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By Dave Rose, David G. Meadows, Mike Westendorf

"Copper Mountain’s concentrator was commissioned in May 2011. The circuit consists of a 34’ x 20’ EGL SAG mill, a Raptor 900 pebble crusher and two 24’ x 39’6” ball mills. Each mill is equipped with a 2 x 8500 HP dual pinion drive system. The plant was designed to process 1585 mtph of SAG feed. From startup, the mill struggled to meet the required production rates. Over time, a major initiative that involved blasting and fragmentation, optimization of the SAG mill in terms of discharge grates, ball size and slurry density, and operation of up to three mobile pre-crushing plants resulted in significant increases in throughput. In parallel, a number of modeling tools, including JK SimMet, were run based on plant benchmarking exercises. Samples collected at the mine site during ramp up confirmed the very competent nature of the ore with drop weight - A*b values of less than 24 being recorded on a variety of plant feeds and lithologies. After due consideration including demonstration of proof of concept, a new pre-crushing circuit incorporating an XL2000 cone crusher and associated screening equipment was designed, constructed and commissioned at the site in August 2014. This paper reviews the history of the original circuit design, the various optimization steps taken and impacts, together with the final pre-crushing circuit and net results.IntroductionThe Copper Mountain Mine is located approximately 20 km south of Princeton, British Columbia, Canada (refer to Figure 1). The region has a long history of copper mining dating back to 1923. The Copper Mountain camp occurs in the 'eastern volcanic belt' of the Nicola Group (Monger, 1989). It is an alkali copper-gold deposit in which the volcanic strata are intruded by early Jurassic dykes, sills, irregular plugs and zoned plutons (Woodsworth et al., 1992). The stratified rocks are relatively fresh with slight metamorphism in the local contact regions."

Jan 1, 2016

By C. A. Stiles, J. W. Nyhus

Erie Mining Co. is a 10.3-million-tpy pellet producer on the east end of the Mesabi Range 60 miles north of Duluth. Its complex includes facilities for mining, crushing, grinding and beneficiation in addition to a pellet plant and power plant. A 74-mile railroad links the mine and plant to Taconite Harbor on the shore of Lake Superior. The concentrate recovery ratio at Erie is about 1: 3, and this, along with stripping activity, makes it necessary for the company to mine nearly a million tons of material a week. At the outset, all crude ore mined at Erie was hauled entirely by rail, but with expansion into additional mining areas, the company made a gradual transition towards truck-to-rail haulage. Today, in Erie's 11th year of operation, over 50% of all crude taconite mined is transported by truck to loading pockets where it is transferred to rail cars. Future years will see more taconite moved in this manner. Thus, the company has an increasing interest in tire performance.

Jan 6, 1969

By D Hill

In the Ngakuru area zeolite deposits occur in late Quaternary lacustrine vitric tuffs of the Ngakuru Formation and two of the deposits are being mined. The Ngakuru Formation overlies the Ohakuri Ignimbrite dated at c. 240 ka, and is overlain by younger alluvial sands and gravels. Individual zeolite deposits contain 50 - 80 per cent zeolite over a thickness of up to 45 m in thinly stratified vitric tuffs and are localised along NE-trending normal faults. Glass shards in the tuffs are replaced by the silica-rich zeolites mordenite and clinoptilolite. Amorphous silica (opal A), opal-CT, Kfeldspar and smectite are also present. The zeolites and other minerals are very fine grained (<10 8m), with open meshes of crystals that result in high porosities (52 - 70 per cent) in mordenite-rich tuffs. Zeolitic tuff samples typically have cation exchange capacities of 80 to 110 meq/100 g and internal surface areas of 25 - 58 m2/g, which combine to give high liquid and odour absorption capacities. The first zeolite deposit (Mangatete) was found in 1992, and this and the Twist Road deposit are worked by quarry benching into the side of hills. The zeolitic tuffs are dried and crushed to produce a variety of products including adsorbents for soaking up oil/chemical spills and animal wastes, animal feed supplements, water treatment, and sports turf and slow release fertiliser. The Ngakuru zeolite deposits formed at shallow depth (<100 m) along fault zones from reaction of glass-rich tuff beds with groundwater-diluted geothermal water during the late Quaternary, and are as young as 8500 yr BP from 14C dating of plant material in sinter associated with the Mangatete deposit.

