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The process design of a metallurgical plant follows logical steps, one built on another, to define the circuit requirements. The methodology used and documentation produced is the same for a pre-feasibility study, feasibility study or a complete design, regardless of the process complexity or the commodity. The only difference is the amount of detail developed at each stage. SRK Consulting, an independent, international consulting practice that provides focused advice and solutions to clients, mainly from earth and water resource industries, has consulted on many mining projects around the world. The company was formed in 1974 and now employs more than 1,600 professionals in more than 50 offices on six continents. According to SRK experts, the first element in plant design is collecting metallurgical testwork or operating data from an existing plant. The testwork identifies the process, the metallurgical recoveries and product qualities and establishes the process parameters for economic recovery of the commodity. Test samples must represent both the whole orebody and the feed over the life of the mine, showing the mineral?s variability. With this data available, the process design can be developed.

May 1, 2013

By A. Dell’Era, E. Ciro, C. Lupi

The paper explores the recovery of indium via electrowinning from sulfate baths, focusing on the impact of different cathodic supports (AISI 316L and nickel) on process parameters such as electrolyte composition, current density, and temperature. The study compares productivity, morphology, and structure of indium deposits on both cathodes, finding that nickel cathodes generally yield better results.

Nov 1, 2023

By Michael M. Carroll, Zhu-ping Duan, Han-ping Chin

INTRODUCTION The inelastic stress-strain behavior of rocks has urged engineers to seek for the possible application of plasticity to engineering pro¬jects such as tunnels, oil wells, dams, etc. for a long time. Early efforts in this direction have tentatively used the classical theories to solve some axisymmetric problems, in which the rocks were treated as perfectly plastic and nonfrictional materials (Talobre, J. A., 1957). Meanwhile, one of the fundamental assumptions is that the volume strain of elastoplastic material is purely elastic. Drucker and Prager (1952) developed a perfectly plastic and frictional model with a generalized form of Mohr-Coulomb law, which serves as both failure criterion and yield criterion. Although the associated flow rule gives unacceptably large dilatancy, this model is a very important step to deal with the frictional behavior of geological materials. As a further step, Roscoe et al (1963) and Schofield and Wroth (1968) proposed a Cam-clay model, which accounts for the yielding before the material reaches a failure envelope and reflects the plastic volume strain as a strain hardening factor, and the open end of the Drucker-Prager envelope is capped by a family of yield surfaces, the envelope is made conforming with crit¬ical void ratio line. The proposed shapes of the cap have been based on experimental data and on convenience of mathematical descrip¬tions. Drucker, Gibson and Henkel (1957) introduced a spherical cap for soils, while in Cam-clay model the cap is semi-logarithmic yield function derived from the result of triaxial tests. DiMaggio and Sandler (1971) proposed an elliptical model for sand, in which the hardening function depends exponentially on plastic strain. Sandler et al (1976) used a plane cap model to express the behavior of a wide range of geological materials of which the nonlinear hysteretic nature is significant. Mizuno and Chen (1982) illustrated the physical mean¬ing of cap models and their adaption to finite element calculation. In recent years, Carroll et al (1972, 1980) have studied the com¬paction of porous materials under hydrostatic pressure and discussed the mechanism of the nonlinear response thoroughly. Analytical and numerical analysis of the hollow sphere model by Curran and Carroll (1979) predicted an initial yielding surface, dependent on the initial porosity, and showed a strong coupling between hydrostatic and deviatoric effects. All these main features from the abovementioned theoretical research are visualized by the experimental data on Boise sandstone (1984). The combination of such previous work would be logically the construction of a plasticity model for porous rocks which, following the tradition of assigning the name of birthplace to a special model, is called Cal-Rock model (Carrol, M. M., 1984). The results of triaxial tests along different loading paths reveal the compaction characteristics for deviatoric and hydrostatic stress separately. the fitting of the nonlinear stress-strain curves leads to a construction of yield surfaces. Moreover, an uniaxial strain test gives the strength envelope which is the critical state line. The whole model is composed in the frame of elasticity theory. The concept and representation of plasticity used here are in the spirit of Naghdi¬Casey theory (Casey and Naghdi, 1984 and 1984, Naghdi and Trapp, 1975). In order to find the way of using such a plasticity model in engineering problems, the stress field in a thick-walled cylinder of porous material is calculated. This is an axisymmetrical problem with plane strain, which is an idealization of oil well in an infinite medium. Because the constitutive relation is highly nonlinear, a numerical method has been utilized to obtain the solution. CONSTRUCTION OF CAL-ROCK MODEL (1). Elastic-plastic constitutive equations The basic assumption is that the yield surface in stress space depends on one parameter, namely the plastic volume strain, as the data on Boise sandstone suggested. Starting from this point, the theory formulated in stress space and in strain space by Naghdi and his co-workers (1975, 1981) can be simplified. The simplified yield function is

