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By Brian E. Davies, Bobby G. Wixson

INTRODUCTION The mining, extraction and refining of metals into useful materials is an honorable profession with an ancient and productive history. Civilizations have long depended upon metals for their implements, structures and machinery necessary for survival, growth, and development. Today, as in the future, metals and minerals are essential to the progress of mankind as we approach the 21st century with technologies and concepts that will require new concepts and production from the metal mining and processing industries. Today is the tomorrow we talked about yesterday and the implementation of new ideas is essential if we are to achieve "Frontier Technology in Mineral Processing". Unfortunately, the state-of-the-art mining, processing, smelting and refining methods historically employed were less than desirable environmentally, which has caused todays public to view the metal mining and processing industry with concern. Presently the ancient rock and chat tips connected with old Roman lead-zinc mines which were worked in Wales are causing stream contamination problems that must be corrected at considerable expense to the local governmental agencies (Firth, J.N.M., et al., 1981). However, improved progress has been made and the environmental control and clean-up procedures utilized by modern lead-zinc operations in the "Viburnum Trend" or "New Lead Belt" of South East Missouri may serve as a model to illustrate how alternative technologies, environmental concerns and cooperative efforts contribute to efficient mineral production within the confines of a U.S. National Forest region without significant environmental impacts. This area received international attention when it was opened within the boundaries of the Clark National Forest in the mid 1960's. By 1970 it ranked first in the world by producing 432,576 short tons of lead ore and has since continued in this position producing 451,153 short tons of lead ore in 1983 representing 91% of the total United States lead production (U.S. Bureau of idines, 1983). This production comes from a mining area approximately 40 miles long by 10 miles wide extending in a north-south direction. Geologically the lead is disseminated throughout the Cambrain age Bonneterre Formation, mostly a dolomite, at depths ranging from 700 to 1200 ft. (213.4 to 365.8 m). Galena (lead) is the principal ore mined with lesser quantities of sphalerite (zinc), chaleopyrite (copper) and silver being recovered as economic co-products. This new mining development in one of Missouri is most scenic areas could have led to a classic confrontation between industries and environmentalists. Instead, through the cooperation of industries, governmental agencies and university researchers, the Ozark environment has been protected, and may serve as a model for future coexistence of the mineral industry with the environment. Cooperative Program Development As early as 1965 five new mines and two lead smelters were being prepared for production and environmental concern was an essential part of that planning. All the mining companies became acquainted with representatives of the various federal and state agencies and scientists from the University of Missouri-Rolla (UMR). During the next six years, St. Joe Minerals Corporation, American Metal Climax, Inc., Cominco American Incorporated, Ozark Lead Company (Kennecott) and American Smelting and Refining Company participated in cooperative research efforts. The companies also participated in information exchange meetings, the development of improved analytical methods and the utilization of research findings in the modification or construction of pollution-abatement facilities. Early on research was carried out to determine background values and to establish natural baselines of trace metals in the surrounding environment. The unusual topography and drainage pattern of the mining area were helpful since it was possible to establish control sites and test sites below individual mine-mill operations to study waste-water effects on the receiving streams. The location of the ‘New Lead Belt', mines, mills,

