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By P. R. Thomas

This paper addresses the relative long-term cost and resource position of new and existing ferrochromium production in selected Market Economy Countries (MEC'S). The market impact of new ferrochromium production in nations such as India and the Philippines and the continuing change in international trading patterns are also evaluated. This paper draws upon the data and analyses of a recent Bureau of Mines, Department of Interior, Minerals Availability Program appraisal that evaluated the cost and availability of chromite and ferrochromium production from the demonstrated resources of 80 producing or potential mining operations in 10 market economy countries.

Jan 1, 1984

By K. Kim, T. M. Yegulalp

A new explanation of the scale dependency of rock strength is presented based on the theory of extremes. A brief review of past work on specimen size and strength relationship is followed by an introduction to the fundamentals of the underlying theory of extremes and its relationship to the scale effect. It is shown that the weakest link theory is directly related to extremal statistics and that parameters of strength distributions of rock can be derived as a function of the specimen size. Three sets of Brazilian test data are used to demonstrate the use of this approach.

Jan 1, 1994

By Steven McCutcheon

As most of us have learned through prior and often frustrating experience, anyone proposing to construct a new or expanded mining-ore processing facility must first contend with a rather complex array of environmental laws and permitting regulations administered by a number of different Federal, State and local agencies. At our lost count, there were about 55 federal enactments affecting base and precious metals projects. Applicable State and local laws will usually increase that number significantly. The time and costs associated with complying with all these various regulatory programs usually constitutes one of the major areas of uncertainty in the development of a proposed project. There are many in the mining industry who firmly believe that these environmental regulation and permit programs necessarily causes significant delays and increased costs in the development of a project. This belief, unfortunately, is probably a result of a basic misunderstanding of how the environmental permitting and regulatory system actually works.

Jan 1, 1984

By V. Gall

The three-dimensional finite element technique combined with the progressive failure approach was utilized to simulate stress distributions in a mine section which occur in response to a longwall mining operation. Due to the availability of the Cray supercomputer, a large-scale three-dimensional finite element model was developed for the analysis. The Hoek-Brown failure criterion, which describes a realistic behavior of rock masses, was used for the simulation of progressive failure. A comparison of calculated and monitored stresses in the mine has shown that the model gives a good representation of stresses in the mine structure.

