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By J. Sottile, J. L. Kohler

Component failures in the electrical control circuits of mining machines account for a large percentage of the total downtime of the machine. Once a failure has occurred it is always a tedious and usually a time-consuming task to locate the failed component. Moreover, the pressure to quickly locate the cause of a delay can lead to compromises in safety. Thus an onboard diagnostic system, essential for an automated machine, would be a very useful addition to existing machines. This report details U.S. Bureau of Mines development of a generic procedure for synthesizing diagnostic systems for electrical-control-circuit failures in mining machinery. A continuous mining machine is used as the testbed to illustrate the application of the developed methodology. Substantive differences among mining machine control circuits made it impossible to achieve a generic diagnostic system, but a generic approach for the synthesis of the diagnostic system was possible. As the research progressed, it became apparent that an algorithmic approach was better than an expert- system-based implementation. A prototype system was constructed and used to evaluate the diagnostic system. Prototype implementation issues are also examined.

Jan 1, 1993

By Howlett P. F, Courtley S

A problem with secondary breaking at one of the mines of Pasminco Mining led to a study of new rock breaking technologies. Many of the techniques being developed had emerged from the thrust in the USA for continuous drill=break excavation. Such approaches to rock breaking highlighted the applicability of what would normally be classified as tunnelling techniques, to the secondary breaking sector - and possibly the reverse. As a direct result of the investigations for suitable technologies, Pasminco Mining supported the development of two improved rock breaking methods specifically targeting secondary breaking, one of which could be applied to continuous excavation.

Jan 1, 1993

By V. R. Degner

Development of large mechanical flotation machines during the past fifteen years. This success was a contributing factor in recognizing the value in a systematic and rational means of optimizing the flotation circuit, where the preferred circuit arrangement is based on both economic and metallurgical performance considerations applied to a relatively small number of flotation machines. Flotation kinetics and effective pulp residence time models have been incorporated into a computer program, described in this paper, which has proven to be an effective analytical tool to quantitatively relate flotation process parameters, such as feed tonnage and grade, solids concentration, and reagent strategy, to flotation circuit arrangement, machine size and operating condition.

Jan 1, 1993

By Xiangwen Wang

Electrochemical measurements associated with the electrowinning of lead metal from concentrated brine (NaCI) - lead chloride (PbCI,) electrolytes at temperatures in the range 328 to 353°K (55 - 80°C) were conducted. The electrodeposition of lead metal onto a lead rotating-disk electrode may be described by the electrodic reaction: {PbCl 4 2 + 2e- = Pb° + 4Cl-} The deposition-overpotential requirements are low (approximately 41mV per decade of current density - Am+), with a corresponding high exchange current (approximately 0.018 A.cm2). The diffusion coefficient of the electroactive PbC142- species in a 3.5 NaCl electrolyte at 353°K was insensitive to the total PbCI, concentration (0.01 to 0.1M), and its value was found to be (1.21*0.1)~10-5 cm2Is with a temperature-sensitivity coefficient (E,/R) of approximately 1.98x103K-1 (328OK(T<353OK).

Jan 1, 1993

By C. H. Lee, F. Concha, L. G. Austin, P. T. Luckie

The Concha-Almendra batch-settling treatment for concentrated suspensions of single-diameter spheres has been modified. This modified version is used in the differential equations of simple batch settling of a particle size range of different density materials. The equations have been programmed for a finite difference solution, and a number of test cases have been analyzed. By cutting the settling column at a fixed fractional height, the material below this height can be treated as underflow and the material above as overflow. The predicted partition curves obtained from treating the settling in this way have Sharpness Indices in the range of 0.5 to 0.6, in the absence of dispersion effects. The Sharpness Indices decrease as dispersion increases. When the feed size distributions are of the Rosin-Rammler form, the partition curves (corrected for the bypass fraction) fit the Rosin-Rammler equation with reasonable accuracy. The predicted Sharpness Index of a component of a mixture of two materials of different densities was unchanged from that of the same materials settled alone. However, for the same, feed size distribution and volume fraction of solids in the feed, the heavier material settled faster, and the lighter settled slower, than when settled alone.

