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By H. E. Rudi

The advent of open nit mining permitted the development and processing of minerals never before thought possible. New equipment was needed; new techniques were devised; new methods were called for. This development and acquisition of new techniques, methods and equipment did not, however, stir the souls of our industry and educational leaders sufficiently to a recognition of the problem of people, especially the future development of the people needed in open-pit mining. The people problem has been and will be with us as long as there are two of them. The development of people will be required for the same reason. The problem of developing future personnel for open-pit mining is not what must be developed; that is known to all of us and can be briefly stated ashore and better of everything." As I see it, the real problem lies in determining (1) what personnel are really critical, (2) why are they critical and (3) how can we develop them.

Jan 1, 1965

By D. Malhotra

Most primary-molybdenite producers use a selective-flotation process in which molybdenite is floated from the ore while other sulfide and non-sulfide gangue minerals are depressed in the same step (Figure 1). The process was developed at the Climax mill. Reagents used in the rougher-flotation stage include vapor oil (collector), syntex (surfactant), pine oil (frother) and occasionally sodium cyanide and Nokes reagent (depressant). Rougher concentrate is upgraded by cleaner flotation to produce market-grade molybdenite concentrates. Reagents used in the cleaner flotation stage are Dowfroth 250, vapor oil, sodium cyanide and Nokes reagent. The development of the flotation reagent scheme at Climax and the role of the reagents have been well described by Born, et al, (1976) and Malhotra, et al, (1976, 1977a, 1977b, 1977c, 1980). The hydrocarbon collector, vapor oil, accounts for approximately 50 percent of the total molybdenite-flotation reagent cost. Because vapor oil sources are limited, and the cost of vapor oil has increased significantly over the last decade, several studies have been done to evaluate alternate oil-based collectors and/or blends of collectors which would produce similar metallurgical results at a reduced cost, or increase the overall molybdenite recovery at the same cost (Smit and Bhasin, 1983; Hahn, 1969; Smith and Bhappu, 1971). The approach taken in the present study was to evaluate alternate non-oil based collectors and collector systems that are less expensive than vapor oil.

Jan 1, 1985

By G. P. Larson

We define a specialized mineral market as follows: Specialized markets occur where a low volume of a given mineral is used to convey a large benefit to a specific product. Sales of these value added minerals to small markets generally require a different marketing approach than bulk or commodity markets for traditional minerals. Specialized markets are differentiated by several characteristics as listed in Table 1. [Table 1-Characteristics of Specialized Markets 1. Long-term sample evaluation 2. Small volume markets 3. Highly controlled properties 4. Customized specifications 5. Technical selling effort] Many of the specialized markets require long term evaluations before sales can be made. This can vary greatly depending on the type of industry and ultimate end-use of the final product. In some cases, complete evaluations may take from several weeks to years. Length of sample evaluation has no relationship to size of market. That is, the total market may be quite small or fairly large (e.g. from a few hundred pounds to a few million pounds). Uniformity of value added minerals from lot to lot is an extremely important characteristic for these markets. Variations that are of no consequence to one industry (or application) cannot be tolerated in another. This has led to customized specifications and test procedures for specific markets and applications. Because of the greater uniformity and customized specifications, the need for greater technical selling effort is required. This is particularly true in the initial developmental phases and contacts as well as in maintaining the account after the initial order. A small entrepreneurial organization can be used to advantage to achieve goals of sales and profit to these types of markets. The large commodity or bulk producer's sales and marketing organizations are not ordinarily equipped to give the necessary service or technical assistance to the specialized markets. The organization usually required for this type of marketing is given in Table 2. [Table 2- Specialized Marketing Organization Requirements 1. Flexible approach to technical and marketing problems 2. Versatile background in a broad range of industries 3. Laboratory backup when necessary 4. Marketing expertise 5. Technically competent management] In developing specialized markets, a flexible approach to both technical and marketing problems is necessary in understanding the needs and requirements of the industry and the applications involved. This flexibility is also helpful in adapting existing products to new market areas. Having knowledge of a range of industries as broad as possible can be very helpful. It often happens that a product developed in one area or industry can lead to its application in a different area with excellent results. Laboratory assistance for a wide range of tests and test procedures is an important asset in any development program for specialized markets. Laboratories can also assist in competitive evaluations. Marketing expertise and a management with some degree of technical understanding are necessary in to assign proper cost/ benefit ratios to a proposed new product or application of existing products. This is important since the total market volume can be small and the time required for initial contact to first sale can often be lengthy. Also, management's technical and marketing expertise is required in evaluating all possible options that can be considered viable when an application is presented. Once an organization of this type is in place, it is then possible to determine the needs of the marketplace, including when various minerals might have to be customized to fill those needs. There are generally two methods of marketing, as noted in Table 3. [Table 3- Method of Marketing 1. Product Driven -Develop a product with certain desirable properties and try to find a market to utilize those properties. 2. Market Driven -Know market well enough that when a need arises, it is possible to identify a product that will satisfy the need.] These approaches are not mutually exclusive and can be used at the same time. Marketing a value added mineral generally requires the "market driven" approach. Hence, the importance of a knowledgeable management as outlined above. To determine where needs and opportunities exist, several approaches can be used. Table4 lists some of the methods employed.