Jan 1, 1990

By Fritz Kleiner, Walter Meintrup

On Nov. 4, 1981 A/S Sydvaranger's 1-kt/h (1,100-stph) wet-process, iron ore ball mill completed its first four months of uninterrupted, full-load operation in Kirkenes, Norway. This 6.5-m-diam (21-ft-diam) mill is driven by a gearless ring or wraparound 8.1-MW (10,860-hp) motor at 13.1 rpm-a first of a kind in this segment of industry. This article examines reasons for selecting this type of drive over more conventional schemes, lists specific advantages of such large mills, and describes the installation in Norway. History For almost a decade, good operating experiences have been gained with 28 gearless ring motor drives in the cement industry, driving 2.5 to 4-m-diam (8.2 to 13-ft-diam) tube mills with drive powers ranging from about 3-4 MW (4,000 - 8,000 hp). Why then did the mineral ore processing industry hesitate until 1980 to adopt this successful concept for similar applications on ball, semiautogenous, and autogenous mills? There are a number of good reasons in the eyes of conservative mill builders and operators, the most commonly cited ones are: • No operating experience in this segment of specialized industry. • More severe environmental conditions in the wet ore grinding process. • An indifferent attitude of mill builders and electric motor manufacturers towards new drive technologies. • Limited confidence in solid-state power supply systems, such as frequency converters of the required size. There have been and still are numerous problems associated with low-speed geared mill drives of any kind, especially with individual motor/gear sizes approaching or exceeding about 4 MW (5,360 hp). Every mill builder knows about them, but operators learn to accept them as inevitable. The Decision to Change Three things combined to break this technological stalemate: the courage and progressive spirit of one major iron ore processor in Scandinavia, the cooperation of three experienced manufacturers, and an unusual application problem that could not be solved by any conventional approach. The last factor was surely the decisive one, but the first one does not come as a surprise either. The Swedes near Kiruna and the Norwegians around Kirkenes are experienced ore miners and processors, and much credit goes to them for technological breakthroughs in the industry. At A/S Sydvaranger in Kirkenes, above the Polar circle at about the latitude of Alaska's northern tip, the existing grinding facilities, with a total of 14 100 to 240-t/h (110 to 264-stph) ball mills, can not be expanded. Nevertheless, to increase mill throughput, only installing a larger mill in place of an existing smaller one was a practical alternative. For this replacement, the owners set requirements that seemed impossible to meet: • The old 100-t/h (110-stph) ball mill should be replaced with a new ball mill with 10 times the rated throughput, without significantly impairing the operation of the remaining mills, and without significantly changing the mill building. • The new mill should have a variable-speed drive to ultimately optimize the grinding process by means of a closed-loop process¬computer-controlled grinding cycle, and to minimize the specific energy consumption. • Availability, efficiency, and life expectancy of all new components must be higher than those being replaced. • Inrush-current and harmonic loads on the rather weak electric supply line must be minimized to ensure safe plant operation. All old ball mills at A/S Sydvaranger are the geared type, using single synchronous and wound-rotor, slow-speed motors with ring-and-pinion gears. Operators are familiar with the limitations and problems associated with such drives, and they are aware that the following items become major concerns when drive powers are drastically increased: • Gears are subject to wear and tear, require frequent maintenance, and eventual replacement of major parts. • Gears are sensitive to misalignment, overload, and thermal distortion, limiting their useful life. • On dual or quadruple drives, load-sharing and torque oscillations between motors can be a major reason for concern. • At these speeds, ring-and-pinion gears reach their torque transmission capabilities altogether at around 4 MW (5,360 hp) per motor/pinion. To obtain the desired variable-speed performance of the new drive, the only practical and economical conventional solution would have been a frequency-controlled, low- or medium-speed dual motor drive with about 8 MW (10,720 hp) of power. This, however, was not feasible because of limited floor space. Therefore, bids were solicited for the alternative drive method, the gearless ring motor. General Considerations Why are such large mills considered? After all, one could avoid all the problems by simply staying with smaller mill unit sizes. Under competitive pressures of free markets, however, grinding efficiencies and specific energy consumption become key factors in selecting new equipment. Specific energy consumption of ball mills decreases with increas-

Jan 9, 1982

By Joseph O. Cook

I know this is, at best, a frustrating period for the coal mining industry. About 20,000 miners have been laid off, mostly in the Appalachian and mid-western areas, and several mines are working less than 5 days a week; however, the industry is experiencing modern growth and, at least, there is the potential for future growth. The coal industry is probably only operating at about 80 percent of its present capacity, and it is certainly capable of helping this country solve its energy problems. Growth, as a rule, does not come easy, and growth in the coal industry is no exception to this rule. Many formidable challenges have to be overcome. As we all know, mining relies very heavily on the earth sciences, which have advanced significantly in the past few years, but we are always working in a changing environment which in most cases is a hostile environment. Large quantities of material are quickly extracted and rapidly moved in, generally speaking, a very confined area. The very nature of the mining business directly and constantly impacts our environment during this period in which the Nation and the world has become increasingly smaller and more concerned about protecting our environment. In addition, growth brings about an expanding work force which is increasingly younger and less experienced.

Jan 1, 1980

By Jr. Schnakenberg

In 1986 the U. S. Bureau of Mines (USBM) embarked on a major research effort to develop technology that can substantially reduce worker exposure to face hazards simply by relocating the equipment operators to an area of relative safety. This reduced exposure mining system (REMS) research effort enhances the USBM ongoing health and safety research efforts to reduce and control dust and noise and to reduce accidents through training and better mining practices. This paper reports progress of the research that is developing and will demonstrate the technologies required for the computer-assisted tele-remote operation of continuous mining machines, haulage systems, and roof bolting machines.