Jan 1, 1985

By Gary Beerkirkcher

INTRODUCTION The mine hoisting equipment that is selected and installed at a mine is for the lifetime of the mine and, therefore, it is extremely important that a proper choice be made. Several types of mine hoist designs, including double drum hoists, single drum hoists, friction hoists, and various special designs of these, are available to¬day. Each has advantages and disadvantages and they should only be used in suitable applications. Drive systems for mine hoists must be evaluated together with the mechanical systems for each hoist application. It does not make sense to properly select the hoist mechanical system and then choose a drive system that turns out to be a bottleneck. MINE HOIST TYPES There are two basic types of mine hoists available in the world today: the drum hoist, on which the hoist rope is actually stored during the hoisting cycle, and the friction (Koepe) hoist, which merely passes the rope over the wheel during the hoisting process. Drum Hoists Single Drum Hoist: A single drum hoist (shown diagrammatically in Fig. 1) can be used as a service or production hoist with the cage or skip in balance with a counterweight (Figs. 2 and 3). It can efficiently service one or more levels, since the location of the counterweight at any time is not important. As a pro¬duction hoist with skips in balance, the single drum hoist is best used for single level hoisting. All rope adjustments for proper spotting must be done manually for the single drum hoist. This has to be done periodi¬cally to compensate for rope stretch. A variation of the single drum hoist is the divided drum hoist. If multilayer winding is necessary, the single drum hoist must have a divider to allow a sep¬arate compartment for each rope. If a counterweight is used with a divided drum application, the counter¬ weight rope can be wound on a smaller diameter (Fig. 4). Consequently, it moves a lesser distance than the main conveyance and rope adjustment problems are re¬duced. Double Drum Hoist: A double drum hoist in oper¬ation is shown in Fig. 5. Double Drum Hoist With One Drum Clutched: As a service hoist with cage and counterweight, a double drum hoist with one drum clutched (Fig. 6) can serve several levels efficiently. The advantage of having the clutched drum is that it allows rapid adjustment of ropes due to initial stretch. Some users may prefer the single drum hoist with manual rope adjustment, while others consider the added expense of the second drum and clutch is justified to make rope adjustments quickly. The value of this feature for a particular application should be discussed with the hoist manufacturer. As a production hoist with skips in balance for a multi¬level operation, the clutch can be adjusted for efficient hoisting from any level. Double Drum Hoists with Both Drums Clutched: There are also double drum hoists that have both drums clutched (Fig. 7). The main advantage claimed for this type of hoist is that if something happens in one of the two compartments, the hoist can operate in the other compartment to raise and lower men and sup¬plies. This feature is particularly favorable if there is only one shaft entrance to the mine. Multiple Drum Hoist: The multiple drum hoist, a South African innovation, is a type of drum hoist about which everyone should be aware. Basically, it uses two hoist ropes per conveyance which at great depths per¬mits use of smaller ropes and smaller drums. There are none in use in the United States today. However, they should be considered in very deep mines. Friction (Koepe) Hoists This hoist (Fig. 8) was introduced to the mining world by Frederick Koepe in 1877. The basic prin¬ciple of the friction hoist is that the hoist rope passing

Jan 1, 1982

By G. A. Kordosky

Solution mining followed by solvent extraction-electrowinning (SX-EW) is one possible way to economically extract copper from ore bodies which cannot otherwise be profitably exploited. Published costs for the unit processes of SX and EW are out of date especially in view of the newer reagents now available and the newer circuit configurations, This paper updates the costs for SX-EW in 1985 dollars and also discusses some of the trade-offs which must be made when designing an SX-W plant.

Jan 1, 1986

By K. N. Han

Coal is becoming increasingly important as a major energy source in the face of the world's depleting energy mainly based on oil reserves. Coal is by far the most abundant fossil fuel both in the United States and abroad. Currently, because of increased mine mechanization, the fineness of preparation plant feed is increasing. Further, in the future as the grade of coal diminishes and the sulfur content increases, upgrading preparation of coal is very important. Because the density of coal is less than that of rock materials that occur as impurities, coal is separated from such waste largely by gravity-controlled processes for particle size between 5 inches and 28 mesh. If the size of coal particles is below 28 mesh, froth flotation is a good method for upgrading fine coal. Previously, numerous investigators have tried to upgrade coal values by froth flotation(1-16) and have achieved moderate success. However, the recovery and grade of coals in the concentrates are not always satisfactory, especially when the particle size is small. In general, when the size of coal is below 100 mesh, the above methods suffer from poor grade and low recovery. The reason for this is that as size decreases, the effects of gravity diminish, and other forces take effect.

Jan 1, 1985

By Joseph W. Murray

Prior to 1950 Magma's ore production came from two parallel, steeply dipping, east-west striking mineralized faults, one called the Main or Magma vein, and the other the Koerner vein, which lay about 1100 feet to the south, This vein system has been explored and mined over 9000 feet horizontally and 4800 vertically. In 1950 continued exploration led to the discovery and subsequent development of replacement ore bodies in the Devonian limestone zones adjacent to the veins. These replacement deposits occur in the eastern part of the Magma Mine, and follow the strike and the 30" east dip of the host limestone. Strike length of the ore bodies varies from 250 to 500 ft., and thickness from 15 to 125 ft. The ore bodies are large tabular masses with chalcopyrite and bornite being the dominant ore minerals. Hematite and pyrite are the most abundant gangue minerals. Incompetent limestone, shale, or a porphyry sill hanging wall is charactertistic of substantial portions of the replacement beds. In many instances the ore itself is blocky, badly fractured, and intermixed with layers of limestone gouge, pyrite and hematite.

