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By Randy Ynchausti

ERIC GUTIERREZ, Knowledgescape: Our next speaker is Randy Ynchausti. He's the director of development, Knowledgescape systems division, of EIMCO Process Equip- ment Company. The title of Randy's talk is "An Expert Control System for Phosphate Beneficiation." RANDY YNCHAUSTI: System integration. How does the systems integrator survive when caught between plant engineers, plant management, and third-party engineering firms, and stay within the budget of the corporate goals? I'm not sure that anyone knows how to do all of that on one project. Results are critical when we talk about how systems integrators work with operating people, how the operating people want systems integrators to work with them, and how both groups work together so that at the end of a project, you have been provided with solutions that meet your needs and solve your problems at a fair price. How does the integrator's role change when working with different types of professionals, such as plant managers, plant engineers, engineering firms, or other system integrators? Finally, what is the dynamics of people working with machines and providing services and solving needs? The average number of employees per pound of copper processed has decreased significantly during the past 15 years. I would dare to generalize and say that the average number of employees per whatever unit of measure we have in whatever industry we work in has decreased over the last 15 years. From a system integrator's perspective, there are some clients who lack a bit of internal expertise as corporate downsizing occurs, and that's one reason why we go out to system integrators or third-party vendors and buy things from them to solve our problems. Downsizing really amounts to savings, but more than that, I think Brian expressed this and I agree with him, it also amounts to a cost. Unfortunately, most of us count the savings and none of us count the cost in that approach. It's easy to count the savings, which is one reason why we count it so quickly. Maybe that also accounts for why we set our pencils down so quickly after we get that dollar value. Maybe we should pick that pencil up every once in awhile and refigure the expense, the cost to us, and determine what we're going to pay during the next year or two or three in losing that expense, or that staff. A broad experience base accumulated over projects at various plants helps system integrators to provide services to clients. This experience enables the system integrator to

Jan 1, 1998

By J. A. Herbst, Y. C. Lo

An attempt has been made to parameterize the population balance model for a ball mill based on measurements of the elementary breakage process obtained using an ultrafast load cell device. Detailed insight obtained concerning the fragmentation of particle assemblies with the ultrafast load cell leads to a better understanding of ball mill grinding. The ball mill breakage function and specific selection function are derived from an average single event representing the multiple breakage events which occur in ball mill grinding. Since both the breakage function and the specific selection function depend on the loading mode in the mill, predictions of breakage mechanisms in ball mills are possible by using data obtained in various elementary loading modes. The application of this model to the description of batch ball milling behavior has resulted in reasonably accurate predictions of product size distributions for various energy inputs.

Jan 1, 1992

By J. A. Burger

Research in the eastern U.S. has shown that productive mine soils and forests can be restored using the following guidelines: (1) cooperation among the mine operator, landowner, and regulatory authority in developing the mining permit; (2) replacing topsoil or creating a desirable medium in which trees are planted; (3) loosely grading non-compacted topsoil; (4) using native and non-competitive domestic ground covers that quickly protect the site; and (5) planting a proper silvicultural mix of crop trees for their commercial value along with nurse trees for wildlife and soil improvement.

Jan 1, 2002

By Osamu Shoji, Mamoru Kato

In order to continue improving the quality of telecommunication services to meet the expectations of the people and to increase reliability in the case of emergency such as disasters, Nippon Telegraph and Telephone Public Corporation (NTT) is now constructing cable tunnels which connect main urban telephone offices. However, almost all the large cities in Japan are built in river deltas, so that their chief underground features are low strength fluvial deposit and a high ground water level. In this saturated soft ground, the ground surface at an installation site has occasionally subsided through deep excavations for cable tunneling construction. As these settlements have sometimes caused accidents, especially in densely populated large cities, NTT has made much effort to avoid such accidents. These accidents have occured mainly in flexible sheeting due to its inward movement. Therefore, after the investigation into forecast method of sheeting deflection with accuracy, NTT has reserched a system which forecasts ground surface settlements. This paper describes an outline of the ground settlement forecast system and practical example on the site.

