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By A. F. Alsobrook

Specialty silica materials, as defined in this chapter, are rocks that consist predominantly of silica (SiO2) and are produced as chunks, round pebbles, and sawed or trimmed blocks and other shapes for nonconstruction applications. The rock types include quartzite, sandstone, novaculite, flint, chert, and vein quartz. Other terms used commercially include jasper, silex, lascas, and rock crystal. In its publication, Minerals Yearbook, the US Bureau of Mines (USBM) reports the production and consumption of some specialty silica materials under several headings. Quartzite, sandstone, and novaculite used in abrasive applications are addressed by the USBM under Abrasive Materials. Lascas, a type of vein quartz used in growing synthetic quartz crystals and in fusing applications, is discussed under Quartz Crystal. Silica gravel used in manufacturing silicon metal and ferrosilicon, as metallurgical fluxstone, and as a filtration medium is covered under Industrial Sand and Gravel. Information on

Jan 1, 1994

By R. A. Jankowski

Laboratory tests were conducted to evaluate the silica collection efficiency of flooded-bed scrubbers using six different filter panel designs at two operating velocities. Test results indicated that reductions in filter density negatively impacted respirable dust collection. Silica collection efficiency for the least-dense filter was as much as 33 % lower than the collection efficiency of the most-dense filter. At the low operating velocity, the least-dense filter allowed more than 40% of the respirable silica dust in the scrubber intake air to pass through the unit and back into the mine environment. Operation of the scrubber at the higher test air velocity increased silica collection efficiency regardless of the filter panel tested The density of the filter panels also impacted the quantity of air moved through the scrubber, with higher-density filters reducing scrubber airflow. For each filter, the relationship between dust-collection efficiency and air-moving capacity must be considered to determine the overall effectiveness for each mine application.

Jan 1, 2000

Laboratory tests were conducted to evaluate the silica collection efficiency of flooded-bed scrubbers with six different filter panel designs and at two operating velocities. Test results indicated that reductions in filter density negatively impacted respirable dust collection. Silica collection efficiency for the least dense filter was as much as 33 % lower than the collection efficiency of the densest filter. At the low operating velocity, the least dense filter allowed over 40% of the respirable silica dust in the scrubber intake air to pass through the unit, where it would be discharged back into the mine environment. Operation of the scrubber at the higher test air velocity increased silica collection efficiency, regardless of the filter panel tested. The density of the filter panels also impacted the quantity of air that is moved through the scrubber, with higher density filters reducing scrubber airflow. For each filter, the relationship between dust collection efficiency and air moving capacity must be considered to determine overall effectiveness for specific mine applications.

Jan 1, 1998

By W. J. Nosek

Reserve Mining Company completed construction on a major process modification project in June of 1980. These modifications enabled Reserve to reduce and control its final iron ore pellet silica content from 9.0 20.77 percent to 5.0 50.26 percent. The paper outlines the implementation of neutron activation on-line analysis and associated computer control loops for measuring and closely controlling the silica content of the iron ore concentrate at Reserve Mining Company. It contains a general overview of Reserve's taconite processing facilities and a presentation of the theory and operation of the neutron activation analysis equipment coupled with the computer silica control loops.

Jan 1, 1983

By F. N. Kissell

U.A. Mine Safety and Health Administration (MSHA) coal dust compliance data sometimes shows high silica levels at roof bolters. However, it is unclear whether this silica normally originates from the bolter itself or from other dust sources upwind of the bolter research studies to answer this question at individual mines have been conducted. However, operational practices vary from mine to mine thus, the information gleaned from any one study cannot be accurately extrapolated to describe silica dust sources in most mines. In this paper, three decades of bolter dust research are reviewed the results showed that, while inadequate maintenance on the bolter dust collection system can result in excessive dust, more likely reasons for high silica levels are inadequate ventilation of the mine entries being bolted and dust traveling downwind from the continuous miner to the bolter. Scrubbers on continuous miners may not be removing as much silica dust as expected. Mining Engineering, 2011, Vol. 63, No. 10, pp. 78-82. Official publication of the Society for Mining, Metallurgy and exploration, Inc.