Jan 1, 1986

By John Relser

The production processes that are developed in the mining and minerals industry are manufactured to be exposed to very aggressive environments. Chemical, abrasion, and impact expose structures and equipment, steel or concrete, to a significant deterioration. This causes damage and adds high costs to operations that can be reflected in the destruction of equipment and structures in the arrest of the production process, which becomes very costly. Also, there is the potential for personnel accidents, which would require large sums of compensation for an employee, thus directly harming the image of the mining operation and company. Manufacturers of paints and coatings that have major centers for research and development (R&D Labs) distributed globally have developed high-tech products for durable protection from the elements for structures and equipment used in the mining industry. The difference between these paintings and coatings and what is normally known as conventional paints (e.g., those called domestic or decorative), is its chemical composition, structured around polymeric components that have highly resistant, chemical and physical properties to cope with extreme conditions to which they are exposed. With this, and only this, longer life of components can be achieved for equipment and structures used in the production processes of the mining industry. Today, in addition to the important features mentioned, some manufacturers of the paints and coatings dedicated to this highly modernized process have invested large sums of money in developing new products that add operational elements to the painting process. These coatings provide added value and significant performance to companies mining operations and that we can describe in three fundamental concepts:

Feb 1, 2014

By Bruce Kennedy, Charles Bruce

MINERAL EXPLORATION 'The Function of Exploration Mineral exploration aims at locating the presence of economic deposits and establishing their nature, shape, and grade. As all ore bodies are finite, exploration is essentially the lifeblood of the mining industry. It is divided into two phases, reconnaissance and target investigation. It involves geological mapping, geophysical prospecting (aerial and ground or both), geochemical surveys, prospect drilling, and/or exploratory under-ground workings. Successful exploration is followed by development drilling, mine development, and eventually operation. In underground mining, the term "ore" is applied rather loosely to metalliferous rock that can be profit- ably mined, but nonmetallic industrial minerals and energy related materials constitute a large and growing portion of the tonnage extracted by underground methods each year. It is appropriate, therefore, to consider exploration as the search for any useful substance occurring in the earth or in the oceans that is of sufficient value as to volume, grade, chemical and physical com- position, and location as to make extraction by mining commercially profitable for the investment required. The Selection Process The search for ore includes hundreds of mineral commodities. The more successful exploration organizations tend to restrict the search to the mineral commodities for which they have strong exploration expertise and which have a high probability of being concentrated in areas open to exploration and development in sufficient volume, grade, and proximity to the surface to warrant the large expenditures of risk capital in finding an ore body. Special expertise is needed to engage in mineral exploration and development for the extended periods required for success. Individual prospectors continue to discover mineral occurrences, but it generally takes an organization with strong financial resources to carry the exploration process forward to the point of developing "ore." Still greater corporate resources in the form of management, engineering, and sales capability are needed to develop an ore body into an operating mine. In the past, companies other than those engaged in mining rarely conducted exploration, since they lacked the technical skills and know-how to bring a mine to fruition. A notable trend in recent years has been the success of other resource-oriented firms, such as petroleum companies, that have not only acquired the necessary skills to engage in exploration for hard minerals, but are doing so on a far more intensive scale than known in the industry heretofore. The desire to diversify from increasingly regulated oil and gas, the potential for the discovery of a bonanza, and the large scale of mining projects for these capital-intensive firms are the attractions. US government and certain international organizations, such as the United Nations, have fielded sizable exploration programs in the past decade on behalf of Third World countries wherein many of the world's higher grade deposits and scarce mineral resources are located. The level of overall mineral exploration in the industry is, regrettably, closely geared to the business cycle. Accelerated search during the periods of strong demand, shortages, and high prices, together with the long lead times necessary to develop mineral finds, often creates surges in supply which invariably are followed by a collapse in prices. The trend is, therefore, to exploration funding by larger better-endowed firms having the staying power to weather the cyclical nature of mining. Tax incentives, tariff policies, and other incentives have a decided impact on the level and nature of exploration. Surface mining regulations and environmental forces have fostered a renewed interest in under- ground development despite the lower average costs of surface mining. Spiraling inflation has caused mining costs to outpace prices for many mineral substances. Organizations increasingly are directing their search away from high- grade but limited tonnage occurrences toward low-grade disseminated bulk tonnages amenable to mining on a vast scale. Mining continues, therefore, to grow even more capital-intensive with half-billion-dollar mine-mill- smelter complexes now commonplace, compared with the hundred-million-dollar projects of a decade ago. Reconnaissance Exploration Having elected to search for specific mineral commodities, the exploration company narrows its focus to a reconnaissance of those regions offering the best potential. A working hypothesis which is constantly up- dated concerning the geologic controls for ore occurrence guides the search. The possibilities for discovery are best in areas of existing mines and known ore bodies, where the probabilities are high for additional ore occurrences. In such areas, published data on the trends and geologic controls of known mineral occurrences aid the search. Even in some remote territories, a variety of geologic data is available to the explorationist. The major sources of basic geologic data are the libraries of the US Geological Survey (USGS), the state geological surveys, the American Institute of Mining, Metallurgical, and Petroleum Engineers (AIME), the US Bureau of Mines, and various institutions such as Colorado School of Mines. Overseas, virtually all of the countries have their own geologic survey groups which are associated directly, or indirectly, with their respective ministries of mines. The objective of reconnaissance exploration is to narrow the search by pinpointing target areas having interesting mineralization. These favorable areas are then investigated in detail to delineate potential ore bodies.