Jan 1, 1979

By Thomas R. Kuesel

All engineering designs are based on assumptions regarding the behavior of the structure or facility being designed. These assumptions may be based more or less heavily on theory, but are credible only if verified by observations of field performance. Dr. Peck's "State-of-the-Art" paper has described the semi -empirical process of soft ground tunnel design, emphasizing the importance of records of field performance of actual projects constructed under a variety of conditions. This paper will present the principal results obtained from measurements made during construction of the soft ground tunnels for the San Francisco Bay Area Rapid Transit System. SCOPE The BART System comprises 75 route miles, including 14 miles of soft ground tunnelled subways in San Francisco, Oakland, and Berkeley. All tunnels are single-track sections, approximately 18 feet in diameter. Usually there are two parallel tunnels at the same level, but under Market Street in San Francisco there are four tunnels (two over two), and there is also a three-track section (two over one) in Broadway, Oakland.

Jan 1, 1997

By J. P. Matoney

The operation of a modern coal preparation plant, particularly in western Canada, is a very complex task. Most western Canadian operations are processing two or more, sometimes up to ten, different seams through the same plant. This requires a sophisticated multi-circuit plant that needs close operational control. Add the soft nature and large amounts of natural fines of western Canadian coal and you have a formidable cleaning task. To assist in the operation, programmable controllers and sophisticated control concepts are being more widely used. Two of the newest coal preparation plants in Canada have been designed by Raymond Kaiser Engineers Inc. and its Canadian subsidiary, Phillips Barratt Kaiser Engineering, Ltd. The use of programmable controllers and control systems will be illustrated by showing their application in a "typical" western Canadian coal plant. This example will cover flowsheet design, control concept systems application, and possible future uses.

Jan 1, 1983

By Richard Seal

Nabarlek is situated in the Arnhem Land Aboriginal Reserve about 270 km due east of Darwin in the Northern Territory of Australia. During the dry season (May to November) Nabarlek is accessible from Darwin over the Arnhem Highway-- a distance of 330 km. Throughout the wet season (December to April), except for a few days, access is provided by aircraft from Darwin to the Nabarlek airstrip. Because of the limited access during the wet season, reagents and supplies have to be stock- piled for six months on the site to maintain operations. With the mine and plant being remotely located on private Arnhem land with very limited access outside the site fence, operating personnel are flown to Darwin every six days for their days off.

Jan 1, 1980

By M. L. Free

Several studies of the fluorite/oleate flotation system have shown that under certain conditions calcium dioleate is formed at or transported to the fluorite surface. Adsorption of significant amounts of calcium dioleate is generally observed above oleate concentrations of -6 -5 between 4 x 10 and 4 x 10 M, yet little explanation of the onset of calcium dioleate adsorption is provided. In this study in-situ and ex-situ FTIR/IRS experiments have been performed in connection with thermodynamic solution phase analysis to better understand oleate adsorption as well as the onset of calcium dioleate formation. Results from this study are analyzed and compared to industrial practice.

Jan 1, 1995

By C. D. Anderson

"IntroductionTungsten carbide is a valuable material used in a variety of different applications, including the manufacturing of cutting tools, bearings and as a cost-efficient alternative to industrial diamonds. Both the high hardness value (Mohs 9) and scratch resistance of this material make it a valuable commodity for use in the mining industry.Usually, the production of tungsten carbide is a multistep process involving one or more of the following unit operations: hydrometallurgical digestion, solution purification, crystallization (as ammonium paratungstate), calcination, hydrogen reduction and carbon synthesis. The proposed three-step process eliminates three of these steps (crystallization, calcination and hydrogen reduction) by implementing a combination of hydro/pyrometallurgical techniques. These include alkaline pressure leaching, carbon adsorption and carburization roasting. By eliminating some of the intermediate processing steps, there is potential to reduce energy consumption and decrease overall operating costs.Methods and resultsInitially, alkaline pressure leaching with sodium carbonate (Na2CO3) was employed to selectively leach tungsten, as tungstate (WO4 2-), from an industrial Scheelite (CaWO4) flotation concentrate. Experimental variables included lixiviant (Na2CO3) concentration, temperature and residence time. Experimental constants, based on previous work, were percent solids at 13 wt% and agitation at 400 rpm (Queneau and Strathmore, 1969). Leaching results showed it was possible to extract 97% of the tungsten present. The most favorable conditions for leaching were determined: 2M Na2CO3, temperature of 180° C and a residence time of 30 minutes."