Jan 1, 1993

By S. I. Sobol

Completeness of cobalt recovery from slag requires decomposition of maggemite and non - ferrous metal desorption with polymerized silicon-acid. Cobalt losses are reduced in leaching tai1s up to 200 g/t of iron.

Jan 1, 1993

By B. J. Arnold

Froth removal rate is perhaps the most important parameter in scaling up from laboratory tests to plant froth flotation circuits. The WEMCO froth factor, the percentage of the froth height over the lip of the cell, accounts for the difference between laboratory and plant froth removal rates. As laboratory tests are generally run with a high pulp level, laboratory results are directly comparable to plant results only when a high froth factor (high pulp level) is run in the plant. When a plant does not have a high pulp level, laboratory results must be modified by using a ratio between laboratory and plant kinetics to predict plant results. This ratio, which accounts for the froth factor is important in testing any new reagents or reagent dosage levels. CQ Inc. researchers have used predictive scale-up equations using this froth factor coupled with equations for kinetics and the residence time distribution in the froth flotation cells. These equations show that modifying the froth factor in the plant can have a large impact on flotation cell yield and reagent use. EQUATIONS DESCRIBING FROTH FLOTATION Scaling up from laboratory- to plant-scale coal froth flotation has been the subject of much research and debate over the years. Determining the proper rate equation to describe flotation kinetics and an equation to describe the residence time distribution in a bank of flotation cells have been particular areas of study. As shown in Tables 1 and 2, various rate equations and residence time distribution equations have been proposed in the literature. These equations consist of one or two parameters giving the rate constant(s) in units of time-1 and a parameter for recovery at infinite time, [Roo]. Dowling, Klimpel, and Aplan (1985) evaluated the rate equations in Table 1 for their ability to fit froth flotation kinetic data and found that all of the equations give reasonably low standard errors. Several of these equations, however, proved to have superior confidence limits for the parameters. Other equations have also been proposed to describe the recovery versus time profile. Most recently, Diao et al. (1992) proposed a first-order form with a sine wave distribution. As indicated in Table 2, investigators have suggested many equations to describe the residence time distribution in continuous froth flotation. To measure the water residence time distribution in a bank of cells, a soluble tracer is often used, with the level of tracer being measured over time at the tailings discharge. This response is then put on a dimensionless basis as described by Austin et al. (1984) in order to compare mixing behavior between cells or under different conditions. Coal flotation cells are generally of the flow-through or hog-trough variety allowing for some degree of backmixing and short-circuiting. While the water residence time distribution (see Figure 1) at the end of one cell in a bank of 1.4 cu ft WEMCO froth flotation cells may approximate perfect mixing conditions (Arnold, 1989), the water residence time distribution at the end of a bank of cells does not. Figure 2 shows the RTD for various flotation cell types compared to that for perfect mixers in series. To better describe the water residence time distribution in coal froth flotation cells, Van Orden (1986) used an equation similar to the perfect-mixers-in-aeries equation. This

Jan 1, 1993

By J. F. Hutwelker

A pilot plant was constructed and operated to investigate the column flotation of 20 x 200 mesh North Carolina phosphate ore, using high throughput, high solids operating conditions developed at the NCSU Minerals Research Laboratory. Flotation was performed at 45% solids in a 9.5 cm (3.75 in.) diameter by 2.26 m (7.4 ft.) tall column at throughputs of 19.1 t/hr/m2 (2.0 stph/ft2) and 31.7 t/hr/m2 (3.3 stph/ft2). Recoveries in excess of 98% of the phosphate value were obtained at the lower throughput -- while obtaining concentrate grades containing over 28% P205 (61.2% BPL) at that recovery. Recoveries of about 95% of the phosphate value were obtained at the higher throughput, while making a concentrate averaging 27.6% P209 (60.3% BPL). In addition, a better understanding of the variables governing the column flotation of coarse nonmetallic minerals was gained. Low air flow rates adversely affected concentrate grade at the lower throughput. At the higher throughput, phosphate recovery decreased at an elevated air flow rate. An unexpected result of the study was the effect that frother type had upon phosphate metallurgy. Use of Nottingham Econofroth 925 provided better flotation selectivity than American Cyanamid F-65 at the low throughput. This is significant since the high&apos; throughput tests were conducted with F-65 exclusively. It is reasonable to expect further improvement in high throughput performance when the optimal frother type and dosage are determined.

