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By Nikhil Dhawan, Veeranjaneyulu Rayapudi

This study investigates upgrading of low-grade banded hematite quartzite iron ore (Fe ~31%). Conventional beneficiation was found to be futile. The susceptibility of iron phases to microwave exposure and their selective absorption assists in the liberation of iron values. Microwave exposure of coarse particles at 540 W for 10 min yielded a concentrate with Fe 56.30% and recovery of 50.68%. Conventional carbothermic reduction at 500 °C, 60 min and 9% charcoal yielded a concentrate with Fe 57.6% and iron recovery of 68%. The presence of sufficiently bonded silica leads to an easy formation of a fayalite phase. The microwave reduction design yielded FeG of 57.6%, FeR of 47% and a yield of 24% at an optimal condition of 540 W, 8 min and 6% charcoal. It was found that a small fraction of microwave-irradiated ore-charcoal mixture melted rapidly, and pure ferrite balls were observed within 8 min. An optical micrograph of a ferrite ball reveals the retained austenite and martensite phase.

By Rambabu Pothina, MELO EDUARDO PIMENTA DE, Rajive Ganguli

 The mining industry is home to a mass of sensor-generated data that are critical to real-time and long-term optimization. This heavy reliance on sensor data has resulted in an undesirable development. The industry is reluctant to verify the accuracy of sensors as it would mean shutting down important processes. Sensors are typically calibrated once a year, if at all. Errors in sensors go undetected until the next calibration or until errors are so gross as to be obvious

By Pratt Rogers, Aaron Young

This paper considers the mining industry’s need for digital transformation (DT) and presents a three-part review of the foundational components of the DT process: ubiquitous data, connectivity and decision-making. It also provides a discussion on the future of DT in mining as well as a research direction, which identifies the need of academia to provide support for mining companies in the form of both research and the education of digitally literate, dynamically capable mining engineers into the coming decades.

By Robert R. Beebe

At first glance, mineral processing on an industrial scale might seem entirely in the realm of macro-engineering, with large machines operating on minerals and rocks to achieve size reduction, classification, chemical treatment, separation and dewatering. These operations must be conducted on a large scale to be of practical interest. But the machines and processes may not be designed and operated to take fullest advantage of micro-engineering factors. At the same time, idealized designs based solely on micro-engineering research may require adjustments to gain the desired results in the larger scale, operational context. Using micro-engineering research in this way allows the design and implementation of more efficient versions of the machines and processes currently used, while aiding the revolutionary developments unlikely to come from macro-engineered, trial-and-error solutions. Thus, from an industrial viewpoint, micro- and macro-engineering are complementary functions.

Jan 1, 1992

By Cem Şensöğüt, Özer Ören, Yaşar Kasap

The mining sector, which has an important place in terms of raw material and energy supply, is referred as a sector with one of the highest fatal accidents in comparison with other sectors. In this century, where occupational health and safety awareness has increased, it is important to review the past accident statistics and to determine the current deficiencies by using the information in the inventory. In this study, the Malmquist total factor productivity index (MPI) has been utilized to investigate the changes in the work accidents occurring in the Western Lignite Corporation (Turkey), where underground and surface production methods are applied, and to determine the measures to be taken. According to the results obtained, both the decrease in production amount and the increase in the number of accidents caused inefficiencies during the period in concern due to the expected 10-year economic life of the mechanized system operating in the underground production panel that came to an end in 2007 and the flooding took place in early 2017. Compared with the underground operations, it has been determined that production can be carried out at the appropriate scale despite the heavy working conditions encountered due to the changing climatic conditions and the progress of production in the surface operations.

By C. G. Buttleman, W. C. Brice

In Minnesota, reclamation of active aggregate mining sites is primarily regulated through local permits issued at the county, township, or municipality. However, for abandoned or depleted aggregate mining sites, a responsible party for reclamation is often no longer available. Since 1995, the Minnesota Department of Natural Resources has reclaimed several abandoned aggregate sites using innovative public/private partnerships and emphasizing native plant materials. The purpose of these projects is to demonstrate cost effective reclamation methods that can be utilized by both aggregate operators and local government and to promote mine planning and resource identification as it relates to reclamation.

