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By J. Yianatos

The collection zone residence time distribution (RTD) of mechanical self-aerated flotation cells was characterized for liquid and solid per size class (-45 mm, +45-150 mm and +150 mm). It was found that a single large industrial cell with a volume of 130 to 250 m3, now used in plant operations, can be well represented by an LTST (large and small tank-in-series) model plus dead time. From a scale-up point of view, results showed a similar mixing behavior for industrial cells ranging from 130 to 250 m3. Also, single mechanical cells showed a similar mixing pattern (RTD) when compared to large pneumatic flotation columns. It was confirmed that for practical purposes, the mixing condition in a flotation bank of three or more cells in series can be well described by the classical N tanks-in-series model.

Jan 1, 2008

By F. Maciosek, D. Denton, J. Johnson

Researchers from the Spokane Research Laboratory of the National Institute for Occupational Safety and Health and personnel from Coeur Silver Valley, Wallace, ID, conducted tests using rock strain strips and Split-Set rock bolts instrumented with strain gauges to monitor wall rock strain at the Galena Mine, Osburn, ID. The objective of the test was to identify whether strain on the rock bolts increased prior to a rock burst. Although results were inconclusive, researchers learned that the Split-Set rock bolts yielded in stick-slip fashion in the highly jointed walls of the stope. The bolts were also bent as stress was redistributed following blasting and subsequent movement along joints in the wall rocks.

Jan 1, 2004

By Brendan Demich, Joseph McGuire, Emily J. Haas

Near misses recorded and reported by workers can provide awarenessto the potential causes of injury and prompt safety management initiatives. Although most companies require near-miss reporting, it is unclear what the value of these reports are, if any, and how they influence subsequent actions or controls to reduce on-the-job risks. Researchers at the National Institute for Occupational Safety and Health (NIOSH) conducted a case study with an aggregates company in which near-miss reports were analyzed at each of their locations over an entire quarter during the summer of 2018. Within that quarter, workers recorded 249 near misses. Of those, 167 were valid near misses that occurred at work. Researchers coded the reports using a qualitative 5 × 5 risk matrix. Of the 167 near misses, 19% were deemed low risk, 25% moderate risk, 30% high risk, and 26% critical risk. Several patterns in the near-miss incidents were documented, including classification of incidents and common corrective actions referenced (i.e., elimination/substitution, engineering control or redesign, work process/procedures, and personal protective equipment). The analysis provides insight into ways that risk communication and management programs can be improved to reengage workers and their situational awareness on the job.

By Dexter C. Hatch

At MacIntyre Development of the National Lead Company, Taha s, New York,, the flotation plant was set up to recover ilmenite from the finer size fraction of the ore that cannot be efficiently treated in the main gravity-magnetic separa¬tion process. It was later expanded to handle the reground middlings from the tables wetherill magnetic separators. The ilmenite-magnetite ore is ground to minus 20 mesh in five 6 x 12 ft. rod mills in closed circuit with DSM screens. The minus 20 mesh screen undersize is pumped to four parallel sections each consisting of two rougher wet-magnetic separators and one cleaner separator for magnatite removal. The screen undersize from the fifth section is distributed to all four sections. The magnetite removed in the roughers is pumped back to the cleaners and the cleaner magnetite is dewatered in rake classifiers and carried by belt to the winter plant or the stockpile area. The nonmagnetic sands from rougher and cleaner magnetic separator are sized for table feed in eight pocket hydraulic sizers. The slime overflows from the Crocketts, the sizers, and the magnetite rakes are collected and pumped to three-inch cyclones for thickening and desliming. The cyclone underflow is the principal flotation plant feed.

