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By John O. Marsden

"This article is an attempt to capture a presentation given at the 2016 SME Mineral & Metallurgical Processing Division (MPD) Luncheon held on Feb. 24, 2016, in Phoenix, AZ. It was presented as a tongue-in-cheek, lighthearted view of several of the issues facing our industry, while identifying some of the challenges and opportunities available to new engineers entering the industry today.Disclaimer• What you are about to read includes personal preferences, biases and occasionally arbitrary opinions.• Some readers may have dissimilar opinions on the contents and/or the rank order of the lists.There are eight top ten lists offered in this article: (1) Industry realities (2) Things a metallurgical or mineral process engineering graduate should do (3) Books every metallurgist should have on their shelf (4) Things I wish I had known (5) Legends of metallurgy (posthumous, with highlights) (6) Things we’ve forgotten (7) Mineral processing innovations of the past 20 years and, finally, (8) The future? For some items, additional context or clarification is provided after the item, while for other items no further explanation is warranted and none is offered. Top 10 industry realities1. Metal price cycles.2. Bigger is better (except when it isn’t).3. Ore grades declining across the board of metals/commodities.4. Ores becoming more complex.5. Three-fold increase in capital costs between 2004 and 2015.6. Three-fold increase in operating costs between 2004 and 2015.7. Less capital availability/challenging financial markets.8. Environmental constraints increasing.9. Socio-political constraints increasing.10. The mine manager is always impossible to work with.As Table 1 shows, there was more than a three-fold increase in gold operating costs between 2004 and 2014. The increases for copper, iron ore and other commodities were similar."

Aug 1, 2016

By Roger K. McLimans

Sphalerite in the ores is multi-banded. Based on color and textures, bands in samples separated by a few kilometers may be correlated. Darkness of color is directly related to iron content. Isotopic and fluid inclusion data indicate that temperatures of ore deposition were 225°C-50°C. The agreement between these two sets of data suggests that chemical and isotopic equilibrium were established. The salt content and hydrogen and oxygen isotopic compositions are similar to present-day values of oil field brines suggesting a similar mode of origin. Ore transport and deposition are not adequately explained by either chloride or bisulfide complexing. Necessarily, other mechanisms were involved.

Jan 1, 1979

By S. K. Kawatra

It has been observed in some mineral processing plants that grinding circuit efficiency varies seasonally, such as in some plants which are located in the northern U. S. and Canada and undergo large seasonal temperature changes, with the grinding circuit efficiency different between summer and winter. This indicates that the temperature of grinding circuit slurry has a noticeable effect on grinding performance. The effect has rarely been studied. To this end, an investigation to examine the effects of changing temperature on efficiency and determination of the mechanism responsible has been carried out. Plant investigations and laboratory experiments have been conducted in order to study hydrocyclones. It was demonstrated that under otherwise constant operating conditions, the d50(c), size decreased linearly with increasing temperature, while the shape of the reduced efficiency curve remained constant. This effect was determined to be due to changes in slurry viscosity with temperature.

Jan 1, 1988

By Robert E. Charles

Much has been said about digital computer control of metal and mineral ore dressing processes, but little has been done. This pa- per discusses what practical use can be made today of a digital computer in an ore concentrator and how such application can be made successfully. A hypothetical, but commercially common, grinding and flotation circuit is presented in terms of analog measurements which can and are being made in existing plants and a centralized computer control system which is reasonable in terms of today's technology. Dangers and possible disadvantages of such an approach are discussed as well as estimated benefits. Possible future benefits are presented in terms of improved control technology. Development of new measuring devices is not considered as a criterion for computer benefits. The control systems described have been utilized successfully in existing ore dressing operations. However, the degree of success or failure of analog systems is generally left to the interpretation of management rather than absolute analysis. Many factors affect the economic operation of a mineral recovery circuit such as size of facility, flow sheet design, number of operating personnel, percent of recoverable mineral in the ore body, loss to tails, and haulage rates. In existing mills where little or no instrumentation has been used, it is extremely difficult to prove or disprove the advantage of analog control systems on one mill line versus its sisters due to the lack of standards and the lack of ability to separate final products by ton.