Jan 1, 2011

By Romeo Jurani, Ralph Dresel, Fred Kissell, Charles Parker

This report describes actions taken to control silica dust at the Yucca Mountain Exploratory Studies Facility (ESF), a tunnel located in Southern Nevada that is part of a scientific program to determine site suitability for a potential nuclear waste repository. The rock is a volcanic tuff containing significant percentages of both quartz and cristobalite. Water use for dust control was limited because of scientific test requirements. A major dust reduction was achieved with an intermediate air cleaning station located on a rear deck of the TBM trailing gear.

Jan 1, 1999

By R. H. Grau

The National Institute for Occupational Safety and Health's Pittsburgh Research Laboratory is now involved in research to identify silica dust generation in underground metal/nonmetal mines. The ultimate goal of this research is to develop control technologies to reduce worker exposure to respirable silica dust. Commodities and job classifications with the highest silica dust exposure have been identified through analysis of the Mine Safety and Health Administration's compliance dust-sampling database. Dust surveys were conducted in an underground limestone and gold mine to investigate silica dust sources, generation levels and the controls being used. A summary of the mining operations, sampling procedures, resulting data and suggested methods to improve dust control are provided.

Jan 1, 2003

By R. H. Grau

NIOSH’s Pittsburgh Research Laboratory is currently involved in research to identify silica dust generation in underground metal/nonmetal mines. The ultimate goal of this research is to develop control technologies to reduce worker exposure to respirable silica dust. Commodities and job classifications with the highest silica dust exposure have been identified through analysis of the Mine Safety and Health Administration (MSHA) compliance dust sampling database. Dust surveys were conducted in an underground limestone and gold mine to investigate silica dust sources, generation levels, and controls being used. A summary of the mining operations, sampling procedures, resulting data, and suggested methods to improve the dust control will be provided.

Jan 1, 2002

By Alan T. Nelson, Ronald D. Mariani

The Tilden concentrator was originally constructed in 1974 for the processing of low grade hematite. Flotation is a key concentrating process in the operation, and therefore flotation optimization has been a major concern since the plant startup. This paper will discuss some of the modifications made in the process to achieve optimization. The conversion that now enables the plant to process magnetite as well as hematite also will be discussed. INTRODUCTION The Tilden Mine, located in Ishpeming, Michigan, is managed by Cleveland-Cliffs Iron Company and is owned by Cleveland-Cliffs and two Canadian steel makers. It was constructed and started production in 1974 and expanded in 1979 for processing a low grade, fine-grained hematite iron formation for which there was previously no technology available. Several papers have been written describing the unique character of the concentrating operation. The hematite plant consists of 12 grinding and concentrating lines, which utilize two stages of autogenous grinding with crushing of an intermediate sized product. The ground product is deslimed in a highly dispersed alkaline environment to reject silica. Corn starch, the flocculant, has a high affinity for iron at the operating pH range of 10.5 to 11.0. The ore is upgraded from 35% to 45% iron in the desliming step. The deslime thickener underflow is the feed to flotation. Each flotation line consists of a bank of 10 rougher cells, followed by four scavenging banks incorporating 5, 4, 3, and 3 cells each. The Wemco flotation cells are each 14.1 cubic meters (500 cubic feet) in volume. A total of 12 flotation lines are available. [ ] A reverse flotation process is employed, using a straight-chain, 8 to 10 carbon primary ether amine silica collector. At the levels used in the circuit, the amine also serves as a frother. A final concentrate is produced in the rougher cells. The concentrates from the four scavenging steps are combined and recirculated to the feed end of the roughers, with the fourth scavenger froth being discarded as a final tailing. Upgrading to about 65% iron is achieved, with control of the circuit based on final concentrate silica grade. Starch is again used, this time as a depressant for iron. During the years of operation, several key areas of the flotation process have been targeted for optimization. The most significant improvements have been realized in the following areas: *Grade Control Automation *Control of Water System Chemistry *Flotation Spray Water This paper will focus on these areas, but other minor improvements also will be briefly discussed.