Jan 1, 1993

By D. F. Scott

Spokane Research Center personnel have been investigating the use of seismic tomography to monitor the behavior of a rock mass, detect hazardous ground conditions, and assess the mechanical integrity of a rock mass affected by mining. Seismic tomography can be a valuable tool for determining relative stress in deep (> 1220 m) underground pillars. If high-stress areas are detected, they can be destressed prior to development or avoided. High-stress areas can be monitored with successive seismic surveys to determine if stress decreases to a level where development can be initiated safely. There are several benefits to using seismic tomography to identify high stress in deep underground pillars. The technique is reliable, cost-effective, efficient, and non-invasive. Also, investigators can monitor large rock masses, as well as monitor pillars during the mining cycle. By identifying areas of high stress, engineers will be able to assure that miners are working in a safer environment.

Jan 1, 1997

By G. B. J. Leon, M. Karmis, C. Newman

"The prediction of surface deformations due to underground mining operations has been a long recognized practice with case studies documented as far back as 1556 in Georgius Agricola's De Re Metallica (Latin for On the Nature of Minerals). There is currently increased public awareness and regulatory scrutiny on the potential impacts of underground longwall and second mining operations, but this time the focus is placed on environmental impacts to overlaying bodies of water such as streams, rivers, wetlands, lakes, etc. (Karmis and Agioutantis, 2015). Community residents and environmental groups, as well as federal and state regulatory agencies, have often cited adverse stream impacts and demanded stronger measures and scrutiny in issuing mining and reclamation permits (Booth, 2006). Mining companies are required to focus on the protection of sensitive bodies of water through the monitoring of stream flow and water quality, management and rehabilitation techniques, as well as the adoption of ""no mining zones,"" which potentially sterilize large portions of minable coal reserves. This paper examines the use of an empirical modeling approach for the protection of surface streams based on evaluation of ground strain magnitudes. Utilizing enhanced features of the Surface Deformation Prediction Software (SDPS), ground movements can be predicted accurately in the vicinity of surface bodies of water. The modeling of ground movements can aid in establishing optimum extraction sequences, while the magnitudes of anticipated subsidence can be used in the evaluation of mitigation plans when undermining surface bodies of water. INTRODUCTION When utilizing high recovery underground mining methods, such as longwall or room-and-pillar mining, the movement and deformation of the overburden propagates toward the surface and may affect the integrity of overlying surface streams (Peng et al, 1996). Published studies cite three major mechanisms of subsidence as most likely to impact streams: displacement, slope, and strain. While subsidence-induced vertical displacement cause little structural damage to the stream bed, it may create adverse drainage and stream flow issues as the subsidence trough allows for ponding (Dawkins, 2003). Subsidence initiated changes to the slope, or tilt, of a stream may have adverse effects on water flow. As the stream enters the subsidence trough, the gradient increases providing potential erosion control problems. When exiting the subsidence trough, a reduction of the gradient may inhibit stream flow, causing localized ponding (Peng, 2008). While vertical displacement and tilt both may have detrimental effects to surface streams, subsidence induced strains have been documented as being the most damaging to surface streams and structures causing distortion, fractures, or failure (Singh, 1992). When stream beds are subjected to high tensile strain, tensile cracks may form at the surface level allowing for the direct loss of stream flow through fissures. When stream beds are located in areas of high compressive strain, rock layers forming the stream bed can fail as the stream bed, ""ruptures,"" upward blocking stream flow or having the stream diverted into the facture zone at the base (Iannacchione, et. al., 2010)"

