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By John T. Crawford

Open pit limit analysis techniques of various types have been utilized for many years to design ultimate pit surfaces. In the last 15 years there have been many advances in the development of sophisticated computer methods to aid this process. The extensive capability of the computer has led to multiple alternative approaches to problem solving. Computerized open pit limit analysis methods can be applied to a broad scope of long-range and intermediate-range mine planning and design questions. A single computer run develops a pit design from a set of data. A set of nonsequential runs is used to evaluate changes in pit slopes, property restraints, and mineral model variables. Ore reserve economic sensitivity and intermediate-range mining plans can be developed using sequential computer runs. Present value methods are incorporated by using iterative sequential techniques. Multiple ore processes, dump leaching credits, and the trade-off between open pit and underground mining can also be handled. Many of the applications described are representative of current practice. The remainder are suggested extensions.

Jan 1, 1979

By I. P. Giannopoulou

Flotation tailings resulted from the mineral pro-cessing of mixed sulfides ores represent the main source of the generation of acid mine drainage (AMD). These solid wastes remain un-utilized in the disposal areas (tailing dams), while for their stabilization and the immobilization of the contained heavy metals highly costly management techniques are required. In the present paper the geopolymerization of the flotation tailings resulted from copper sulfide ores dressing process is investigated, as an alternative method for their treatment aiming at immobilize the contained heavy metals and utilize the produced materials as raw materials in the construction materials industry.

Jan 1, 2006

By A. Adu-Acheampong

The Mid-Tennessee Zinc (MTZ) mines, comprised of the Gordonsville, Elmwood, and Cumberland sites, last operated 4 years ago and are undergoing rehabilitation to begin production in 2008. The mines utilize a random room-and-pillar mining method that results in complex ventilation networks. Upon decommissioning, the mechanical ventilation units were removed and disposed of and several shafts sealed. In an effort to re-open the mines and operate in compliance with imminent Mine Safety Health and Administration (MSHA) diesel particulate matter (DPM) regulatory limits of 160TC µg/m3, a new ventilation system was required. The new ventilation system was developed primarily based on the diesel equipment required to meet production. Particular emphasis was placed on the DPM, diesel equipment utilization, main fan sizing, and fan locations to enable the mines to meet MSHA?s ventilation requirements in a cost efficient manner.

Jan 1, 2009

By Jacques LeBel

After a brief definition of asbestos and a review of regulations, the elements of asbestos dust control are outlined for various asbestos manufacturing industries. To prevent the asbestos dust to become airborne, the general procedure is to control the dust at the source by enclosure and exhaustion. The asbestos dust is collected and removed from the air with bag filter collectors of high efficiency (better than 99%) to ensure that the air emitted to the general environment or returned to the workplace are below the existing asbestos emissions regulations. Dust control systems should be regularly inspected and serviced to maintain at all times the efficiency and reliability of the equipment. Other effective procedures for asbestos dust control are also considered.

Jan 1, 1984

"Outotec’s TankCell® e500 flotation cell was commissioned during 2014 at the Kevitsa Mine in northern Finland. The TankCell® e500 is the first cell in this size class (500m3) to be run in an operational duty and it has been working as the first rougher in the copper flotation circuit. Treating around 850tph with an average grade of 0.3% Cu the TankCell® e500 has run with an average copper recovery of 71% and an average enrichment ratio of 50. In addition the cell has proved to be very energy efficient, operating with a specific energy of around 0.4kW/m3 under production conditions. This presentation will provide a review of the installation and operation of the TankCell® e500 at Kevitsa and will summarize the results found in the published literature from the various testing campaigns conducted around the cell. INTRODUCTION The TankCell e500 was installed and commissioned at the Kevitsa mine in northern Finland in 2014. Post startup the cell was initially run for testing and optimization with various test campaigns undertaken. but was subsequently taken into a production duty (Mattson et al., 2015a). At Kevitsa the cell is run as the first copper rougher replacing the previous two copper roughers (both 160m3) in this duty. The unit is running at between 38-40% solids at a feed rate of approximately 850tph. Since operational the average copper recovery from this single cell has been around 71% copper. This is typically with an enrichment ratio of around 50 being fed with an average head grade of 0.3% copper. More details on the circuit configuration and production performance of the e500 at Kevitsa can be found in Mattson et al., (2015a) and Murphy et al., (2016). In addition through the optimization program with the use of a variable speed drive controlling rotor speed it was found the the e500 was very energy efficient under production conditions. During this work the cell was found to run at a specific energy of around 0.4kW/m3 which exceeded design expectations (Xia et al., 2015)."