Jan 1, 1962

By M. Bunch

"THE SUPER CYCLE IS GONE The utopia of the rising sales volume, for mining companies from 2002-2011, was entirely due to rising production volume and prices. The Australian mining sector experienced an 18 percent annual growth rate in revenues, and 11 percent growth in prices. (1) However, EBIT remained flat during the same time period. In addition, Australian mines saw a 7 percent annual decline in both labor and capital productivity. (2) Mines in the U.S. and Canada produced similar results, whereas the world-wide mining industry has seen a productivity drop of 40% since 2001. (3) The decade “Bull Run” of rising prices was trashed by companies that chased low-quality assets while increasing debt on their balance sheet. It seemed everyone believed the “super cycle” would last forever, while completely ignoring the history of cycle downturns. Worldwide mining operations are as much as 28 percent less productive today than a decade ago, according to new McKinsey research. The results from McKinsey’s new MineLens Productivity Index (MPI), which adjusts for declining ore grades and mine cost inflation, show that the pronounced decline in productivity is evident across different commodities and is seen in most mining players and geographies. (4) McKinsey sees three important areas of focus to address the root causes of productivity decline. 1) Embed effective management operating systems at mines 2) Prioritized operational excellence and capabilities development 3) Focus on innovation Reality has now settled back in and companies are struggling to make ends meet. The basic management staple of controlling costs and improving the production/productivity that was lost in the excitement is now back in play. Traditional cost-cutting approaches, such as across-the-board spending cuts, layoffs, and hiring freezes are only short-term initiatives and will not permanently improve a company’s cost structure or improve long- term competitiveness. This can only be accomplished by engaging front-line employees and empowering them to make necessary improvements in their daily work. It is time for leaders to lead and develop cultures of continuous improvement within their organizations in order to sustain their mining project to the end of mine life. Successful operating managers require two different skill sets of Leadership and Management; knowing how to lead people in their organization and how to manage the work they do."

Jan 1, 2016

By H. Akbari

Ordinary portland cement (OPC) is the key pozzalonic component of the concrete mix widely used as a construction material worldwide. B illions of tons of OPC are used in the construction industry each year. However, calcinations of limestone and silica that produce OPC also produce almost an equal amount of C O2 during the cement manufacturing process. Thus, OPC production accounts for nearly 7% of all anthropogenic C O2 emissions each year. The main objective of this study was to develop a geopolymer-based composite to be used as a substitute for OPC in concrete application to significantly lower the carbon footprint of the construction industry. A waste material produced during the coal combustion process was used as the main raw material for the geopolymer-based composite. It was mostly the nonmetallic content of the F-type fly ash produced from the combustion of bituminous coal. The authors envisioned extracting some of the valuable metal oxides from fly ash prior to using the major nonmetallic portion of the fly ash for geopolymer concrete application. The results obtained from this study showed that the compressive strength of geopolymer concrete compares favorably with that of conventional concrete prepared using OPC.

Dec 1, 2013

By J. A. Ober

"In 2015, the estimated value of nonfuel mineral production in the United States decreased by 3 percent from that in 2014 (Table 1), mainly as a result of decreased metal and metallic mineral prices, especially iron ore, copper and precious metals. Lower metal prices were attributed to decreased consumption, especially in China and increased global inventories. Several U.S. metal mines were idled in 2015, including the only U.S. rare earths mine at Mountain Pass, CA. Downstream processors also were affected, with smelters and refiners either shutting down or idling production lines. Increases, however, took place in the value and quantity of production of industrial minerals, especially those used in the construction sector, including cement, construction sand and gravel and crushed stone. Trends in mineral-related sectors of the domestic economy, except for iron and steel manufacturing, aluminum manufacturing, coal mining and metals mining, all experienced growth (Table 2).Discussion of mine production is frequently segmented according to the type of materials produced within the broad categories of metals and industrial minerals (also known as nonmetallic minerals). Industrial minerals can be further subdivided as construction aggregates and other industrial minerals. Metals tend to have higher unit values but very low production quantities compared with those of industrial minerals, which have higher production quantities but are lower-valued materials, such as crushed stone or construction sand and gravel. Therefore, for discussion and analysis of the performance of the nonfuel minerals industry, the value of production is used rather than the tonnage produced. Tonnages of construction aggregates are orders of magnitude larger than those for most other mineral commodities thus making direct comparisons based on weight meaningless (Fig. 1).Mineral industry performanceThe estimated value of domestic nonfuel mineral production, including metals ($26.6 billion) and industrial minerals ($51.7 billion), in 2015 declined to a total of $78.3 billion, from $80.8 billion in 2014 (Table 1). However, as shown in Fig. 2, minerals remained fundamental to the United States economy, contributing to the real gross domestic product at several levels, including mining, processing and manufacturing finished products. Net exports of mineral raw materials and old scrap were $14.4 billion. Domestic raw materials, along with domestically recycled materials, were used to produce mineral materials worth $630 billion. These mineral materials, including aluminum, brick, copper, fertilizers and steel, and net imports of processed materials (worth about $32 billion) were, in turn, consumed by downstream industries with a value added to the gross domestic product estimated to be $2,490 billion."