Jan 1, 2005

By William R. Barton

COLUMBIUM (niobium) and tantalum are similar refractory metals with closely related properties and uses and close association in ore deposits. Until recently both metals, particularly columbium, were essentially laboratory curiosities. However, since the beginning of World War II, applied technology, under the impetus of national security requirements, has realized many chemical, electronic, nucleonic, and missile and rocketry applications, where high temperature or corrosive environments require the use of columbium or tantalum. At the same time, advances in these fields have resulted in intensive research on the geological distribution, resources, metallurgy, and properties of these two metals; their alloys and compounds; and the development of a full-fledged columbium-tantalum industry. The future appears to promise continued acceleration in such studies and ever-increasing demand for these elements. The raw material supplies of columbium are abundant, and the extractive metallurgy of columbium is well enough advanced to assure adequate supplies of the element at reasonable prices to meet any projected demands. Although the extractive metallurgy of tantalum is similarly well developed, raw material supplies are so limited that, lacking new ore discoveries, an increase in demand to five times the 1959 level would severely tax ore-production facilities. Approximately 120 tons of tantalum and about one-half as much columbium was produced in 1959. Additional quantities are consumed as compounds or additive alloys such as ferrocolumbium and ferrotantalum columbium (55).3

Jan 1, 1962

The Macraes Mining Company Limited was listed on the New Zealand and Australian stock exchanges in January 1990, and the proceeds of the float were used to purchase a 70 per cent interest in the Macraes Gold Project, previously owned by BHP Gold Mines (NZ) Limited. Macraes Mining has had a 30 per cent interest in the project since May 1984, when it was incorporated. Project financing in the way of a gold loan was secured in February 1990 and construction commenced shortly afterwards. The mine construction activities were completed within nine months and the mine commenced operations in October 1990.

Jan 1, 1991

By Joseph D. Davis

Selection of a suitable coal or coals for the manufacture of coke of desired quality with due consideration of the purpose for which the coke is intended requires careful thought, and often it will pay to go to considerable expense in testing such coals as may be available. In general it will

Jan 1, 1942

By R. S. Dean

In addition to the normal work and that pertaining to strategic minerals, the Metallurgical Division has been made responsible for carrying on major investigations in the development of processes' for the treatment of low-grade domestic manganese ores that heretofore have failed to yield products suitable for the preparation of ferromanganese, an alloy essential to every ton of steel produced. These investigations are particularly important at this time because of their part in tucking this country self-sufficient with regard to manganese when the stock-piled ore becomes e exhausted and as foreign shipments of ferro-grade ore are cut off. The results indicate that there is a good probability of accomplishing this objective, while at the same time conservation may be promoted through the use of normally useless material from the large, low-grade ore deposits.