Jan 1, 2000

By G. A. Munoz

Gold leaching of an auriferous pyrite ore from the Portovelo deposit in Ecuador indicates that noncyanide leaching systems, such as thiocyanate and thiourea, are not as effective as the traditional cyanide system. For example, whereas approximately 95% of the gold can be leached from the ore with cyanide, only about 50% gold dissolution can be achieved with a thiocyanate leaching system. Electrochemical measurements indicate that gold is not cathodically protected by pyrite in these systems. Based on the results of preliminary diagnostic experiments, it appears that gold dissolution in thiocyanate and thiourea systems is limited by passivation due to the formation of either elemental sulfur or sulfur compounds on the gold surface.

Jan 1, 1999

By Rihab Guellala

In Tunisia, the Paleocene-Eocene series has an important socio-economic interest. It contains profitable oil and water accumulations. Moreover, it encompasses phosphate reserves. The present study uses seismic reflection prospection and borehole data for the reconstitution of the Paleocene-Eocene deposit structure in the Jerid area (southwestern Tunisia), a crucial step for the phosphate exploitation. Firstly, lithostratigraphic correlations incorporating water and petroleum wells were established according to different directions for a tentative approximation of the Paleocene- Eocene deposit geometry by following their lateral evolution. To give more details, seismic reflection profiles were interpreted in the second step. The Paleocene-Eocene formations were associated with their corresponding reflectors on the closest seismic profile using the relation of time and depth in petroleum wells. Analysis of lithostratigraphic correlations shows notable variations in the Paleocene-Eocene series thickness and depth. Seismic profile interpretation explains these variations by highlighting different buried tectonic features. The results confrontation reveals that the phosphatic deposit geometry in the Jerid area is mainly influenced by the (1) emergence of the Saharan platform and the Chott northern chain since the Late Cretaceous, (2) syn-sedimentary normal activity of E-W and NE-SW faults during the Paleocene-Eocene epoch, (3) reverse-reactivation of these faults, and (4) major Tortonian folding phase. This study can enormously enhance the Jerid area socio-economic development by presenting useful findings that may orientate the phosphate exploration.

Aug 15, 2021

By M. Ralchenko, C. Samson, M. Svilans, C. Walsh

"Through-the-Earth (TTE) radio has been proposed as a means of emergency communications in mines. The propagation of a TTE radio signal depends chiefly on the subsurface conductivity distribution. Robust forward models of signal propagation can be computed based on a realistic conductivity estimate. These models can be used, for example, to optimize frequency, estimate signal range, identify zones of anomalously strong or weak signals, or to optimize the position of the above-ground TTE radio unit. A method was developed to determine the conductivity distribution of a mine overburden using TTE radio transmission data. At multiple locations in an underground test mine, we recorded a wideband electromagnetic signal, spanning a frequency range of approximately 500 to 8,500 Hz, transmitted from a vertical magnetic dipole at the surface. Using a finite-difference time-domain forward modeling code, a layered Earth conductivity model that accounts for topography was fitted to the observed data, which minimizes the difference between the calculated and observed attenuations for each transmitter-receiver pair, for each frequency of interest. Introduction and objectiveThrough-the-Earth (TTE) radio has been proposed for emergency underground communications. The most common type of TTE radio is based on the transmission and reception of signals by electromagnetic induction. These signals are in the extremely low to very low frequency range — in practice, between 400 and 9,000 Hz. This technology was historically developed for mine safety, although recently other applications have been suggested, such as communications in civilian infrastructure like high-rise buildings or tunnels, in the military, and even for wireless detonation and activation. In a coal mine, which is a setting of particular importance for TTE radio due to the higher risk of accidents, day-to-day communications can be done through a wired link. High-frequency line-ofsight systems, whose signals cannot penetrate rock, are also used for communications from nonfixed points. Another option is a leaky feeder system, which is a permutation of a line-ofsight system and a wired link, where a partially shielded coaxial cable allows the signal to “leak” (Delogne, 1982). In an incident such as a mine collapse or explosion, a TTE radio system can still provide a communication link, as wired systems can be severed, and line-ofsight systems cannot penetrate through collapsed portions of the mine, or to the surface (Forooshani et al., 2013; Yarkan et al., 2009)."