Jan 1, 1996

By R. W. Lake

The decision to develop an ore body can lead to multi-million dollar profits, or equally substantial losses. Accordingly, the effort required to adapt a valuation model to the specific proposal at hand, or even the development of a new model from basic principles, is clearly warranted. In the formulation of a model of this nature, one is faced with some major questions. For example, with the long term obligations that it implies, on what basis should a decision to initiate mining operations be made? Furthermore, how can the vagaries of inflation and the uncertainties that shroud the future be accommodated? Beyond the general principles by which mineral deposits are evaluated, specific cost behaviour is a function of the geology of the deposit, and of the mine design. Moreover, mine design, during the life of the mine, must be a continuing process somewhat akin to dynamic programming. An initial, apparently optimal, design is selected and mining commences. With production, a continual process of information updating leads to revisions. Thus if the maximum value is to be obtained, the mine design must be adjusted to conform to the changed conditions.

Jan 1, 1977

By V. O. Tenorio, A. M. Sanzana

"INTRODUCTION This report summarizes a research about mines which are transitioning from surface to underground mines. It is a guide to make strategic decision in these increasing amount of mines. Capital and operating costs are linked with major strategic decisions in the exploitation of an ore body. This is the reason to analyze costs related to this transitioning world trend. There are multiple reasons for transitioning from Open-Pit (OP) to Underground (UG) mining. The primary economic incentive for going UG is that the cost per unit of ore from OP mining eventually exceeds that from UG extraction. This is due to the excessive amount of waste that must be extracted when the depth of the pit increases. In addition, the reduced footprint of UG operations contributes to diminish the environmental impact on the surface. Furthermore, it becomes more difficult to find new, easily accessible ore deposits. Then, a cost model helps to guide strategic decisions in the transition from OP-to-UG mines. Objectives • Propose a methodology to guide strategic decisions in the transition from OP to UG mining. • Create an integrated cost model based on existing OP and UG individual cases. • Identify and characterize a group of mines transitioning from OP to UG. • Analyze operating and capital costs of a particular transitioning from OP to UG mine. MAIN CONCEPTS Open Pit Mining (OP) The main decisions in OP mines are: Cut-off grade, Stripping Ratio (SR), equipment size, stockpiling, pushback sequencing and processing capacity. The stripping ratio is measured as the tonnage of waste required to be removed to reach and extract one tonne of ore. The material extracted from an OP exploitation can be classified as waste and ore. This classification depends on the cut-off grade. The cut-off grade indicates the minimum amount of material with economic value in a block. The waste from the mine is going to the waste dump and the ore is going to stockpiles where will be store and then going to the processing plant (leaching or concentrator). The waste of this process is going to the tailing pond big pools. And the product is sell in the market. Another important issue is the mining capacity which is going to define the investment in mining equipment. Underground Mining (UG) The first decision to be made in order to open an underground mine is selecting the mining method. Caving methods are the more productive and have lower operating costs. There are three caving methods: Block Caving (BC), Panel Caving (BC) and Sublevel Caving (BC). The access development could be an horizontal adit or a straight or downspiral decline. A shaft could be used for inclined or vertical access. Other key issues are: equipment capacity, cut-off grade and production sequencing."

Jan 1, 2016

By L. Schlink

Impacted waters, often complex, are created in mining which at some point in the mine life cycle will need to be attended. The simplest and most cost effective method of handling impacted water is to reuse it as makeup water for operations. At the end of mine life, operational reuse will not be an option and the impacted water will require treatment to achieve alternative reuse goals. Conventional mine impacted water treatment is successful in removing unwanted constituents but create brine and sludge that may require special handling or additional treatment, resulting in additional liabilities and costs. Freeport-McMoRan Copper & Gold has taken an approach to water treatment that focuses on transformation not concentration. The Water Treatment Test Facility located at Sierrita Mine has three test plants that are piloting the mine impacted water transformation process. Two plants have been designed for the removal of calcium and sulfate with products of gypsum and sulfur. The third plant removes metals from process water and transforms them into marketable metal sulfides. The transformation, rather than concentration, of mine impacted water solutes greatly reduce long term risks.

