" and "clay" will be used interchangeably in this analysis because of the common practice of using these terms in the paper industry. Major reasons for kaolin's widespread industrial usages center on the mineral's (kaolinite) physical features of good color, low viscosity and inertness. Kaolin is described as a hydrous aluminum silicate with approximate composition Of 2H20.A1203.2Si02. As will be shown later, a new version of the product, calcined clay with modified hydration content, is gaining widespread usages. Components of any particular kaolin in addition to alumina and silica are viewed as impurities. The more valued deposits and, hence, higher priced kaolin products are those of highest purity.

Jan 1, 1986

By E. R. Dotson

Kaolin is an important industrial mineral. It has unique properties, which combined with its low cost, make it suitable for use in a wide variety of products. Kaolin is defined as "any of a group of clay minerals, including kaolinite, nacrite, dickite, and anauxite, with a two-layer crystal in which silicon-oxygen and aluminum-hydroxyl sheets alternate; approximate composition is AlZ03-ZSiOZ-1/ ZHZO".-The kaolin discussed here is composed chiefly of the mineral kaolinite. Kaolin is also commonly referred to as "china clay". Approximately 4.9 kkg (5.4 million short tons) of kaolin was sold or used in the United States, and .8 million kkg (.9 million short tons) was -exported in 1974. In domestic usage, paper coating and filling accounted for 43% of the total, fol-2/ lowed by refractories, rubber, and ceramics.-Figure 1 shows the amount of kaolin sold or used by domestic producers for specified uses for the years 1963-3/ 1973.- Kaolin was produced at mines in 14 states, but Georgia accounted for 75% of the 1974 domestic production. The average value for all grades was $36.00/kkg 4/ ($32. 67/ton) .-

Jan 1, 1977

By A. R. Negele

Kaolin-based pigments are the most widely used pigments in the paper industry. Several types are available and include standard hydrous, delaminated, calcined, chemically-structured, and most recently, composite pigments. Within each category, a spectrum of products is available to satisfy the application requirements of paper producers. The paper industry has a broad range of applications including fillers in woodfree and groundwood-containing papers, pigmented size press applications, ultra-lightweight and lightweight coated papers, coated merchant papers, cast coated papers and coated paperboard. Each application has its own set of performance criteria and suppliers must work with mills to identify appropriate product(s) to fulfill these requirements.

Jan 1, 1993

By O. M. S. Rodrigues

The kaolinite presence in bauxite ores increases caustic soda consumption during the digestion step in the Bayer process. Depending on the kaolinite content, the utilization of the ore in the Bayer process may be unfeasible. This investigation addressed the variables involved in kaolinite flotation through microflotation experiments in a Hallimond tube and zeta potential determinations. The tests were performed with a pure sample of kaolinite (96%). Five collectors were tested: Duomeen T (DT), cetyl pyridinium chloride (CPC), cetyltrimethylammonium bromide (CTAB), dodecylamine (DDA) and Flotigam EDA (EDA). Four of them performed well as collectors, at a concentration of 1x10-4 mol/L: CPC, CTAB, DDA and EDA. The kaolinite isoelectric point (IEP) was determined at pH = 4.6. The IEP was shifted towards higher pH values in the collectors? presence, indicating specific adsorption onto the mineral surface.

Jan 1, 2011

By John M. Smith

Kaolin is an important industrial mineral because of its unique properties and low cost. Strictly defined, kaolin is the name given to a group of hydrous aluminum silicates of which kaolinite is the most common mineral (1). Through common usage the mineral, kaolinite, is called "kaolin" or "china clay". In 1972 over 4, 000, 000 tons of kaolin will be beneficiated and shipped by domestic producers. By far the largest user of kaolin is the paper industry which utilizes approximately 65 to 70 per cent of the total production. Kaolin is used in paper as a filler in the interstices of the sheet and as a coating to impart smoothness, gloss, brightness, and printability to the paper. The rubber industry is also a large user of kaolin where it is used as a filler because it adds strength, abrasion resistance, and rigidity to both natural and synthetic rubber goods. Kaolin is used as an extender in paints because it is chemically inert, has a high covering power, gives desirable flow properties, and is low in cost. In ceramics, kaolin is used in whitewares, tile, insulators, refractories, and in some face brick where a white color is desired. Kaolin is also used extensively in plastics as a filler in thermosetting and thermoplastic mixes to give smoother surfaces, a more attractive finish, good dimensional stability, and resistance to chemical attack. Many other process industries use kaolin as a filler, suspending medium, or for color improvement.