Jan 1, 1969

By Steve Kral

In December 2013, the Colorado Department of Transportation (CDOT) completed the widening of the eastbound tunnel on Interstate 70 (I-70) from two lanes to three. Work on the westbound tunnel began earlier this year and is scheduled for completion in December. The Twin Tunnels project is located in the mountains about 55 km (35 miles) west of Denver. They were bored during the 1960s when I-70 was being built and became the main access to Colorado?s growing number of ski areas and the state?s Western Slope. Throughout the decades following their construction, traffic on I-70 continued to increase and now the tunnels have a major bottleneck. Com-mutes to and from the mountain resorts, particularly on weekends, have become long and slow. Adding a third lane through the tunnels will help alleviate the congestion. (A complete report on the project can be found in T&UC, December 2013, page 61.) Once the eastbound tunnel was completed late last year, CDOT authorized the funding to begin work on the westbound side. That made economic sense, as the equipment used on the eastbound tunnel needed to only be shifted across I-70 to begin work on the westbound side, rather than removing it in December and bringing it back in March when construction began on the westbound tunnel. Work on the westbound tunnel uses essentially the methods that were used on the eastbound tunnel ? removal of the existing concrete lining and using drill-and-blast methods for tunneling widening. The main difference between the two tunnels is that the westbound side requires more blasting on both ends to widen I-70 to three lanes.

By J. K. Whyatt

In situ stress on the scale of a tunnel or mine may be distorted by geologic structures. The resulting variations of in situ stress have a direct bearing on the potential for mining-induced seismicity. New evidence from the Lucky Friday Mine collected by U.S. Bureau of Mines researchers, as well as a review of case studies, demonstrates that in situ stress variations affect the spatial distribution of mining-induced seismicity. Although overcore stress measurements have been useful in these studies, they are too expensive and, depending on conditions, may be too difficult, to use routinely in mapping stress variations. However, information from borehole and raisebore breakouts; deformation of mine openings; and patterns of seismicity, ground control problems, and rock burst damage can be used to build a stress database. This database can then be used in con-junction with maps of mine structure and geology and models of rock mass behavior to build a map of in situ stress variations. Such a map provides a means to anticipate patterns of mining-induced seismicity that are likely to be encountered and, hence, provide a means for planning appropriate measures to ameliorate rock-burst hazards.

Jan 1, 1995

By Robert R. Dorfler

We ought not look back unless it is to de- rive from past errors, and for the purpose of profiting by dear bought experience. - George Washington During the mid 1960's, the application of automation was introduced to Climax by two process control companies. In 1969 Climax decided to seriously consider improved control of selected areas of their milling process after preliminary research had been completed on two rougher ball mill grinding circuits. In 1971 the Climax Mill Department developed a direct digital control scheme for rougher milling, designed a remote control center for handling process water, planned to automate the central steam heating facility for energy conservation, and convert other plant areas to automation. All twenty rougher grinding mills and the industrial water system were automated by 1977. The idea of automating central heating and other areas was abandoned although some fuel conservation items were installed at the heating plant. During this period from 1971 to 1978, the mill capacity was expanded from 39,000 metric tons per day to 43,000 metric tons per day and cyclone classification was introduced to rougher milling. Ore quality changes degraded the milling recovery from over 90% to less than 85%. This report describes the procedure the mill used in developing the automatic process and the occurances that affected the timing and fina1 control logic. The report deals primarily with the automation of the ball mill grinding, classification and flotation process as this was the bulk of the seven-year project.

Jan 1, 1979

By Robert J. Pruett

The Georgia kaolin District is the world's largest producer of kaolin. Georgia production tripled from 2,344 million metric tons in 1964 to 7,570 million metric tons in 1994. Development of the Georgia kaolin industry can be traced to the mineral resource, the adoption of innovative process technologies, and the market growth for kaolin. Georgia kaolin is an abundant and high-quality resource that shows a range of advantageous properties. Technical developments in wet processing, delamination, and calcination allowed production of high-value products. The application of kaolin pigments to the paper industry provided a market that could absorb rapid growth.

