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By S. G. Malghan

Steel consumption forms a significant part of the operating cost of a minerals processing plant. An estimated one-quarter billion kilograms of steel in the United States and over one-half billion kilograms in the world are consumed each year in wet grinding alone. The depletion of ore grades and the necessity of finer grinding of abrasive ores are expected to increase the steel consumption even higher. Through continued research and development by the mining industry and the suppliers of steel products several remedies to reduce steel consumption have evolved. This paper critically reviews the mechanisms involved in steel wear, and currently available methods, materials and operating conditions for reducing steel consumption. Particular attention is given to liner design modifications and substitution of steel liners with rubber liners.

Jan 1, 1981

By Bernard F. Anderson

INTRODUCTION In this chapter, the term "down-the-hole drill" (DTH drill) is used as a generic name that encompasses the various trade names and other references such as "downhole drill," "in-the-hole drill," etc. This chapter is limited to a description of DTH drills used in stoping large underground ore bodies. DTH drills differ from conventional drills by virtue of the placement of the drill in the drill string. The DTH drill follows immediately behind the bit into the hole, rather than remaining on the feed as with ordinary drifters. Thus, no energy is dissipated through the steel or couplings, and the penetration rate is nearly constant, regardless of the depth of the hole. Since the drill must operate on compressed air and tolerates only small amounts of water, cuttings are flushed either by air with water-mist injection or by standard mine air with a dust collector at the collar. HISTORICAL DEVELOPMENT Mine managers have long known the economies enjoyed by quarry and open-pit operators in producing large quantities of ore. The savings are due primarily to the availability of massive equipment, capable of drilling large blastholes to reduce the amount of drilling, increase the fragmentation, reduce secondary blasting, and im¬prove the flow of the product. In an attempt to reduce underground mining costs, various methods are used for long-hole drilling, includ¬ing standard pneumatic percussion drifters and diamond drills. These systems have their shortcomings; percus¬sion drills are limited to small hole sizes and they ex¬perience excessive deviation and significant loss of energy with increased depth. The diamond drills provide deeper and straighter holes, but only at high cost. Both systems suffer from high noise levels, low penetration rates, and poor explosives distribution, among other problems. When the mining companies approached the drill manufacturers for a compact and portable large-hole jumbo for underground use, they specified not more than 1 % deviation on 60 m (200 ft) of vertical hole and a penetration rate of 15 m/h (50 fph). On Dec. 23, 1960, a test unit was placed in service in Montana and met the performance criteria. Though lacking the so¬phisticated features available today, the economies of surface blasting were brought underground. Unfortunately, the first system did not gain immedi¬ate acceptance in the industry. Among the factors con¬tributing to its demise were resistance to change, the need to alter development methods for the ore bodies, and a lack of flexibility in moving the rig from setup to setup and from level to level. In 1972, the mining industry again challenged the drill manufacturers to provide a workable jumbo that would combine compactness, ease of maintenance, relia¬bility, and efficiency, all on a self-propelled chassis. The manufacturers responded by providing improved jumbos, which have been accepted with enthusiasm throughout the mining industry. Today's DTH jumbos are capable of drilling from 100 to 200 mm (4 to 8 in.) diam holes that can be reamed to even larger diameters. The holes can be drilled to depths of 150 m (500 ft), depending upon ground conditions and the capability of the jumbo to retrieve the steel and drill. Fig. 1 illustrates a typical DTH jumbo. APPLICATIONS The uses to which DTH drill jumbos have been put are quite numerous, with new uses being found regularly. For convenience, these uses may be classified as primary blastholes and nonblasting holes. Primary Blastholes The original purpose for the development of the DTH jumbo was for drilling primary blastholes that could be mined by open-stope methods. Prior to the advent of the DTH jumbo, extensive development was required before production drilling could begin. Sub¬levels were required to allow access for column-and-arm stopers or ring/fan jumbos, to the extent necessary based on the effective penetration of the chosen machine. With the DTH jumbo, the mine engineer is able to reduce preproduction time and development costs. How¬ever, the most significant saving results from an im¬proved cost per ton of broken ore in the production phase. To utilize a DTH system, only a top heading and drawpoints are necessary. The top heading can be the width of the ore body with a 3.7-m (12-ft) back. A drop-raise pattern is drilled and shot to begin the stoping operation, providing a free face for subsequent blasting. A typical layout is illustrated in Fig. 2. The advantages of this system include: 1) Drilling and blasting are independent operations, and blasting can be performed at a rate congruous with the mine's ton-per-day capacity. 2) The development layout is simplified. 3) Good explosive distribution is achieved, provid¬ing more uniform fragmentation. 4) Environmental conditions for operators are im¬proved, including improved safety with all work directed downward (not overhead), lower noise levels, little fog, and a reduced dust count. 5) Improved production per manshift. 6) Simplified and easier operator work cycles. 7) Reduced cost per ton of product. 8) Fewer holes lost due to ground shifts. Nonblasting Holes With the introduction of the compact DTH jumbos, other practical uses became apparent, including the drilling of: 1) Holes for sand fill, from level to level and from level to stope. 2) Drain and dewatering holes. 3) Power and communications cable holes.