Jan 7, 2018

By Z. Hyder, A. Urquidez

"INTRODUCTION The Waste Isolation Pilot Plant (WIPP) is located approximately 26 miles southeast of Carlsbad, New Mexico and is the nation’s first underground geologic repository for transuranic (TRU) and TRU-mixed waste (see Figure 1). The WIPP facility was opened for operation in 1999 when the first TRU waste shipment arrived at the WIPP facility for disposal.WIPP facility does not employ typical production aspects of a conventional mine. Instead, the mining focus is on the quality of the excavation to ensure safe disposal of TRU and TRU-mixed waste (Walls, 1991). GEOLOGY WIPP underground repository is mined within a 2,000 feet-thick bedded-halite formation (Salado Formation) (see Figure 2). The WIPP underground repository is located approximately 2,150 feet beneath the surface near the center of the Salado Formation. Geologic criterion and site-selection factors evaluated for the selection of the repository included topography, depth, thickness, lateral extent, lithology, stratigraphy, structure, erosion, dissolution, subsidence, surface water, aquifers, hydrologic transport, climatic fluctuations, manmade penetrations (U.S. Department of Energy, 1980).FACILITY DESIGN Profit did not play a major role in the WIPP’s conception like in a conventional mine. This was due to the extensive amount of additional regulations and safety controls that had to be built into the WIPP facility. Since it is nuclear and hazardous waste disposal facility, it must meet certain federal and state requirements for TRU-mixed waste. One of the major regulatory drivers for the WIPP facility is defined in the WIPP Land Withdrawal Act (LWA). One of the requirements in the WIPP LWA requires the DOE to submit documentation of continued compliance with Title 40 CFR Part 191, Subparts B, and C. These standards are regulated by the Environmental Protection Agency (EPA). The DOE must submit documentation of continued compliance (recertification) with these regulations every five years. In addition to the LWA, the Resource Conservation and Recovery Act (RCRA) is another major regulatory driver for the WIPP facility. Since the WIPP facility is categorized as a “Miscellaneous Unit” under 40 CFR, it must meet extensive environmental performance standards. These standards are defined in the WIPP Hazardous Waste Facility Permit (HWFP). The HWFP defines the terms and conditions that the Secretary of the New Mexico Environment Department has determined necessary to protect human health and the environment (U.S. Department of Energy and Nuclear Waste Partnership LLC, 2015)."

Jan 1, 2017

By Umay Cinarli, Ahmet Turan

High-energy consumption in primary aluminum production (from bauxite ores) makes secondary aluminum production (from metallic raw materials such as scrap and dross) very critical. Aluminum dross, as a waste, arises in pyrometallurgical processes, and it is the mixture of metallic Al, Al2O3, other metal oxides, metal halides, and some other compounds like AlN. Aluminum dross has two subgroups (white and black) with respect to its metallic aluminum content. White dross is a secondary aluminum resource because of its high metallic aluminum content, whereas black dross, having low metallic aluminum content, is generally disposed in dumping areas. In the present study, it was aimed to develop a simple technique to valorize aluminum black dross in the form of alumina-based ceramic materials through pyrometallurgical (calcination) and hydrometallurgical (leaching) operations. Moreover, thermochemical simulations were conducted by using HSC Chemistry 6.12 software to simulate calcination conditions. After leaching experiments, an alumina-based ceramic containing approximately 36.8% Al2O3, 61.4% MgAl2O4 with 1.8% Na2FeO4, which might be available to use as a spinel refractory in steel smelting furnaces, was obtained in the experiment carried out in a solution containing 10 mLH2SO4 and 40 mL distilled water (3.5 M). Moreover, the sinterability of the alumina-based ceramic was investigated at the temperatures from 1350 to 1550 °C. In the sample which was sintered at 1550 °C, a density value of 3.15 g cm−3 and a hardness value of 69.58 HV were measured.

Oct 26, 2020

By M. P. Roy, P. K. Singh, A. K. Mishra, Ashish K. Vishwakarma, Vivek K. Himanshu

Ground vibration is one of the major hazards produced by rock-blasting operation. The accurate prediction of vibration is necessary for designing controlled blasting parameters. The existing vibration predictors consider maximum explosive charge weight per delay and distance as the parameters responsible for ground vibration. These predictors are based on the assumption that the geometrical parameters of the blast will be constant for a site. However, the mining sites with bigger production targets have varying geometrical parameters to suit the excavator utility. Accordingly, the other blast design parameters will also have an impact on ground vibration intensity. A principal component analysis is a dimension reduction technique. This technique along with multivariate logarithmic regression has been used in this paper to predict the ground vibration. The technique has classified the blast design parameters into four principal components. The regression with the scores from these principal components has been carried out. The evaluation of the model performance of predictors along with the existing empirical predictors has been carried out using R2 and RMSE values. The evaluation suggests that the predictor with logarithmic regression followed by principal component analysis gives better performance with respect to the existing empirical predictors.