Jan 1, 1993

By Weller KR

Completely dry or completely wet materials are comparatively easy to screen, but materials with moisture contents between these two extremes can present varying degrees of difficulty. The presence of moisture can impair the performance of a dry screening plant in a number of ways: ò agglomeration of fine undersize particles onto larger oversize particles, resulting in the fine particles being misplaced to the oversize; ò increasing attractive forces between particles that hinder stratification and particle presentation to the screen; and ò blinding of the screen apertures caused by fine moist particles clinging to the screen which reduces the effective aperture size and the open area of the screen. Test work on full-scale screens has shown that the agglomeration of fine particles onto larger particles only occurs once the equilibrium moisture content of the ore is exceeded, and that the quantity of adhering fines present is proportional to the surface area of the larger particles. An -adhering fines screen model has been developed from this work, and by using relationships derived between the model parameters and feed moisture content, the effect of changes in feed moisture on both product quality and operation of iron ore dry screening plants is predicted.

Jan 1, 1993

By Forssberg KSE

The behaviour of cationic and anionic collector mixtures in the feldspar-quartz flotation system has been investigated througl conductivity, surface tension, zeta-potential and flotation studies. Tht results show the formation of molecular complexes between oppositel; charged collector ions through charge neutralisation. The molecular complexes are found to have a higher surface activity than the individua components. The mole ratio of the mixed composition is found to have, significant effect on flotation. Mole ratio less than unit} (anionic/cationic) of collector mixtures increases the flotation recoveries If the mole fraction of the anionic collector is greater than the moh fraction of cationic collector in a mixed composition, flotation ceases The flotation selectivity principally depends on the inherent differences it the surface charges of feldspar and quartz at the flotation pH values of

Jan 1, 1993

By T. W. Camm

The Bureau of Mines conducts studies of the economic impacts of regulations on federal lands. These studies are part of the Bureau Potential Supply Analysis (PSA) program. To meet the needs of these studies, a methodology was developed to estimate operating and capital costs for a mineral deposit given its tonnage, grade, and depth. The format for the cost models in this study was developed at the Bureau&apos;s Western Field Operations Center (WFOC), Spokane, W. A., for studies of known and undiscovered resources on Federal lands. These cost models are described in a Bureau publication by Camm (1991).

Jan 1, 1993

By Raymond G. F

Geostatistics - a tool used by geologists and mine planning engineers to estimate grades and rapidly evaluate alternative mining strategies has reached an advanced stage of development for the silver-lead-zinc orebodies at Isa and Hilton Mines. Geostatistics has been used for over a decade in the massive copper orebodies but the stratiform lead-zinc orebodies are much more complex and provided a completely different set of challenges. Recent increases in computer processing speed and power provided by the Integrated Mine Planning System (IMPS) has aided the development of the geostatistics package. Also the formation of a project team and the subsequent in-house development which has drawn together the expertise of geologists, engineers and system analysts has contributed significantly to the success of the project.The most important feature of any approach to modelling the lead-zinc orebodies is that the kriging search must consider estimate and sample points according to their positions relative to bedding surfaces. By transforming co-ordinates as perpendicular offsets from a plane representing the local strike and dip, it is possible to elongate the ellipsoidal influence to parallel bedding. By interactively modelling surfaces using CAD facilities and then specifying these surfaces as &apos;hard&apos; or &apos;soft&apos; boundaries, the geologist has complete control over the kriging process.