Feb 23, 2014

By A. G. Belova

With the federal climate change legislation in progress, there is a need for demonstration-stage technologies aimed at providing clean energy from coal. Our research aims to experimentally illustrate the feasibility of capturing CO2 on a novel sorbent system from a gaseous stream. The gas is then released resulting in a regenerated sorbent and a pressurized stream of pure CO2 to be used for storage. The proposed sorbent is a ceramic honey-comb structured monolith coated with CaO supported on a high-surface area alumina. CaO is a natural acceptor of CO2 and our design ensures the physical stability and chemical reactivity of CaO over a large number of CO2 capture/release cycles. Furthermore, the use of the monolith ensures a uniform flow through the reactor, minimizes pressure drop across the reactor, and maximizes the surface reactive area. In this paper, we will present the results from a flow-through laboratory-scale reactor that establishes the efficiency of the proposed system to capture CO2. Future applications of the reactor include integration within the new-generation coal gasification power plants, such as IGGC, as means of providing decarbonized electricity.

Jan 1, 2010

By Y. Xi

In this paper we present an availability approach for determining the capacity of a major bucket wheel excavator (BWE) system to be used in Yuabaoshan surface coal mine in China. Based on previous time studies on other BWE systems for delay times due to internal and external causes, and a four-level maintenance and repair schedule, we develop a model taking into account all random failures and present a fast and simple solution to this highly complex problem. A procedure employing the Markov renewal theory for determination of the distribution of random failure times and failure rate of the whole system, as well as some other factors useful for calculation of the overall system capacity are discussed in the paper.

Jan 1, 1993

By F. Grajales Munoz

The Cienega project, now under construction by Penoles group, is located in the mountains of the State of Durango, Mexico. The gold and silver deposits are found in the 4-km long system of veins, which will be extracted by underground methods. The planned 1000 tpd process plant will contain a countercurrent cyanide circuit for oxide ore and a flotation circuit for sulfide ore. Considerable resources have been devoted to development of infrastructure in the isolated location, as well as for the mitigation of environmental impacts. Startup is scheduled for the third quarter of 1994.

Jan 1, 1994

By Poltak Sinaga

PT Kaltim Prima Coal's 13.1 km overland conveyor was commissioned in 1991. It is of conventional 3 roller 350 troughed belt type. Cost and performance optimisation during initial design ended up with 5.4m/s belt speed, 1,000mm belt width to convey 1,350tph, and 7mtpa of coal. Despite high initial figure, the belt speed was lifted to 6.5 mps in 1996 to accommodate mine throughput increase. In 2002, new low loss ST2100 1,100mm wide belt replaced the old ST2250 due for change-out. An upgrade project was initiated at the end of 2003 to further increase the belt speed to 8.5 mps, hence to increase the OLC capacity to 30mtpa. Performance data, experience of site personnel, site observation and tests, benchmarking, and information from equipment manufacturers were major inputs to the design review. The project fast track was another challenge in addition to executing modifications on a production lifeline. The project was completed within fifteen months and the OLC was successfully commissioned at 8.5 mps belt speed in February 2005. The OLC has been to date conveying 4200tph satisfactorily.