Jan 1, 1982

By James L. Kelley

The Twin Buttes Mine, one of the more recently developed large copper mines in the United States, is in the Pima Mining District about 25 miles south of Tucson (Figure 1). Other copper producing mines in the district are the Esperanza-Sierrita mining operations, five miles to the southwest and the Pima and Mission Mines, seven miles to the north. Copper metal production from the Pima District in 1974 totaled 276,728 tons and the Twin Buttes Mine's share was 46,473 tons or about 17%.' The district's copper production was 31% of Arizona State's production and nearly 17% of the production from the United states in 1974. The Pima District thus ranks as one of the major copper producing areas in this country.

Jan 1, 1976

By Judson C. Higgins

The paper addresses changes in surface transportation methods in the Industrial Minerals business starting with history, the changes to present time including such areas as energy costs, improved highways, changes in regulations and deregulation, and attempts to project future transportation trends. Transportation methods such as rail, piggyback, truck and barge are compared, and their impact on Industrial Minerals producer's costs and profits examined. The customer impact on our businesses due to deregulation is also discussed.

Jan 1, 1983

Coal-derived flue gases contain CO2/SO2 and these contaminants preferably have to be captured by cheap sorbents. This remediation approach is from the standpoint of addressing issues such as global warming, acid rain and development of Advanced Power Generation Systems and to realize the economic gain as well. Conventional and existing dry scrubbing technologies use regenerable sorbents which are pollutant specific and require expensive stabilizers in order to attain versatility. This paper discusses the use a novel class of sorbents prepared from the heavy metal contaminated Berkeley Pit water (Butte, Montana) by a proprietary process developed at The University of Nevada, Reno. These sorbents are activated mixed spinel ferrite (MxFe,_X04)' Preliminary experimental results show that the sorbents have good desulfurization and CO2 decomposition capacities. The decomposition effectiveness of these mixed spinel ferrites was studied at 300°C and compared against the synthetic magnetite obtained from ferrous sulfate solution in our laboratory. The results indicated that the mixed spinel ferrite had good affinity for the adsorption and decomposition. The CO2 decomposition data of both sorbents fitted the first order reaction kinetics. Even though the surface area of the magnetite was higher than that of mixed spinel ferrite, the CO2 decomposition rate of the mixed spinel ferrite was estimated to be 2.5 times higher than that of magnetite under identical conditions. The carbon analysis deposited on the sample indicated that the CO2 was 100% decomposed into carbon and other carbon! hydrogen compounds by the mixed spinel ferrite whereas the conversion was 43% by the magnetite. In terms of specific adsorption of carbon, ferrite was 3-5 times more efficient than magnetite.