Jan 1, 1973

By C. O. Lee

The Grand Isle Sulphur Mine is located in the Gulf of Mexico, approximately seven miles off the coast of Grand Isle, Jefferson Parish, Louisiana. The depth of water at this location is about 50 feet. The deposit is on acreage covered by oil, gas, and mineral leases which were originally issued in favor of Humble Oil & Refining Company by the State of Louisiana, and which were continued, maintained, and redesignated by the Department of the Interior of the United States, pursuant to Section 6(b) of the Outer Continental Shelf Lands Act. On September 19, 1956, Freeport Sulphur Company acquired from Humble Oil & Refining Company the sulphur rights underlying the tracts. This assignment was approved by the Secretary of the Interior on July 12, 1957. The Director, United States Geological Survey, approved Freeport Sulphur Company as Operator on July 31, 1957. Actual design began in September 1956; the first structural contract was let December 15, 1957, and offshore erection began in June 1958. The initial phase of construction will be completed and production started in early 1960. The estimated total cost of the project is $30,- 000,000, of which $8,000,000 is the extra cost for being in the Gulf of Mexico.

Jan 1, 1959

The viability of physico-chemical purification methods such as selective flocculation for separation of two components having similar chemical composition and same crystal structure but different surface properties is demonstrated. Loss of selectivity was observed in a dolomite-dolomite mixture with Polyethylene Oxide (5 million molecular weight) as the flocculant. Hetero-flocculation was minimized using a low molecular weight PEO (MW -105) as the site blocking agent (SBA). Near complete separation was achieved at pH 10.5 at 100% recovery level.

Jan 1, 1993

By R. L. Clayton

The Bagdad district is 67 kilometers west of Prescott, Arizona, (Figure 1). The area north of the Old Dick and Bruce Mines was originally mapped by Anderson, Scholz and Strobell between 1943 and 1945, (1). The region is perhaps better known for the Bagdad porphyry copper deposit of tertiary age. However, 2 to 5 kilometers south of this deposit are several small massive sulfide occurrences in a eugeosynclinal Precambrian greenschist environment. More specifically, in. the Bridle formation of the Yavapai schist series. Three of these mines - Old Dick, Bruce and Copper Queen - were mined by Cyprus Mines Corporation between 1957 and 1977, and produced nearly 2mm tons of 3.6% copper and 12% zinc. These deposits occur at the interface between andesite and rhyolite and are stratiform in character. Certain structural and textural properties of the Bruce orebody suggest that remobilization of the massive sulfides occurred at some period during the metamorphic history of the area.

Jan 1, 1978

By W. Porter Place

The Trolleyphone was the first successful application of carrier current techniques to a DC power distribution system to provide voice communication between fixed points and moving locomotives and traveling cranes, This was a significant breakthrough because this not only in itself provided a useful new tool for industry, but the knowledge gained in the transmission of voice communication is paving the way for many other things, chiefly, remote control and indication systems which promise to have a far reaching effect during the upcoming age of automation. Once it has been established that we can communicate between men who operate machines, the next step will be to operate the machines themselves.

Jan 1, 1958

By David N. Hedges

This paper discusses the actual recovery and installation of a longwall in a bituminous coal mine in Western Pennsylvania. The coal bed mined is in the Lower Freeport seam which averages 42 inches (1.07m) in height locally. Drainage from the mine is approximately 3.5 million gallons of water per day (13.25 million liters per day). This water deteriorates the mines predominately fire clay bottom making it extremely difficult to move equipment. Support removal is accomplished by pulling the 6 ton (5443 kg) shields out under their own hydraulic power and transporting them by track over four miles (6437m) co the next longwall panel. This paper also discusses the changes that will be made to aid in the succeeding longwall recoveries and installations.