May 1, 2016

By Christopher B. Kapes

To reduce concentrate dewatering and drying costs, the Concentrator Division at Phelps Dodge Morenci, Inc. investigated available filtration technologies. Numerous methods were explored, including: drum, disk, belt, pressure, hyperbaric, and ceramic media filtration. An economic evaluation of the individual filtration technologies indicated the advantages of ceramic media filtration for Morenci concentrates. This paper discusses the technological development culminating in the first full scale application of ceramic media disk filters in North America. Low moisture contents are obtained at high production rates and greatly reduced operating costs.

Jan 1, 1994

"INTRODUCTION In recent years, there has been increasing focus on environmental and social impacts of the extractive industries, climate change and resource scarcity. The concept of the circular economy aims to replaces the “take-make-dispose” economic model with one that eliminates waste of all kinds and is restorative by design. Such closed-loop systems implicitly aim to reduce the quantity of primary extracted materials entering the economy, thereby affecting supply and demand dynamics, hence mining industry economics. For the metals industry, the ability to engage in, or adapt to the circular economy can be heavily affected by industry structure and geographical factors. Eco-efficiency initiatives that reduce waste and environmental impact may help the mining and metals industry align with some of the goals of the circular economy. This paper focuses on base metals, and explores case studies in copper, lead and zinc. It analyzes primary and secondary metal production, and recycling. It examines company structures and how these affect engagement with the circular economy. CIRCULAR ECONOMY PRINCIPLES Ellen MacArthur Foundation (2012) describes the circular economy as “an industrial system that is restorative or regenerative by intention and design”, which “replaces the ‘end-of-life’ concept with restoration”, and “aims for the elimination of waste through the superior design of materials, products, systems, and, within this, business models”. The concept is systems focused. For materials such as metals, a series of loops are considered, including maintenance of devices, reuse, refurbishment and recycling. Potential methodologies to achieve circular economy outcomes include disassembly and reassembly of manufactured goods, leasing rather than buying major appliances, and converting to renewable energy sources. The circular economy is partially aligned with the principles of eco-efficiency, which relate to reducing the environmental impact per unit of a material produced. PRIMARY AND SECONDARY METAL PRODUCTION Base metals (copper, lead, zinc and nickel) are essential ingredients in modern economies and are key commodities produced by the global mining industry. Metal production can be categorized as primary or secondary. Primary metal comes from the processing, smelting and refining of metal content extracted from ores, while secondary production comes from metals recovered from recycled streams (e.g. recycled lead-acid batteries, copper wire scrap, etc.). Metals are stored in natural, anthropogenic in-use and anthropogenic waste stocks. An example of the stocks, flows and processes associated with global copper extraction and use is shown in Figure 1."