Jan 1, 2015

By Sean E. Armstrong, Deepak Malhotra

Gold extraction from refractory ores as a percentage of total gold production is increasing. The processing technology options for treating difficult-to-process refractory ores are also increasing. The best processing option is dependent on many factors including feed grade and the cause for ore refractoriness. The causes for ore refractoriness are many foldCpreg-rob­bing, encapsulation in pyrite, arsenopyrite or silica, presence of cyanocides, presence of cyanide-insoluble gold compounds, etc.1. The first step in the process development of a refractory gold deposit is to determine the cause for ore refractoriness. The traditional approach of undertaking detailed mineralogical examination of ore types, major and minor mineral constituents and their association does not necessarily provide the metallur­gist all the information needed for characterization of gold-bear­ing ores. For process development programs it is desirable to complement traditional mineralogical methods with diagnostic leach testing, which attempts to quantify the deportation of gold in various mineral matrices. This paper briefly reviews the diagnostic leaching proce­dures and its applications for a wide range of gold-bearing refractory ores, both primary and by-product.

Jan 1, 1996

By D. J. McKee, D. M. Wiseman

The usefulness of simulation as a technique for metallurgical process design and optimization studies has been greatly extended over the last few years by the development of a number of general purpose simulation packages. The packages, or simulators, all have the common objective of presenting the mathematical models and simulation methods in a form which is readily usable by plant engineers and metallurgists. To date, most simulators have been concerned with steady state simulation, but packages capable of dynamic simulation are now becoming available. The paper outlines the essential features of versatile steady state and dynamic simulators. Typical applications are presented by considering examples of design and optimization studies. Limitation on the use of simulators are also presented.

Jan 1, 1991

By F. W. DeVries

The preoccupation with cyanide as an environmental issue has been described as virtually an obsession for state and federal agencies enacting regulations for environmental protection. This seems likely to continue in legislative planning, as well. This is despite the fact that the only significant group of cyanide-related incidents has been the bird-mortality occurrences, predominantly in arid areas, and these have been greatly reduced by a concerted effort by operators. What follows is a brief list of areas for which the industry may need either additional information or plans for defensive strategies over the next two to five years.

Jan 1, 1991

By W. A. Cincilla, Z. T. Bieniawski, E. Unal

Although coal mine tunnels such as the main haulageways or roadways are the lifelines of coal mines, little attention has been paid to them in terms of pre-construction planning and design. This paper presents the results of research aimed at improving design methods for coal mine tunnels. Studies of the current practice and design needs in the United States were performed for coal mine development entries. A design approach evolved for coal mine tunnels is presented. It is based on field investigations and laboratory model studies aimed at integrating into reinforcement guidelines for coal tunnels. An up-to-date bibliography on coal mine tunnels is provided.

Jan 1, 1981

By L. B. Hales

Color video or digital cameras have been installed over flotation cells to monitor color, bubble size, froth movement, and other characteristics. These systems are designed so that the camera provides flotation performance information just as any other sensor might. Factorial tests have been run to monitor and measure the variation in froth characteristics as a function of flotation control settings. Ultimately, it is envisioned that froth image sensors can be used to monitor and control the flotation performance as effectively and for less cost than current analytical systems.

Jan 1, 1999

By Chuck Hornaday, Brad Miller

Geosynthetic clay liners (GCLs) are manufactured barrier layers containing a high-quality sodium bentonite clay attached or adhered to geotextiles or a geomembrane. The GCL's low permeability and high strength make it an ideal replacement for low permeability soil or clay liners for mineral extraction and processing containment applications. This paper will discuss the advantages of utilizing a GCL versus compacted clay in containment applications. Some of the advantages include: the GCL's lower permeability (5 x 10-9 centimeters per second (cm/sec)) and corresponding better composite liner leakage protection, the GCL' s greater resistance to desiccation, differential subsidence and freeze­thaw, and lastly, the ease and speed of installing the GCL. This paper will also detail a number of important case studies related to the mineral extraction and processing industry. These case studies include using GCL in two large reclamation capping projects, as a secondary liner in two gold heap leach pads, as a composite liner in a dam for stormwater runoff control, and lastly, as a primary liner for a tailings runoff diversion channel.