Jan 1, 1982

By Dale R. Ralston, Roy E. Williams, Gerry V. Winter, George L. Bloomsburg

The literature on four different topics is re¬viewed herein for purposes of mathematical mod¬eling of mine water inflow. The first of the topics reviewed is modeling of fissured or fractured ma¬terials; the second is general Darcy based flow models; the third is field methods for determining fracture flow properties; and the fourth is methods used presently for determining mine water inflows. The four topics are considered in the foregoing order. FRACTURE FLOW MODEL Two basic types of fracture flow models have been developed. The first type uses various tech¬niques for space averaging to obtain the equations. Systems are considered in which the porous media properties vary smoothly enough and the fracturing is sufficiently profuse and well distributed that the locally averaged properties are meaningful when viewed on the macroscopic scale. The final result is that a coefficient is used which is similar to saturated hydraulic conductivity and in many cases, simply is hydraulic conductivity. In other cases, the coefficient is apparent hydraulic conductivity be¬cause the response from flow in the fractures is more rapid than flow in the pore spaces. Faust and Mercer (1980) refers to this method as the contin¬uum approach. Some of the papers on this type of problem are by Duguid (1973), Verner et al. (1974), Owili-Eger (1975), Duguid and Abel (1974), duPrey and Weill (1974), and O'Neill (1978). Duguid and Lee (1977) also considered heat flow in the fluid and the porous medium. These papers all result in various types of computer programs. Some papers on this topic that do not result in computer programs are by Snow (1968, 1969) and Streltsova (1976). Some of the foregoing articles consider con¬solidation of the porous media and the resulting effect on hydraulic conductivity. Barenblatt et al. (1960) developed an analytical solution for fracture flow and discussed the time that is involved in the drainage process and the effect that fracture flow has on the drainage time. The second type of fracture flow model con¬siders the width of the fractures as a function of the pressure in the field. Faust and Mercer (1980) refers to this method as the discontinuum approach. This approach often requires two finite element programs that consider the stress in the material and the flow in the fractures separately. The pro¬grams are then linked to arrive at the final solution. Some of the articles that consider the interrela¬tionship between pressure and the size of the frac¬ture but do not use computer solutions are Gringarten et al. (1975), Narasimhan and Palen (1979), and Witherspoon et al. (1979). Papers that use a linked computer program between stress and flow are by Ayatollahi (1978), Gale et al. (1974), and Noorishad et al. (1971). Ayatollahi's program is primarily for the petroleum industry because it does not consider the effect of gravity. Ayatollahi assumes that pressure effects are very large in com¬parison to gravity effects. This assumption would apply only to very deep aquifers. Articles that consider fracture flow on a more applied basis are by Wittke et al. (1972), who con¬siders that the flow is entirely through fissures and negligible through the pores of the rock. Gringarten and Witherspoon (1972) developed type curves that may be used for analysis of fracture flow systems; the curves are based on the assumption that it is possible to distinguish between aquifers with hor¬izontal and vertical fractures and that it is possible to analyze the system as an equivalent anisotropic homogeneous porous medium with a single fracture with much higher permeability. DARCY FLOW MODELS The Darcy flow models of greatest interest to mine water inflow prediction are those which allow