Jan 1, 2018

By G. Goellner

The thick alluvial sand and gravel deposits along the base of the San Gabriel mountain range in Southern California area have been mined for construction aggregates for over 100 years. Encroachment of high-density urban populations in this area has led to concentrated mining in a handful of open pit mines with single production faces reaching up to 55 m (175 ft) in height, and long transportation distances from the pit to the processing plant. Aggregate producers have responded to these challenges by developing innovative mining systems which enable low-cost, full-face mining of the alluvial material, and low cost delivery of this material to the plant.

Jan 1, 2004

By Charles F. Coleman

Kinetics studies and other rate measurements are reviewed in the amine extraction of uranium and of some other related and associated metal ions. Equilibration' is relatively fast in the uranium sulfate systems most important to uranium-hydrometallurgy. Significantly slow; equilibration-has ' been encountered' in some other systems. Most of the recorded rate information, both qualitative and quantitative; has come from exploratory and, process-development development work, while some kinetics studies have been directed specifically toward elucidation of, extraction mechanisms. In contrast to some other extraction systems, relatively little attention has been given to the kinetics of uranium extraction by amines. This is because investigators have not been troubled by slow extractions. Instead, when rate limitations have been of concern in amine extraction (Amex) process developments, they have been mainly from slow phase disengagement rather than from slow equilibration. Nevertheless, taking uranium together with several other elements that are closely related to it or associated with it in typical processes, a considerable body of rate information has been recorded.

Jan 1, 1979

By P. Rambalee

A multiple coal fired boiler house provides steam for utility usage in various production plants. Maintaining stable header pressure and boiler availability is of critical importance for downstream consumers. Advanced Process Control comprising of a G2 based expert system and Model Predictive Control was implemented to improve the boiler house performance. The results yielded improvements in the main header pressure stability, reduction in boiler saturation and significant saving in coal consumption. All information used for this document is from a published whitepaper written and led by Prevlen Rambalee (Anglo Platinum) and Gustaf Gous (BluESP) titled, ?Control and Stabilization of a Multiple Boiler Plant: An APC Approach?.

Jan 1, 2012

By J. A. Herbst

A state of the art computer simulation package, named UTAH-MODSIM is being developed. This package can run on a mainframe (eg. UNIVAC) as well as on a microcomputer (eg. IBM/PC with at least 512 kBytes of core memory). Friendliness was the major concern in developing this software. The user simply generates a complete flowsheet by presenting the flowsheet on a graphics terminal. This flowsheet defines the circuit to be simulated. With the minimum required data, the user can obtain a complete mass and water balances within a few minutes. Moreover, this package will provide scale-up and capital cost information of specified equipment relevant to design. In order to illustrate the utility of this software, three design examples are given. They are: a) A typical multistage crushing plant. b) A reverse closed grinding circuit comparing one stage with two stage classification. c) A standard closed grinding circuit suitable to liberate a specified fraction of chalcopyrite from a copper ore.