Jul 30, 2022

By P. Moran

A promising and increasingly popular tailings management strategy is to place cemented tailings underground as backfill. The placement of cemented tailings results in enhanced geotechnical stability and a purportedly more geochemically stable tailings form with lower leaching potential. Conventional subaerial tailings management can negatively affect water quality if weathering causes acid rock drainage and metal leaching (ARD/ML) to occur, whereas cemented tailings can limit leaching via porosity and permeability reductions and contribute alkalinity to limit the potential for ARD/ML. Cemented tailings backfill appears to be better, but how can this advantage be proven? Currently, cemented tailings backfill is utilized at mining operations internationally, but there is limited guidance on performing geochemical characterization and associated evaluation of the potential impacts to water quality. As a result, various approaches to simulating the leaching behavior of cemented backfill have been utilized, including some methods that are unlikely to represent weathering under site-relevant conditions. American Society for Testing and Materials (ASTM) Standard Test Method C1308-08 is a diffusion testing method initially developed to assess constituent release rates from solid nuclear waste forms. ASTM C1308-08 uses intact cylinders that more closely represent actual backfill than methods that require crushing or size reduction. It is widely believed that leaching from actual cemented tailings is controlled by diffusion through small pores that exhibit limited exposed surface area, making diffusion testing particularly applicable to cemented tailings placement.

Feb 27, 2013

By D. Kruse

Top-down constructed large-diameter (up to 90 m or 300 ft) shaft design and constructability issues present an interesting suite of challenges and opportunities highlighted in this paper. The study covers 2D and 3D finite element models used to analyze various failure modes, evaluate the shaft liner and internal structures' response to seismic loading, assist in segment design and assess final structural design tradeoffs. Efforts to achieve economic advantage over conventional heavy civil practices have prompted innovative solutions for ring and segment design, ring build assembly and annulus backfill grouting. Intended for soft ground conditions, relationships between soil parameters and structure design are also explored. Mining Engineering, 2011, Vol. 63, No. 9, pp. 81-88. Official publication of the Society for Mining, Metallurgy and Exploration, Inc.

Jan 1, 2011

By Ross W. Smith

In recent years there has been a considerable amount of research work done relative to the effect of pretreatment and aging in water on the surface properties of both simple metal oxides and more complex oxides such as the silicate minerals 1-6. Of particular interest is the work of Somasundaran6 who states that after preparing minerals by size reduction and washing with dilute acids "... it is essential to treat it (the mineral) with water in order to remove any effects of leaching itself." Somasundaran also states, "... it is advisable to use a solution close to the point of zero charge for conditioning purposes." Parksl notes that, "Dehydration, dehydroxylation, and increased crystallinity can be expected to decrease the PZC. The presence of anionic impurities or of pH-independent potential determining ions will decrease the PZC. Cationic species will increase the PZC." Healy and Jellett4 believe that in the Zn0-water system "the surface charge of Zn0 in water and each pH is determined by the concentration and adsorption of each hydrolyzed (charged and uncharged) Zn(II) species." Finally, according to Parks 2, "The PZC of an unaltered com¬plex oxide in a system devoid of specific electrolytes is approximately the average of the PZC's of its component oxides... Equilibration with water results in loss of mono and divalent cations by exchange with H+, thus a loss of influence on the PZC by those cations, i.e., a shift in the PZC with time in the direction of that remaining oxide. The present paper investigates the change of point of zero charge (PZC) of a number of simple oxides and several complex oxides as a function of aging time in water. In some cases acid pretreatment of minerals was performed. However, in most cases the minerals were not acid pretreated. In several systems pH change as a function of aging time in water was monitored.

Jan 1, 1972

By William C. Dixon

Since the mid 60's, several haul cycle simulation programs have been developed. However, most of these programs are believed to employ the continuous, rather than the discrete, event-oriented simulation approach to determine the haul cycle times. This paper describes the recently developed haul cycle simulation approach where time is advanced in varying amounts only as the system changes occur. This approach results in greater computational accuracy and increased computational efficiency. The program is written in FORTRAN and requires equipment performance curve and haul road profiles as input. Unique program capabilities include the handling of switchbacks and intersections. The program uses a master data file concept in which various haul road profiles found during the mine life can be simulated all in one job submission. The results of the model validation using the actual time study data provided by an open pit mine operator near Tucson, Arizona, are also described in this paper.