Jan 1, 1998

By Michel L. Van Sint Jan, Gabriel Fernandez-Delgado, Edward J. Cording, James W. Mahar

INTRODUCTION Shotcrete behavior observed in subway tunnel construction in the U. S. has been primarily in blocky or blocky and seamy rock in which rock loads develop from the self weight of individual rock blocks that tend to loosen from the wall and roof of the opening. Such conditions can be classed as loosening ground, in contrast to squeezing ground in which high pressures are generated on the tunnel lining with time as the ground creeps under the natural ground stresses. In the philosophy often associated with the New Austrian Tunneling method, emphasis is placed on the use of shotcrete and other support elements in squeezing, highly stressed ground, in which the support system is designed to allow controlled movements so that high lining stresses do not develop. In contrast to these conditions, the concern in loosening ground is to provide support soon enough to minimize loosen-

Jan 1, 1979

By G. V. Henderson

Limestone and Dolomite quarries located near Salto-De-Pirapora, Arroia Grande Gaucho, Conde Francisco and Candioita probably represent the closest, major sources of high quality lime and cement grade carbonate rocks to the major population center of Sao Paulo Brazil. The nearest major city to most of the limestone - dolomite sources is Sorocaba and Palma. All of the mining properties visited during this study are located in the state of Rio Grande Do Sul at approximately -32 degrees south latitude and -52 degrees west longitude, southwest of the major port city of Porto Alegre.

Jan 1, 1981

By H. Yoon

Several processes involving injection of sorbent and humidification water downstream of the air preheater in a coal-fired boiler unit, are being developed as low capital cost retrofit S02 control options. Extensive laboratory work, pilot plant programs and larger scale programs have developed performance data and design information. Many of these programs were supported by the U. S. Department of Energy (DOE) as "proofs-of-concept" of three different processes proposed by Dravo, Bechtel and General Electric. Based on these project results, DOE formulated a comprehensive in-duct sorbent injection development program to fully commercialize the technology by 1992. Also, EPRI will conduct a 4 MWe pilot program to develop its HYPAS process. The Consol Coolside process is scheduled for utility demonstration in 1989 on a 104 MWe unit at the Ohio Edison Edgewater Station under partial sponsorship of the DOE Clean Coal Technology Program.

Jan 1, 1989

By S. Slottee

The disposal of plant tailings in a safe and environmentally acceptable manner has taken on increased importance throughout the world, across all types of mineral beneficiation plants. In the U.S. plant life span, expansions and new plants in the current robust mineral markets are faced with environmental pressures to minimize the use of land for disposal by maximizing existing tailings pond capacity. The combination of many drivers from economic to environmental have brought paste thickeners into the coal industry (PasteThick 2007) Thickening tailings to a more concentrated slurry is a common step in the disposal flow sheet. Thickening to a non-settling ?paste?, also called ?thickened tails? or ?tailings stacking?, is a relatively recent development. This paper describes the paste thickener as an alternative for dewatering a fine coal refuse (tailings) stream for deposit as a paste. Initial operating results of the paste thickener are discussed.

Jan 1, 2008

By H. J. Handewith, W. D. Coski

This paper describes the development and testing of the RAMEX excavation system. Incorporating a synergy of low velocity, high energy impact and kerf cutting, this machine offers a competitive alternative to drilling and blasting in hard rock. It is a boom mining machine that incorporates the features of a lightweight roadheader and it can mine nearly any shape opening in hard rock. The RAMEX Tunneler has been developed to satisfy industry demands for a non-explosive, flexible, continuous and rapid underground rock excavation system. It will produce minimum ground vibration in the urban environment and allow the flexibility necessary for thin seam mining conditions. It will also reduce initial ground support costs and has a minimum impact on rock integrity. Developed by RAMEX Systems with cooperative research provided by the U.S. Bureau of Mines, this system, could produce the next step in the continuing evolution of mechanical mining systems.

Jan 1, 1989

By Robert Rautenberg, Ted Budd

The paper will discuss the successful construction of the largest dollar value ($194.5 million, U.S.) TARP (Tunnel and Reservoir Plan) project built to date for the Metropolitan Water Reclamation District of Greater Chicago. The mining and lining of the 18.5km (11.54 miles) tunnels will be emphasized. The tunnels were driven utilizing three TBMs ranging in size from 9.85m (32.33 ft) to 3.70m (12.16 ft) in diameter. The operations surrounding the 11,546m (37,876 ft) long 9.85m (32.33 ft) diameter tunnel will be highlighted. A total system concept was utilized to attain mining rates up to 29.3m (96 ft) per shift and lining productions of 58.5m (192 ft) per day. The reliability of these systems was instrumental in the completion of the project more than a year ahead of schedule.