Jan 1, 1993

By Paul Mitchell, Amy Wheaton, James Rybock

Acid rock drainage (ARD) represents one of the most intractable problems faced by the non-ferrous metal and coal mining sectors, and the creation in the recent past of a number of high-level national and international initiatives reflects the growing concerns of industry, government and other stakeholder groups. ARD is certainly considered one of the most serious environmental impacts caused by mining and the industry's greatest environment-related technical challenge. Additionally, the global depletion of non-acid generating oxide ore deposits and the increasing dominance of sulphide ores means that the potential for ARD incidents will continue to increase. Once initiated, the cycle of chemically and biologically mediated and catalysed reactions leading to ARD generation is difficult to stop. While there is evidence to suggest that the degree of contamination of ARD will decrease rapidly within a relatively short timeframe (Wood et al., 1999), experience in historic mining regions of the world indicates that the problem may persist for centuries at certain sites. Current best practice in dealing with ARD puts the emphasis on prediction and prevention, planned from the outset of the operation and integrated with each phase of the mine site life cycle. The elements that constitute best practice are becoming more clearly defined and as this process of clarification continues industry will undoubtedly accelerate the process of best practice implementation, burying at last the image of mining as a despoiler and polluter of landscapes, an image based on past, rather than current, practices. However, it is equally clear that despite the best efforts of industry and regulators, many sites will continue to generate ARD during operation and following closure - in many cases, a legacy of ARD has been derived from operational and strategic decisions made decades ago, before the risks and impacts of the self-sustaining cycle of ARD generation were properly understood. Add to this ARD generation from poorly managed operations and from historic and abandoned sites, and it becomes clear that the treatment of ARD will be required for the foreseeable future to protect water quality, and ecosystem and human health.

Jan 1, 1999

By A. L. Anderson, J. T. Rybock

KEECO has developed the Silica Micro Encapsulation (SME) technology for the treatment of acidic, metal-laden waters. Utilizing a silica-based chemical formulation that entails chemisorption and micro-encapsulation of heavy metals in a permanent silica matrix, encapsulated particles settle quickly and are effectively isolated from the surrounding environment, producing a stable sludge that is characteristically non-hazardous. In a number of independently-verified pilot and full-scale applications (including the Bunker Hill Mine, Leviathan Mine, Wheal Jane Mine, and Meldon Quarry), SME has been proven highly effective. The technology has been featured in a number of mining publications and selected for innovative technology awards.

Jan 1, 2000

By L. C. Morales

Mexico has an area of about 2 million km2 (772,260 sq miles), with volcanic activity, large shores and mountainous areas reaching as high as 6000 m (19,680 ft) above sea level. These conditions are favorable for most mineral deposits, some of commercial value and others as a source of mineral samples. In addition to its vast mineral wealth, Mexico has another valuable asset in its people. Even before the discovery of America, natives were successfully mining metals. During the colonial days, the mineral deposits were mined to increase the wealth of Spain. All this experience was passed from generation to generation. It created a tradition of mining and minerals processing engineers that currently accounts for about 182,000 people supported by mining-related activities. Nonmetallic minerals in Mexico have been mined by natives since the early days. They knew the value of kaolin clays for pottery, as evidenced by archeological findings. This experience was also passed from generation to generation and has become recognized worldwide as ceramic wares of high quality. The Talavera ceramic from Puebla is an example of family traditions many generations old.

Jan 1, 1994

By L. C. Morales

During my College days in Mexico City, my Mineralogy Professor used to say "Mexico is the Horn of Plenty, rich in minerals, and it is easier to say which minerals are not found instead of stating all that exist. He said that the only ones missing are bauxite, diamonds and titanium ores." Today, twenty years later, a rutile mine in Oaxaca is in successful operation. Mexico has an area of approximately two million square kilometers, with volcanic activity, large shores and mountainous areas reaching as high as 6,000 meters above sea level. These conditions are favourable for most mineral deposits, some -of commercial value and others as a source of mineral samples only. (fig. No.1) In addition to vast mineral wealth, Mexico has -another valuable asset in .his people. Even before the discovery of America, natives were successfully mining metals, and during the Colonial --days, the mineral deposits were mined to increase the wealth of Spain, and it increased the --knowledge of mining. All this experience was passed along from generation to generation, and created a tradition of mining and minerals processing engineers, that currently account for approximately 182,000 persons supported by mining related activities.