Jan 1, 1978

At long last, mining is on the rebound in Minnesota?s Iron Range and the excitement is starting to show. The SME Minnesota Section?s annual meeting was once again held in the heart of Iron Range country, at the Duluth Entertainment and Conference Center on the Duluth waterfront. The conference boasted a record attendance of 475 people and its largest-ever trade show. Appearances by Governor Mark Dayton?s new Iron Range Resources & Rehabilitation Board (IRRRB) appointee, Tony Sertich, as well as a local Fox news crew (see clip on SME website [link: http://fox21online.com/news/duluth-mining-conference-breeds-optimism-tech-innovation]) made clear that a lot of eyes [ ] are on the industry as it dusts itself off from the 2008-2009 recession. While the early years of the 21st century were very good to the Iron Range, the global drop in commodities prices and production left many companies reeling and brought back bad memories of the collapse of the industry in the 1980s. However, two years of solid growth and a rebound to above pre-2008 production levels have let the Minnesota mining industry to relax a little and talk seriously about long-term growth and stability.

Jan 1, 2011

By William G. Pariseau

Solvay Chemicals Company mines trona in south-central Wyoming and has done so for many years. The mine is one of several in a mid-continent sedimentary basin that hosts the largest trona resource in the world. Trona is an evaporite, a sesquicarbonate that occurs in several seams of varying thicknesses and depths. Trona is processed into soda ash which has a number of industrial uses in the manufacture of glass, detergent, paper and chemicals. Figure 1 shows the location of the Solvay Mine. A ventilation shaft was recently excavated at Solvay Chemical Company’s mine in the trona patch. In fact, a 22 ft (6.7 m) diameter shaft (inside diameter) was bored upwards from the 1500 ft (457 m) level to the surface. The first bored section was 26 ft (7.9 m) in diameter that allowed for a 2 ft (0.6 m) thick concrete liner. This section began at a depth of approximately 1500 ft (457 m). A second bored section was 24 ft, (7.3 m) in diameter that allowed for a 1 ft (0.3 m) thick concrete liner. This section began at a depth of approximately 750 ft (229 m). This shaft is the #5 Shaft. Figure 2 shows the cutter head used to excavate the shaft.

Feb 1, 2025

By R. Scheffel, R. Washnock, G. Zarate

"The second survey of global copper leaching operations has been completed, the data published in 1998 has been updated. A survey questionnaire was sent to 40 identified copper leach operations around the world including those leach properties still in operation that responded to the 1998 survey. This paper lists the results of 26 operations that responded to the survey. Selected information from the survey is represented in graphical form. INTRODUCTION Copper leaching was first performed by truck dumping huge monolithic stockpiles of ore and flooding the surface with leach solution or lixiviant with little understanding to the parameters that support optimum recovery of the metal. Heap leaching has evolved into a controlled process whereby a complex low grade ore is stacked in shallow lifts (under 10 m in most cases). The ore is usually crushed and agglomerated, conveyor stacked on an engineered containment system (leach pad) and irrigated in a controlled manner. The lixiviant chemistry is designed to extract the optimum amount of metal from the ore. At first glance, heap leaching appears to be simple in nature. In fact, it is a very complex process. A plethora of technologies such as material handling, environmental control, analytical techniques, solution chemistry, hydrology and many others contribute to the design and operation of a heap leach. Heap leaching requires an inter-disciplinary approach between geologists, mining engineers and metallurgists. Many operational factors affect heap leaching. The process must address climatic factors, flexible operation, quality control before and after leaching, physical characteristics of the ore, geology, mineralogy, reagent consumption, solution application rate and methods (wobblers or emitters), particle size, and favorable conditions for bacterial growth and survival. Predicting, troubleshooting, and optimization of leach recovery is a significant challenge when considering the number of variables involved and their interactions The survey updates many of these key operating parameters to the current state of the art. It should provide the reader an excellent benchmarking summary of these factors on a site-by-site basis."

Jan 1, 2016

By Luttrell. G.

The profitability of coal mining operations is highly dependent on the performance of the coal blending and processing facilities. Many companies have recognized this fact and have instituted optimization programs that require large amounts of coal characterization data, extensive operational information and complex costing models. Unfortunately, this brute force approach to optimization is often overwhelming in terms of time and cost and is generally too inaccurate to be of value in day-to-day field operations. A simpler and more practical approach involves the use of ?micro-price? optimization throughout the coal supply chain. This fundamental concept assigns unit values to each type product (particle or groups of particles) passing through the production units. True optimization occurs whenever all particles with positive worth are recovered and passed to market, while all particles with negative worth are rejected. This paper describes the fundamental workings of the micro-price concept as applied to coal blending and processing operations. Several examples are also included to demonstrate the economic gains that can be realized via the application of this concept.

Feb 23, 2014