Jan 1, 1993

By Alesse V, Belardi G

A new class of collectors, Mercapto-Benzo-Oxazoles (MBO), exerting selective action on copper sulphides in the presence of Pb, Zn and Fe sulphides (galena, sphalerite and pyrite), has been synthesised in co-operation with Enichem&apos;s Donegani Insitute. The collectors have a mixed aliphatic-aromatic structure and contain functional groups which form chelates with copper. Some reagents of this class having hydrocarbon chains of various lengths have been laboratory tested on a complex sulphide ore containing chalcopyrite, galena and sphalerite in pyritic gangue. Comparative flotation tests have permitted selection of the best collector for chalcopyrite, namely Methyl-Mercapto- Benzoxazole (MMBO). Systematic flotation tests have been performed with this reagent, varying collector concentration, grain size of the feed, pH and flotation time. The results obtained show that the synthesised collector is much better than potassium-amylxanthate (KAX) as regards selectivity towards Pb and Zn. Moreover, it is possible to work at natural pH (6-7) and the flotation rate is higher. In fact in the rougher stage with 80 g/t of collector at natural pH, a copper grade of 7.14 per cent was obtained with a recovery of 73.87 per cent, while the grade with KAX did not exceed 2.11 per cent for a recovery of 73.54 per cent. The amount of Pb and Zn reporting in the copper concentrate was eight per cent and ten per cent respectively, while with KAX it was no lower than 24.34 per cent and 22.71 per cent in that order. After two minutes flotation a copper grade of 5.2 per cent with 52 per cent recovery could be attained, against a grade of 2.5 per cent and a recovery of 44 per cent in the case of KAX. The efficiency of this new collector has been ascertained on two samples of complex sulphide ores of diverse mineralogical composition.

Jan 1, 1993

By R. J. Pugh

The coagulation of dispersions of weakly magnetic oxide mineral ultrafines (such as natural hematite or chromite) in an external magnetic field can be described from inter-particle forces. Essentially, coagulation occurs when the short range London-van der Waals interactions and the long range magnetic forces outweigh the stabilizing electrical double layer repulsion. From the classical colloid chemistry theory, we have calculated the various components of the potential energy for different sized particles at a series of ionic strengths and magnetic field intensities. We have related this theoretical analysis to experimental studies where the magnetic field-induced coagulation of ultrafines of natural hematite and chromite in aqueous suspensions was investigated using a laboratory scale electromagnetic solenoid. The experimental results relate the coagulation process (as determined by magneto-sedimentation analysis) to the particle size, the slurry pH and the external magnetic field. In the magnetic fields, maximum coagulation occurred near the pH of zero point of charge (pHzpc) of the minerals (where the electrostatic double layer repulsion was reduced to a minimum) enabling the particles to enter the "primary minimum" energy sink. On the other hand, in cases where the electrostatic repulsion was not suppressed, then the long range magnetic forces enabled coagulation to occur in the "secondary minimum". This caused the formation of chains which appeared to be relatively stable during sedimentation.

Jan 1, 1993

By P. Mottahed, E. K. S. Passaris, J. Q. Ran

"The jointed roof of underground mine openings in stratified rock can be analyzed in terms of a voussoir beam. Because of the essential indeterminacy of the structure, previous attempts of theoretically solving the equilibrium equation have been unsuccessful. Numericalanalysisby the finite element method taking the geometrical and joint non-linearity into consideration combined with the experimental method has been adopted to study the performance isopara of the voussoir beam. Deformation and failure mechanism is analyzed in relation to the failure modes. Equations are proposed to estimate the elastic buckling strength and the crushing strength of the voussoir beam and to verify the failure mode of shear sliding. For application of the mechanism of the voussoir beam in mining operations, methods are described to predict the stability of a jointed roof and to design the dimensions of mining openings.IntroductionThe roof stability of an underground mine opening has direct effects on the selection of support methods, opening dimensions and, more importantly, on the safety of mining personnel. The prediction of the roof stability can be of importance in the design of a mining method and in mining operations. The jointed roof of mine openings in stratified rock can be stable under transverse load depending on the roof geometry and properties of the roof material and joints. The stability of this type of roof can be analyzed in terms of a voussoir beam which was introduced by Evans (1941) to study the strength of underground strata. Brady and Brown (1985) analyzed the voussoir beam and suggested that the mechanism of the voussoir beam could be used in the design of underground mine openings in stratified rock instead of the traditional continuous beam theory."