Jan 1, 1994

By Greg Beckstrom

On Oct. 1-3, SME?s Twin Cities chapter (SME TC), in cooperation with the University of Minnesota ? Duluth?s Precambrian Research Center (UMD-PRC), cohosted a symposium on silica sand mining and processing. The conference was held at the Earle Brown Heritage Center near Minneapolis. The symposium was followed by a day-long field trip to operating mines, processing plants and loading facilities located in southwestern Wisconsin. Speakers and attendees at the symposium included university professors, industry experts, regulators, mining company representatives, equipment suppliers, consulting engineers and service companies. Approximately 320 people attended the conference. In addition, about 50 people who oppose mine development and the oil and gas industry showed up to voice their displeasure with the event and those companies that operate in this space.

Jan 1, 2012

By M. J. Zdunczyk

The final 1995 figures on industrial sand and gravel have not yet been compiled by the US Geological Survey (USGS). There is usually about a nine-month lag time in receiving and compiling this information. However, USGS estimates that domestic production of industrial sand and gravel will increase about 4% to 28.2 Mt(31 million st). The average unit price is expected to increase as well. The top five producers during 1995 were Unimin, US Silica, Fairmount Minerals, Oglebay Norton and Morie Co. Glass manufacturing for containers, automobiles and buildings was mixed during 1995. Containers, the largest consumer of silica sand, remained steady, with regional increases. However, silica use in glass containers face increased competition from plastic and recycled glass (cullet). It was reported that the Pepsi Cola announced plans to replace glass containers with plastic during 1996.

Jan 1, 1996

By Rudolph K. Hoagberg

Silica sands, primarily in coarse size ranges, are used to prop open fissures or voids created in the bedrock by hydraulic fracturing. This procedure increases the flow of gas or oil or other fluids through the bedrock. The sands used must meet various specifications relating to their physical and chemical characteristics; these characteristics are in turn related to the geologic provenance of the sand deposit. The Jordan Sandstone, a Cambrian formation which is exposed in Minnesota and Wisconsin, meets the specifications of a proppant sand by virtue of its depositional history and its sedimentary properties.

Jan 1, 1980

By Kostas Fytas, Pierre Bousquet, Bill Evanelou

Acid mine drainage (AMD) is a serious environmental problem that preoccupies the Canadian Mining Industry. Considerable amounts of money are spent every year in an effort to prevent or reduce the acid mine drainage phenomenon. AMD occurs when sulphide minerals (ex. pyrite) contained in rock are exposed to air and water and subsequently oxidise to produce low pH water. This acid effluent has the potential to mobilise any heavy metals contained in the rock. Coating the sulphide minerals with silicates is a new promising technology to reduce AMD. Pynte is treated with a solution containing H2O2, sodium silicate and a buffering agent. H2O2 oxidises a small part of pyrite producing ferric iron (Fe3+) ions. These ions subsequently react with the silicate ions to produce ferric hydroxide-silica that precipitates on the pyrite surface producing a passive coating. This silicate coating can protect the grains of pyrite from oxidation. This paper presents a series of experiments that confirm that silicate coating can considerably reduce AMD.

Jan 1, 2000

By R. Bruce Tippin

The silicates represent the largest and most common group of minerals on earth. Yet in spite of the chemical similarities, numerous mineral processing plants worldwide are operating successfully to yield varied commercial products for numerous uses. The silicates that are commercially produced in the United States by flotation include quartz, feldspar, mica, spodumene, talc, kaolin, and wollastonite. The operation of several plants and the conditions affecting mineral separation by flotation are described. Because the process is usually dictated by the desired market, specifications for the most common products are provided. Potash is a basic fertilizer component, along with phosphate and nitrogen. Potash is typically produced from underground evaporite beds or recovered from natural brine solutions. Flotation of potash is unique in that it is processed in a saturated salt solution. The potash flotation process is outlined and several commercial operations are described.