Jan 1, 2016

By P. Somasundaran

Three major types of solution chemical equilibria involving flotagents (Le. flotation reagents such as collectors, frothers and modifiers), minerals and solution play a crucial role in determining the behavior of complex flotation systems. Minerals of phosphates (apatite and francolite), tungsten (wolframite and scheelite) and associated carbonates (calcite and dolomite) are sparingly soluble in aqueous solution and form dissolved mineral species in bulk solution. Such dissolved species interact with mineral solids, often resulting in surface conversion of the minerals. In addition, they can interact with various flotagents and lead to surface or bulk precipitation and loss of selectivity in the flotation. Relevant solution equilibria of such sparingly soluble minerals and their interactions with oleic acid and structurally modified reagents were determined in this study using a multi-pronged experimental approach. Methods to manipulate and control the solution chemical equilibria and thus achieve selectivity in flotation systems are discussed.

Jan 1, 1990

By D. Noon

Mine production crews and drill-and-blast crews may be exposed to unexpected movement of ground when working under pit slopes. Without specialist geotechnical advice and appropriate measurement systems, mine crews are faced with conducting risk assessments and relying on subsequent controls that may or may not be adequate to ensure their safety. Mine crews need an ?early warning? monitoring system to give them the confidence that they will have time to walk out of the danger zone if the pit slope begins to move. Slope stability radar technology is used by mine geotechnical engineers to assess overall slope stability over an extended period, typically days or weeks, and to critically monitor slopes that are actively moving and may become unsafe. The complexity of slope stability radar allows for geotechnical engineers to assess movement types and movement rates across multiple work areas of a mine from long ranges, with alarm capability to a central location. However there are many mine work areas where production and drill-and blast crews are not adequately covered or alarmed by slope stability radar systems. What is required is an easy-to-use, short-range, fast-scanning tool that can be operated directly by a work crew and can provide a local alarm with sufficient warning when a wall movement occurs within the work area. The Work Area Monitor (WAM) concept has been developed specifically to be operated by a mine production crew. The system comprises a sensitive, fast-scanning radar coupled with a high-resolution camera, built into a mine-standard light vehicle. The system has been designed specifically for ease of use with the output being a local area alarm to warn workers of slope movement in their vicinity, as opposed to the broader pit monitoring and long-term deformation measurements of the known slope stability radar systems.

Jan 1, 2012

By Stavros A. Argyropoulos

The strides that have been made in recent years in applying Artificial Intelligence to pyrometallurgy, are reviewed. The computer reproduction of the way in which a human being reasons and calls on past experience and stored knowledge when faced with problem will be extremely helpful in pyrometallurgy. It is expected that Artificial Intelligence will be applied in all areas of human endeavor. Areas of pyrometallurgy that are most promising for expansion into A1 in the near future are presented.

Jan 1, 1990

By E. M. Frizzell

In an effort to economically and efficiently enhance the erosion control aspects of present surface coal mine reclamation practices, the US Bureau of Mines has recently completed a two-phase research program wherein irrigation strategies and equipment developed under the first phase were field tested on three surface coal mine sites. The fundamental basis for the use of irrigation as a reclamation tool is to provide the plant moisture requirements as a supplement to prevailing natural precipitation, and thereby support the natural growth of drought-hardy native vegetation. Portable solid-set irrigation equipment and several irrigation strategies were tested on large 6-ha (15-acre) sites in Montana, Wyoming, and New Mexico. Results of these tests will be presented which include daily irrigations, precipitation levels, soil moistures, climatic data, and density cover and biomass of the native plants.