Jan 1, 1984

By Alex Lowson, Dan Tempelis

The Riverside Badlands Tunnel segment of the Metropolitan Water District of Southern California’s Inland Feeder Project, was lined with a segmented concrete primary lining and a welded steel final lining with the annulus filled with Low-Density Cellular Concrete (really a grout). The paper describes a numerical modeling technique that was developed to determine safe grout placement procedures to avoid pipe flotation, and shows the relationship between flotation and the rheology of the liquid grout. Design details of the steel liners are often not well suited to grout placement, and recommendations are given on how to improve this.

Jan 1, 2003

By James B. Fletcher

The Miami mine is located near the town of Miami, Gila County, Arizona. The Miami mine started mining in 1910 and finished in July, 1959. The orebody was divided and mined as follows: Tons High Grade 24,400,000 - Top slicing, sub-level caving, etc. Low Grade 105,100,000 - Block caving Mixed ore 9,800,000 - " Low Grade #2 13,100,000 - " Total Mining 152,400,000 GEOLOGY Ore minerals are largely in pre-Cambrian Pinal schist intruded by tertiary Schultz granite porphyry and covered to some extent by Quarternary Gila conglomerate. The structures are highly faulted and shattered. The Miami fault on the east cuts off the ore and the Pinto fault on the southwest caused re-oxidation of enriched sulphides producing mixed ore. MINERALOGY The chief mineral is chalcocite, with chalcopyrite, bornite, covellite, malachite, azurite, chrysocola, cuprite, native copper, and molybdenite as minor minerals. The ore minerals occur in seams, veinlets and disseminated particles. In block caving there is always some dilution, and drawing of ore stops when the grade drops past an economical point. This results in a small amount of copper left in the stopes below the capping. There is some copper in the capping, probably below 0.03% or less than 0.6 lbs. per ton. Over the low grade #2 orebody and portions of the high grade there was an oxide capping which was not mined. The crushed pilars are another source of copper. The leaching at Miami is an attempt to recover this last remaining copper of a worked-out mine. The enrichment at the Miami mine had gone more nearly to completion than most ore bodies in the southwest. There is practically no pyrite in the capping and very little in the ore.

Jan 1, 1971

By Lawrence K. Nordell

The selection of belt conveyor drive systems (*) is the subject of ongoing investigation. Frequently this choice has been governed by an incomplete perspective on the major considerations. A more comprehensive and objective approach is desirable. This paper presents additional factors which hopefully will broaden this perspective. BACKGROUND Conventional belt conveyors are powered by electric or electro-mechanical drives(*) mounted at the conveyor's head, tail, intermediate return span, or a combination of these (Fig. 1). A list of the drives reviewed is given in Table I. The following are main elements influencing the selection of the drive system: 1) dynamic characteristics, 2) economic factors such as capital cost, plant spares compatibility, reliability, availability, maintainability, and 3) environmental constraints. The principal dynamic characteristics of concern are the reactions of belt forces generated by the drive system during starting of the conveyor. Another attribute for consideration is the application of multiple driven pulleys used to 1) lower the conveyor's belt tension requirements, 2) increase the expected tonnage throughput, allowing for possible drive component failures, and 3) increase the plant spares flexibility related to the drive assembly.

Jan 1, 1977

By Adrian Molinari

A radioisotope probe (Minexan 202) capable of simultaneously analyzing a mineral slurry for five elements and pulp density has been developed by Outokumpu Oy, Finland. The probe is designed to operate immersed directly in a process stream, or it can be equipped with a flow cell through which passes a continuous sample of the main stream. A minicomputer (PDPII) is used to control the probes and calculate the assay data. This paper describes the probe as applied to slurry analysis and compares it to the conventional x-ray on-stream analyzer (Courier 300).