Jan 1, 1941

By S C. Labram, A Stabile

"Modern train load out stations are becoming faster and have the ability to load a 100 wagon train in less than three hours. At 70 metric tonnes per wagon, that is an average fill rate of 2333 t/h and considering the train is continuously moving, the instantaneous feed rate into the wagon is in the region of 4200 t/h.The main feed conveyor that maintains the level in the surge hopper, above the final weigh hopper, operates in excess of 5000 t/h to ensure uninterrupted charging of the weigh hopper to not disrupt the train loading operation.To avoid demurrage costs (a charge by the Rail Operating Company for exceeding the contractually agreed loading time) the train has to be handled speedily and efficiently and spend the absolute minimum time at the loading facility. Everything else has a much lower priority, including sampling.Thermo Fisher Scientific’s brief was an engineering, procurement and construction management (EPCM) contract to provide a sampling scheme adjacent to the prepurchased and predesigned load-out facility, but which interfaced seamlessly with the loading system of the trains and provided the following: an instantaneous particle size distribution (PSD) result for each truck loaded, and a final PSD for the total train prior to the train leaving the loading facility a crushed (-3 mm) composite sample for chemical analysis for the whole train a composite physical analysis sample for the whole train.The design presented some interesting challenges to our team, but the end result is a system that not only ‘stands alone’ but interfaces seamlessly with the loading system. This paper discusses the design itself and potential improvements to future systems.CITATION:Labram, S C and Stabile, A, 2017. An automatic sampling methodology to determine contractual particle size distribution in rapid train load out stations, in Proceedings Eighth World Conference on Sampling and Blending, pp 229–234 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

May 9, 2017

By M Eggers, H Baxter

This paper discusses the geotechnical condition of bedding shears and small- and large-scale faults and shears in Archean banded iron formation (BIF) bedrock, based on observations of core and televiewer images. Information that can be collected includes the orientation of defects, infill thickness, strength and material type, defect shape and surface roughness.The spacing and continuity of bedding shears may be critical to slope design where performance is structurally controlled with bedding dipping out of a wall. The intensity of development of the bedding shear is a useful indicator of the amount of shearing a bedding surface has been subjected to. This can allow for engineering judgement to be used in adopting peak or residual shear strengths along defect surfaces when developing the design.The spacing and continuity of bedding shears may also contribute to the blockiness and degradation of a rock mass where the structural orientation is otherwise favourable. Additionally the condition, thickness and strength of infill of major fault structures can affect slope design and performance, depending on orientation.Comparison of the condition of structures observed in core with the corresponding in situ televiewer image has been made to assess what characteristics are most accurately captured by each technique and whether the additional information gathered from using the televiewer technique is justified by the cost. The question of whether the data collected by a televiewer is sufficient to ultimately replace the need for core is considered.CITATION:Baxter, H and Eggers, M, 2013. Fault and shear characterisation in archean banded iron formation bedrock - a comparison between core and televiewer data collection techniques, in Proceedings Iron Ore 2013 , pp 47-56 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

By Samuel A. Reipas

Introduction The ore mining industry has been successful because of technological progress and huge sums of capital investment. But new technology and plants have not come cheap. The problem now is companies will run out of money before they run out of ideas. Survival Strategies Industry survival strategies demand restructuring and new plans. Inland's prescription for the future includes: • Continued emphasis on technological improvements to upgrade pellet quality and lower costs; • Effective use of human resources resulting in employee satisfaction and improved planning and productivity; • Deliberate, well planned, and documented cost-control programs for the short- and long-term; and • Capital investments to support the first three initiatives. Technology Technological changes are not only required by the need for operational improvements, but by product quality improvement dictated by the user - usually the blast furnace operator. Established ambient measurements of pellet quality, such as tumble index, compression strength, porosity, size distribution, and chemical composition, are no longer considered meaningful in predicting pellet performance in a blast furnace. New specifications, called low temperature and intermediate temperature properties, have been recently introduced. Low temperature specifications are characterized by disintegration of pellets in the 500°C (930°F) range in the upper portion of the granular zone during the hematite-to-magnetite transformation in blast furnace stack. Intermediate temperature properties (measured by 1000°C or 1800°F) are characterized by swelling, reducibility, and compression strength after reduction, reflecting conditions in the lower portion of the granular zone of the furnace. These new parameters are being used for pellet quality evaluation at Inland, and will be introduced at its Minorca mine for more routine analysis and correlation with the pellet furnace operation. With increased emphasis on quality, effective communication between the blast furnace operator, research, and the pellet plant operator is critical. At Inland, this is accomplished through technical meetings where the opportunity is provided to solve problems, establish a common understanding on the value of quality, and develop future quality standards and programs. With the degree of sophistication in determining pellet quality as it affects blast furnace operation, the future pellet plant operator will actually be producing a custom pellet. Human Resources Technological change has been a strong point at Inland, and will continue to be. However, human resource management is equally important. Is management giving sufficient attention to employee motivation and involvement? It is a way to improve productivity, reduce costs, and enhance employee job satisfaction. The industry is beginning to understand the principles and the potential for tapping employee brainpower. The payoff can be handsome. Management has to be willing to share both information and power if participative management is to live up to its potential. It has to become more flexible and be willing to adapt to change on the human side. Management should embrace rather than fear employee involvement. Given time, joint problem solving will replace adversarial attitudes and pay dividends for both sides. Productivity and product quality will improve and new dimensions of employee job satisfaction will be achieved. But, it will not happen overnight. Attitudinal change must permeate the organization from top to bottom. This change is needed to support the working relationships and give everyone a sense of direct and meaningful involvement.

