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By D. E. Ranta

Orebodies with intricate three-dimensional shapes (such as porphyry molybdenum deposits) are difficult to model using geostatistics or other computer-assisted methods. The strong trends in their spatial grade distributions occur as mathematically complex shapes and prevent the customary assumption of local stationarity that is required for accurate ore reserve estimation. "Zoned Kriging", a new method developed by AMAX, solves this problem directly by using the geologist's interpretation of the ore zones as a parameter in the kriging equations. The geological basis and methods used in the Climax ore zoning technique are reviewed and discussed relative to their application in zoned geostatistical modeling. The Zoned Kriging technique is described and demonstrated using data typical of mineral deposits.

Jan 1, 1984

By Dennis S. Kostick

Soda ash is the common name for sodium carbonate (Na2CO3), an alkali compound that is the 11th largest inorganic chemical in terms of production of all domestic inorganic and organic chemicals, excluding petrochemical feedstocks. Despite that most people have never heard of soda ash, it is an important industrial compound used to manufacture glass, chemicals, soaps and detergents, pulp and paper, and many other familiar consumer products. Natural alkalis have been used by mankind for thousands of years; however, their industrial manufacture dates back to only the latter half of the 18th century. Natural deposits of sodium carbonate have been known as early as about 3500 BC, when the Egyptians used natural soda ash in making glass. They also mixed lime and soda ash to make sodium hydroxide (caustic soda) that was combined with silicate minerals found in the Sinai desert. This made a soluble silica, which when added to aluminum-rich silt from the Nile River, produced a silica- aluminate cement mortar with excellent bonding properties for construction. The Romans in the first century AD also used natural soda ash in glass manufacture but expanded its use medically for the treatment of colic pains and skin eruptions, and in the making of bread. Elsewhere, people used the ashes of wood to obtain their source of alkali. People learned over time that different types of wood yielded various ashes with different properties; therefore, various plants were burned specifically for their ashes. Ash from plants grown in salt-bearing soils (such as saltwort) and from kelp and other seaweeds, especially Spanish barilla, were so different from ashes obtained from other vegetation that it became known as soda ash (due to its sodium content) versus pot ash, a potassium-based alkali ash. About 13 t of barilla ashes produced 1 t of sodium carbonate and 14 kg of iodine as a byproduct. The difference between these two ashes was relatively obscure until Duhamel Dumonceau made the distinction clear in 1736. The word soda ash developed from common usage and is perhaps more well known today than its synonym sodium carbonate. One of the primary ores of soda ash is trona, a sodium carbonate-bearing mineral that's name is traced back to Arabic origin. Trona also is known internationally by other names such as urao (Venezuela), kaum (Nigeria), natron (from Greek nitron and Latin natrium), and szekso (Hungary). The beginning of the Industrial Revolution in Western Europe in the late 18th century soon put a strain on the availability of raw materials to meet consumer demands. One of these scarce materials was soda ash. Because of the Seven Years War with England and the Napoleonic wars with other parts of Europe, France could not obtain sufficient quantities of Spanish barilla or other supplies of vegetable alkali to meet the growing demand. Efforts were needed to synthesize soda ash. In 1775, the French Academy of Sciences offered a large prize of 2,400 livres to someone who could find an inexpensive method to make soda ash. In September 1791 at St. Denis, Nicolas Leblanc (1742- 1806), a French chemist, developed such a technique using salt, sulfuric acid, coal, and limestone. The French Revolution interfered with its development, and his patent and factory were confiscated with Leblanc receiving only token compensation. Napoleon returned his factory to him; however, Leblanc was not able to raise enough capital to reopen it, and he committed suicide in 1806. A small, but not particularly successful, Leblanc plant was established in England in 1814. It was not until 1823 when the process first became commercially successful in Liverpool, England. The process was introduced in Germany in 1843 and in Austria in 1851 (Harness and Coons, 1942). Soda ash production by the Leblanc process reached its peak of about 599 500 t in 1880, after which it began to decline as the Solvay process became more popular. The Leblanc process was used to a limited extent in Europe during World War I but had disappeared by World War II. The Solvay process, also known as the ammonia-soda process, was developed by Alfred and Ernest (1 838-1922) Solvay in 1861 based on a concept by Fresnel that had been known since 1811. For the next 50 years, the implementation of the idea evaded industrial chemists because no large-scale and economic means could be found to commercialize the concept. Although Ernest Solvay was unaware of the existance of an ammonia-soda concept, he solved the problems by utilizing carbonating towers. The Solvay process produced soda ash from salt, limestone, and coke, with ammonia as a catalyst. With a capital of 136,000 francs, the first plant was built by the Solvay brothers at Couillet, Belgium, in 1863 with production commencing in 1865. Synthetic soda ash production amounted to 1.5 tpd in 1866, but reached 10 tpd by 1872. They patented their use of carbonating towers in 1872 that had made ammonia-soda manufacturing a successful continuous process. Their second plant was built in 1872 at Dombasle, France. In 1874, the first Solvay plant in England was built at Northwich by Ludwig Mond, the namesake of Brunner Mond and Co. (formerly Imperial Chemical Industries), the company that currently operates the two English Solvay plants. In the United States, William B. Cogswell in February 1879 heard a presentation on the Solvay process and sailed to Europe to meet with the Solvay brothers to seek their support for using their process in New York. At first, the brothers were not interested; however, Mr. Cogswell was persistent and ultimately gained their support. The Solvay Rocess Co. was formed Sep. 2 1, 1881, and construction began immediately on the first Solvay plant at Geddes, near Syracuse, NY. The plant came onstream Jan. 10, 1884, and produced 11 180 t in its first year of operation. In 1910, rotary calciners were installed that increased capacity to 1 000 tpd. By 1930, plant capacity was up to 2 400 tpd. The facility remained in continuous operation for more than 100 years. By 1939. 10 Solvay soda ash plants were in operation in 6 States throughout the nation. The Syracuse plant was officially closed Jan. 6, 1986, with total shutdown completed by Feb. 1986. Ironically, this facility was the first Solvay plant as well as the last. Other than the first Solvay plant beginning in 1884, the majority of US soda ash supplies during the 19th century came from imports. The remainder of the US supply