Jan 1, 2016

By Chee Theng

"What do you think are the most important topics in mineral processing today? It is a question that begs to be asked when more than 100 of some of the best and brightest in Colorado mineral processing and their invited guests are gathered in one room. They are there for the 66th Annual Colorado MPD Meeting held at The Broadmoor in Colorado Springs: three days of finely curated talks and social events where participation was strong, and information was exchanged and connections forged in a relaxed, informal atmosphere.Water, tailings and social licenseNot surprisingly, water management, with the associated issues of tailings and social license, was high on the minds of those present. The Mount Polley and Samarco tailings dam failures have had repercussions across the industry. “There are big challenges with respect to tailings, and social and environmental pressures to find better ways to treat them,” said Steve Hearn of Huntsman Corp., a view echoed by Bob Kilborn of Kilborn Group LLC. Metso Minerals director Keith Butler said, “Water conservation is a key issue today. Many mining activities are now located in remote areas, so it has social and economic impacts on mining operations.” For Brian Olson of Samuel Engineering, wastewater and reclaimed-water treatment is interesting.Fittingly, the first talk of the meeting was on dry stack tailings by Michael Blois of Takraf USA, who went over both the advantages and disadvantages. “The average now is over one tailings dam failure a year,” Blois said, “and that is one too many.” But the technology may not be the right fit for all projects. In his talk on the KSM project, Jay Layman, president and COO of Seabridge Gold, showed how it isn’t practical for KSM and how Seabridge reached the decision on a cyclone sand tailings managementfacility as the preferred management strategy.The luncheon keynote also dealt with a tailings pond spill, but of a different kind. Bob Schafer, chief executive of Eagle Mines Management, spoke on the federal missteps that led to the spill into the Animas River from the Gold King Mine, a mine that had been a dry mine throughout its life and up to the 1990s."

Jun 1, 2016

By K. N. Han, M. C. Fuerstenau, T. B. Onlin

A mathematical model describing the concentration profile of fine particles in the axial direction in liquid fluidized beds has been developed for the removal of fine particles. A forward finite differentiation technique has been used to solve a continuity equation with a source term to predict the concentration profile and, hence the recovery as a function of time. With the aid of experimental results obtained using a fluidized bed of 3-cm diam, dimensionless parameters were identified. These parameters were used to predict the concentration profile of fine particles in fluidized beds of larger sizes. Four different sizes of fluidized beds, namely, 1.3, 3.0, 4.0, and 7.5 cm in diam, were used in this investigation. The amounts of bed particles used included 4, 8, 16, 24, 59, and 120 g, and the size of bed particles were 48x100, 100x150 and 150x200 mesh.

Jan 1, 1987

By Brian E. McGee

The Federal Coal Management Program represents the culmination of several years of effort by the Department of the Interior (001) to reformulate the manner in which coal owned by the United States is leased and developed. These efforts began in 1970 with a study by the Bureau of Land Management (BLM), which indicated that unless drastic changes were made in. the federal coal leasing procedures, federal coal lands would be leased almost for the asking while production of coal from those lands had been decreasing. Consequently, informal action was taken in 1971, which resulted in no further leasing being authorized until February, 1973. At that time, a formal moratorium on most coal leasing was established, with exceptions granted only for leases needed to satisfy short-term needs such as maintaining existing mines or supplying reserves for new contracts in the immediate future. This leasing policy embodied a long term objective of developing an entirely new planning system for federal coal leasing, as well as to schedule the preparation of a programmatic impact statement for this new system. As a result of the 1973 moratorium and the ensuing application of short-term criteria, only 10 federal coal leases (covering approximately 30,177 acres) were issued from February, 1973, through January l, 1976.

Jan 1, 1982

By Anthony Delvescovo, Gregory F. Aluce, Joseph A. Sopko, Lyle C. Smith

Construction of a 13m shaft through approximately 100m of water bearing soils and another 100m of bedrock was attempted using the Slurry Diaphragm Wall Method with a combination of deep dewatering wells. During excavation within the slurry wall, unexpected groundwater inflows occurred in a structure of loose silty sands. Artificial ground freezing was selected as a remedial method to seal the leaking slurry wall, and as a primary excavation support and groundwater control method for the 30m of overburden material below the base of the wall. Design of the ground freezing system required analysis of both the structural requirements of the unsupported soil, the frost effects against the existing slurry wall and the groundwater control in the area of the breech in the wall. These design procedures are summarized, and construction and excavation techniques and corresponding schedules compared in this paper. Advanced drilling techniques, ground freezing quality control and general contractor procedures for efficient shaft construction are discussed.