Jan 11, 1983

By H. M. Lizama, R. L. Stephens

Secondary leaching of previously leached supergene copper ore has been developed and implemented at Teck’s Quebrada Blanca operations. This consists of using in-situ leaching techniques aided by geophysics to recover the residual metal value from dormant copper leaching heaps. These heaps of crushed and agglomerated ore had been leached 20 years previously but still contained significant copper values. The concept was first tested on a 3,200 m² sector, where injection wells introduced leaching solution into a production zone and electro-resistivity tomography was used to track solution movement within. Operating parameters such as well spacing and injection flow rates were determined. Copper recovery and leaching performance were evaluated based on solution and metallurgical balances. Both ferric leaching and bacterial leaching were enhanced through strategies to pull air into the heap. Positive results from the initial test prompted a larger, industrial pilot test on a 60,000 m² area and 97 injection wells. This larger test obtained a copper recovery of 30% in 457 days. Secondary recovery is now being implemented to all of the abandoned heaps at Quebrada Blanca and has become a production stream. This technology has the potential of wide application to mature copper heap leach operations, and Teck has patented the process and associated methodologies. INTRODUCTION Heap leaching of copper secondary sulphides has been carried out at Quebrada Blanca (QB) since 1994. Ore from the supergene deposit was crushed and agglomerated prior to leaching. Originally, the ore was leached in 6 m lifts stacked one on top of another, known as a static pad configuration. However, in 1998, after the second lift, the operation changed to a dynamic pad configuration; the ore was leached in a single lift and the resulting residues were removed to make way for fresh ore (Yáñez, Ahlborn, & Ramos, 2007). The first two static lifts were left in place and served as a foundation for the dynamic lifts above. Those two buried lifts of leached residues, some 16.8 million tonnes and covering an area of approximately 0.71 million m², remained buried under the dynamic pad.

Jan 1, 2019

By F. Agterberg

In his 1978 monograph ‘Lognormal-de Wijsian Geostatistics for Ore Evaluation’, Professor Danie Krige emphasized the scale-independence of gold and uranium determinations in the Witwatersrand goldfields. It was later established in nonlinear process theory that the original model of de Wijs used by Krige was the earliest example of a multifractal generated by a multiplicative cascade process. Its end product is an assemblage of chemical element concentration values for blocks that are both lognormally distributed and spatially correlated. Variants of de Wijsian geostatistics had already been used by Professor Georges Matheron to explain Krige’s original formula for the relationship between the block variances as well as permanence of frequency distributions for element concentration in blocks of different sizes. Further extensions of this basic approach are concerned with modelling the three-parameter lognormal distribution, the ‘sampling error’, as well as the ‘nugget effect’ and ‘range’ in variogram modelling. This paper is mainly a review of recent multifractal theory, which throws new light on the original findings by Professor Krige on self-similarity of gold and uranium patterns at different scales for blocks of ore by (a) generalizing the original model of de Wijs to account for random cuts; (b) using an accelerated dispersion model to explain the appearance of a third parameter in the lognormal distribution of Witwatersrand gold determinations; and (c) considering that Krige’s sampling error is caused by shape differences between single ore sections and reef areas.