Jan 1, 1972

By K Nilsson, D Connelly

Troy Resources acquired the Karouni Gold Project in Guyana, South America in 2014 and immediately proceeded to a Pre-Feasibility Study and project implementation. The study considered two open pit mines feeding a conventional carbon in leach (CIL) gold plant with a capacity of 1Mtpa. The study assumed a total of 2.61 million tonnes of ore with an average grade of 3.84 g/t gold with a recovered gold production of 303,526 ounces over a three year mine life.The project development involved drilling metallurgical test holes, securing second-hand major pieces of equipment where suitable, and arranging shipping to Guyana. The remote location meant logistical considerations were paramount. The plant consists of conventional two-stage crushing with single stage ball milling and a gravity circuit. The tailings circuit includes DETOX.The extremely high rainfall presented challenges with water management and the necessity to dispose of clean water to the environment. The DETOX was also mandatory due to the highly sensitive environment and past history in the area. The criticality of this meant that in the design, any cyanide in the tailings would precipitate in a plant shutdown.Lessons were learned and the project has been both profitable and successful for Troy Resources in a new operating location. In addition, the project has created jobs, delivered royalties and brought new skills into an area where previously there was little current mining activity.CITATION:Nilsson, K and Connelly, D, 2015. Karouni Gold Project from drill core to commissioning, in Proceedings MetPlant 2015, pp 197–206 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 7, 2015

By A. E. Brugger

SOME 2,000 years ago Pliny is supposed to have said, "Out of Africa always something new." It may perhaps even now be news to a great many that the Belgian Congo has in recent years been producing approximately a quarter of a ton of diamonds annually. For that is what the 1 1/4 million carats, the recovery from 40-odd operating mines, and about 20 or 25 per cent of the world's normal consumption, amounts to. In 1915, first exploitation operations produced less than 50,000 carats from two mines. The rapid expansion of operations following the Euro¬pean war meant a most rapid development of a virgin land. The interior is now reached by air in one day from the mouth of the Congo River, where steamers unload mail and passengers from Antwerp. This trip formerly consumed 4 to 6 weeks by a narrow-gage, wood-burning, railroad around the rapids of the lower Congo and Livingston Falls; by river boat to the heads of navigation, Djoko Punda on the Kasai or Luebo on the Lulua; and thence by caravan of native porters over narrow-trails to head¬quarters on the Tshikapa. Hundreds of miles of automobile roads have been constructed over veldt and through forest, bridging streams and ferrying rivers. The railway from Capetown to the Katanga copper district to the East, once two months away by trail is now reached in 2 or 3 days over fair automobile highway. Native "boys" who a few short years ago wore little more than a smile and a string of beads and to whom a wheelbarrow was a complicated piece of machinery, are today driving Fords, tending boilers and engines and operating electrical equipment, or are capable mine workmen, machinists and artisans, and dressed in all manner of cast-off white man's clothing. Even as late as 1920, due to difficulties of securing and transporting machinery during and just after the war, the crudest hand operations were the rule for the excavation, sizing, and concentration of the diamondiferous gravel. All washing and concentration is now mechanized, using steam or electric power, and where operations are sufficiently large to permit competition with native labor costs, excavation and transportation are also accomplished by machinery.

Jan 1, 1932

By Ryan P. Sullivan, Ben D. DiFiore, Robert J. Auber, Michael A. Piepenburg, Lisa M. Smiley

Pollution to Lake Erie will be significantly reduced by the Westerly Storage Tunnel (WST) system, which is mainly comprised of a 10,000-ft long tunnel and a dewatering pump station in the downstream tunnel shaft. Separate construction contracts for the tunnel and pump station required careful management of the interface risks. A key decision was to decouple the projects by relocating the mining shaft away from the pump station. The need to receive the tunnel boring machine (TBM) in the pump station shaft was eliminated by dismantling the 28-ft diameter TBM in the tunnel then carrying it back through the tunnel and up the mining shaft. This paper discusses how interface risks were successfully managed during design and construction to limit overall schedule impacts.