Jan 1, 1996

To maintain its brand position in the competitive market of mining equipment, the Volvo Construction Equipment (Volvo CE) engineers were challenged to develop top-performing wheel loaders and articulated haulers even faster than before. To start, this meant reducing prototype test cycles by two-thirds. The final goal? Chopping in half the virtual prototyping time in early design phases. Creating a unified co-simulation solution In this ground-breaking project, the Volvo Construction Equipment design team in Eskilstuna, Sweden, replaced its piecemeal department-by-department process with a single solution based on LMS Imagine.Lab AMESim. With one unified model, they could simulate the behavior of four major vehicle subsystems in wheel loaders and articulated haulers: hydraulics, powertrain, thermal management and the actual driver. Subsystem models exchanged data seamlessly.

Jan 1, 2011

By R. Shields

"Hard rock mines move large volumes of material. But the conveyors essential to this movement suffer lots of problems, including carryback, spillage, dust, and belt wander. Many of these issues are created at the transfer points where the belts are loaded. This presentation will start with an overview of the latest transfer point systems that incorporate safety and serviceability by design. It will then report on recent projects. One project is the Conveyor B Transfer at the Coeur Rochester silver mine near Lovelock, Nevada. Here performance was improved with the installation of belt support cradles, engineered chute walls with external wear liner, and a compact dust collector. A second project is the improvement of belt support idlers and skirtboard sealing in a long loading zone of a conveyor under the concentrator at an Arizona copper mine. THE IMPORTANCE OF TRANSFER POINTS Conveyors are essential in mine material handling. Their performance will often make the difference in mine productivity and profitability. A key to conveyor performance are the transfer points where the conveyor belt is loaded and discharges. At these transfer points, many of the problems encountered with the conveyor system are created. The problems that arise at the transfer stations include off-center and segregated loading, mistracking, blockages and plugging. And there are a variety of problems originating with fugitive material—cargo released in the form of carryback, spillage, or airborne dust—that are created or exacerbated in the transfer points. These fugitive materials turn into other conveyor-related problems, including shortened component life, unplanned outages for conveyor maintenance, unexpectedly high labor costs for maintenance and cleanup, worker health and safety problems, and issues with community relations. As estimate attributed to the U.S. Mine Safety and Health Administration (MSHA) notes that 85 percent of conveyor maintenance is a result of fugitive material at conveyor transfer points. TECHNOLOGIES TO IMPROVE TRANSFER POINTS A number of techniques to improve the performance of conveyor transfer points have been developed. They include: • Absorbing impact, to prevent damage to belt, belt support systems, and conveyor structure, and reduce spillage caused by the impact energy arising from long material drops or large lumps of material loaded onto the receiving belt. • Stabilizing the belt line, to eliminate sag that allows spillage and encourages material entrapment that can damage the belt. • Protecting the skirtboard seals, by sheltering the sealing strips from the mass of cargo pushing material toward the edges of the belt. • Using self-adjusting, multiple-barrier edge seals, to keep material on the belt by providing long-lived seal efficiency with minimum maintenance requirements. • Controlling and centering the belt’s path, to eliminate belt wander and the spillage and damage it can cause. • Allowing dust to settle, through the incorporation of chutework that provides expanded stilling zone and the use of dust curtains at the points where the belt enters and exits the transfer. • Adding supplemental dust control systems, through the installation of systems for passive dust gathering, water-based dust suppression, and/or active dust collection."

Jan 1, 2017

By I. H. Gundiler

Although cyanidation has been universally applied in the processing of gold and silver ores, the search for less toxic alternatives continues. Difficulties encountered in processing ores containing oxidized copper minerals and the inherently slow kinetics of cyanidation have generated a renewed interest in thiosulfate leaching. This process, as well as the catalytic effects of copper ion, were well recognized and widely applied towards the end of the past century. In this study, the effects of copper, ammonia, and thiosulfate concentrations on gold dissolution were investigated using the rotating disk technique. Extraction of gold and silver from an oxidized copper-bearing ore was also studied utilizing a statistical experimental design, and these results were displayed in the form of contour plots.