Jan 1, 2015

By WenJun Dong

This paper presents the stability assessment of the steel pipe piles that are used to support a deadman beam to anchor an adjacent bulkhead wall. Finite element analyses are performed to assess the stability of the bulkhead wall and determine the required tie-back force to the pile. The piles are relatively close to the bulkhead wall such that their soil resistance wedge zones are not fully developed but truncated by the bulkhead wall. The reduced lateral resistance capacity of the anchor piles is determined by applying the Coulomb wedge method on the truncated soil passive zones between the pile and wall. Both the conventional soldier pile stability (in terms of force and moment equilibrium) and Winkler soil spring (for soil-pile-interaction) analyses are used to assess the stability of the anchor piles.

Sep 8, 2021

By Robert B. Bittner

"AbstractLarge diameter tubular piles offer significant advantages in terms of design performance and economy for major marine structures. This is particularly true for foundations of major overwater bridges in regions of high seismicity such as the west coast of North America. The use of large diameter piles in the range of 2 to 3 m diameter means that fewer piles are required, and the size and mass of the pile caps can be significantly reduced, thereby greatly reducing lateral load demand during seismic events. Another advantage of using larger diameter piles is increased pile stiffness that allows the pile caps to be located at or near the waterline rather than being positioned at or below the mud line. This elevating of the pile cap offers significant cost savings by eliminating the need for deep cofferdams. However, relocation of the pile cap creates new problems and opportunities in regard to the means and methods used to construct the pile cap. With the pile cap at depth, conventional steel sheet pile cofferdams with thick tremie seals are typically used to isolated the cap location and allow dewatering for construction of the cap. However with pile caps positioned up off the bottom, conventional bottom founded cofferdams are no longer cost efficient. Float-in or lift-in cofferdams have been developed to address the need for a more cost efficient method for cap construction. This paper describes the key features of the concept and provides three case history examples of its successful implementation.Pier Construction Using Conventional Sheet-Pile CofferdamsCofferdams are temporary structures used in the construction of bridge piers and other marine structures. Their primary purpose is to hold out water and unstable soil from the construction area, and thereby, allow in-the-dry construction of the permanent structure below the water line and quite often below the mud line. Typically, cofferdams consist of long interlocking steel sheet piles driven through water into the bottom of the waterway. The sheet piles form temporary exterior walls which are typically braced internally with wales and struts. The bottom of the cofferdam is typically sealed with tremie concrete or an impervious clay layer if one exists. The depth at which this type of cofferdam can be used is typically limited by the length of steel sheet pile that can be transported and handled by conventional marine equipment."

Jan 1, 2014

By Cathy Aimone-Martin, Brent Meins

A comprehensive instrumentation program was implemented at the Howland Hook Marine Terminal on Staten Island, NY during proximate underwater rock blasting in 2014. Forty-two blasts took place over a 4-week period to deepen the 1200-ft (366 m) Berth 3 from -45 ft (-14 m) to -50 ft (-15 m) MLW to accommodate Post-Panamax vessels. Approximately 86,000 yd3 (65,752 m3) were blasted 120 to 9 ft (37 to 2.7 m) from the wharf to a total depth of -57 ft (-17.4 m). Pre-blast planning included developing and implementing a comprehensive monitoring plan and setting vibration and strain limits to protect the wharf. The plan outlined methods to measure vibrations on five corners of four concrete deck sections, on five concrete-filled pipe piles just below the pile cap near deck corners, and in bedrock adjacent to pile sockets. Water overpressures were measured near instrumented piles for 19 blasts closest to the wharf. A total of 19 geophones were secured to the wharf structure and buried 12 ft (3.7 m) in drilled holes.

