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By Steven B. Van Kouteren

Value added is a loosely used qualifier in the industrial minerals industry. What exactly does it mean? What does it take to make a value-added product? More importantly, how does a company maintain the value added to its products? Most people agree that value-added means the value of a mineral minus the cost to produce it. This is misleading, though, because producing value-added products does not necessarily guarantee the profitability of the products. In some cases, firms that make value-added products are not very profitable. It is important not only to understand how to make a value-added product but also how competitive forces in the market can erode the value added. Therefore, when looking at value-added opportunities, producers must understand how to obtain the value added and how to maintain that value. Four major factors limit a company's ability to add value to its products. This paper examines these factors. It uses the ground calcium carbonate and mica industries as examples.

Jan 1, 1990

By Peter Chou, Pooyan Asadollahi, Danny Lin

To maintain flexibility and ductility of tunnels crossing active faults, various mitigation measures are being utilized depending on fault offset movements and seismic design criteria. Examples of those approaches are simple bell and spigot joint, articulated joint, and complex deformable longitudinal bolt and spring joint system with seismic isolation washer. This paper presents a summary of tunnel fault crossing mitigation approaches and design considerations using previous relevant experiences in California as well as case histories from Japan, Taiwan, Turkey, Greece, and Italy found in literatures. Comparisons are made between large and small diameter tunnels, transportation, and utility tunnels, as well as bored, mined and cut-and-cover tunnels. Recent innovations, such as Japanese and Italian techniques, for tunnels crossing active faults are also discussed.

Jun 13, 2021

By J. W. Craven, M. Katom, K. M. McCaffery

At Ok Tedi, ore type and SAG feed size distribution vary widely and frequently. This makes control of the SAG mills by application of the power/pressure relationship difficult. Power logic has traditionally been conservative due to power spikes associated with rapid size distribution changes. A new expert system was installed in early 2000. The system incorporates multiple state fuzzy logic to deal with frequent and radical ore type and size variations, along with monitoring of motor temperatures. A short term power spike no longer warrants immediate radical action. This has resulted in increased mill throughput and improved circuit stability.

Jan 1, 2001

By Lee Browne

The transformation of Peru’s Tintaya copper project from a state-owned company to a private company is under way and the results have been successful. Since Magma Copper Co. assumed operating management in December 1994, production and costs have improved dramatically. To understand the transformation of Tintaya, the transformation of Magma Copper must also be understood.

Jan 1, 1996

By D. J. Turk

Stillwater Mining Company’s, Nye Operation has been producing PGM concentrate since 1987.Several expansions have allowed for increasing capacity from the initial rate of 500 tons per day, to its present capacity of 3,000 tons per day. The expansions were performed with minimal impact upon production and maximum utilization of the existing equipment. The latest expansion incorporates a 6’ X 18’ SAG mill, 13’ X 20’ Ball mill, pebble crusher, rougher flotation cells, 1250 Hp tertiary grinding mill, middling and scavenger flotation cells, and cleaner column flotation cells. This paper will describe the concentrator flow sheet, and controls for improved concentrator performance.

Jan 1, 2000

By R. Sharma, S. Svoronos, S. Gupta, N. A. Abdel-Khalek

This paper presents the results of column flotation of a fine feed sample of Florida phosphate. A central composite design is used to study the main and interaction effects of parameters affecting column efficiency. The statistical design is also used to determine the optimum conditions. The results indicate that, depending on the experimental conditions, it is possible to achieve a concentrate of high grade and recovery. A concentration of 15 ppm of non-ionic frother is found to be enough to maximize the recovery at the pH of 9.5.