Jan 1, 1993

In 1993, the United States' economy grew at a rate of about 3%. The Gross Domestic Product rose to $6.4 trillion. With more than 258 million people - 599,000 in mining including petroleum - the United States has more than 100 million dwelling units and more than 190 million licensed motor vehicles. New private housing starts rose 7% to 1.3 million units, new car production fell 3% to 5.5 million units and truck and bus production rose 21 % to 4.9 million units. The rate of inflation was under 3% and the prime rate of interest 6%. The Producer Price Index (1982 = 100) was unchanged from 1992 for fuels and re¬lated products and power at 80 and met¬als and metal products at 119, while chemicals and allied products rose 2% to 128 and non-metallic mineral prod¬ucts rose 2% to 120. The merchandise trade deficit rose 27% to $116 billion.

Jan 1, 1994

By B. Anameric, S. K. Kawatra

Pig iron nuggets were produced in a laboratory scale furnace at Michigan Technological University. These nuggets are produced from pellets consisting of a mixture of iron oxide, coal, flux, and a binder, which are heated to 1450°C.These pellets then self-reduce to produce a solid, high-density, highly metallized (96.5% Fe) pig iron. During the nugget production process, a separate slag phase forms that cleanly separates from the metal. The physical and chemical properties of the pig iron nuggets are similar to pig iron produced by blast furnaces, which is distinct from Direct Reduced Iron (DRI).

Jan 1, 2004

By M. Shriwas, F. Calizaya

"Controlled recirculation may be considered as a beneficial means in mines of cold climate, where heating of air is required, and in deep or extensive mines, where cooling of air is required. Controlled recirculation can be designed by proper sizing of the booster fans with respect to main fan. Intuitively, it seems that the buildup of methane at the face will cease when a steady state condition is attained, and also that, at that same time, the maximum concentration at the face will remain same as in the return air. This supposition is proved by mathematical analysis that considers uniform mixing of methane in air in successive cycles of recirculation. This study includes two scenarios to show the effect of controlled recirculation on methane concentration in a sample network. Firstly, when recirculation crosscut exists near the working face; secondly, when recirculation crosscut exists away from the working face. The later scenario shows lesser buildup of methane concentration than the former one. INTRODUCTION The controlled recirculation is designed purposefully to allow a partial fraction of used air that increases the air velocity due to increased quantity of air and consequently allows effective dilution of contaminants to improve local ventilation condition at the working face. It can be designed by proper sizing of booster fan with respect to main fan in a ventilation network. Controlled recirculation may be categorized as crosscut, in-line or combined system based upon the configuration of the booster fan locations in a district ventilation network. Research on controlled recirculation has shown numerous benefits of controlled recirculation especially in deep or extensive underground mines, where further heating or cooling is required (Calizaya 1990; McPherson 1993 and Jones, 1987). However, fear of buildup of concentration has misled the mining communities to view the controlled recirculation as a hazard and deprived the mining industry to derive benefits from recirculation. Intuitively, it seems that the buildup of methane at the face will cease when a steady state condition is attained, and also that, at that same time, the maximum concentration at the face will remain same as in the return air. This supposition is proved by mathematical analysis that considers uniform mixing of methane in air in successive cycles of recirculation. This study includes two scenarios to show the effect of controlled recirculation on methane concentration in a sample network. Firstly, when recirculation crosscut exists near the working face; secondly, when recirculation crosscut exists away from the working face. The later scenario result shows the less buildup of methane concentration than former scenario result."

Jan 1, 2016

A portable electronic instrument was developed which will measure change of longitudinal wave velocity with change of uniaxial stress in rock columns. The instrument is a solid-state device powered by nickel-cadmium batteries. It uses a probe of two piezo-electric crystals spaced inches apart to send and receive a pulse through a stressed rock. A one-inch cathode ray oscilloscope visually displays the longitudinal wave. A reference chart is used to find the stress. Laboratory results have indicated that the average stress on a sandstone column can be found to within 35 psi. The feasibility of using this instrument to determine stresses in mine pillars is to be studied. The instrument may be used to investigate physical properties of rock.