Jan 1, 2008

By Naomi H. Harley, Daryl E. Bohning, Isabel M. Fisenne

INTRODUCTION Underground mines in many parts of the world have elevated levels of short-lived 222Rn daughters. Lung cancer implicating exposure to short-lived daughters is documented in the U.S., Czechoslovakia, Canada, Sweden, the U.K., France and Newfoundland. An elevated lung cancer mortality (in excess of that expected) has been observed when cumulative exposure to alpha emitting short-lived 222Rn daughters (218Po, 214pb 214Bi 214Po) is greater than about 60 working level months (WLM) [1]/ (Hewett, D. 1979). This is equal to an absorbed alpha dose of about 30 rads to shallow basal cells in bronchial epithelium. Long-lived alpha emitters are also present in underground mines, and especially uranium mines because of airborne particulates containing uranium. The 238U parent of this primordial series supports other long-lived emitters 234U 230Th, 226Ra, Pb(210Po) which are in some degree of radioactive equilibrium with the parent 238U. Airborne particulates can be present due to drilling on the face of the ore body as well as in all parts of the mine through resuspension from the mine floor. Particles from 1 µm to about 5 µm penetrate the nose with reasonable efficiency and deposit primarily in the tracheobronchial tree. They are removed by ciliary motion (the bronchial escalator) but deliver an alpha dose to basal cells in bronchial epithelium during clearance in the same manner as short-lived 222Rn daughters. It is the purpose of this work to indicate the alpha dose to basal cells in bronchial epithelium delivered by the long-lived emitters 234, 238U. The dose calculations reported here based upon a few measured values of these isotopes in air in uranium mines in New Mexico and Colorado. MEASURED 234, 238U IN URANIUM MINE ATMOSPHERES In 1979, the U.S. Bureau of Mines undertook a study to evaluate personal monitors to be worn by miners to measure short-lived 222Rn daughters. One of these devices sampled air at 100 cm3/min through a 13 mm glass fiber filter, with a small pump worn on the belt. Alpha particles emitted by 222Rn daughters on the filter were measured continuously by a thermoluminescent dosimeter (TLD) chip. Each monitor was worn by a miner for a 170 hour working month and approximately one cubic meter of air was sampled during this period. Six different mines were selected for the test in New Mexico and Colorado. The mines used either wet or dry drilling methods. Miners in each location were equipped with the personal monitors. Subsequent to their use in evaluating the shortlived daughters, Dr. Robert Droullard of the Bureau generously gave us these filter samples along with a few blank glass fiber filters from the same box of filters used in the study so that long-lived emitters present in these mine atmospheres could be determined radiochemically. Four of the samples have been run for 234, 238U. The radiochemical procedure for uranium is adapted from USDOE, Environmental Measurements Laboratory Manual (Harley, J.H., 1976). Briefly, the samples were placed in platinum crucibles, spiked with 232U tracer and pretreated with nitric and hydrofluoric acid. The residue was fused with potassium fluoride to transpose to pyrosulfate. The fused cake was dissolved in 7 [N] hydrochloric acid and the solution passed through an anion exchange column to isolate uranium. Iron was removed using mercury cathode electrolysis. Uranium was electrodeposited onto platinum dies and counted using solid-state alpha spectrometry. The samples from each type of mine (wet and dry) were analyzed. The samples in the "wet" mine in New Mexico were selected on the basis of the original TLD measurement because they were near the maximum occupational standard for radon daughters. These samples should also represent upper limits to longlived activity encountered, since they were obtained at drilling operations on the face of the ore body. Samples collected in the "dry" mine in Colorado were pot associated with a particular location in the mine and should be representative of a month long overall exposure in many locations and operations. The values are shown in Table 1. The two uranium isotopes are in equilibrium and their alpha activity

Jan 1, 1981

By E. Asselin

Passivation of Fe-Ni-Co alloys during the Caron leach process is thought to result in low cobalt recoveries in ammoniacal ammonium carbonate solutions. A brief review of the available thermochemical data for the (Fe, Ni, Co)-NH3-H2O systems has been undertaken. The stability of the Co(II) and Co(III), Ni(II) and Fe(II) am-mines was examined through the use of speciation and Pourbaix diagrams at 298 and 333 K and at 6 M total ammonia. Increasing the temperature reduces the stability fields of the ammines and generally constrains the thermodynamic window for the leach. The Fe(II) ammines are only thermodynamically stable under reducing conditions. Polarization experiments show that these ammines are unlikely to form if oxygen is present. Fe-Ni-Co alloy passivation may be alleviated by careful management of potential.

