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By A. Noble, R. Q. Honaker, J. Werner

Recovery of rare earth elements (REE) from coal-related resources has recently received significant interest due to supply concerns and their key roles in critical industries and defense-related technologies. An integrated flowsheet consisting of sorting, crushing/grinding, physical separation, acid leaching, solvent extraction, and selective precipitation was designed to achieve continuous production of rare earth products from various coal-related resources such as coarse refuse and acid mine drainage. A pilot plant was constructed that enabled continuous testing of the circuitry on a range of different coal-based feedstocks. Despite achieving significant success in producing high-grade rare earth oxide products, low REE recovery values and high operational costs necessitated a re-evaluation of the process flowsheet. This article describes the circuitry improvements that were based on both laboratory and pilot plant test results. Roasting as a pre-leach treatment was found to significantly improve the leaching rate and overall REE recovery values. After roasting West Kentucky No. 13 and Fire Clay coal refuse materials at 600 °C, REE recovery increased by 60 and 40 absolute percentage points, respectively. Rare earth concentration in the pregnant leachate solution (PLS) was increased to around 700 ppm prior to solvent extraction using a staged precipitation method. REEs in the precipitate were re-dissolved, purified, and extracted from the PLS using solvent extraction and selective precipitation to values of around 80%. As a result of the improvements, chemical consumption in the acid leaching and solvent extraction processes was significantly reduced. A techno-economical assessment of the improved flowsheet indicated significant commercialization potential.

By O. Konovalov, M. Zhuravkov

In report the results of performance of research works on building up of the connected geoecological and geomechanical monitoring system for modelling and study of a state of mining massif in a region with large-scale underground mining works are discussed. The connected geoecological monitoring requires radical change of methodology of carried out works. To carry out modelling and researches it is impossible without construction of the integrated connected information model of region. Basis of construction of information systems and databases for all sections of Earth Sciences is the set of the approaches, among which, for example, methods of remote sounding, GIS- and GPS-technology etc. Computer technologies are basis on the "supercomputer" technology. The results of performance of some researches for regions of excavation of deposits of potash salts in Russia and Belarus are presented.

Jan 1, 2005

By J. A. Delgadillo

Computer simulation and mineral modeling was applied to the optimization of a grinding circuit in a plant processing 256 t/h magnetite. These tools were used to develop a grinding and classification configuration to decrease the grade of silica in the magnetite concentrate, which is produced by the plant. Empirical grinding and classification models were finely tuned using plant experimental data. The JKSimMetTM 5.0 software was used to simulate the grinding and classification units. By applying changes in the original circuit, a throughput increment of 100% was achieved with an important reduction in the energy consumption. The silica content in the magnetite concentrate can be decreased by regrinding the coarse fraction of fine screens into a separate ultrafine grinding unit instead of returning this flow to the ball grinding mills.

Jan 1, 2008

By A. Noble, R. Q. Honaker, J. Werner

Recovery of rare earth elements (REE) from coal-related resources has recently received significant interest due to supply concerns and their key roles in critical industries and defense-related technologies. An integrated flowsheet consisting of sorting, crushing/grinding, physical separation, acid leaching, solvent extraction, and selective precipitation was designed to achieve continuous production of rare earth products from various coal-related resources such as coarse refuse and acid mine drainage. A pilot plant was constructed that enabled continuous testing of the circuitry on a range of different coal-based feedstocks. Despite achieving significant success in producing high-grade rare earth oxide products, low REE recovery values and high operational costs necessitated a re-evaluation of the process flowsheet. This article describes the circuitry improvements that were based on both laboratory and pilot plant test results. Roasting as a pre-leach treatment was found to significantly improve the leaching rate and overall REE recovery values. After roasting West Kentucky No. 13 and Fire Clay coal refuse materials at 600 °C, REE recovery increased by 60 and 40 absolute percentage points, respectively. Rare earth concentration in the pregnant leachate solution (PLS) was increased to around 700 ppm prior to solvent extraction using a staged precipitation method. REEs in the precipitate were re-dissolved, purified, and extracted from the PLS using solvent extraction and selective precipitation to values of around 80%. As a result of the improvements, chemical consumption in the acid leaching and solvent extraction processes was significantly reduced. A techno-economical assessment of the improved flowsheet indicated significant commercialization potential.