Jan 1, 1999

By E. Baliktsis

We have searched and analyzed several modern technologies aiming at the best applications of environmental management, the studying of quarrying ? mining as well as the excavation sites ? utilization ? rehabilitation. We have used long-range reflectorless laser surveying systems, so as to achieve the fastest and most accurate surveying of the extractive work sites. We also used them, in order to collect field data, measure distances, surveying monitoring stations and environmental parameters ? data. Furthermore these systems can make the field work quite faster, more reliable and credible and have low cost in collecting data even in dangerous and non-approachable areas. We have used and processed on the field data in G.I.S. applications, in order to create 2-D and 3-D digital ground models. These G.I.S. applications present the existing relief and the management of the final stage of the area. The suggested techniques and works needed, for reclamation and utilization of the areas, could be tried, evaluated and well presented. The evolution and utilization of these ?smart? modern tools for the effective environmental management of quarrying ? mining ? extractive activity sites, will be presented by using case histories from the Hellenic territory.

Jan 1, 2002

By P. A. Plunkert

Metallurgical-grade bauxite was imported into the United States from 11 countries in 2004. The principal suppliers of this 10 Mt (11 million st) of imported ore were Jamaica (33 percent), Brazil (25 percent), Guinea(23 percent) and Guyana (11 percent). The average value of imports, cost, insurance and freight (c.i.f.) U.S. ports, was $31/t ($28/st). Calcined refractory-grade bauxite imports were 165kt (182,000 st) with an average value of $146/t ($132/st), c.i.f. U.S. ports. China supplied 70 percent; Guyana, 22

Jan 1, 2005

By Earl Rau

Introduction Will cogeneration be a major power source in the future? The location of electric power generating plants has changed. In 1900, more than 50% of electricity was generated by industrial plants. Since then, industrial plant generation of electricity greatly decreased to 17% in 1950 and to only 3% in 1980. Changing economics in electric power generating costs, though, may allow cogeneration to reverse this trend. Cogeneration has been defined as the simultaneous production of electric (mechanical) and thermal energy from a single energy source. Some applications are considered to be byproduct generation of electricity from industrial, thermal operations. Cogeneration is not new to the mining and minerals industry. Smelters and steel mills have used waste heat to generate electricity. Public Utilities Regulatory Policies Act of 1978 The potential for increased industrial cogeneration of electricity is related to the March 9, 1978 enactment of the Public Utility Regulatory Policies Act (PURPA). The US Supreme Court ruled that PURPA is constitutional. The court upheld requirements that utilities interconnect to cogenerators. It also ruled that 100% of avoided costs be used as the guideline for electricity sales by a qualifying facility (QF) to a utility. The state of New York established a floor price $0.06/kWh for electricity sales from a QF to a utility. It is obvious, then, that a cogenerator must first establish price and then become a qualifying facility in order to sell electricity to a utility. Proposed cogeneration plants The estimated industrial cogeneration potential for the years 1986 to 2000 is 9500 to 25,000 MW. Industries represented in this cogeneration estimate are pulp and paper, petroleum, chemicals, food, textiles, rubber, plastics, steel, lumber and wood, cement, glass, metal fabrication, and industrial parks. A cogeneration plant has been proposed for the Union Carbide chemical plant in Institute, WV. A steam turbine/generator would be installed to replace the pressure-reducing valve in the 2.7 MPa (400 psig) header. Scott Paper Co., Mobile, AL, proposed a cogeneration plant using a coal- and wood-fired boiler and a turbine/generator to produce process steam and electric power. A cogeneration system has been proposed for a large oil refining plant. A pulverized coal boiler would produce high-pressure steam to operate a turbine, generator. The exhaust steam from the turbine will go to the process and an existing turbine. Kansas City, MO's Armour meat-processing plant has proposed a cogeneration plant. This proposal is to use a natural gas or oil-fired, gas-driven turbine and a generator. The waste heat from the gas turbine would go to a heat recovery boiler for use as process heat. Dade County, FL is implementing a central energy system to supply electricity, air conditioning, and domestic hot water for five buildings in downtown Miami. The cogeneration system is to provide flexibility, to optimize fuel use efficiency while serving the variable thermal demands. Generation of electricity from municipal waste is not considered to be a cogeneration process but is covered by PURPA. Special considerations are provided for waste/electric power generation to encourage the development of these systems. ?