Jan 1, 1994

By Dominique Francois-Bongarcon

The rational and optimal determination of the design of a mining exploitation is a very intricate and difficult problem : the parameters are numerous, some technical, some economic or technico-economic which cannot be fully controlled; beside, deposits are estimated from very limited information and the choice criteria are not always quantitative, the economic context has to be anticipated by several years, and even the technological limits can change tomorrow. So, although very clever and performing numerical algorithms have been developed in recent years for open-pit design, we consider that this problem has not really been solved satisfactorily until now. The reasons are that people have concentrated their efforts on informatical algorithmical problems, and have assumed that the technical and economical data are well defined at the time of the study, which is generally not true. In particular, the mere fact of assigning dollar- values to blocks in order to maximize the total cash-flow is generally unrealistic because of the uncertainty of the data used. Consequently, the significance of the unique pit obtained as a result of these algorithms is questionable.

Jan 1, 1981

By R. G. Bradburn

The events which led to computer control of the grinding circuit at Brenda Mines are described, beginning with mill operating philosophy. High production rates are encouraged so that, despite severe upstream disturbances, a manual control method to meet this philosophy had developed. Unfortunately, due to the time interval between manual control adjustments, losses in production resulted. An analog control method was devised and, although superior to manual control in some situations, was found to suffer from several practical limitations. The data logging capabilities of a control computer seemed warranted. Circuit test- work combined with an analysis of operating data showed that (1) metallurgical personnel, at times could increase production rates by as much as 10 percent over that achieved by grinding operators, (2) the chosen data base required an increase of 2 percent or more to be statistically significant and (3) for a 2 percent increase there would be a significant rate of return of investment in a computer installation, Consequently one grinding circuit was fully instrumented, and a rented control computer was installed by Brenda personnel. Prior to installation, Brenda metallurgical and instrumentation personnel were trained in the use of the computer. An experimental program was devised with short and long term objectives. The short term objective was to develop a practical control strategy which would yield immediate production improvement. This goal has been met as described in this paper. Statistically significant increases in excess of 2 percent have been established. Work is being completed for the permanent installation of computer control on all four grinding circuits at the present time. Long term objectives are (1) off line analysis of the circuit using mathematical models of process units, (2) on line experiments to study alternative contol tactics, and (3) possible expansion of computer facilities to the crushing plant.