Jan 1, 1986

By C. E. Jordan

The U.S. Bureau of Mines investigated flotation hydrodynamics to improve the recovery of coarse phosphate. Fluid velocity profile measurements were used to characterize the hydrodynamics within commercial phosphate flotation cells and laboratory flotation cells. The effects of agitation, aeration, and pH on coarse phosphate recovery were measured in the laboratory flotation cells and correlated with the hydrodynamics measurements. Test results revealed that the agitation energy and aeration level had a significant effect upon flotation response. By optimizing these two parameters, 92 pct of the phosphate was recovered in a rougher flotation concentrate grading 28 pct P2O5?

Jan 1, 1994

By G. W. R. Kuzyk

The Underground Research Laboratory (URL) , a major geotechnical research facility, is currently being developed by Atomic Energy of Canada Limited (AECL) , 120 km northeast of Winnipeg, Manitoba. The URL is part of the Canadian Nuclear Fuel Waste Management Program, which is assessing the concept of nuclear fuel waste disposal in a vault deep in stable plutonic rock of the Canadian Shield (Simmons, 1986). Comprehensive geotechnical research and development activities are being carried out in conjunction with excavation? and construction of the underground facilities.

Jan 1, 1989

By Y. FUJII, E. CHANDA, J. KODAMA, D. FUKUDA, M. NISHIHARA, Y. NAKAYAMA, P. SINKALA

This paper describes a creep damage model that was proposed to clarify the rockburst mechanism for the Mufulira underground copper mine in Zambia. Cumulative rock damage was evaluated for the edge elements of each sidewall of the mining drives based on normal stresses by the 3-D displacement discontinuity method (DDM) (Crouch and Fairhurst, 1973). The rockburst occurrences were well hindcasted.

Jan 1, 2023

By Lewis L. Oriard

The authors outline the development and application of blasting methods put into use 11 years ago at the Berkeley Open-Pit Mine, Butte, Montana. The blast design uses a very short delay (5 milliseconds) between detonation of explosives charges, a feature challenged several times in principle despite its success for Anaconda. Concern is expressed over the categorical rejection of very short delay blasting which can make the difference between success and failure of major mining operations. There is ample evidence to show that the method can be used successfully and not violate the concerns of the public.

Jan 1, 1980

By C. E. Jordan

The fundamental characteristics of ultrafine chalcopyrite flotation were investigated by the Bureau of Mines to establish techniques to improve recovery of ultrafine chalcopyrite. Intense agitation during conditioning was found to improve flotation recovery of the ultrafine chalcopyrite. A split-circuit flotation design, treating the plus 38-µm-size ore by the conventional method and treating the minus 38-µm-size ore with intense agitation conditioning followed by flotation, recovered 95.6 pct of the copper in a 28.3-pct-copper concentrate, This was a 5-pct increase in copper recovery over the conventional chalcopyrite flotation method.

Jan 1, 1986

By H. Cetin

The availability of coal resources of selected 7.5-minute quadrangles of southwest Indiana was examined in this study. Resources were defined as original coal in place, remaining after mining, and currently available considering land-use and technological restrictions. The amount of coal mined from each study area varies depending on the mining practices of the companies operating within the area. Of the three quadrangle investigations, the available resources range from 50 percent to 79 percent of the original resources. Most of the coal resources under deep-minable category were not available because of technologic restrictions, such as insufficient coal thickness.

Jan 1, 1996

By Francesco Chiappalone, Marco Invernizzi, Franco Gasperin, Fabrizio Fara

As part of the Ship Canal Water Quality Project, 2.7-mile Combined Sewer Overflow tunnel is excavated with a 21.5-foot diameter EPB Tunnel Boring Machine. Due to the difficult geological and hydrogeological conditions, the tunnel is excavated maintaining a ground support pressure between 1 and 3 bar imposing significant challenges to the projects. The first part of the paper describes the general characteristics of the project while the second part focuses on the challenges and technical details of the pressurized breakthrough that took place in a deep shaft excavated in urban environment as part of the project.