Jan 7, 1987

By S. Murdock, R. L. Fleischer, H. W. Alter, J. E. Gingrich

The use of solid state track deters allows totally passive, integrating measurements of 222Rn (radon) or of 220Rn (thoron) plus radon. A track-detecting solid is placed in a holder that is closed by a selective membrane and exposed to the atmosphere of interest to produce an accurately time-averaged record over times of interest that range typically from a week to a year. By selection of the proper membranes, dosimetry can be done for radon or for the sum of radon and thoron. A different membrane is appropriate for measuring radon under humid conditions such as are found in the ground. Large numbers of measurements have been made with these systems both in the ground, where radon levels are high, and in indoor environments, where levels are orders of magnitude less. Calibrations have been carried out at both high and low concentrations of radon. New results in the air at the site of the Shirley Basin mine and mill give reproducible results with month-long integrating periods. The off-site background levels are in the range 0.7 to 1.0 pCi/l (26-37 Bq/m3). The average yearlong on-site level is 1.5 pCi/l (56 Bq/m3); at the mill it is 2.6 pCi/l (96 Bq/m3); and the level measured at the backhoe in the open pit mine is 3.9 pCi/l (144 Bq/m3). The region of significantly elevated radon levels is confined to a radius of 1.6 km of the mine and mill. All of the on-site radon concentrations are less than but comparable to the typical values found in the living areas of modern energy-efficient homes.

Jan 1, 1981

Fluorspar was not mined in the United States during 2004, although a small amount of usable synthetic fluorspar (CaF2) was produced from industrial waste streams. The majority of fluorspar consumed in the United States came from imports or stockpiled material purchased from the National Defense Stockpile (NDS). In addition, consumption is supplemented by use of by-product fluorosilicic acid produced at phosphoric acid plants. In 2004, annual production of fluorosilicic acid was 50kt (55,000 st) or about 88 kt (97,000 st) of 92 percent fluorspar equivalent. In 2004, annual production of fluorosilicic acid was 50kt (55,000 st) or about 88 kt (97,000 st) of 92 percent fluorspar equivalent.

Jan 1, 2005

By A. Kosiór

Many remnants of gold exploitation in the Middle Ages were found in the Lower Silesia region. The oldest evidence of such activity was found in the neighborhood of Zloty Stok and comes from the 7th century. Mining of precious and non-precious metal ores has a great relevance in the late Middle Ages when advanced metallurgic technologies were mastered, that allowed to obtain gold, silver, lead, copper, zinc and arsenic from complex ores occurring in the oldest middle part of Sudetes. Historically it concerned the area of the Swidnica Principality and Klodzko County. Experience obtained in Freiberg, which is located close to the Lower Silesia, was used in the development of mining. A high level of mining and metallurgic technology was obtained in the 15th century that caused significant increase of production of the metals mentioned above. Unfortunately, the good time of Lower Silesian mining lasted only up to the 18th century; the notion of preservation of cultural heritage was unknown at that time. The Lower Silesian medieval mines were not in such a fortunate situation as the ?Wieliczka? and ?Bochnia? mines, which are operating to present-day, and which made preservation of the most interesting headings and objects possible. All these objects are now available for visitors. However, in the case of the middle Sudetes it seems that it is often sufficient to localize old shafts and headings on the basis of careful observations and old maps and carry out some earthwork to uncover medieval headings and objects of underground mining activity. They are often preserved in amazingly good state; this also pertains to mining devices. Another issue is of course the permanent preservation of that heritage and its possible availability for re-searchers and tourists. Some success has been achieved in that field (Zloty Stok Gold Mine is a good example), but also problems were encountered in many cases. The Lower Silesian Coal Basin, which has not been exploited for 10 years is an evidence that there is not a holistic conception of mining heritage renovation. Many attractive mining objects disappeared irrecoverably from the mountainous landscape of the Middle Sudetes despite common consciousness of their significance for cultural development of Silesia and other regions.