Jan 1, 1995

By Grover Wallace

At is important for today?s mining executives and leaders not to underestimate the fact that, while the recent downturn in the economy did take its toll on balance sheets and productivity, factors such as emerging countries, aging workforces, globalization and individual knowledge growth did not lay dormant while the economy was in a lull. It is key for mining leaders to be proactive in their talent strategies. Successful mining companies are developing a clear, concise and communicated strategy and placing a high priority on recruiting the right talent in global markets that parallels their business strategy. They are focused on placing the right people in the right jobs.

Jan 1, 2011

By Anthony Edey

It is a generally accepted and widely discussed fact that the world in general, and the United States in particular, face a shortage of energy at the present time which will become worse in the future. There is, however, no sign of a similar concensus as to the actions which would prevent or overcome this expected shortage. An immense variety of solutions has, however, been put forward, ranging from the purely political to the outer fringes of sophisticated technology. One resource which surprisingly is often only cursorily included in this discussion is the immense known petroleum reserve lying within the United States. When this subject is discussed, indeed, it is usually in the context of the improvements in production or new discovery rate that could be expected to result from possible politico-economic actions that would raise the real price obtained for domestic crude. This interest in the potential for improved domestic production is undoubtedly justified, but very little attention is normally drawn to the fact that even under the most favorable policy framework the majority of the oil that has been, or will be, discovered will remain in the ground due to the inherent limitations of production through surface wells.

Jan 1, 1979

By Terry B. Linde, William M. Dowall

The recently completed In-Pit Crushing and Conveying Project at Phelps Dodge's Morenci Mine is rated among the world's leading materials handling projects. The operation involves the crushing and transport of more than 109,000 tonnes per day of copper ore, utilizing regenerative conveyors capable of providing over 5.5 megawatts (7,000 hp) of equivalent electrical energy. This paper describes the key aspects of the project and includes: Original project objectives; System design criteria; System description; Optimization studies; Major design features; Equipment description; and System commissioning.

Jan 1, 1993

By P. Kawahata

Newmont?s Twin Creeks Mine, located in northern Nevada, is producing gold ore from surface mining operations. The ore is currently processed at three different on-site facilities depending on ore type and grade. Processing facilities operate under stringent geochemical blending constraints that must be met from mine ore deliveries and off-site sourced ore. To analyze various strategic options, the technical team utilizes the mathematical optimization approach. However, due to the size and complexity of the operation, there are unique challenges in optimizing life-of-mine production scheduling. This paper describes those challenges and methods developed to take advantage of different scheduling software to effectively compensate each other and result in reasonable guidance. This paper also describes how those scheduling results are reflected in detailed mine plan and cost estimate work.

Jun 1, 2013

By R. L. Grayson, S. B. Bealko, L. L. Chasko, D. W. Alexander

In response to recent mining disasters and new mine rescue team legislation, NIOSH researchers conducted meetings across the United States with mine emergency response experts to investigate current needs and issues. Some of the issues include emergency response preparedness, mine rescue contests, real-life training capabilities and training facilities. Many new teams are being formed that must be trained for mine rescue team competitions as well as be ready to respond to a variety of mine emergencies, including a fire or explosion, a massive roof collapse, mine inundations or vertical shaft rescue situations. Therefore, it is important that these teams are adequately prepared and trained. This paper presents a summary of domestic and international coal mine rescue training facilities and identifies those that provide unique, real-life and/or state-of-the-art training. Research findings from this report will be used in further NIOSH investigations to improve coal mine rescue training.

Jan 1, 2010

By D. Panias

Alumina hydroxides such as gibbsite (Al(OH)3) and boehmite (AlOOH) are precursors of many types of alumina that find important industrial applications. The thermal decomposition of AlOOH, which is a more energy saving precursor compared to gibbsite, gives rise to the formation of ?-, d-, ?- and a-aluminas that are used for the production of catalysts. The applications of the aluminas are governed by their properties that are a function of the precursor material and its microstructure. The microstructure in turn is a factor of the method and conditions applied, as well as, in the case of soft chemical processes, on the anions present. Towards these ends, this study was focused on the effect of different anions on the physicochemical characteristics of the alumina hydroxides precipitated in the first 5 minutes after the perturbation of the stability of a supersaturated sodium aluminate solution (Bayer liquor).

Jan 1, 2006