Jan 1, 1976

By A. Bruynesteyn

Results are presented from a series of tests designed to determine the beneficial effects of the microorganism Thiobacillus ferrooxidans upon the leaching of uranium from a pyritic uranium ore. Minus 1-inch (-25mm) 0.0711 percent uranium containing, pyritic ore from the Rio Algom Mine at Elliott Lake, Canada was leached with lixiviants of various Eh and pH as well as being subjected to a biologically-assisted ferric iron leach. In all cases, the biological leach gave superior extraction. At pH 1.6, the biological leach gave 100.6 percent extraction and the ferric iron leach 69.8 percent. This improvement in extraction is associated with a relatively rapid biological breakdown of the pyritic material, thus liberating uranium mineralization associated with these pyritic materials and regenerating the ferric sulphate lixiviant in situ.

Jan 1, 1981

This paper presents the results of an investigation of the stability of the mass flow rates and average pellet size in the different streams of an industrial-scale balling circuit. The variables in this study include water content, drum speed and fresh feed rate. It was found that both the mass flow rates and pellet diameter are greatly disturbed when a change, positive or negative, in any of the variables takes place. For most of these disturbances to be damped don, a period of one hour or so is required. When a disturbance in the feed rate was made, the transient period extended to more than one and half hours (the duration of the experiment). It was observed that there is an interaction between the drum speed and moisture needed for producing an acceptable green ball product. The moisture content of the product pellets was found to be a function of the pellet size, with the larger pellets retaining a higher moisture content.

Jan 1, 1980

By V. F. Hollister

Although it is apparent that porphyry copper deposits may have formed in the Andean orogen from Permian time onward, commercial deposits thus far developed appear to have Cenozoic ages only. Following Chilean useage, the porphyry deposits are divided into either: (a) a stockwork, or (b) a tourmaline breccia model. Stockwork type deposits tend to occur on major strike-slip structures which may be either transcurrent or transverse faults related to plate movements, while the tourmaline breccia type may more frequently form independently of regional faults. Stockwork types may be conjugate fractures that intersect and ramify as a network of veins and veinlets, cutting altered rock, and genetically related to a major regional fault, or in other cases they may reflect the intersection of two large fault structures. Circular fracture patterns may more rarely occur in stockwork deposits in response to a specific intrusive. Tourmaline breccia types are characterized by circular and radial fractures genetically connected in some way with tourmaline breccia pipe development or an intrusive piercement that preceded it. Each structural model contains mineralized intrusive8 which have a close time-space relationship to ore and in each model, mineral paragenesis is similar, regardless of age or location in the plate. Also, each model contains the same type of alterntion halos (phyllic, argillic, prophllitic) as are developed in intru- sive centers in porphyry copper deposits found in North America. The potassic zone is exposed best in the older deposits. Examples of each type of deposit are illustrated, demonstrating the feature evolved.

Jan 1, 1973

By R. Q. Honaker

Recent research has shown that enhanced gravity separators provide the opportunity to effectively clean I mm x 37 micron coal. At Southern Illinois University, a detailed experimental program was performed on a continuous Falcon Concentrator, which was found to achieve separations at mass throughput capacity values in excess of 100 tonnes/hour. The apparent particle separation density for I mm x 73 micron coal was about 1.60 with relatively high efficiency (Ep = 0.12). Typical ash and sulfur rejection values of 85% and 70%, respectively, were achieved while recovering 85% of the combustible material. Metallurgical and efficiency data from the evaluation are presented in this publication.

Jan 1, 1998

By Hun-Joon Sohn

Chemical metathesis and electrochemical reductive conversion of chalcopyrite in the presence of cupric ions were studied in sulfuric acid solutions for temperatures up to 90°C. The process results in the displacement of iron in the chalcopyrite lattice by copper ions with rejection of ferrous ions to the aqueous phase. The rate of reaction was found to be very slow, requiring subsieve-sized particles for extensive reaction to occur. The reaction was insensitive to copper ion concentration. Stirred ball milling of chalcopyrite introduces lattice strain. The reaction rate with strained particles was markedly higher than with annealed chalcopyrite. The reaction rate was found to be diffusion-limited, showing two distinct reaction stages corresponding to the formation of CuS (covellite) followed by Cu1.8S (digenite). The experimental activation energy for the first stage was 102 J (24.4 kcal) and the second stage 123 3 (29.4 -kcal) per mole. The rate-controlling process is diffusion of lattice ions, probably iron. The enhanced rate after milling is attributed to a recrystallization process which provides new paths for diffusion along dislocations and grain boundaries.