Jan 1, 1993

By F. G. Miller

Over the past 30 years, the coal industry has been continually striving to perfect methods for cleaning fine coal to acceptable ash and sulfur contents while maintaining maximum product yield. The flotation process has been part of this effort and its importance is expected to grow as new utilization technology demands finer and purer coal products. The work outlined in this paper is part of a larger effort aimed at development of new and improved flotation systems for removing sulfur and ash from as-mined coal as well as for producing super-clean coal for future markets. The concepts and data presented are now serving as a basis for designing fine-coal circuits in which improved efficiency is obtained by optimum use of flotation.

Jan 1, 1986

By Kevin Erwina, Rajiv Chandramohana, Connor Meinkea

This paper explores prevalent operational challenges encountered globally in SAG mills, including suboptimal throughput, liner wear, excessive energy consumption, and SAG mill load stability. The paper delves into the root causes behind these issues, such as ore variability, poor operating strategy, or inadequate process control. Drawing on industry experience and case studies, the paper highlights the significance of addressing these challenges to enhance overall mill performance and efficiency. It underscores the necessity of tailored strategies, encompassing improved monitoring, optimized liner designs, and refined control techniques to mitigate these challenges and promote sustainable SAG mill operation.

Feb 1, 2024

By C. R. Tinsley

In maybe the world's first in a mine project financing, a US $55 million Rehabilitation Indemnity was given on behalf of the banks in a US $250 million loan to develop the Ranger uranium mine, Northern Territory, Australia. The basis of the financing was an estimate of removal of the tailings and replacement into the pit. The Indemnity was amortized by a sinking fund from the mine's revenues. Such a concept could be valuable for mineral developments in sensitive areas or jurisdictions such as British Columbia or Alaska.

Jan 1, 1992

By Jey K. Jeyapalan

A characteristic common to most tailings dam failures caused by earthquakes or excessive rain storm is that the tailings tend to liquefy and flow for substantial distances as a viscous fluid, with the potential for extensive damage to property and life. Failures of El Cobre, Chile (1965), Mochikoshi, Japan (1978), Aberfan, Wales (19661, Buffalo Creek, West Virginia (1972) are examples of such catastrophic incidents. In these four incidents more than 400 lives were lost, and the loss of property was approximately $200 million. In order to be able to assess the potential for damage in case of such a failure, it is necessary to predict the possible extent of flow slide movement. This paper discusses simple procedures for performing such analyses. Also, in order to illustrate the use of these analysis procedures in tailings dam design, two case histories are analyzed.

Jan 1, 1982

By M. Kaya

This paper presents an experimental method to determine the degree of gangue entrainment in mechanical flotation cells and proposes new and inexpensive methods to lessen it. The applicability of froth washing and vibration was studied in laboratory, pilot plant, and plant scales. The effect of wash water on metallurgical performance was tested with various streams from the Falconbridge Strathcona mill at laboratory, pilot, and plant scales, with the 2nd cleaner at the Eastmaque Kirkland Lake mill, and with the 2nd and 3rd zinc and 3rd and 4th copper cleaners at Les Mines Selbaie mill. It was found that gangue recovery was closely related to water recovery in all systems. Wash water at an optimum superficial rate from 0.03 to 0.07 cm/s reduced entrainment by anywhere from 30X to 70X. Wash water can be further assisted by mechanical and ultrasonic vibration of the froth. A further rejection of 10 to 20X becomes possible. As a result of this work, a number of plants in Canada and in the United States have evaluated and/or are now using froth washing.