Jan 1, 1970

By Richard J. Waxweiler, Frank E. Lundin, Robert J. Roscoe, Victor E. Archer, Michael J. Thun, Joseph K. Wagoner

[Introduction] Since excess lung cancer mortality was first noted in the late 1800's among Joachimsthal-Schneeberg miners, there have been a number of studies of the long term health effects among various types of miners exposed to elevated levels of radon and its radioactive decay daughters. Substantial excesses of lung cancer have been noted among miners in the Joachimsthal mines (Sevc, 1976) , lead-zinc miners in Sweden (Axelson, 1979) , fluorspar miners in Canada (DeVilliers, 1971) , iron miners in Sweden (Renard, 1974) , uranium miners in Canada (Hewitt, 1976), and metal (Wagoner, 1963) and uranium miners in the United States (Lundin, 1971; Archer, 1976). The latter prospective cohort has also been shown to be at an excess risk of death due to tuberculosis, nonmalignant respiratory disease, and accidents when followed through September 30, 1974 (Archer, 1976). This report extends the followup of this cohort of miners through December 31, 1977 and expands the mortality analysis to investigate more cause-specific categories. [Methods] During the decade beginning with July, 1950, medical teams from the United States Public Health Service (USPHS) examined 3362 white and approximately 780 nonwhite males who had worked underground in uranium mines in the Colorado Plateau at least one month by January 1, 1964. Occupational, medical, and smoking histories were obtained during the examinations and often updated/confirmed during subsequent annual censuses of the miners conducted by the USPHS. The white miners now have been followed-up through December 31, 1977 using the Social Security Administration, Internal Revenue Service, direct telephoning and various other sources. Death certificates were obtained for the deceased and coded directly into the Seventh Revision of the International Classification of Diseases, Adapted, using the rules in effect at the time of death. Deceased miners for whom no certificate has yet been located were assumed dead on the date specified by the reporting agency, cause of death unknown. The uranium miners cohort was analyzed using a modified life-table system developed by the National Institute for Occupational Safety and Health (NIOSH). Person-years at risk of dying (PYAR) were calculated for each miner from his first USPHS medical examination date or date upon completion of one month of underground uranium mining if that was later. PYAR were calculated specific for five-year age groups, calendar periods, and periods after first underground uranium mining. The numbers of cause-specific observed deaths among the cohort occurring by December 31, 1977 were compared to the numbers of expected deaths. The expected deaths were calculated by multiplying the appropriate PYAR by the United States death rates for white males specific for five-year age groups, five-year calendar periods, and cause. The results were summed over the age and calendar period specific categories to obtain the total expected deaths for each cause. Standardized Mortality Ratios (SMR's) were calculated for each cause by dividing the observed number of deaths by the expected number of deaths and multiplying by 100. In some tables, two-sided 95% confidence intervals for the SMR's were computed using either Fisher exact confidence limits, if the observed frequency was less than eight, or approximate confidence limits, if the observed frequency was eight or greater, to indicate statistical significance. Because a priori hypotheses had been well established, one-sided lower confidence limits were used for tuberculosis, lung cancer, other nonmalignant respiratory disease (ONMRD), accidents, and total mortality. [Results] The cohort included 589 miners first examined in either 1950, 1951 or 1953; 753 first examined in 1954; 1235 first examined in 1957; 5 first examined in 1958; and 782 first examined in 1960. In Figure 1 the distribution of the cohort by first year of underground uranium mining indicates that 13.7% started before 1947 and would have thus had an opportunity to be followed beyond 30 years

Jan 1, 1981

By S. J. Root

The mineral processing industry supplies raw materials to a wide variety of manufacturing sectors. Large companies such as Ford, Microsoft, and Johnson&Johnson have pledged carbon neutral supply chains in the coming decades, leaving suppliers to reevaluate their energy sources [1–3]. National Renewable Energy Lab [4] has partnered with over 700 organizations with similar goals in mind. The energy needs are broad in scope in the mineral processing industry. Generation IV of nuclear reactors, which is currently under development in both the private and public sector includes a class called microreactors like the small modular reactor XEnergy plans to install at Dow Chemical’s Gulf Coast facility by 2023 [5]. As the name implies, these are smaller than the utility scale nuclear power plants in operation today, and are intended to be more versatile. A specific reactor core design, along with modules could be selected to fit a certain application without needing to design a greenfield power plant. Basic water cooled designs could easily supply shaft work, electricity, and low grade process heat to a facility. More advanced designs, such as molten-salt-reactors and high-temperaturegas-reactors can achieve higher temperatures needed for ore roasting. Similarly, these reactors could produce hydrogen by high temperature electrolysis to use as combustion fuel and reducing atmosphere in blast furnaces.