By C. Newman

"Over the past decade, as conventional underground deposits have been depleted, mining operations have been forced to produce at greater depths and in more geologically and geometrically challenging conditions. As such, there has been a global increase in the application of cemented paste backfill (CPB) in tabular deposits utilizing open stope mining method with a delayed backfill placement. Despite the extensive use of CPB, many fundamental factors affecting the design of safe and economical fill structures are still not well understood. A critical issue in the design of backfilled stopes is the determination of stress states within the fill material itself as well as the surrounding rock mass. Analytical equations provide a means of quickly evaluating the effectiveness of a given design. However, in developing these equations large assumptions are implemented to simplify the design problem. It is important that one understands these simplifications as well as their effect on the overall design. This paper investigates common analytical equations utilized in the evaluation of single vertical backfilled stopes and their assumptions through comparisons to numerical modeling results. INTRODUCTION AND BACKGROUND As the mining industry continues to produce at greater depths and in more geometrically and geologically complex conditions, cemented paste backfill (CPB) has gained traction as a means of providing localized ground support in modern stope-and-fill mining operations. The application of CPB in stope-and-fill mining as a ground support material has led to the reduction of mine waste costs, while increasing both mine production and stability. In an attempt to achieve total extraction of the mining reserve, stope-and-fill mining operations often employ a primary-secondary excavation-support sequence (see Figure 1). In this practice, primary stopes are initially excavated and then backfilled in a two-stage pour; plug and final pours. During the first stage (plug), a CPB material with increased cementitious content is placed at the bottom of the stope providing a strong base from which to build a backfill structure as well as protect mine works from material breakthrough. Following placement, the backfill plug is allowed to cure to a given strength as designated by the mine design. Upon achieving the required cure strength, a less cementitious CPB material is used to backfill the remaining stope area. This is referred to as the final pour stage. With all primary stopes excavated and supported using backfill, the extraction of the secondary stopes commences as primary stopes are utilized as artificial pillars. While the application of CPB in a primary-secondary extraction-support mining sequence allows for a substantial increase in reserve recovery, it is imperative the mining personnel and planning engineers have a clear understanding of the material’s behavior and stress interaction with the surrounding rock mass to ensure the most efficient, cost-effective, and safe extraction of underground deposits."

Jan 1, 2018

By R. Kalra

The current paper looks at evaluating the merits of large geared mills versus gearless driven mills by evaluating the following factors: The capability of currently available systems in terms of power and mill diameter Efficiency in terms of overall electrical power consumed vs mechanical output power Capital cost Running costs Cooling requirements in terms of air versus water cooling Installation and delivery time World?s largest geared drive ? 2x8500kW ? Wushan, China (operating) Among the many reasons that geared drives on large SAG mills are not favoured, is due to not having an efficient variable speed drive option (60 to 80% critical speed), which is required for process reasons. As technological advances have occurred quite rapidly in recent years, this paper uses the latest data in applying these comparisons and attempts to dispel some of the myths regarding Slip Energy Recovery (SER) and variable frequency drive technology on twin pinion drive systems. Early attempts to provide load sharing on twin pinion drives used primitive electronics which have since been developed to eliminate the problems encountered in earlier attempts. In particular, torque pulsations between the twin motors have been overcome using a higher number of devices (pulses) and better electronics. With successful operation of 2 x 6.5MW (Phu Kham, Laos) and three 2 x 7MW units under manufacture (Pascu Lama) and a further 40 projects worldwide, energy efficient Hyper Synchronous SER drives are now mature and ready for use on 2 X 10MW dual drive mills. Speed variation required is in the range of +/- 15% of synchronous motor speeds. VVVF drive packages from ABB and Siemens are also available for 2 x 10MW in low and high speed options. Dual hydraulic inching drives provide a much safer and convenient operation with the added advantage of locked charge detection.

Feb 27, 2013

By F. Calizaya

This paper describes the basic requirements for the utilization of belt air to ventilate working sections at remote locations in relation to the main fans. It highlights the risks involved, potential problems, and the provisions that must be followed by mine operators for the safe use of belt air. The paper also presents a brief review of the current regulations, conveyor belting tests, atmospheric monitoring system requirements, and the experience gained by mine operators to utilize the belt entries to ventilate remote working sections or areas where mechanized equipment is being installed or removed. The paper concludes with a set of recommendations with respect to the utilization of belt air and the composition of belt material in under-ground coal mines.

Jan 1, 2008

By U. Paschedag, H. Bussmann

"Bucyrus manufactures the most comprehensive product portfolio of mining equipment worldwide. Its mission is to have a positive, lasting effect on our world. Bucyrus makes sustainable development a fundamental way of doing business through economic, environmental and social initiatives that support, educate and benefit our employees, customers, shareholders and other stakeholders. Our participation in GRI (Global Reporting Initiative), a network-based organization that has pioneered the most popular sustainability reporting framework will be discussed as well as examples will be given on each major field of engagement. Two examples from surface machinery are most fuel efficient haul trucks as well as the Highwall mining system which allows access to coal reserves which are lost not making use of this kind of system. Two examples from underground machinery are Bucyrus’ automated plow systems for the mining of medium and thin coal seams with minimum rock and Bucyrus’ intelligent CST drive system for high-powered armored face conveyors (AFCs) for efficient use of energy."