Jan 1, 1990

By Paul H. Rylund

Substantial priming was a considered necessity for proper initiation of ammonium nitrate-fuel oil mixes as ANFO began to carve its niche in the mining industry in the latter fifties. Heavy priming accompanied the introduction of prills and oil to many blasting operations, large charges of high explosives were commonly used at the bottom, top and frequent intervals through-out the column. As the quality of ammonium nitrate improved and operators became more experienced, primer costs began to diminish. Increased experimentation continued with reduced primer costs a main objective. Cast primers were introduced and became accepted as an excellent companion for ANFO. Although the trend toward larger diameter boreholes became increasingly popular, emphasis on lower and lower priming costs continued. A primer was simply required to produce any type of initiation within the ANFO column to be considered adequate. Suddenly ANFO priming had digressed from excessive to marginal. Early experimental data developed at "test site" and laboratory locations indicated that ANFO had a tendency to react inefficiently in the initiation region of the column unless substantially primed. This was evidenced by the presence of unstable reaction rates detected with newly developed detonation velocity measuring equipment. These 10" order or "transient" velocities were believed to originate because of inadequate primer strength or a primer diameter to column diameter mismatch. How-

Jan 1, 1972

By John J. Mancini

Elastomeric liner products have been used for over two decades in a wide variety of uses including pond liners, hazardous waste barriers, dam face rehabilitation and mining applications. Asphalt blended with polymers is enjoying renewed interest in the engineering community because of its durability, high yield attributes, fewer CQA steps due to seamless installation, and ease of installation and repair. As in other lining technologies, advancements in polymer chemistry and improvements in installation techniques have had dramatic impact on the quality of fluid-applied asphalt (FAA) membranes. Membrane 6, man­ufactured by Deery Oil, Inc. for over 16 years is a hot-applied polymer modified asphalt membrane that can be applied to a variety of substrates in a reinforced configuration or installed directly on an asphalt surface. By blending thermoplastic polymers with asphalt, very favorable stress/strain characteristics can be achieved (Chambers, 1980). Typically the membrane will yield under rel­atively low stress and also exhibit high elongation capability. In service applications where puncture resistance is a concern, fluid applied asphalt materials have the flexibility and com­pressive strength under heavy loading that leach pad designers may find attractive. Additional security is achieved if long term service life is important as in the case of radioactive waste con­tainment. The Department of Energy selected Membrane 6 over seamed liners for a surface barrier that must isolate and contain radioactive waste for 1000 years. Asphalt has a long history of use as a water-stop material and it is believed that this natural construction material combined with SBS polymers will per-form for a millennium. (Freeman, 1994) The process of installing Membrane 6 varies according to job size and the type of surface to be protected. Lining applica­tions on compacted substrates require the membrane to be applied to a scrim cloth (fig 1). Some early pioneers in FAA technology neglected this step and therefore never achieved per­formance levels that satisfied regulatory guidelines. The scrim provides a cohesive surface that promotes membrane flow while achieving high impermeability (2Xl0 '11).

Jan 1, 1996

By L. Zhou, D. Bahrami, Y. Xue

Underground mine fires are a threat to the safety and health of mine workers. The timely determination of the location and size of an underground fire is of great importance in developing firefighting strategies and reducing the risk of any injuries. Machine learning was used in this paper to develop a predictive model for fire location and fire size in an underground mine. The ventilation data were obtained by simulating different mine fire scenarios with MFire. The ventilation data of all airways were used as features to predict the fire location. Based on the feature importance, five airways were selected to monitor, and the airflow data of the selected airways were used to predict the fire location and fire size. An accuracy score of 0.920 was obtained for the prediction of fire location. In addition, in-depth analyses were conducted to characterize the wrong predictions with the purpose of improving the performance of the random forest model. The results show that the occurrence of fire at closely connected airways at some locations can generate misleading ventilation data for each other and the model performance can be further improved by grouping them. Fire size is another factor affecting the model performance and the model accuracy increases with increasing fire size. The result from this study can help mine safety personnel make informed decisions during a mine fire emergency.