Feb 1, 2023

By August E. Vandale

I speak to you today on the subject assigned to me, "Subsidence - a Real or Imaginary Problem", as a representative of Consolidation Coal Company (a wholly owned subsidiary of Continental Oil Company). The information I relate to you is our experience in the Pittsburgh Coal Company Division of Consol and covers the Pennsylvania properties and mines with particular emphasis on the mines in the south- western portion of the State or in the immediate vicinity of Pittsburgh, Pa. Mining of Freeport and Pittsburgh seams of coal in the Pittsburgh vicinity dates back over one hundred years. Consol, or its predecessor, Pittsburgh Coal Company, has been actively engaged in mining in the area since Pittsburgh Coal Company was organized in 1900. Pittsburgh, Pennsylvania came into prominence as the Steel City largely because of the vast reserves of high grade metallurgical coal readily available in the immediate vicinity and also because of its favorable river transportation. Early in the 1900's we operated over 100 small coal mines, with operations located in the Counties of Allegheny, Fayette, Washington, Westmoreland. We have also operated mines in Somerset and Greene Counties. Titles in Pennsylvania can be in three estates: (1) title in fee, (2) title to the mineral, (3) mining rights permitting the removal and extraction of the mineral with or without waiver of surface damage. Consol has over the years acquired good legal title to the coal lands purchased from individual farm owners, with good broad mining rights, and in 98% or more of its title has a complete waiver of surface damage or the right to subside the surface land. In the early days of our Company, individual coal farms were purchased from land owners. Many of these titles severed the coal estate from the in fee title and good mining rights with waiver of surface were conveyed in the original severance deed. Thus, minable coal reserves were put together by the purchase of the coal under many individual farms in an area. In the early years, the mines practiced hand dug mining - later going to mechanical cutting with hand loading of the coal. Systems used were entry driving with room and rib panels. We have practiced full recovery mining as far as practical during the years of hand loading, as well as in the later years when the mines were mechanized. Mining system layouts, methods and procedures have changed from time to time to keep pace with improved mining machinery and new inovations, such as roof bolting and rubber tired haulage.

Jan 1, 1967

By G. Hwang, S. Park, H. Kim, J. Choi, P. Seo

"In the mineral processing, clay minerals have negative effects on the flotation of valuable minerals. In this study, we investigated how the floatability of malachite (CuCO3·Cu(OH)2) is affected by presence of the clay minerals in the fundamental aspects. Flotation experiments were conducted by using Na2S and PAX (potassium amyl xanthate), and the floatability of malachite was compared between the cases in the presence and absence of clay minerals. The results showed that floatability was greater in the absence of clay minerals than in the presence of clay minerals and decreased with increasing weight percent of kaolinite under same conditions applied. In addition to examine how clay minerals affect malachite floatability, we conducted flotation experiment with changing clay adding order. The results indeed showed that malachite floatability was affected by clay adding sequence. INTRODUCTION The demand of copper is growing as industrial development increases, but mineral resources are limited. Therefore, studies for Cu oxide flotation are being conducted to improve their recovery(1-3). However the mining industry is well aware of the difficulty in treating copper ores in the presence of clay minerals(4). Clay minerals have unique properties and these properties may affect flotation. In the previous studies, the effect of slime coating of clay minerals on flotation was investigated(4-6). For example, Zhao and Peng (2014), Peng and Zhao (2015), and Arnold and Aplan (1986) found that clay slime coating on chalcopyrite, chalcocite and coal surfaces through the electrostatic attraction reduced surface hydrophobicity and then depressed the flotation. Other researchers have also reported clay minerals have impact on pulp rheology. Especially in the case of bentonite, pulp viscosity increased with increasing amount of bentonite and the higher pulp viscosity have deleterious effect on copper recovery(7, 8). However, these studies only focus on slime coatings and pulp rheological behavior. Forbes et al. attempted to decoupling rheology and slime coatings effect on flotation but this study has limitation that individual role of two clay species either attached to mineral or suspended in bulk solution was excluded(9). Hence, in this study, we aimed to investigating the effects of individual clay (suspended and attached) on malachite flotation."