Jan 1, 2016

By E. L. Singleton

The Bureau of Mines investigated extraction of aluminum from aluminum-silicon alloys as a means of utilizing domestic aluminum silicate ores for aluminum production. Aluminum was extracted from aluminum-silicon alloys by electrolysis in molten electrolytes of NaCl-KCI-AIC13 and NaCl-KCI-AIF3 in a laboratory-scale cell. Six alloys with aluminum contents ranging from 20 to 87 percent aluminum were tested, and aluminum products of primary grade or better were obtained. More than 80 percent of the aluminum was recovered with current efficiencies as high as 91 percent. Recovery of a metallurgical-grade silicon product from the anode residue by an acid leaching procedure was possible with the 50-50 and 65-35 Al-Si alloys.

Jan 1, 1972

By M. M. Tilman

Etchants containing hexavalent chromium and sulfuric acid are used in a variety of surface-finishing operations. When the resultant spent solutions are discarded, substantial quantities of chromium are lost and pollution prob¬lems are created. To minimize the undesirable environmental effects while improving metal and minerals recycling technology, the Bureau of Mines is con¬ducting research on a method for the economic inplant recycling of these waste etchants. Trivalent chromium, produced when the etchant reacts with a substrate, is oxidized in the anode chamber of a diaphragm cell; other metals, dissolved during the etching operation, are transferred to the catholyte. When waste brass etchants are treated in this manner, all of the trivalent chromium is oxidized and more than 40 percent of the copper and zinc is removed. Similar copper removal and chromium oxidation are achieved with waste printed circuit board etchants and rinse waters from plastic etching operations. The electrical energy needed to regenerate 1 kg sodium dichromate is less than 9 kwhr. Regenerated brass etchants evaluated by two companies equaled or exceeded the performance of fresh etchants.

Jan 1, 1979

Laboratory induced polarization measurements were made on representative samples of concentrated sulphide ores from three environments in New South Wales Comparisons were made with the membrane polarization exhibited by an argillaceous sandstone. The sulphide samples showed a strong polarization effect, the magmtude of whIch depended directly on the conductivity of tlIe pore electrolyte.

Jan 1, 1969

By Gill Montgomery

This report covers operations at the Crystal-Victory and Minerva No. 1 mines in Hardin County, Ill., which are operated by the Minerva Oil Co., Fluorspar Division, with offices in Eldorado. It describes the exploration, development, and mining practices, giving costs of each. Transportation, equipment, power, labor, and other influencing factors also are discussed. The mining methods employed are those most applicable to the flat-bedded replacement deposits common to the Cave-in-Rock section of the Southern Illinois fluorspar district. The fluorspar beds occur from surface exposures to 1,000 feet deep. In this district churn drilling is the method practiced for exploring flat-bedded deposits from the surface. Aerial photography and geochemical methods for indicating mineralization have been helpful in planning a drilling program. A program usually includes enough drilling to obtain only sufficient data on the value of the ore body and its structure to justify initial development and purchase of the mineral rights under option.

Jan 1, 1960

By R. A. Hatch

This report summarizes the results of nearly 8 years research on and production of synthetic mica at the Electrotechnical Experiment Station of the Federal Bureau of Mines, Norris, Tenn. This program was undertaken at the request of the United States Department of the Navy and was financed mostly by the Army Signal Corps and the Navy Bureau of Ships through a contract with the Office of Naval Research, The original objectives included fundamental studies of fluor-phlogupite and other fluorine-micas and production of synthetic mica sheets on a pilot-plant scale. The first 3 years of this project were devoted mainly to a search for practical solutions of the many problems involved in designing and constructing a pilot plant for crystallizing fluor-phlogopite mica. The first and most urgent need was a suitable container for the corrosive mica melt. After extensive study, it was concluded that platinum, graphite, high-silica fire clay, and silicon carbide were the most promising refractories for crucibles; but none was perfect. Silicon car¬bide seemed to have the better combination of qualities, combining good corrosion resistance with oxidation resistance.

Jan 1, 1957