Jun 23, 2024

By Ron Drake

The Anderson Dam Tunnel Project is a high-priority, urgent project under construction by the Santa Clara Valley Water District in California. The project will provide a new low-level outlet for the Anderson Reservoir enabling the seismic retrofit of the Anderson Dam as mandated by the Federal Energy Regulatory Commission. This paper describes planning for construction of the tunnel through the dam’s right abutment crossing several faults in challenging and variable soft and hard ground conditions. The construction methods include SEM, hard rock drill and blast techniques, and a mechanized 8-foot (2.5 m) diameter microtunneled lake tap.

Dec 1, 2022

By G. Brien, O&apos

Selective in-plant breakage was investigated at a Central Queensland, Australia mine. Component seams and size fractions from in-plant samples were characterized petrographically and probability analysis of vitrinite reflectance data used to track the distribution of seam proportions through the plant. Results show that the 2 seams reported differentially to coarse and fine circuits, mainly as a function of coal type rather than rank. Seams were also preferentially concentrated in different size fractions of the coarse circuit. Breakage in the coarse coal centrifuge generated approximately 4% of -0.5 mm fines, but was not seam specific.

Jan 1, 1996

By R. J. Piniazkiewicz

Talc orebodies are mined in Asia, Australia, Europe, North America, and South America. Operators in North America must be efficient quality suppliers to thrive in a talc market in which many overseas suppliers have advantages such as lower hourly wages, shorter distances to ports, and less government regulation and intervention. Continuous improvement through teamwork and innovation is needed in the following areas to thrive amidst worldwide competition: 1) Maximization of the in-place value of ore. 2) Research and development to yield new processes and products. 3) Safe productivity. 4) Involvement in legislative processes. 5) Wellness programs to lower health care costs.

Jan 1, 1993

By J. Kallioinen

The paper describes industrial size experiments with a 100 m3 flotation cell validating the Size Specific Flotation concept and the Tank Cell design. It discusses some variables affecting the flotation of coarse particles. The results were good. The flotation recovery of coarse particles increased up to 50%. In finer sizes the flotation improvement was 5-15% The enhanced flotation of especially the coarsest particles increased the total recovery close to 10%-units compared to conventional cells in a porphyry copper flotation. The related power draw was only 50-80% of the power of conventional cells.

Jan 1, 1995

By Andrew I. Hustrulid

The discrete element method has successfully been used to model the behavior of material flow in transfer stations. With position, velocity, and applied forces for every particle and boundary in the simulation available at increments of 10-5 seconds, the next critical step is the presentation of this data in a concise and beneficial form. This paper discusses several methods of presenting the data from discrete element simulations that are used to improve the performance of a transfer station. These measurements are also used as a learning tool to better understand and visualize how material transfers from one belt to the next.

Jan 1, 1998

By Richard M. Crowell, Laurie M. Tahija, Keith D. Dagel

Echo Bay Mines Ltd. operates a gold heap leach in Round Mountain, Nevada, U.S.A. In the past two years, the mine has expanded operations from 13.5 kt/d (15 kst/d) to 41.0 kt/d (45 kst/d), making it the world's largest gold heap leach operation. The expansion is a separate system from the previous 12 year old plant, yet very similar. The flowsheet contains open circuit primary, secondary, and tertiary crushing with interstage screening. A leach pad stacker loads reusable asphalt leach pads. The process plant features carbon adsorption, pressure strip, electrowinning, and electrorefining.

Jan 1, 1990

By Maxine Wiber, Ross D. Gallinger, Brain A. Lewis

Poirier was an underground copper and zinc mine located in Northern Quebec that operated between 1965 and 1975. There are 5 million tonnes of acid-generating tailings, which have contributed acidity and metals to the Kananewesig and Kistabiche Creeks. The final closure plan incorporates the placement of all reactive material into the tails basin, installation of a geomembrane liner over the tailings deposit and a one metre soil layer to protect the liner. The environmental effect of the residual seepage was assessed from an ecological risk perspective. The Reclamation Plan has been accepted, and work commenced in 1998 to restore the site.

Jan 1, 2000