Jan 1, 1977

By Keith K. Griffiths

Computers are a valuable tool to the aggregate industry and should not be overlooked. The selection of proper mechanical components is necessary. Merely the addition of a computer to operate a mechanical system will not guarantee that the system will work. Material delivery by rail or truck for stock-piling and intra-plant material transfer can be accurately supervised by automation with simplified controls for the layman to use. There are mechanical problems that occur in material blending and load-out systems when such a system is automated. Such things as material flow, bridging, stockpiling methods, overloading of equipment and safety must be considered. How these problems can be overcome by proper selection of compatible mechanical and computer equipment will be discussed. Also, there are many individual material circuits in a plant that can be computerized at a nominal cost. This type of computer installation will not necessarily result in increased production, but it will produce greater efficiency in manpower. These small computers, binary counters, memory circuits and other devices and their application to the aggregate industry will also be presented. A careful evaluation of the mechanical and computer inter-relationship by someone understanding both "Rocks and Electronics" is essential to proper handling of material by computers. Computers for the mining industry may be either digital or analog computers. Unless the computer is to control some type of chemical process, such as a cement plant, the, analog computer is not required and the digital computer' will be quite adequate and less expensive.

Jan 1, 1967

By Milan Yekich, Emanuele Cauda, Justin Patts, Cody Wolfe

A worker’s personal exposure to respirable dust in occupational environments has traditionally been monitored using established methodologies which entail the collection of an 8-hour representative sample that is sent away for laboratory analysis. While these methods are very accurate, they only provide information on the average exposure during a specific time period, generally a worker’s shift. The availability of relatively inexpensive aerosol sensors can allow researchers and practitioners to generate real-time data with unprecedented spatial and temporal granularity. Low-cost dust monitors (LCDM) were developed and marketed for air pollution monitoring and are mostly being used to help communities understand their local and even hyper-local air quality. Most of these integrated sensing packages cost less than $300 per unit, in contrast to wearable or area dust monitors specifically built for mining applications which have been around for decades but still average around $5,000 each. At the National Institute for Occupational Safety and Health (NIOSH), we are leveraging the power of high-volume data collection from networks of LCDM to establish baseline respirable hazard levels and to monitor for changes on a seasonal basis as well as following any application of control technologies. We have seen the effective use and advantages of monitoring live data before, during, and after events like shift changes, operational changes, ventilation upgrades, adverse weather events, and machine maintenance. However, many factors have prevented a systematic adoption of LCDMs for exposure monitoring: concern for their analytical performance, the complexity of use, and lack of understanding of their value are some factors. This contribution outlines a one-year case study at a mine in Wisconsin USA, covering the installation, maintenance, data visualizations, and collaboration between NIOSH researchers and the industrial hygiene professionals at the mine.

Feb 1, 2024

By T. G. Melkus

A Setaram C-80 heat flux micro- calorimeter was used to study the surface and interfacial properties of fine coal particles in water containing flotation agents via heat of immersion measurements. Heat of immersion (?Himm) is usually a small exothermic quantity and can be used' to characterize a solid in terms of its relative hydrophobicity or hydrophilicity. The effects of coal type, surface oxidation, mineral matter content, kerosene concentration, and pH on the wetting characteristics were investigated. Results obtained from the calorimetry experiments correlated well with results from independent flotation experiments.

Jan 1, 1987

By M. Westerstrand

It is known that the water chemistry of the process water during ore refinement can affect product quality, such as iron pellet strength. The main objective of this study was to quantify the amounts of major elements, such as Ca, Mg, Na, S and Cl carried by process water and by magnetite grain surfaces to the end product, iron ore pellets made from magnetite ore from the Kiirunavaara Mine in northern Sweden. In addition, the amount of colloids (0.22µm ? 1kD) in the process water was examined by ultrafiltration. The amounts of various elements sorbed to the magnetite surfaces were estimated by leaching with Milli-Q water, MgCl2, NH4-acetate and Na-acetate. Total dissolved solids were between 1,446 and 1,775 mg/l, dominated by Ca, S, Na and Cl (89%). The colloidal fraction was less than 3% for major ions. For Ca and Mg, sorption to magnetite surfaces was a much more important transport mechanism for the pelletizing process than evaporated process water, but for Na, Cl and S process water was an important carrier.