Jan 1, 1984

By Vincent C. Grimshaw

High pressure fluid energy grinding, or jet milling, is a versatile method of continuously fracturing solids into fine particles to gain substantial increases in exposed surface area. Applications in the minerals industries include calcium carbonate, talc, barytes, mica, diatamaceous earth, bauxite, rutile, coal, kaolin, sepiolite, diamonds, etc. The basic principles can be extended to provide continuous drying and delivery of discrete particles from a wet process slurry. The main design and operational features of jet mills and dryers are described, relating energy consumption for both air and steam milling and hot air drying techniques. Mean particle sizes in the order of 1 micron are achieveable from pre-milled feeds, or maintained from similar slurries in the drying mode. Aspects of feed preparation and multi-stage processing are discussed.

Jan 1, 1983

By I. Iwasaki

The effects of percent solids, mill loading and grinding time on product size distribution and ball wear were studied in a laboratory ball mill for a taconite ore. Mild steel balls and HCLA steel balls were used to examine the role that ball hardness play in grinding. Net production of minus 325 mesh - material reached maximum at 70% solids, whereas the ball wear decreased as pulp density increased. HCLA steel balls ground the taconite ore finer than mild steel balls under otherwise identical conditions. Examination of ball surfaces with a scanning electron microscope suggested that grinding with mild steel balls involved nipping rather than attrition, whereas grinding with harder HCLA balls involved both nipping and attrition.

Jan 1, 1984

By J. J. Renton

The iron disulphide minerals, pyrite and to a lesser extent marcasite, are ubiquitous to coal and coal associated rocks and are the source of nearly all the environmental problems associated with the mining, processing and utilization of coal. The iron disulphides as well as the other minerals in coal exhibit systematic spatial pat- terns of distribution on both regional and local scales and show predictable associations, most of which are determined by the geochemical-sedimentological controls under which they form. It is the purpose of this paper to discuss the geochemical-sedimentological conditions responsible for the formation of coal minerals with special emphasis on the formation of iron disulphides, to illustrate the regional and local patterns of mineral occurrence within coal, to present the microscopic associations of the iron disulphides and finally, to discuss the most important single environmental aspect of the iron disulphide content of coal and coal associated rocks; the production of acid mine drainage.

Jan 1, 1986

By Edwarde R. May

The Flambeau volcanogenic massive sulfide deposit located in northwestern Wisconsin occurs within the southern lobe of the Canadian Precambrian Shield. The steeply dipping tabular body occurs in a complex pile of cyclic schistose intermediate to felsic fragmental volcanics. No chloritic alteration pipe is recognized but adjacent rocks have undergone magnesia metasomatism and subsequently were metamorphosed to the upper greenschist and lower amphibolite facies. Although modest in size the deposit is of special interest in that it has an extensive and well preserved supergene enrichment blanket. Economic minerals found within a pyritized quartz-sericite schist are chalcocite and bornite overlying primary chalcopyrite.

Jan 1, 1976

By M. K. Rizkalla

This paper discusses the time-dependent behaviour of rock when it involves the presence of several layers of rock strata in the vicinity of mine openings, mining in sequences and the placement of backfill. The paper describes numerical techniques which proved useful when such situations are encountered in practice. The model is elastoviscoplastic. At given time stations, short term loading or changes can be made to the creep behavior of the rock. The modelling technique is first described and is followed by simulations of stresses and displacements in a potash mine with the primary objective to demonstrate the effect of such aspects as mining and fill sequences in 3-D. This involves cutting finite elements representing the strip of the mining face and simultaneously filling those elements representing the newly placed fill. The stiffness of the fill varies with the degree of compaction at each point. In this way, the effect of the time of fill placement, the gap between the top of the fill and the back as well as the degree of compaction are simulated. The second example is a 2-D problem simulating the long term effect of backfill, as a material compacting with time, on the settlement of the layers above it as well as the closure of the room.