Jan 1, 2016

By H. W. Hitzrot

Introduction Mechanical classifiers consist of a settling tank with parallel sides and a sloping bottom equipped with a mechanism which continuously agitates the pulp and removes the settled solids. The functions served by mechanical classifiers include the following: (1) allow the particles larger than the desired size to settle in the tank and provide an overflow product with a minimum of oversize particles, (2) produce an overflow product of sufficiently high solids content to meet the requirements of the subsequent processing steps, (3) agitate the pulp and permit separation of the entrapped undersize particles so they can report in the overflow product, and (4) drain and remove the underflow solids from the settling pool. Various types of mechanisms have been used to agitate the pulp and remove the settled solids, which include: (I) endless belt and chain drags, (2) reciprocating rakes, (3) helical flights mounted on a rotating shaft which extends through the settling pool, (4) helical flights inside of a rotating drum which contains the classifier pool, (5) troughed conveyor belts forming the settling pool in the concave curve of the belt closely following the tail pulley, and (6) low-speed impellers agitating the underflow settled in the apex of cone-type mechanical classifiers.23 The principal use of mechanical classifiers has been in closed¬-circuit wet grinding; however, this application has been widely displaced over the past few decades by the hydrocyclone. The hydrocyclone installation, including its feed pump, offers lower capital costs and requires less floor space. Nominally it produces an overflow prod¬uct of higher solids content, compared with a mechanical classifier, for comparable classification size up to 400µm (35 mesh). However, these advantages of the hydrocyclone are being gained at the sacrifice of some of the advantages of the mechanical classifier. The mechanical classifier requires less power and has lower maintenance costs than the hydrocyclone and its feed pump. The underflow product from the mechanical classifier can have a higher solids content and contain less entrapped undersize particles than the comparable product from the hydrocyclone. Consequently, it is capable of operating at a higher classification efficiency. A reduced circulating load24, 25 results under these conditions in a closed-circuit grinding application. Other applications for mechanical classifiers include desliming, dewatering, and washing operations. Sand-slime separation may be achieved using one or more stages of mechanical classifiers. Typical applications would include washing and deslimining of concrete aggre¬gate or sand; glass sand; abrasives; oyster shells; phosphate rock; iron, nickel, and chromium ores; alumina; zeolites; solar salt; and precipitates from chemical processing. As an example for the latter, Bitzer26 recommended the use of mechanical classifiers for countercur¬rent cementation-in-pulp of copper from the leach liquor. Similarly, mechanical classifiers are used in uranium processing27 for separation of the barren sands from the pregnant leach solution. Depending on the particle size and the effectiveness of the sand¬slime separation, the sand product from mechanical classifiers may be drained to solids content approaching 84%. Thus, mechanical classifiers are frequently used as dewatering equipment for various applications, such as: 1) Make a product having suitable solids content for subsequent transport by belt conveyor. 2) Provide a drained product to reduce cost of drying. 3) Provide a drained, washed, heavy sand product for return to the circuit. 4) Recover fine values from dilute plant effluents from coal, sand, phosphate-rock, and iron-ore washing plants and from steel-mill flue¬dust scrubbers. 5) Drain residual reagents of a preceding process stage prior to conditioning with reagents of different characteristics, e.g., cationic¬anionic flotation of phosphate rock, iron ore, etc. Design and Operating Features The proper selection of mechanical classification equipment re¬quires that the properties of the solids and liquid are adequately de¬fined. The following descriptive information regarding the solids is desired: feed rate, chemical and physical composition, density, tem¬perature, size analysis, and desired separation size. For the liquid used, the following data would be needed: feed rate, density, viscosity, pH, and temperature. Settling Area. The pool area required to permit a particle larger than the separation size to settle depends on the density and shape of the particle and on the density and viscosity of the pulp within the classifier pool. These criteria of the solids and pulp determine the settling rate which, in turn, determines the settling area required. Determination of the settling rate by long-tube batch tests can be used to calculate the settling area. A theoretical approach for estimat¬ing the settling area requirements is discussed in Chapter 1, Classifica¬tion Theory. This procedure can be used when neither test data nor empirical data from similar operations are available. Data on settling-area requirements and settling rates have been compiled by the manufacturers of mechanical classifiers. The approxi¬mate settling area required for a particular separation size can be estimated by using the curve shown in Fig. 65. This curve applies for closed-circuit grinding applications. For dilute velocity classification in open circuit, desliming, the length of the overflow weir, W, multiplied by the weir's mean distance from the feed opening, E, is used as the design criterion, instead of the settling area, in sizing the classifier. The area requirements, W X E, for dilute velocity classification can be expressed in terms of volumetric flow, Q, and settling rate, Rs, as follows: W x E = Q/(18.06 Rs) where W and E are feet, Q is gallons per minute, and Rs is inches per second. Overflow Weir. The hydraulic head, and thus the velocity at which the overflow crests the overflow weir, is one of the factors controlling the particle size of classification. Consequently, the length of the overflow weir must be designed to provide the overflow velocity which allows the particles larger than the desired size of classification to settle in the working area of the pool. Obtaining the necessary