Jan 1, 2011

By Christopher Snee

??care has to be taken that the design is driven by sound geological reasoning and rigorous engineering logic rather than by the very attractive images that appear on the computer screen.??Hoek 1999 Design of a cavern is inextricably linked to the engineering geology of the site. The importance of sound geological reasoning will be illustrated by transportation projects in New York City where there are proposals for at least 11 caverns. These caverns have been the subject of advanced exploration techniques and geological interpretation but even so the raw data falls short of the sophistication of modern numerical methods. This paper will give geological explanations for the engineering characteristics of the rock in New York City which will provide guidance for practitioners when approaching cavern design in New York and elsewhere.

Jan 1, 2008

By António Fiúza, Anthony Danko, Patrícia Leitão, Aurora Futuro, Cristina Vila, Lurdes Dinis

The average global recovery rates for processing scheelite ores by physical methods are normally in the range 50 to 70%, and it is problematic to attain a minimum grade of 60% WO3 in the concentrates without penalizing further this yield. Direct hydrometallurgical processing of low-grade concentrates or medium- to high-grade ores may become an interesting global economic alternative as it allows increasing the recovery rate, avoiding major penalizations due to the grade of the concentrate and increasing the added value of the final product. Leaching of scheelite by sodium carbonate presents several advantages such as its selectivity regarding the dissolution of troubling metals like iron and aluminium, allowing for a simple and flexible process diagram. However, it has the disadvantage that it is performed at high temperature and pressure with a high consumption of reagents. The feasibility of leaching is appraised by the extraction yield and selectivity, but also by the operating cost. Considering these aspects, a relevant objective of the research was to transform alkaline pressure leaching into a feasible processing alternative directly applicable to both medium- and high-grade ores and simultaneously to low- and high-grade concentrates produced by physical methods. The research used ore samples and low-grade concentrates from a typical skarn orebody as well as high-grade concentrates from a chalcopyrite-scheelite orebody. Different operating conditions were tested. Temperature, pressure and reagent concentration showed to be fundamental, but not exclusive, in determining the leaching behaviour. The operating conditions are milder than the ones generally proposed in the literature or currently in use in industry, but with higher carbonate consumptions. The research was oriented towards potential industrial implementation allowing for the application of optimization methods and straight scale-up to pilot-plan design and project.

While SME is hosting its Annual Meeting at the Phoenix Convention Center, Feb. 28 to March 3, one of the finest collections of mining history will be on display just 15 blocks away at the Arizona Mining and Mineral Museum. Inside the museum, visitors will be treated to a treasure trove of minerals, gems, me¬teorites, rocks, fossils, mining artifacts, historical exhibits and interactive displays on modern mining. The museum is located at 1502 West Washington. For SME Annual Meeting attendees, this is a free, eight-minute Dash bus ride 15 blocks west of the Phoenix Convention Center.

Jan 1, 2010

By Paul Eger

The use of wetlands to treat mine drainage has become increasingly common, particularly as more information is available on their operation and construction. However, the lifetime of each system is still, at best, an estimate. Treatment lifetime depends on the types of processes that provide the majority of the metal removal. Anaerobic systems (vertical flow systems) rely primarily on sulfate reducing bacteria, which reduce sulfate to sulfide and generate alkalinity. Metals can be precipitated as sulfides, and acidity is neutralized. These systems can remove over 90% of the metals and increase pH from around 4 to over 7. The bacteria will remain active as long as the system remains anaerobic and contains an adequate supply of sulfate and small chain organics. Although estimates of lifetime made on the total carbon in the system suggest that lifetime should exceed 20 years, data from field and laboratory studies show that the rate of sulfate reaction decreases with time, and that after several years rates decreased substantially. To maintain acceptable treatment, either additional organic material must be added or the total metal and acid load to the system would need to be reduced substantially. Aerobic systems (overland flow wetlands) can effectively remove metals from neutral mine drainage by reactions with organic material in the substrate. Over 90% of the copper and nickel have been removed in aerobic systems treating mine drainage in Minnesota. The primary removal processes in these systems include adsorption, ion exchange and complexation, which are finite; removal will cease unless new removal sites are generated. Two wetlands built in Minnesota have been successfully treating mine drainage for 12 years. At one of the wetlands, the annual production of new removal sites has been estimated to be equal to the annual metal input, and, as a result, metal removal should theoretically continue indefinitely.