Jan 1, 1986

By Carlton M. Ray, William P. Levy, Thomas Lindberg

"The District of Columbia Water and Sewer Authority (DC Water) is implementing its $2.6 billion DC Clean Rivers Project to reduce combined sewer overflows to the District’s receiving waterbodies and mitigate chronic sewer flooding in District neighborhoods. The First Street Tunnel project is a major component of the DC Clean Rivers Project, designed to mitigate sewer flooding and basement backups in the District’s historic and densely populated Bloomingdale neighborhood. Bloomingdale has been historically affected by sewer flooding and was severely impacted by four storms in the summer of 2012 that caused significant damage to homes, the environment and public property. As a result, DC Water accelerated the design and construction of the First Street Tunnel in order to mitigate the effect storms have on the undersized sewers serving the neighborhood. The infrastructure designed to mitigate flooding, including the tunnel, are located within the highly urbanized neighborhood – with some structures being less than ten feet from residents front door steps. The success of a large public works project of this magnitude and in this unique location depends on a well informed and supportive public. With the local community impacted by flooding but concerned about heavy construction impacts, this paper details the components of a successful public outreach plan and lessons learned throughout the design and construction process. Early identification of community mitigation, working cooperatively with stakeholders and frequent dissemination of accurate information required the project team to establish a culture of problem solving collaboration with the community. BACKGROUND Chronic Flooding in the Northeast Boundary Sewershed The Northeast Boundary sewershed, in which the Bloomingdale neighborhood is located, is served primarily by a combined sewer system and has a long history of chronic flooding problems during moderate to severe storm events. The sewer system that serves the Northeast Boundary drainage area was constructed by the Federal Government in the late 1800's when developed areas of the District terminated at what is now Florida Avenue. Since construction of the system, population within the sewershed area has grown at an exponential rate. In meeting the growing needs of the population, the District experienced development that transformed previously low-density rural areas into new communities. Impervious areas have increased drastically since the sewer system was constructed and consequently, the existing sewer system does not have the capacity to convey storms with return frequencies beyond the 2-year storm without flooding. As a result of the capacity limitations, many of the low-lying areas have become chronic flooding areas due to the surcharging of sewers."

Jan 1, 2016

By Warren H. Weisz

A cement, in the broad sense, is any substance which will cause various materials to adhere to each other. Clay was probably the first material to be used by man as a cement or binding agent. Water occurs in or is mixed with the clay to make it plastic, so that it can be formed in place. The sun and air remove the water from the clay and on drying strength is developed. The clays unless fired are not too resistant to water, therefore, their use is best when restricted to dry areas. Gypsum used as a cementitious material is not the subject of this paper, but its use dates back thousands of years. Gypsum mortars were used by the Egyptians in building such massive masonry structures as the pyramids. The Egyptian mortar consisted of a mixture of sand with burned gypsum (of an impure type of 81.5 per cent calcium sulphate and 9.5 per cent calcium carbonate) for the cementitious material. The burning of this type of cementitious material took place at relatively low temperature. These burning reactions will be covered later when the dehydration of gypsum is discussed. The setting of the partially dehydrated gypsum is considered to be crystallization from a supersaturated solution which deposits crystals of dihydrate (gypsum). In low water-content mixes, the interlocking of the needle-like crystals helps to produce higher strengths. Slaked lime made from limestone burned at higher temperatures (1648 F is generally considered as the calcining temperature, although under certain conditions incipient calcination will take place at 1250 F) is another early-period cementitious material. During slaking with water, a colloidal or amorphous hydrated lime is formed. When it is allowed to dry, it hardens and develops low strengths. On exposure to the carbon dioxide of air in the presence of some moisture, carbon dioxide is adsorbed and part of the calcium hydroxide is converted to calcium carbonate. Structures in which a lime mortar is used continue to grow in strength as this reaction proflesses. Hydrated lime has the disadvantage of not setting under water.

Jan 1, 1960

By J. F. Burr, D. P. Snyder, G. W. Luxbacher

"The Mine Improvement and New Emergency Response Act (MINER Act) of 2006 (PL 109-236, 2006) established the Office of Mine Safety and Health, functioning as the Office of Mine Safety and Health Research (OMSHR) within the National Institute for Occupational Safety and Health (NIOSH) and provided authority for awarding contracts related to the development and implementation of new mine technology and equipment. The OMSHR external contracts program was formed in accordance with the MINER Act and has since issued more than 150 contracts focused on worker health and safety. Initial funding for this program was provided by the United States Congress through two emergency supplemental appropriations and was focused on emergency oxygen supply, communications and tracking, and refuge chambers (also referred to as refuge alternatives). Since the MINER Act, Congress has continued to fund the program through the annual NIOSH mining appropriation. The program was supplemented starting in 2009 with an academic capacity building program directed toward developing university tenure-track faculty and facilities and supporting graduate students in the area of mine ventilation. Ground control was added as an additional focus area in 2011. A short synopsis of each contract is published on the NIOSH Mining website (www.cdc.gov/niosh/ mining/researchprogram/contracts/index.html) and final reports are available in digital form on request. A summary of the progress OMSHR has made over the 10-year period since the Act was published previously (Snyder et al., 2016).External contracts are broadly classified by the following areas:• Communications and tracking.• Emergency response.o Self-escape and breathing air supply.o Refuge alternatives.o Escape and rescue.• Equipment safety.• Fires and explosions.• Ground control.• Mine environmental systems (mine ventilation and atmospheric monitoring).• Worker/workplace health and safety.Contracts are issued under a request for proposal (RFP), through a broad agency announcement (BAA) or under an interagency agreement (IAA). An RFP solicitation includes a specific problem description and a well-defined scope of work to guide the offeror in preparing a bid to conduct the research. Under the BAA several problem areas are described and the offeror develops the scope of work and deliverables for the proposed research. An IAA is very similar to an RFP except it is a contract between two federal government agencies."