Jan 1, 1985

By R. H. Bartlett

Hydrometallurgical processes for copper flotation concentrates avoid the S02 emission problems associated with smelting, but they require oxidation of copper to obtain solubilization during leaching. The resulting copper ions must be reduced to metal, which normally requires large amounts of energy or energy equivalent reagents such as hydrogen or iron. The conventional reduction method is electrowinning which is labor intensive and involves 35 to 40% of both the en-tire operating and capital cost of the better hydrometallurgical processes. Smeltermen are correct in criticizing the available hydrometallurgical processes for being more energy intensive than modern smelting processes. Clearly, there is considerable incentive to reduce the cost and energy required for reducing copper ions from solution. Furthermore, it is thermodynamically possible to do this using sulfur contained in the concentrate itself. In fact, the thermodynamic potential of oxidizing sulfur from S+4 to the S+6 state is greater than required to reduce cupric ion to metallic copper. (1) Realization of this potential in a practical process would significantly reduce the cost of hydrometallurgical processing of sulfide concentrates because sulfur would become a cost-free reducing agent. An apparently practical method is to use SO3 and HSO3 ions, obtained by ammonia scrubbing of SO2 from a concentrate roaster gas, to reduce leached copper to metal in an autoclave. This reduction step is the Jumau 1907 patent. (2) A series of steps including sulfite reduction constituting a crude flowsheet was suggested by Parker in 1976(3), but apparently little development work has been done by him, since he has been interested in new routes of refining the resulting copper powder. The purposes of the present paper are to elaborate on the Jumau-Parker thrust. Describe a detailed complete sulfite process flowsheet based on materials and energy balances, discuss the chemistry, and discuss further work that is required to develop this process. The results of the present paper are largely based on a synthesis of the steps using handbook chemistry. Process materials, utilities costs, and energy requirements are projected to be unusually low.

Jan 1, 1978

By E. J. Wasp

The transportation of mine products incurs a cost which can have a significant bearing on the competitive position of the manufactured product. Clearly, the engineer who is responsible for selecting a mode of transport must base his decision, at least in large measure, on economic comparisons. And today, the engineer usually finds that he has to choose between several modes, including slurry pipelines. For the purpose of an initial economic screening, it is not necessary to go deeply into the technical details of a slurry system. What is usually needed, however, is a method with which the engineer can make a quick economic assessment to determine whether a slurry pipeline should be included in the detailed final analysis. This paper presents a rapid method for making such a preliminary appraisal. Experience with commercial slurry pipeline systems in several countries and with a variety of solid materials has shown that if several assumptions pertaining to critical design variables are made, it is possible to roughly estimate the transportation cost of a slurry system on the basis of only three factors: the specific gravity of the solid material, the length of the system, and the quantity of slurry to be pumped each year. It is assumed that conditions pertaining to field construction, corrosion inhibition, and the like, will be favorable. This assumption is critical because any factor which analysis shows to be particularly unfavorable will raise the total transportation cost estimate which this paper establishes. If the engineer employs this estimating procedure and decides that the use of a slurry pipeline is economically unattractive, his chances of being wrong are small. Conversely, if his quick appraisal indicates that the use of a slurry system is economically favorable, the engineer is justified in committing the time and money needed to make a more detailed investigation of the slurry pipeline potential.

Jan 1, 1969