Jan 1, 1997

By John G. Watson, Judith C. Chow, Richard T. Egami, Daniel L. Freeman

A methodology for apportioning ambient PM-10 (particulate matter) concentrations to sources is described and applied to PM-10 concentrations in the vicinity of a large gold mining operation. With this methodology, samples representative of particulate sources such as desert overburden, diesel equipment, milling operations, road surfaces, and others are collected and analyzed to derive chemical source profiles. Ambient 6-hour PM-10 samples collected downwind from the mine are analyzed and used with the Chemical Mass Balance model to apportion ambient PM-10 among the various sources. In an example application, primary contributing source types are found to be desert overburden and diesel equipment. Relative contributions vary according to time of day, with diesel equipment frequently being the dominant contributor during nighttime periods.

Jan 1, 1991

By William H. Schiffbauer

Research is being conducted toward making underground mining equipment autonomous. This will facilitate improvements in safety by relieving workers of dangerous tasks and will increase production by providing more accurate control with less down time.. A Bureau of Mines developed microcomputer network has enhanced this research by permitting a group of diverse computers to interact with a mining machine as well as with each other over a common data link. The network is composed of specially integrated off-the-shelf hardware and industry-standard operating system and programming languages. Using the network, researchers can conduct various experiments with the mining machine using a diverse group of intelligent sensors, computers, and microcontrollers. Descriptions of the mining machine, the mining machine control computer, control algorithms, -the microcomputer network architecture, and communication protocols are discussed.

Jan 1, 1989

By K. Burke, G. Zhan, A. Mayer

A cover with capi1lary barrier effects (CCBE) is being constructed an the AA leach pad at the Barrick Goldstrike mine near Carlin, Nevada. The purpose of the cover is to eliminate/minimize infiltration of meteoric waters into the leach pad. Laboratory and numerical analyses indicate that Carlin Formation siltstone (TCS), a locally available material, has the necessary hydrologic characteristics when placed on the leach pad to act as a CCBE. A pilot study was conducted on a mall-scale test cover placed on the AA leach pad to examine the cover performance under irrigated conditions. The preliminary test results demonstrate that the designed cover is capable of preventing meteoric water infiltration.

Jan 1, 2002

By C. N. Greene

I am sure it is obvious to all of you that a complete program of casualty and property insurance is as necessary for any tunneling contractor as it is for anyone else involved in trade in the United States today. Going beyond those general undefined terms, there are many areas that need specific attention, particularly for contractors, regardless of size. WORKERS' COMPENSATION Workers' Compensation is mandatory in all states and the District of Columbia. In most of the states, private insurance provides this coverage. In a few states, the state operates Workers' Compensation funds, some of which are competitive with the private sector and others are operated on a monopolistic basis. Under a monopolistic setup, you have no choice, you must buy coverage from the state. Self insurance of the Workers' Compensation risk is also an alternative in most jurisdictions. With a contractor operating only in the U.S., the coverage extensions are few in number. If your work brings you anywhere near navigable waterways or land extensions thereof, you should have both U. S. Longshoreman and Harborworkers' coverage, as well as Employer's Liability coverage for the master or members of the crew of a vessel.

Jan 1, 1983

By Hans von Michaelis

This paper examines the process options available for treatment of "refractory" gold ores. As more and more of the easily leached oxidized gold ore zones are exhausted, the pressure is on to find more economical ways of treating refractory gold ore deposits. Historically, refractory ores were generally concentrated, e.g. to make a flotation concentrate that could be roasted. A major development is taking place in the USA in which ores from which gold cannot be concentrated well by flotation are being treated using whole ore oxidation processes prior to cyanidation. Refractory gold ore treatment processes are generally expensive to install and operate. Thus, for a refractory gold ore project to be economically viable, the grade must generally be higher than for free milling gold ores.

Jan 1, 1993