Jan 10, 2018

By Victor Romero, Steve Redmond

All Rights Reserved. Printed in the United States of America. Information contained in this work has been obtained by SME, Inc. from sources believed to be reliable. However, neither SME nor its authors guarantee the accuracy or completeness of any information published herein, and neither SME nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that SME and its authors are supplying information but are not attempting to render engineering or other professional services. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. Any statement or views presented here are those of individual authors and are not necessarily those of the SME. The mention of trade names for commercial products does not imply the approval or endorsement of SME.

Dec 1, 2011

By Adam Shang Robert Fu

The Yung-Chung-Tunnel in Taiwan, constructed for the Taiwan-East Railway Bureau, collapsed during construction when a water bearing, fractured marble zone was intersected. The inflow was approximately 4,000 liters/second. In spite of 30 relief holes the total inflow into the tunnel remained constant. The pre-excavation grouting through the re-aligned tunnel had to be conducted under extreme flow-conditions. A hot bitumen grouting program was selected for technical and economical reasons out of 13 international proposals. The technical challenges were: grouting under severe flow conditions high formation water pressures to be injected with hot bitumen at high temperatures and pressures The hot bitumen grouting program resulted in a dramatic reduction in the hydraulic conductivity and stabilization of the formation and facilitated a problem-free excavation.

Jan 1, 2007

On June 4, Kennecott Utah Copper (KUC)marked the centennial of the founding of the original company. Bill Champion is president and chief executive officer of KUC. He said, “What has happened during the past 100 years far surpassed even the most optimistic visions of men like Daniel C. Jackling and Robert Gemmell when they promoted the concept of mass production techniques for a low-grade deposit of copper ore. At that time, it was a totally new way of doing things and the mining leaders of that day scoffed at the idea. They said it would never work,” Champion said. The company will celebrate this once-in-a-lifetime occasion with a few special projects, mainly for the benefit of our employees, said Louie Cononelos, director of government and public affairs for KUC. The company has designed and minted a commemorative copper coin that reflects early steam shovel and locomotive operations on one side, and today’s modern electric shovels and huge haulage trucks on the other side. “The history of the company stems from the ores of the Bingham Canyon Mine. That coin has been encased as part of a10-panel brochure that captures the company’s 100 year history,” he said. KUC also developed special centennial banners and comparable framed posters that were displayed throughout its operations and at selected community locations that have enjoyed a long-time partnership and special relationship with the company. Some of the plants also designed their own centennial hardhat decals.

Jan 1, 2003

By William G. Fischer

This paper attempts to close the gap between extensive rock testing with field measurements and the mine operator's need for safe mine layouts and alternatives. It was found that many of the variables that influence mine geometry and worker safety are relatively unimportant while others are critical. The development of empirical relationships which tie the critical variables to the "safe useful life" of a trona mine layout and observations made in 140 production areas where the variables were researched over a fifteen year period are discussed. The concepts presented may have applicability in mine design for other bedded deposits.

Jan 1, 1984