Jan 1, 2005

By M. Ahrens, J. Gonser

Gearless mill drives are a well established solution for grinding applications in the minerals and mining industries. The paper describes the functionality and technical features of such drive systems as well as their advantages compared to other drive solutions. Due to the variable speed operation the grinding process can be optimized for ores with varying grinding properties. This leads to significant optimization potential for the plant design as well as for its operation. Furthermore, energy and cost savings due to optimized operation, high system efficiency and high system availability are shown.

Jan 1, 2007

By S. Kawatra, K. Lewandowski

Heap leaching efficiency is reduced by poor solution flow characteristics (channeling and ponding), which result from fines migration. Agglomeration of the ore can immobilize fines, but copper leaching requires an acid-resistant binder to stabilize the agglomerates. Until now, there has not been a satisfactory way to evaluate whether a binder was effective, other than squeezing a handful to see if it “feels right”. We have developed procedures to quantitatively determine whether a binder gives good performance in an acidic solution, and have identified several binders that will be suitable for copper heap leaching.

Jan 1, 2007

By H. Lyn Bourne

This is the fifth annual tabulation of mineral royalty information. This tabulation, like the previous editions, includes all of the earlier data. There are also 60 new entries. In addition to royalty information, some entries show the cost of purchased reserves. Two articles relative to the evaluation of minerals reserves appeared in December, 1986. R.H. Paschall (In the Aggregate, ME, p 1139) wrote a good article, although it lacked specific royalty data. However, this author takes exception to two ideas in Paschall's column. Paschall contends that the royalty rate does not affect the mineral appraisal. This present author could not disagree more. Paschall also claims the location of an industrial mineral deposit is the only serious or practical caveat in comparing royalties. Comments received here from readers helped make the list of caveats that are cited each year. The readers will decide which factors influence the mineral value for their commodities of interest. Paschall's point about the relationship of the parties who are negotiating a royalty agreement is important and very well taken. The other article, written by William Vernon (Pit and Quarry, December 1986), gives a step-by-step process on how to conduct a mineral appraisal. The article cites three reasons for an appraisal: transfer rights; collateral for a loan; and taxation. A fourth reason is to establish adequate compensation for reserves lost through condemnation. This author has appeared in several court cases where compensation for loss of mineral reserves through condemnation required a mineral appraisal. Royalty rate becomes an important factor in the appraisal process, although the Pit and Quarry article refers to that part of the valuation equation as "profitability." Both articles were well written and are recommended reading for those interested in mineral valuations. The same caveats that have appeared in previous columns relative to factors that influence the value of reserves are restated. The data in the table serve as a general reference and are not intended to present an absolute scale of reserves costs. Several factors influence the value of any mineral commodity. The factors include: • location/transportation - especially significant for most industrial minerals; • market conditions both for the commodity and the company acquiring the right to mine; • quality or grade of the deposit as it reflects the amount of processing/beneficiation necessary to produce the finished product; and • legislative restrictions and conditions for mining a given material at a given site. These and other factors will significantly influence the cost of reserves. The table shows the range of royalties and the variations in the basis of computing the fees. In a few instances, it gives the cost of acquired reserves based on purchase price and quantitative estimates of the material in place. The table lists the commodity in column 1, and the subsequent columns give: • the location by state, US geographic area, or Canadian province ; • the cost - R for royalty and P for purchased cost; • the year in which the lease or purchase agreement occurred; and • comments or footnotes for more information. The cost column requires more explanation. The units may refer to cubic yards (/cu yd), cubic feet (/cu ft), short tons (/T), or acres (/A). 1 cu yd = 0.76 M2 1cuft = 0.28m3 1 st = 0.9072 t 1 acre - 0.4047 ha or m2

Jan 7, 1987

By F. Habashi

The Republic of South Africa is a heterogeneous mixture of Black Africans, Afrikaans, British, Indians, Malayans, French Huguenots, and many others from Europe and Asia. A decisive date in its recent history is the collapse of the Apartheid Regime in 1994. For a metallurgist, South Africa is the country of diamonds, gold, platinum, and many other metals. In 1887 Cecil Rhodes (1853-1902) was able to take control of the De Beers Mining Company after the discovery of diamonds at Kimberly in 1866. It was there where the so-called School of Mines was inaugurated in 1896.