Jan 1, 1987

By A. Athousaki

The Ecological Footprint is a resource accounting tool used to address underlying sustainability questions. Aggregates consist of natural, artificial or recycled materials. The production of aggregates is the fastest growing activity worldwide since huge quantities are required by the construction industry. This paper presents a parametric investigation of the ecological footprint of transporting aggregates for urban use as a function of tonnage and distance.

Jan 1, 2008

By Thomas D. Henderson, Wayne R. Hopkins, Arthur Lynch

Brought on stream in 1975, the 10,000-tpd copper oxide processing plant of Anamax Mining Co. at Twin Buttes, Ariz., is now at design capacity. Based on acid agitation leaching, solvent ion exchange, and electrowinning, the Anamax plant bridges an ore to metal gap by producing mine site copper cathodes from lime-bearing oxidized feed. Until recently, such material was considered submarginal because copper recovery was uneconomic using conventional methods. The new Twin Buttes oxide plant, the largest of its kind in North America, is one stage in the expansion of Anamax, a joint venture owned equally by The Anaconda Co. and Amax Inc. Other phases include an accelerated stripping program in the pit, an expansion of the sulfide concentrator from 32,000 to 40,000 tpd, and construction of a 57 MW diesel generating station for the oxide plant. Once the basic oxide flowsheet had been selected, Anamax awarded a contract to a joint venture of Arthur G. McKee and Co.' (Western Knapp Engineering Div.) and Davy Powergas' (a member of the Davy International group). The contract covered process design, engi¬neering, procurement, and construction. The property, identified by Banner Mining Co. in the 1950s and developed by Anaconda, was put into production in 1965 as an open pit mine equipped with a 32,000-tpd sulfide flotation concentrator. The Twin Buttes mine has since become one of the largest earth¬moving operations in the world, excavating some 10 tons of waste per ton of ore. At the original sulfide mill feed rate, the mining fleet moved 375,000 tpd of material (225,000 tpd alluvium and 150,000 tpd of rock). The most significant copper mineral in the ore body is chalcopyrite, which is scattered in pockets of weak mineralization. Cap oxidation has progressed to depths of several hundred feet, principally as chryso¬colla. Present estimates place minable reserves at 347 million tons of sulfide ore grading 0.6% copper and 55 million tons of oxide ore grading 0.9% recoverable copper from 1.25% total copper. The nonre¬coverable fraction is composed of native copper and insoluble copper oxides and sulfides. The oxide ore has been partially stripped, and 25 million tons having a copper content greater than 0.6% have been stockpiled. The stripping of oxide ore to expose sulfides will continue for several years. The copper oxide studies launched by Banner Mining in the 1950s were continued by Anaconda. Process routes investigated included: acid leaching; cyanide leaching; segregation roasting; chlorination, oxidation, and reduction; flotation in combination with leaching; cal¬cite flotation plus leaching; copper oxide flotation; and sulfidization flotation. By late 1968 test work favored a low temperature roast followed by an ammonia-ammonium carbonate leach of the ore. During this period, acid leaching had been discounted because of excessive con¬sumption of expensive acid by the high limestone ore matrix. Restric¬tive SO2 emission controls in 1971 suggested an increase in acid production and availability at a lower cost. Research then switched to acid leaching, resulting in development of the present flowsheet. Mechanically agitated leaching in a cascaded series of tanks was selected in preference to vat leaching after piloting a stirred-tank system. Preliminary testing of vat leaching indicated that inter-vat solution clarification problems could be caused by gas evolution from leaching of high limestone ore. Lack of research time for resolution of this problem, plus success of the pilot agitation system, dictated the final flowsheet selection. In 1973 Anamax decided to proceed with agitation acid leaching to produce liquor for a solvent ion exchange (SIX) and electrowinning (EW) installation. At that time, such systems were proving their eco¬nomic viability, and they allowed direct recovery of high quality cath odes while bypassing the smelting and refining of lower grade cement copper precipitates. The Anamax oxide plant processes a grade of about 1% recovera¬ble copper from stockpiled sources and new mine production. Unit operations include size reduction, agitation leaching, countercurrent decantation washing of residue, pH adjustment of solution, clarifica¬tion, solvent ion exchange, and electrowinning of copper, with a mini¬mum of environmental impact. The feed to the primary crushers is composed of: 1) -10-in. stockpiled oxide ore, which has passed through the mine crusher and has been grade-segregated to allow blending for a consistent feed material. 