Mar 2, 2022

By D. G. Kotlyar

Oxidized sulfide minerals, commonly formed by weathering, increasingly are becoming important resources as primary sulfide deposits are depleted. Oxidation, in general, reduces selectivity and recovery in flotation. The objective of this research was to determine the mechanisms of oxidation and collector adsorption in sulfide systems as a step towards developing improved technologies for beneficiation of oxidized sulfides. Data from microcell flotation tests are combined with electrochemical and spectrophotometric measurements. The adsorption of ethyl xanthate (EX) on oxidized sulfides was characterized using AC impedance techniques and correlated to flotation response. The floatability of chalcocite, chalcopyrite and pyrite was dependent on the extent of oxidation. Oxidation for 1?) d at 65? C inhibited flotation of chalcocite, and chalcopyrite even after the addition of a large amount (1 x 10') M) of collector. Heavily oxidized (27 d) chalcocite remained unfloatable. However, longer oxidation of pyrite and chalcopyrite restored the floatability. Oxidation resulted in an electrically resistive, nonporous surface layer.

Jan 1, 1993

By Andrew Chegwidden, Tara Wilk

Construction of Shaft 17B-1, a part of The New York City water supply system, required an excavation of approximately 38 m (123 ft) through water-bearing overburden soil and more than 152 m (500 ft) of gneiss bedrock to make a connection to Water Tunnel No. 3. Ground freezing was the specified method to provide temporary earth support and ground water control for the overburden material. The ground freezing process relied on a supplemental geotechnical investigation and comprehensive laboratory testing of the frozen soil to evaluate the potential long-term creep behavior of the soil and the elimination of a temporary lining system. This paper describes that process as well as the drilling and installation methods of the ground freezing system. Additionally, the methodical system of excavation and insulation is discussed that permitted a safe and timely excavation followed by the installation of the permanent concrete liner.

Jun 13, 2023

By W. L. Dalke

The Minntac complex is a facility for production of iron ore pellets located on the Mesabi Range at mountain iron, Minnesota. It consists basically of a mine, crushing plant, concentrator, and a pelletizer producing twelve and one-half million tons of pellets annually. This paper deals with some of the aspects of the grinding circuits; but prior to that discussion, it might be well to briefly describe the flow of material in the operation. The crude ore, containing from 20% to 25% magnetic iron, is mined by 14-yard electric shovels. .the blasted ore is loaded directly into 50-yard side dump railroad cars and hauled to the crushing plant. Crushing is done in three stages, originally, two 60" primary crushers; four 7-foot standard secondary crushers; and six 7-foot short head tertiary crushers were installed, when the plant was expanded to double its capacity, five secondary and ten tertiary crushers were added. These were duplicates of the original 7-foot standard and short head crushers used in the original construction, there was no expansion of the primary crushers but a one-half-million-ton surge pile of tertiary crusher feed was added.

Jan 1, 1976

By J. L. Watson

n the U.S., lead has been produced via blast furnace processing for over a century, and the slags from that pyro-metallurgical process have been accumulating on industrial sites over that extended period. Lead blast furnace slags typically contain both lead and zinc compounds in an iron-silicate matrix, and it appears highly likely that such materials will have to be processed in the near future to meet with EPA regulations. Thus it is appropriate to investigate possible processing routes to render the slags non-hazardous and simultaneously to recover metal values to partially off-set the inherent high cost of processing such materials. There are two major processing alternatives: one being pyrometallurgical and the other hydrometallurgical. The research reported here investigates leaching/solution purification/recovery processes for lead and presents experimental data for the treatment of lead blast furnace slags from S.E. Missouri. The results of the research suggest that both lead and zinc can be removed effectively from the slag, and that metallic lead can be recovered directly from the organic extractant utilized for solution purification.

Jan 1, 1995