Jan 1, 2011

By E. Asselin

Passivation of Fe-Ni-Co alloys during the Caron leach process is thought to result in low cobalt recoveries in ammoniacal ammonium carbonate solutions. A brief review of the available thermochemical data for the (Fe, Ni, Co)-NH3-H2O systems has been undertaken. The stability of the Co(II) and Co(III), Ni(II) and Fe(II) ammines was examined through the use of speciation and Pourbaix diagrams at 298 and 333 K and at 6 M total ammonia. Increasing the temperature reduces the stability fields of the ammines and generally constrains the thermodynamic window for the leach. The Fe(II) ammines are only thermodynamically stable under reducing conditions. Polarization experiments show that these ammines are unlikely to form if oxygen is present. Fe-Ni-Co alloy passivation may be alleviated by careful management of potential.

Nov 1, 2011

By M. Niec

Poland lies at the junction of three geologic provinces: the East European Precambrian platform, the Middle European Paleozoic platform, and the Alpine orogenic belt comprising the Carpathian Mountains. However most of the rocks that contain mineral deposits and many of the recently explored and mined deposits are commonly hidden under thick overburden, sometimes up to over 500 m thick. The discovery of these mineral deposits was due to the combination of geologists talents for inference and the keen interpretation of geophysical data ultimately tested by drilling. Examples of such use of the state-of-the-art geology include the following: 1. Sedimentologic and paleogeographic reconstructions led to the discovery of 8.8 Gt of bituminous coal under 500 m of Jurassic and Cretaceous cover in the Lublin basin, 2. Tectonic and paleogeografic data suggested a potential for discovery of burried Upper Permian copper de-posits on the Foresudetic monocline; subsequent exploration discovered 75 Mt of copper and 0,17 Mt of silver, 3. Geological interpretation of gravity and magnetic da-ta combined with sedimentologic data and regional subsur-face geology resulted in the location of 1.3 Gt of Fe-Ti-V ore in the Precambrian basement of northeastern Poland under -500 m of cover 4. A combination of metallogenic theory and geological interpretation of regional geophysical mapping led to the discovery of Caledonian-Hercynian granites and grano-diorites with accompanying porphyry-type Mo-W-Cu ores below 300 m cover on the northeastern border of the Upper Silesian coal basin 5. Tectonic reconstructions based on gravity and seismic data combined with theory on the origin of native sulfur led to the discovery of 1.0 Gt of native sulfur under cover up to 300 m thick. Five deposits were found at the northern margin of the Carpathian Foredeep. The other deposits found include lignite, polyhalite, lead-zinc ores.

Jan 1, 1996

By C. E. Jordan

Direct digestion of phosphate ores by the acid-alcohol method offers improved leaching selectivity for the exclusion of iron and aluminum in the product acid. The leaching kinetics of this process will have a major role in the eventual application of this technology. The Bureau of Mines investigated apatite dissolution to determine the reaction rate and mechanisms of the leaching kinetics. The dissolution kinetics were monitored on various sized fractions of pure apatite. The "shrinking-core" kinetics model was applied to the data to determine the rate controlling mechanisms. For each size fraction, the initial reaction rate was controlled by the dissolution reaction. After an hour the dissolution rate slowed indicating a diffusion controlled reaction caused by the formation of calcium sulfate hemi-hydrate coating on each particle. For complete dissolution of the apatite, the phosphate rock should be ground to near 10 µ m size.

Jan 1, 1993

By D. Shuck

Incorporation of a 2,727 mtpd, $5.7 million flotation circuit into the Mclaughlin flowsheet was completed in November 1991. This capital addition reduced overall operating costs and improved the gold recovery of the low grade refractory reserves over that expected for direct cyanidation. In addition, flotation provided a means to generate a sulfide concentrate which is utilized to supplement feed to the pressure oxidation circuit.

Jan 1, 1994