2) -4-ft ROM oxide ore stockpiled in the early mining operation. 3) -10-in. ore currently being mined. Ore is delivered in 100-ton mine trucks to a dump pocket, where an apron feeder transfers the ore to an inclined 6-in. fixed grizzly. The grizzly oversize passes through a 48 x 60-in. primary jaw crusher, where it is reduced to -6 in. The fixed grizzly undersize and the crusher product are conveyed to a 4-in. vibrating grizzly. Oversize from this grizzly reports to a 7-ft Standard cone crusher, where it is reduced to -1 in. The crusher product and the vibrating grizzly undersize are conveyed to two 8 x 20-ft double-deck vibrating screens that operate in closed circuit with two 7-ft short head cone crushers. Screen undersize (-1/2 in.) is delivered to a covered conical fine ore stockpile with a designed live capacity of 15,000 st. Beneath the stockpile are ten Pioche belt feeders feeding two conveyor belts that supply the milling circuits. Each group of five feeders has two variable speed and three fixed speed drives. Grinding to 95% -48 mesh is done in two parallel lines, each consisting of an 111/1 x 18S -ft rod mill and a 12' x 30-ft ball mill in open circuit. Water is added to maintain a pulp density of 72% solids in the mills. Further water additions are made to the ball mill discharge sumps to create a 60% solids slurry for transfer to the leaching reactors. The nominal grinding rate is 440 tph solids. A splitter box on the product from the mills separates the incoming slurry into two streams, one for the leaching reactors and the other for the pH adjustment reactors. This split is determined by the lime content of the feed material and the pH of solution entering the pH adjustment reactors. Five 30-ft diam by 31-ft high mechanically agitated, rubber-lined leach tanks are arranged in cascade, with gravity transfer from one to another by enclosed launders. Concentrated sulfuric acid (93.2%) from storage is added to the pulp principally at the first leach tank, and the reacted slurry leaving the cascade after a 5-hr residence time at 50% solids is pumped to countercurrent decantation (CCD) wash thickeners.' At this point, most of the soluble copper has been leached from the ore. Up to 250 lb of sulfuric acid is consumed per ton of ore, the acid being supplied in tank cars from a nearby smelter. Leached slurry at 50% solids is washed countercurrently with return raffinate from the SIX plant in a series of four Doff-Oliver center caisson, 400-ft diam thickeners. Solids advance from thickeners No. I through No. 4 to the tailings dam. SIX raffinate advances from thickener No. 4 to thickener No. l, where a pregnant solution overflows to pH adjustment. To optimize solvent extraction, the pH of the pregnant solution from CCD thickener No. I is adjusted from 1.5 to 2.5 by adding unreacted ground slurry (split from the grinding circuit) to the preg¬nant overflow of No. I CCD thickener. The resulting slurry is retained for 45 min in three mechanically agitated leach tanks. CO, generated during leach and pH adjustment is ducted to a demister, where entrained acid droplets are removed. The cleaned CO, and the No. 4 CCD underflow are the only effluents from the plant. The underflow of No. 4 thickener mixes with tailings from the sulfide concentrator and is neutralized. Slurry exits the pH adjustment vessels at about 10% solids and

Jan 1, 1985

By Hill McDonald

Sand and gravel deposits may be explored by many different methods. The methods used by The Standard Slag Company are primarily two in nature. One is using an auger which is limited in depth by various soil conditions. The other is a heavy wall dry sampler and a heavy wall wet sampler. The heavy wall dry sampler takes continuous uncontaminated samples up to seven inches in diameter. The heavy wall wet sampler takes continuous uncontaminated samples up to six inches in diameter. For us, the maximum depth of the heavy wall samplers has been two hundred fifty feet of which one hundred feet was above the water table and one hundred fifty feet was below the water table.