Jan 1, 1996

By R. Stefanko

Rock bolting as a method of support continues to increase with applications in many other industries in addition to mining. Nevertheless, with nearly 55,000,000 roof bolts installed in coal mines alone last year, this remains as the single greatest use. While bolts have frequently supported ground where conventional timbering could not, there are relatively few design criteria; and trial-and-error procedures prevail. Furthermore, development of suitable instrumentation that is simple to install and readout, sensitive, durable, reliable, safe and economical in evaluating the effectiveness of a bolt over long periods of time lags behind. Therefore, the pull test continues to be the most popular method of evaluating the applicability of a certain type of roof bolt under specific installation conditions. At Penn State in the Department of Mining, research has been conducted for a number of years to measure bleedoff in carefully controlled laboratory experiments as well as in underground investigations.1,2,3,4 Unfortunately, most of the instrumentation developed has been primarily suitable only for research purposes, not possessing all of the aforementioned characteristics desirable for routine underground use. Other groups also have met with restricted success. Therefore, while relatively crude, the torque wrench continues to remain as the most widely used load measuring device. While both field and laboratory tests continue to be conducted, analytical analyses are attempted to discover the more important design parameters in order that more efficient anchorage might be devised.

Jan 1, 1969

By Y. J. Wang

This paper deals with the application of linear programming to the solution of mine ventilation network problems which involve only the controlled splitting of air. An airway whose air quantity is to be controlled to a prescribed value is called a "fixed-quantity" airway. In a network where the fixed-quantity airways are increased in number and are distributed such that the air quantities for the remaining airways are uniquely determined by Kirchhoff's first law, the problem reduces to determining the head losses and locations for air regulators and fans. This is one of the network problems encountered most often in underground coal mines. By formulating Kirchhoff's second law as a set of linear constraints and the total air horsepower supplied by fans as a linear objective function which is to be minimized, the problem is analyzed through the technique of linear programming. Some important properties of the problem are discussed and examples are presented.

Jan 1, 1971

By Madan M. Singh

It is estimated that through 1975, there were 1.69x109 m2 (418 000 acres) of urban land threatened by potential subsidence due to mining with a value of over $12 billion (19;3 dollars; USBM, 1979). With increased coal production to meet the energy needs of the nation, both these figures may be expected to increase. Hence greater attention to controlling surface damage due to subsidence is merited. In fact, the Surface `lining Control and Reclamation Act of 1977 (SMCRA) (Public Law 95-87) mandates that underground coal mining operators "adopt measures consistent with known technology in order to prevent subsidence causing material damage to the extent technologically and economically feasible, maximize mine stability, and maintain the value and reasonably foreseeable use of such surface lands, ..." The term "subsidence," as used in this paper, implies the total phenomenon of surface effects associated with the mining of minerals, and not only vertical displacement of the surface as is sometimes inferred in the literature.

Jan 1, 1984

By J. T. Tanner

The research activities of the Minerals Research Laboratory, which is a part of North Carolina State University, is normally confined to solving beneficiation problems, and developing flotation processes for the mining industry. In recent years the laboratory has veered from its main purpose somewhat and has placed some emphasis on the manufacture of products from mineral concentrates. This has been the result of requests for help from industry. One such request came to the MRL from a talc producer in North Carolina who was having a difficult time competing with foreign imports of steel marking crayons. He felt that if a process could be developed whereby a satisfactory crayon could be produced from powdered talc at a low cost that he could compete.

Jan 1, 1986

By Vas P. Srinivasa

This paper examines the role of the heavy media separator in the mineral industry. Procedures used in selecting the separating vessel, developing the process flowsheet, and designing a heavy media circuit are discussed. For comparative purposes, the capital investment and operating costs of different types of operation are included.

Jan 1, 1981

By Mark A. White

Arch Mineral has developed several computer programs that aid the surface mine planning function. These programs are utilized to perform long term projections for various area or semi-area stripping operations. The program generated reports include yardage, tonnage, quality and ratio information for the user-specified time periods. The projections are used to anticipate the annual budget, to compare alternative mine plans and to analyze acquisition candidates. The programs are user friendly, fast and accurate. Geological Grid File Two data files must be set-up and used in conjunction with the mine planning programs. These are a geological data file and a general input file.

Jan 1, 1984