Jan 1, 2006

By R. L. Virta

Common clay is a natural, fine-grained material composed of hydrous aluminum silicates. Shale is a laminated sedimentary rock that is formed by the consolidation of clay, mud or silt. Production About 160 companies produced common clay and shale in 41 states. In states not reporting production, common clay and shale probably was mined and sold for construction applications by companies not participating in the U.S. Geological Survey’s canvass of producers.

Jan 1, 2005

By J. O. Marsden

This paper presents an overview of the innovative methods for gold and silver extraction that have been put into actual practice in North America since 1987. It is an update of a paper of the same title which was presented by Sass and Mansanti at the AMC conference in San Francisco in 1987. New practices, new equipment and variations of older practices that have been introduced in the last five years are discussed in each of the following categories: process selection trends, comminution, gravity concentration, flotation, oxidation, agitated and vat leaching, heap leaching, solution concentration and purification, zinc precipitation, electrowinning, tailings disposal detoxification, and reclamation.

Jan 1, 1993

By Y. Nien Wang

The Devil?s Slide portion of Highway 1 between Pacifica and Montara is often closed due to the instability of the adjacent slopes. Following many years of public input and careful evaluation of alternatives, Devil?s Slide will be by-passed via two inland tunnels, providing a safe, dependable highway between Pacifica and Montara. For the twin tunnels, each 9m diameter tube will accommodate only one traffic lane. Each tunnel tube will accommodate a 3.6 meter roadway, 0.6 meter and 2.4 meter inside and outside shoulders respectively, and 1.2 meter walkways on each side. Cross passages will connect the bores at about 120 meter intervals and jet fans will provide tunnel ventilation. The twin tunnels are approximately 1,250 meter long and 9 meter wide. Excavation will progress from south to north using tunneling techniques that rely on inherent rock strength for support known as the New Austrian Tunneling Method (NATM). Both tunnels will be excavated at the same time, one tunnel face approximately 40 meters ahead of the other. Staggering the tunnels reduces the likelihood of damage from blasting in alternate tunnels. The work schedule is 24 hours a day, 7 days a week resulting in a 24-month timetable to break through to the north portal.

Jan 1, 2008

By Jack T. Work

Spiraling costs in every segment of the open-pit mining cycle is a fact of life that every operator must reckon with. The introduction of various shock absorbing devices for rotary drilling is one recent innovation that may significantly reduce overall drilling cost, increase drill availability, and lower maintenance requirements. In a recent all-inclusive test in taconite ores, shock absorbers on Bucyrus-Erie BE 60R and Gardner¬Denver GD 120 rotary drills were directly responsible for overall savings of up to $41.06 per hour. What is It? A shock absorber is simply a device installed between the rotary drive head and drill steel that cushions the two. It functions in the same manner as springs and shocks on an automobile. Some benefits associated with use of the tool are readily apparent on a daily basis; other benefits are realized over longer time intervals and through continued use. A properly designed shock absorber will: •protect the drill from severe vi¬brations, improve rock bit performance, allow application of the best weight-on-bit and rotating speed under all drilling conditions, •function effectively over a wide range of applied bit weights, • have a spring rate soft enough to perform its primary function of absorbing both rotary and vertical vibrational forces generated by rough drilling, •be reliable and subject to as little maintenance as possible, •be easy to install and remove, and • be of such an economic benefit so as to offset the added expense of its application. A shock absorbing tool developed by BJ-Hughes Inc. was used in a recent test. The "Smoothdrill" is just one of the products currently available. This unit absorbs both rotary and vertical shock loads and has no mechanical parts so lubrication is unnecessary. A rebuild of the unit consists of removing the worn rubber element and inserting a new element, an operation taking less than one hour. Minimizing Vibrations Severe vibrations on a blasthole drill operating in broken and discontinuous formations have visible effects. These vibrations often cause structural damage when allowed to' continue, resulting in fatigue cracks in the mast and related structural components in the drill. When rough running formations are encountered, drilling must be interrupted and possibly shut down. Usually, the drill operator resumes drilling using less down pressures and various rotational speeds until firmer drilling is encountered. An effective shock absorber can substantially reduce these vibrational forces so more down pressure can be applied in bad ground. It is generally accepted that longitudinal vibrations and cyclic forces are more effectively reduced if a tool is designed to incorporate a relatively "soft" shock absorber. The softness of any shock absorbing tool is best judged by its spring rate-the weight required to produce a given amount of deflection, commonly expressed in units of kg per mm or pounds per inch of deflection. All shock tools use a resilient member such as rubber springs, steel springs, fluid, or gas springs to absorb