Dec 1, 2022

By Steve Kral

Worker safety is an issue that transcends industries, whether it be mining, construction, manufacturing or even general office work. In the mining industry, safety and training are particularly important because mining is a dangerous occupation. Throughout the years, federal and state safety regulations have been written and revised to keep up with the changing technologies. And mine operators have installed their own safety and training programs. They have come to realize that a safe and healthy workforce has positive effects on productivity and profitability —not to mention avoiding the high costs of injury-related absenteeism.

Jan 1, 2003

Despite two large projects represented in the keynote docket, the mood of the 2011 SME Arizona Conference was summed up best by Ferol Baker, general manager of New Mexico Copper Corp. (a wholly owned subsidiary of Themac Resources Group), ?In the past, it seemed like you couldn?t go to a conference like this without hearing about one big new greenfield project after another. Now what you see is companies doing internal expansion or small-scale brownfield development.? Overall, the tone of this year?s meeting, held at the J.W. Marriott Resort at Starr Pass in Tucson, AZ, was upbeat, yet practical. From the keynote and luncheon addresses to the six panels of sessions, the projects described were positive about the future, yet focused on the details required to make those projects come to fruition.

Jan 1, 2012

By D Rubery, C Croker

The Boddington Gold Mine (BGM) is located 120 km south east of Perth, Western Australia. The operation is managed by Worsley Alumina Pty Ltd and mined by contractor Henry Walker Eltin (HWE). The mine has been operating since 1987 with ore extracted from a series of pits along strike. Ore is contained within the basement rock, which is overlain by a cap rock layer and transition zone. Cap rock and basement zones require blasting.As the mine neared completion, a high-grade deposit was discovered within 50 m of an existing Western Power substation and 100 m from the processing mill. The substation provides power to the Boddington area and is a back-up power supply to the city of Perth. Due to the delicate nature of the transformers located at the power station, overhead power lines and the mill, blasting in the area was considered very high risk. As such blasting needed to be controlled for flyrock, airblast and most importantly peak vibration and frequency limits which had the potential to damage the transformers.The mine was due for closure in March 2001. The decision to mine the pit was based on its high grade, ability to be blended with lowering grades from other pits and changing of the processing technique with the expansion. This decision extended the life for a further six months.Due to the high potential risks a detailed risk assessment was conducted by Orica, Worsley and Henry Walker Eltin. The completed assessment and the major design parameters were presented to Western Power for approval. The ability to reduce the blasting risk was focused on limiting of vibration through controlling maximum charge initiated per delay, blast timing and firing direction, and other innovative control measures. OricaÆs SHOTPlan« and Sabrex« computer modelling packages were used to predict the outcome of blasts.The success of this project has opened the doors for other high risk blasting projects, which otherwise may be left unmined.

Jan 1, 2002

By T D. H McGrath, W P. Staunton

Benchmarking, comparing an operation or process with the industry standard, is known to be a useful method for identifying plant optimisation opportunities, and in many cases providing the pathway to realise the benefits. The difficulty is generating the database of plant data necessary for a benchmarking exercise. Larger companies can benchmark internally; this option is not available to smaller companies, and the full value can only be realised with a comprehensive “industry wide” approach.The Gold Technology Group at Curtin University through the AMIRA P420 series of projects has undertaken several comprehensive metallurgical industry surveys in the gold industry over the last two decades. Analysis of these surveys has demonstrated areas where many operations can benefit from re-assessment of their operating practices.This paper will review the work undertaken by the Group in this area, in particular the 1999 surveys of gold companies in the Australasian region, and the 2012 international survey of the industry. The challenges of, and opportunities arising from these surveys will be discussed. Some of the highlights from analysis of these databases will be presented as well as noting changes in processing practices observed by the Group over the last 20 years.CITATION:McGrath, T D H and Staunton, W P, 2018. Keeping up with the Joneses – the value of industry surveys and benchmarking, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 509–516 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By Barlow S

The Kelian Gold mine project won two excellence awards from the Victorian Division of the Institution of Engineers, Australia. It was a challenging project, fast tracked in a remote and inhospitable tropical environment. The creation of a profitable and efficient mine was a significant engineering and project management achievement. The difficulties encountered and the way they were managed provide valuable lessons. These include the importance of sufficiently detailed engineering in all aspects of the job to enable the best estimates possible to be prepared during feasibility studies, the need to prepare the project scope and execution plan with disciplined and rigorous attention to detail by a highly experienced team and the value of identifying, assessing and mitigating risk and uncertainty during execution. The practical benefits of applying these lessons were demonstrated in the successful management of technical uncertainty on the recent diversion of the Kelian River to allow the expansion of the Kelian mine.