Jan 1, 2010

By R. Schwarz, E. Pusch, A. Juch

"The paper describes in general the objectives, goals as well as theoretical background of "METSI"-project proposal submitted to German BMBF (Federal Ministry of Education and Research). The METSI project is a starting point for technology and know-how transfer of German water management and water treatment technologies to South African Mining industry. "METSI" is Setswana, one of the eleven official languages in South Africa, and means "water". It stands also for "Management System for the Implementation of Environmentally Sound Water Supply Technologies in South African Mining Areas with Involvement of all Relevant Stakeholders". The project focuses on development, design and implementation of mathematical models that consolidate and evaluate existing data and generate substantiated projections of "water" amount and quality. METSI covers a wide range of scientific, technical, social as well as economic questions related to "water in mining"."

Jan 1, 2011

By W. D. Monaghan

One of the major ignition sources of fires and explosions in underground U.S. coal mines is flame cutting and welding. On May 20, 2006, a flame-cutting operation at the Darby Mine No. 1 led to an explosion that resulted in five fatalities. On Jan. 22, 2003, another explosion caused by flame cutting at the McElroy Mine resulted in three fatalities and three serious injuries. On June 22, 1999, a flame-cutting and welding operation at the Loveridge Mine caused a fire that required sealing the mine for an extended period. On March 19, 1992, an explosion initiated by welding at the Blacksville No. 1 Mine resulted in four fatalities. These examples of mine incidents demonstrate the need to conduct research to develop best practices for safely conducting flame cutting and welding in underground coal mines. The National Institute for Occupational Safety and Health (NIOSH) conducted a study on fires and explosions in underground U.S. coal mines that were caused by flame-cutting and welding operations to determine the root causes of these types of incidents. The methodology included interviewing mining personnel who perform flame-cutting or welding operations in underground U.S. coal mines and visiting mines to observe these operations. In addition, MSHA reports of investigations and accidents statistics were analyzed. The findings were used to identify and compare differences between flame-cutting and welding practices and techniques in small and large mines, eastern and western mines, low-seam and high-seam mines, room-and-pillar and longwall mines, and between experienced miners and new miners. As a result of this study, best practices were developed to reduce the number of ?res and explosions caused by flame cutting and welding. This paper provides a summary of this research.

Jun 1, 2010

By S. F. Diehl

Weathered mine waste consists of oxidized primary minerals and chemically unstable secondary phases that can be sources of readily soluble metals and acid rock drainage. Elevated concentrations of metals such as Cd, Cu, Fe, Mn, Ni, Pb, and Zn are observed in deionized water-based leachate solutions derived from complex sedex and Cu-Pb-Zn mine wastes. Leachate (USGS FLT) from the Elizabeth mine, a massive sulfide deposit, has a pH of 3.4 and high concentrations of Al (16700 ug/L), Cu (440 ug/L), and Zn (8620 ug/L). Leachate from the sedex Faro mine has a pH of 3.5 and high concentrations of Al (2040 ug/L), Cu (1930 ug/L), Pb (2080 ug/L), and Zn (52900 ug/L). In contrast, higher-pH leachates produced from tailings of polymetallic vein deposits have order of magnitude lower metal concentrations. These data indicate that highly soluble secondary mineral phases exist at the surface of waste material where the samples were collected. Sulfide minerals from all sites exhibit differential degrees of weathering, from dissolution etched grain rims, to rinds of secondary minerals, to skeletal remnants. These microscale mineral-dissolution textures enhance weathering and metal leachability of waste material. Besides the formation of secondary minerals, sulfide grains from dried tailings samples may be coated by amorphous Fe-Al-Si minerals that also adsorb metals such as Cu, Ni, and Zn.

Jan 1, 2011

By F. -J. Wodopia

Sustainability of energy supplies has been an issue of general interest for a long time. Whilst in the past the continuous productive use of natural commodities was in the fore, its compatibility with the environment and climate and ultimately also social aspects have recently gained more and more attention. Today many discussions focus on the climate compatibility of individual options to act. Fossil fuels, in particular coal and lignite, are generally challenged because coal use makes a significant contribution to global man-made CO2 emissions. The drastic increase in the consumption of fossil fuels is not explained by the fact that coal utilisation technologies are not or cannot be sustainable but rather by the growing world population and the endeavours numerous national economies trying to catch up economically. Coal is the world’s No. 1 fuel and, in the view of many experts, will keep this position also in the foreseeable future. The access to its deposits plays a significant role for the economies of the emerging countries. Consequently the aspects of energy security and economic efficiency need to be considered at eye level with climate compatibility. In Germany, however, the public acceptance of fossil fuels and of large industrial projects is in the focus of attention.

Jan 1, 2011