Jan 1, 1972

By Pieter-Jan Kleiterp

Highwall mining is a mining method to extract coal from a final boundary in opencut mining, trench mining or contour mining. This boundary may have been reached because of economic constraints (economic strip limit) or geographic constraints, such as spoil heaps and rivers. Coal is mined from visible, horizontal, or near-horizontal coal seams by making rectangular, parallel, unsupported drives with an unmanned cutterhead and coal transport system. This is controlled from a mining unit, or launch frame, positioned outside the drive, in front of the highwall. Removal of overburden is not required or is limited to small quantities only.

Jan 1, 2010

By Armine F. Banfield

Selection of a plant site is becoming increasingly more difficult and important, mainly due to advances in technology, antipollution laws and changing economic, social and community conditions. Discussion falls naturally under three headings: economic considerations, terrain considerations and environmental considerations. Aside from acquisition of surface rights, problems having to do with terrain, or topography, usually can be dealt with by management alone. Economic considerations largely involve decision-making by management plus negotiations with government regulatory agencies acting under set rules. Environmental considerations, such as air and water pollution, townsites, housing, schools, noise abatement, appearance, surface rehabilitation and the like usually are under the control of federal, state or municipal bodies with a large degree of decision-making. Successful solution of environmental problems often requires lengthy negotiations, during which public relations by the mining company play an important part. Existing union regulations or customs may confine decision- making and the establishment of wage rates, working conditions and regulations. These usually require considerable planning and negotiation. Initial production often is delayed by formal negotiations involving environmental considerations. Surface facilities usually can be divided into two broad categories: those for concentrating ores--such as gold, silver, base metals, low-grade iron ore and potash-which should be close to the mine to reduce ore-transportation costs to a minimum, and those where the ore is shipped elsewhere for treatment, such as direct-shipping iron ores, complex high-value ores requiring specialized treatment and ores from which special products are derived for local markets. The long-term aspects of plant-site selection too often are given no or insufficient consideration because of immediate financial limitations. As a result, additional capital expenditures may be required later for relocation of townsites, roads, railroads and plants to provide additional room for extension of open-pit operations, tailings disposal, storage, or danger to foundations through underground subsidence or open-pit mining. In the past, hillside sites for concentrating plants were preferred to take advantage of gravity-feed methods The modern trend, however, is to place as much equipment as possible on approximately the same level. Some costs relating to plant sites are included in this section. They are ranges as of the year 1970, and are offered only as general guides. Such costs will vary widely with geographical location and, of course, are subject to escalation due to increases in wage rates and cost of materials. Items in the bibliography contain more detailed and comprehensive data on specific subjects. Most contain bibliographies of their own.

Jan 1, 1973

By Frank X. Bellini, Marc Saidman, Allen J. Hulshizer, Anthony J. Stewart

The cooling water system for the Seabrook Nuclear Station involves 10.25 Km (33,623 ft.) of 6.7 m (22 ft.) OD hard rock tunnels, over one third of which is under and terminating over 1.6 Km (a mile) out in the Atlantic Ocean. The major excavation is accomplished by two TBM's concurrently driving the intake and discharge tunnels which by mid-January, 1981, completed 92% of the excavation. This paper presents the case history of the excavation work and describes a computer program developed to evaluate major activities of TBM excavation on a shift-by-shift basis. Details and summaries of the production efforts are computer plotted in different forms to facilitate the evaluation of production performance, trouble spots and trends.