Jan 1, 1997

By K. S. Liddell, L. A. Smith

"Kell is a hydrometallurgical treatment option for the recovery of platinum group metals (PGMs), gold, silver, and base metals from flotation concentrates to refined products on site. The process is cyanidefree, while eliminating emissions of sulphur dioxide, arsenic trioxide, and other toxic species often emitted by smelters and roasters. Kell has been tested on a range of concentrates, including PGMs (UG2, Merensky, Platreef, Great Dyke, Great Lakes, Lake Superior and others), refractory gold-silver, coppergold, and polymetallic concentrates. High extraction efficiencies (>95%) are achieved for value metals (Pt, Pd, Rh, Au, Ag, Ni, Cu, Co) and secondary metals (Sb, Zn, Pb, and others). Studies comparing Kell with smelter-refining show economic benefits: capex 18–33% of smelting; opex 51–66%; electricity consumption 13–46%; and environmental benefits: greenhouse gas emissions 57–61% of smelting, acidification 5–27%, human toxicity 37–62%, and freshwater ecotoxicity 43–55% of smelting. Synergies for Kell plants alongside smelter-refineries include utilization of recovered acid from sulphur abatement systems and excess capacity in precious metal refineries. Kell is unconstrained by concentrate grade and impurities, allowing the co-location of Kell plants for treatment of non-smeltable concentrates alongside existing smelters.Kell has been demonstrated in a nine-week integrated pilot campaign at 1:1000 scale, supporting a bankable feasibility study for a 110 000 t/a plant treating a UG2-Merensky concentrate at Pilanesberg Platinum Mine (PPM), owned by Sedibelo Platinum Ltd, which has along with South African Industrial Development Corporation (IDC), invested in Kell. Zimbabwean Mining Development Corporation (ZMDC) has signed a Memorandum of Agreement (MOA) with KellTech for a centralized PGM concentrate processing plant."

Jun 1, 2019

By K. S. Liddell

The Kell Process has been developed for the extraction of platinum group metals (PGMs) and base metals from sulphide flotation concentrates. The process has been successfully tested on several different sulphide flotation concentrates, including those from the UG2 chromitite horizon and the Platreef mafic/ultramafic layer. It has been shown to provide high (>95 per cent) and selective extraction efficiencies for the key valuable metals, i.e. Pt, Pd, Rh, Au, Ni, Co, and Cu. The Kell Process consists of several commercially proven unit operations. S, Ni, Co, and Cu are first selectively removed by use of a pressure oxidation step during which the dissolution of PGMs is minimized. The residue from pressure oxidation is subjected to a thermal treatment to ensure efficient PGM recovery by subsequent chlorination. All the core steps are very similar to well-proven conventional unit operations in common use, as are the subsequent metal recovery steps to provide marketable end products. Typical metallurgical responses of flotation concentrates from UG2 and Platreef to the Kell Process are provided, and key outcomes of an energy comparison study with smelting are summarized in this paper. Kell presents a potentially substantial improvement in PGM concentrate processing technology, in terms of economics via much-reduced power costs, ease of processing, and various environmental benefits. It allows for the treatment of high-chromium low-grade 'dirty' concentrates, such as secondary concentrates from the platinum industry's 'mill-float-mill-float' (MF2) flotation circuits and concentrates from retreatment of tailings. It allows greater concentrate mass pulls, has higher tolerance to gangue intergrowths in concentrates, and its use can provide substantial increases in overall PGM recovery. Its adoption would be a step change in the platinum industry, and given the commercially proven unit operations embodied in the Kell Process, at much-reduced risk compared with other more experimental technologies. Since the initial process development work, significant improvements and refinements have been introduced as a result of further compre¬hensive testing and process modelling. Pilot-scale testing and engineering study work is in progress for several selected sites.

Jan 1, 2012