Jan 1, 1993

By H. T. Mulryan

Talc is used as an essential ingredient in a variety of plastics applications ranging from polyester body patch compounds through polypropylene automotive, appliance and household furniture components to high performance parts made from liquid crystal engineering resins. This paper focuses on polyolefin applications, the three-tier market for talc in polypropylene, the effects of various tales in typical compounds and trends in each market segment. Emphasis is given to emerging markets, examples of which are polypropylene compounds that mimic higher cost resins, and polyethylene films. Customer requirements, for tales for these purposes are discussed.

Jan 1, 1993

During the 1960s chalcocite ore was mined from the Black Rock open cut. A large amount of this uneconomic material was not treated by the No 3 Concentrator at the time and as a consequence a surface stockpile was created which contained 750 000 tonnes of material at an average of 1.5 per cent copper.Laboratory trials indicated that due to oxidation, an average of 25 per cent of the copper was water soluble and the remaining copper was leachable using a sulphate/ferriclbacterial leach. On the basis of these trials it was decided to investigate the feasibility of producing copper via a leach SX-EW process. The investigation proved the process was feasible, so began the design, construction and commissioning of a 10 tpd (cathode copper) Copper Leach SX-EW Pilot Plant. CMPS Pty Limited in a joint venture with John Holland Engineering Pty Limited were awarded the turnkey contract for the design, construction and commissioning of the Pilot Plant.

Jan 1, 1993

The initially cautious approach taken towards ground support and reinforcement at the Porgera Underground Gold Mine in the Highlands of Papua New Guinea has evolved rapidly in the two years since stoping commenced. The confidence to continue the evolution process has grown from an increasing knowledge of mining conditions as stoping has progressed, to the extent that reinforcement requirements have decreased by 50 to 75 per cent depending on local circumstances. Changes to mining practices have significantly assisted and influenced this process.Empirical observations of ground behaviour, assisted by a deliberately selective extensometer monitoring program, provided the stimulus for early changes to ground support and reinforcement practices. Further optimisation of the ground support and reinforcement effort is being pursued through an active monitoring, measuring and analysis program. Ultimately, situation rather than site specific design will ensure continuing high quality ground support and reinforcement installations. However, local structural and lithological factors will continue to become more critical as the optimum position is reached.

Jan 1, 1993

By Richard F. Hammen

Mineral extraction from sulfide ore deposits usually leads to the combined action of oxygen and water on the newly exposed ore. The result is acid mine drainage, a low pH solution of various metal sulfate salts and sulfuric acid. Paradoxically, the valuable metals dissolved in acid mine water are a liability because they are too toxic for discharge but too dilute to recover economically. The expense of compliance with water quality release standards has reduced the profitability of many mining operations. Solid phase extraction (SPE) columns have been developed to extract metals from acid mine water. These columns are designed to remove the toxic elements from water and recover the metals as purified fractions. This article describes the results of a Phase 1 bench-scale project to test the performance of the SPE columns. The tests were conducted with water collected from the abandoned Berkeley Pit copper mine in Butte, MT.

Jan 1, 1993

By Nevolina VG, Zakharova IB

The results of a study on the flotation of baddeleyite and associate minerals are presented, together with effective flotation reagents. Detailed microcrystallomorphological analysis of the benefication products were made to find out the features of distribution of different baddeleyite generations between froth and chamber products. To reveal the dynamics of interaction of technological properties of minerals with their morphology and constitution, a method of onthogenetic analysis was used. It is well known that the difference between technological properties of the particles of the same mineral depend greatly on its genesis, but also the relation is direct - by means of constitution (habit). Thus, flotation behaviour of minerals depends on morphology microinclusions, distribution of impurities, dislocations and physical properties of individual particles. The microrelief of baddeleyite grains and crystals from froth and chamber products was studied with an electron scanning microscope. Chemical composition was determined by means of laser, microprobe and chemical analyses. The difference between baddeleyite generations, their distribution in benefication products, and the effects of grain sizes, number of inclusions and chemical compositions were valuated. Conclusions on baddeleyite flotation properties were made. Mineralogical study on eudialite grains from rough ore and eudialite concentrate was carried out. The interrelation between eudialite and associate minerals and negative effect of aegirine on technological properties of eudialite were revealed as well.

Jan 1, 1993