Jan 1, 1981

By T. P. Meloy

Improvement of grade and recovery requires the use of optimum processing circuits. Critical to an optimum circuit is the set point for separation. With the introduction of the concept of circuit analysis (Meloy, 1982), it became possible to determine optimum circuits for a given task. No analysis, however, has yet been made as to the grade requirements of the larger circuits. Williams and Meloy (1982), reviewed the literature and concluded that, within the operating range, most unit operations involved in particle separation behave linearly. For the purposes of this analysis, linearity will be assumed. Grade, G, is defined as the weight of the coal mineral, C, that appears in the product, divided by the weight of the coal mineral plus the weight of the gangue mineral or waste mineral, Q, which appear in the product.

Jan 1, 1982

By J. C. Yingling

[New stochastic process models are developed to calculate the probability of various fill levels in section feeders as a function of vehicle interarrival times, payloads and feeder-discharge rates. These models may be utilized to establish the minimum feeder-discharge rate necessary to prevent a feeder, with a particular surge storage capacity, from constraining the section's production rate. In addition, it is shown how the output from these models may also be utilized to calculate the probability of various flow rates at junctions in the conveyor haulage network, enabling one to size gathering belts. The model provides a basis for optimizing, (in economic terms) capacity specifications for feeders and conveyor belts in the materials-handling system by considering tradeoffs in the size of the two types of units.]

Jan 1, 1997

By Peter T. Luckie, Mark S. Klima

INTRODUCTION A physical separation partitions a stream of particles into two streams - one containing a concentration of a desirable constituent; the other containing a defficiency - on the basis of a difference in physical properties. Separating ores into concentrates of increased grade and gangue minerals has been practiced for thousands of years. Physical properties of materials which have been used to achieve separations include size, relative density, shape, magnetism, surface charge, color, characteristic emission, resilience and strength. The study of physical separations has also been termed attribute tracking. The term attribute is used to describe the content of the material of interest, or, sometimes, properties not used as a basis of the separation. The content is usually given by its assay; e.g., %Cu, %Fe, etc. Attribute tracking involves material balancing. For a separation using two physical properties, say x and y, the balance is

Jan 1, 1986

By F. F. Roberto

Many techniques that are used to characterize and monitor microbial populations associated with sulfide mineral bioleaching require the cultivation of the organisms on solid or liquid media. Chemolithotrophic species, such as Acidithiobacillus ferrooxidans and Leptospirillum ferrooxidans, or thermophilic chemolithotrophs, such as Acidianus brierleyi and Sulfolobus solfataricus can grow quite slowly, requiring weeks to complete efforts to identify and quantify these microbes associated with bioleach samples. Real-time PCR (polymerase chain reaction) assays in which DNA targets are amplified in the presence of fluorescent oligonucleotide primers, allowing the monitoring and quantification of the amplification reactions as they progress, provide a means of rapidly detecting the presence of microbial species of interest, and their relative abundance in a sample. This presentation will describe the design and use of such assays to monitor acidophilic microbes in the environment and in bioleaching operations. These assays provide results within 2-3 hours, and can detect less than 100 individual microbial cells.

Jan 1, 2009

By Noris Del Be1 Belluz

Drilling underground in the Grasberg dewatering drifts has routinely hit water aquifers with high flow rates and pressures. Two types of holes are used. Pilot holes probe ahead of the tunnel development to intersect aquifers ahead of the face. And dewatering holes dewater rock formations that will drain water from the Grasberg pit and allow tunnel development to proceed safely. Recently, static pressures of >8.3 MPa (> 1,200 psi) have been recorded with flows from a 100 mm (4 in.) HQ core hole measured at 5,700 L/min (1,500 gpm). The waterflows can be slightly acidic, necessitating the use of stainless-steel collar gear to resist corrosion. These rates were anticipated and contingencies were planned early on to deal with these conditions. PT Freeport Indonesia (PTFI) established procedures to maintain the safety of the drill crews, to enable coring of the rock, and to maintain the safety of the miners driving the drifts. The collar gear controls the waterflows because these drill holes are a vital source of water for the concentrator.

Jan 1, 1998