Jan 1, 1999

By Lee S. Richardson

Silicon is usually considered to be a useful metallic alloying element. To be more truthful, it is not a metal at all, but a semiconductor, whose electrical resistance (when pure) is high and decreases with temperature. We will join the metallurgists, at least for this paper, and refer to it as a metal. In its commercially available form, silicon is metallic in appearance, brittle, with a density of 2.33, less than that of aluminum. Silicon dioxide or quartz has a high heat of formation, which not only makes the metal a useful reductant for other materials, but also makes it difficult to reduce from its ore. The melting point is 1412°C, slightly less than steel, but substantially higher than aluminum or cast iron. The alloys of silicon with iron, usually called ferrosilicons, have some unique advantages. The melting points of most alloys are substantially below those of iron or silicon (Fig. 1). The two major compounds formed (FeSi and FeSi2) help somewhat in the reduction of silicon by their energies of formation, but the influence of these phases on the mechanical properties is more important. Four major groups of alloys are made -- silicon metal (>95% silicon), 75-85% ferrosilicon, 50% ferrosilicon, and silvery pig iron (12-22% silicon). The alloys between 50 and 65% silicon and between 25 and 40% silicon are normally avoided because of structural instabilities, presumably of the two compounds, leading to disintegration of the alloys on cooling.

Jan 1, 1974

By R. C. Burtan

Long before recorded history, man began to dig into the earth's crust in a never ending search for useful materials. It is well known that more than half of the earth's crust is composed of silicon dioxide (SiO2), also known as silica. Silica and silica-containing material have a great many uses in modern society. This material, however, is potentially an extreme health hazard. Silicosis: Not a New Disease Centuries before the Christian Era, Hippocrates wrote of a lung disease common to those who mined in hard rock. He was obviously describing silicosis. It is also apparent from ancient writings that the Egyptians were aware of this malady. Dioscorides also wrote on this subject in the fifth century B.C. It is undoubtedly the oldest and best studied of the occupational lung diseases. Silicosis was certainly described by Agricola in his De Re Metallica published in 1556. Here he described lung disease among hard-rock miners. The original document was written in Latin and then translated in 1912 by Hoover and Hoover. One of these translators was Herbert L. Hoover, a former US president who once made his living as a mining engineer. More recently, there are numerous references in medical literature in the 19th and 20th centuries relating silica exposure to silicosis. There are specific references to mining in hard rock, as well as to sandblasting and a host of other industrial exposures. In 1919, Winslow described standards for measuring the efficiency of exhaust systems in polishing shops using sandblasting. These standards were equally applicable in the mining industry. As early as 1920, Winslow explored the efficiency of certain devices used to protect sand-blasters against the dust hazard. These devices were equally applicable in the hard-rock mining industry. The medical community recognized the silica health hazard in the early 1900s. Middleton described the illness in the British Medical Journal in 1929. He noted the danger to health at that time. D. Hunter mentions in his book, The Diseases of Occupations (1969), the monumental work of Merryweather in 1936, in which he surveyed the silicosis risk in Great Britain. He showed statistically that the average employment length of sandblasters who ultimately died of silicosis was 10.3 years, compared to 40.1 years for all fatal cases, irrespective of occupation. Sandblasting and hard-rock mining and drilling, obviously, are very hazardous occupations. Weil and Zisking of Tulane University wrote in 1975 that "it was known as early as 1935 that the course of silicosis is much more rapid in sandblasters than in miners or foundry workers. This can be explained by the fact that sandblasters are exposed to an almost pure siliceous dust containing high concentrations of respirable particles within the range of 1 to 3 micron size." Protecting the Worker The medical community recognized in the early 1900s the need for proper protective equipment for all of those who worked with siliceous materials. Middleton, writing in 1929, said: "The worker is then protected by a close fitting helmet with an air feed, much as in the case of an underwater diver. In spite of these precautions, cases of silicosis among sandblasters are being met with today. It is a matter for serious consideration whether a substitute, such as steel or iron grit, could not be used to replace the siliceous grit as the abrading material." C. E. A. Winslow, a professor of public health at Yale School of Medicine, and others wrote of the need to protect sandblasters by

Jan 7, 1984