Jan 1, 2010

By George L. Atwood

The Monsanto Company's Henry Mine is located 17 miles northeast of Soda Springs, in the southeast corner of Idaho. Ore being mined is phosphate rock which lies in the Permian Phosphoria formation. The ore is the raw material for Monsanto's three furnace elemental "P" plant near Soda Springs. The finished product from the furnaces is elemental phosphorus which is subsequently used in the manufacture of detergents, food preservatives, fire retardants and other consumer items. Mining is by open pit methods using 0-9 crawler tractors to rip and push-load rubber tired scrapers in stripping and mining operations. The equipment spread consists of six D-9G crawler tractors, four Caterpillar 6578 scrapers, eight Euclid S-24 scrapers, one Reich T750 drill and one Caterpillar No. 16 patrol plus various support equipment. Stripping is performed on a 12-month basis, two shifts per day. Mining is performed mainly in the summer months on a one shift basis. The hauling season begins May 15 and ends November 1 due to freezing weather and snow conditions. Annual production is 1,000,000 tons of phosphate rock and 2,500,000 to 3,000,000 yards of stripping. Stripping, mining and hauling is performed for Monsanto by Dravo-Soda Springs, a mining contractor. Dravo-Soda Springs owns, operates and maintains all equipment used in stripping, mining and hauling. The contractor is paid for stripping by the bank yard and for ore mined and hauled on a tonnage basis. The Monsanto elemental phosphorus plant began production in 1952 with ore being trucked to the plant from the Ballard Mine. Haulage was over public roads in 15, 24-ton semitrucks. A private haul road was constructed from the Ballard Mine to the Monsanto Plant in 1958 and 1959 to accommodate trucks with two twenty-yard trailers. This 11/ mile road was first used in the 1959 hauling season. In 1965, five new Kenworth tractors with two, 'forty yard trailers were introduced into the haulage system. These units carried 120 ton payloads and were used until

Jan 1, 1972

By R. Heiser, J. Vendetti, B. P. Connor, E. J. Haas

"DISCLAIMER The findings and conclusions in this paper are those of the authors and do not necessarily represent the views of the National Institute for Occupational Safety and Health. Reference to specific brand names does not imply endorsement by the National Institute for Occupational Safety and Health. ABSTRACT Health and safety indicators help mine sites predict the likelihood of an event, advance initiatives to control risks, and track progress. Although useful to encourage organizations to work together, executing such risk assessments comes with challenges. This paper focuses on one trona mine’s experience in the development and implementation of a field level risk assessment program to help its entire organization understand and manage risk to an acceptable level. Through a transformational process of ongoing support and communication, Solvay Green River fostered a culture of trust and safety grounded in risk assessment, safety interactions, and hazard correction. The application of consistent risk assessment (RA) tools was critical to create a participatory workforce that not only talks about safety, but actively identifies energies that contribute to hazards and potential incidents. In this paper, reflecting on the mine’s process of RA implementation provides examples of likely barriers that sites may encounter when trying to document and manage risks. As discussed, consistent efforts to establish a participatory risk management program are worth the initial struggle to ultimately reduce incidents. INTRODUCTION Work-related health and safety (H&S) incidents often account for lost days on the job, contributing to organizational/financial and personal/social burdens [1-2]. Accompanying research demonstrates that risk and ambiguity around risk contribute to almost every decision that individuals make throughout the day [3-4]. In response, understanding individual attitudes toward risk has been unquestionably linked to predicting H&S behavior [5]. Although an obvious need exists to identify more comprehensive methods to assess and mitigate potential hazards, some argue that risk management is not given adequate attention in occupational H&S [6]. Additionally, research suggests that a current lack of knowledge, skills, and motivation are primary barriers to mitigating workplace risks [3-6]. Therefore, enhancing knowledge and awareness around risk-based decisions, including individuals’ abilities to understand, measure, and assign levels of risk to determine an appropriate response, is increasingly important in hazardous environments to predict and prevent incidents. This paper focuses on tailored approaches to field level risk assessment (FLRA), measurement, and common barriers to participating in such activities. The authors use a trona mine in Green River, Wyoming, as a case study to illustrate how the organization overcame widespread and site-specific challenges to implement a proactive risk management program. By discussing the mine’s tailored FLRA program, this case study contributes to the literature by first, providing examples of critical components that need to be in place to ensure successful risk management and second, context for continuous quality improvement that can foster a higher level of trust and empowerment on site."

Jan 1, 2017