Jan 4, 1980

By R. W. Kobler

The pelletizing process for low grade iron ores has undergone continual changes since its inception over twenty years ago. These changes have necessitated filtration equipment changes in order to produce a product suitable for balling. With modern techniques it is now possible to produce pellets of 68% Fe from ores containing as low as 26% Fe. Low grade ores require fine grinding to liberate impurities This shift to finer grinds over the years has necessitated major changes in the filtration steps. Techniques are now available for producing suitable product from ores with Blaines as high as 3600 cm2/gram. This has been made possible by the development of high performance filters. Recent developments have reduced maintenance costs and produced higher production reliability. The paper discusses iron concentrate filtration from its beginning to present day design. It will be shown that the dewatering step prior to balling has gone through four generations of filters. Particular emphasis is placed upon hydraulic studies which have allowed today's optimum designs.

Jan 1, 1978

By A. W. Czarnowsky

More than ever before, mining projects are besieged from growing regulatory, political, public, and special interest group pressure. Administrative and legal appeals to permits and environmental documents can delay project start-up and add tremendous cost to mineral development. Some mining projects have been canceled given undue external constraints. Successful managers must learn to cope with these constraints. This paper will discuss controversy and present a number of environmental management tips to minimize the potentials for delay and to lessen the impacts from government and anti-mining pressures.

Jan 1, 2001

By Harvey W. Parker

The underground industry is challenged by many complex technical and non-technical issues and risks. The most obvious of these are the traditional technical issues that we usually try to address with risk management techniques. However, there are many other non-technical risks that our projects face on a daily basis which we often fail to fully recognize or appreciate. This paper addresses some of the less-technical broad-based risks in order to put them into perspective with the technical risks we face day to day in underground planning, design and construction. The good news is that Risk Management techniques are not always about bad things. For obvious reasons Risk Management is always thought of in terms of the ?downside? of risk (i.e., the identification and mitigation of things that can go wrong). On the contrary, there is an ?upside? of things that might go better than expected. Fortunately, if a deliberate effort is made, the same principles and techniques that our industry uses in Risk Management can be applied toward identifying and quantifying the Opportunities and Benefits that might occur. In this way, the process of conducting risk management programs can not only identify the downside risk but can be used to identify and direct projects to take advantage of the upside of uncertainty (i.e., Opportunities as they arise). This beneficial aspect of risk management programs will be highlighted in this paper together with the importance of the non-technical issues.

Jan 1, 2008

By B. Swarbrick

Today’s mining occurs in a dynamic world of conflicting objectives. Mining companies have to look further than a traditional cash flow analysis to determine the potential value of developing a mine. In particular, proposals for new mine developments undergo rigorous scrutiny by a variety of stakeholders including regulators, NGO’s, and the local communities. From a business risk perspective, how mining companies address stakeholder concerns can have a dramatic impact on the success of the project. In today’s mining environment mining companies must continue to ‘walk the talk’ to stay in business, particularly during downturns in the business cycle. Falconbridge’s Raglan Mine is an example of a project that was successfully developed in a region that is sensitive from many perspectives, including environmental, socio economic, and regulatory. Close working relationships with local stakeholders along with strong environmental management systems are necessary elements of continued success for the project.

Jan 1, 2000