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By K. A. McDonald

Hibernia de Mexico SA de CV, based in Durango, Durango, Mexico built and put into operation a 700-t/d (770-stpd) agitated cyanide leach plant in Guanacevi, Durango. Plant construction began in March 1993 and operations began in November 1993. Hibernia de Mexico, a wholly owned subsidiary of Hibernia Holdings, Inc., is a privately held Tucson, AZ-based company. The startup procedures described here deal with Mexico's legal, import-export and finance requirements, and labor and security requirements. The 700 t/d (770 stpd) Guanacevi project is located next to the town of Guanacevi. The project is an agitated cyanide leach plant built to process about 2 Mt (2.2 million st) of flotation tailings over its life. The plant is operated by Servicios de Guanacevi, Asociasion en Participacion. It is owned jointly by Hibernia de Mexico and Metalurgica Guanacevi SA de CV. Legal, importation of equipment and financing For a foreign company to operate in the mining industry in Mexico, it must form a Mexican company. A Mexican company presently must be at least 51 % owned by a Mexican entity. The other 49% may be owned by non-Mexicans.

Jan 1, 1994

By G. M. Rao

It has been a universal observation that rich grades of ores and minerals are getting depleted, simultaneously the demands for civilization are ever increasing coupled with occurrence of poor grades of ores and minerals posing a problem to the processing engineers. At the same time, the cost of mining and milling are increasing, creating a situation where the management has to handle and process low grade ores at an economic level keeping environmental stipulations and control to be safeguarded which has been an additional cost for the management to comply with.

Jan 1, 1994

The Henderson Mine is a large underground panel cave molybdenum mine located near Empire, Colorado. Secondary blasting requirements have varied from one shot per 27 tonnes (30 tons) to one shot per 900 tonnes (1,000 tons) of ore. Geology, structure, cave abutment loads, and location of the ore in the column all affect the amount of oversize boulders (greater than three-fourths cubic meter or one cubic yard) that require secondary breakage. The primary method of breakage utilizes cone charges (plastic funnels filled with an emulsion) placed on accessible oversize rocks. Hangups in the brow area of the drawpoint are drilled with a self contained diesel hydraulic drill and loaded with gelatin dynamite. High hang-ups located beyond the reach of the secondary drill are "bombed" in with strategically placed emulsion bundles or ANFO bags loaded in place though a sectioned aluminum pipe.

Jan 1, 1994

By M. J. Friedel

The scale-dependent hydraulic properties in a fractured porphyry copper oxide deposit are investigated for relevance to In Situ Leach Mining (ISLM) design. In most well field designs, mine operators assume that hydraulic properties represent a continuous spatial function, or continuum. The problem, however, is that the representative elemental volume, the volume over which hydraulic properties are described as a continuum, is a domain (if it exists) that occurs between end members representing varying degrees of heterogeneity. At the Cyprus Casa Grande mine, transmissivity fluctuations are spatially correlated. This suggests that, at the scale of ISLM, the hydraulic process is heterogeneous, and a typical continuum representation is inappropriate for design. Alternatively, a conditional stochastic approach using the Simulated Annealing (SA) technique is deemed useful for the imaging of heterogeneous hydraulic properties. Specifically, SA preserves transmissivity extremes and spatial complexity, both necessary for accurate conditioning of a flow simulator. Also, the stochastic continuum approach provides an avenue whereby uncertainty (or risk) may be addressed. Currently, the SA weaknesses are that it is computationally time consuming and that uncertainty may increase when simulating under conditions of statistical isotropy. Recognizing that ISLM exerts a dynamic influence on hydraulic properties with time, the mine design should be re-evaluated at intervals throughout the evolution of the leaching process.

Jan 1, 1994

By Randall E. Hughes, John F. Burst

This chapter describes the nature and occurrence of the principal clay minerals that are used as ceramic raw materials, explains how these raw materials are used to produce finished goods, and summarizes positive and negative trends that will affect future demand for raw materials and products in the ceramic industry. The term ceramics was derived from the ancient Greek keramikos (a clay jar). A ceramic product is a material that has been fired to at least 468.3°C (Mitchell, 1983). In addition to being one of our earliest manufacturing and construction materials, ceramic products are among the earliest records of civilization. The enduring significance of ceramics is shown by the fact that, even today, the manufacture of whitewares, brick and related red-fired wares, refractories, and engineered ceramics continues to be a major sector of the US economy. A wide range of materials can be made into ceramic products, although relatively few earth materials make up most of the ceramics in today's markets (Table 1). Most ceramic products are made from clay or a related material. The long history of clay use in the ceramics industry stems from its variable and sometimes unique physical and chemical properties, as well as its ubiquitous occurrence and relatively low cost. Clay is important to ceramics because of its plasticity, moldability and filterability, chemical content, color. refractoriness, solubility. corrosion resistance, electrical properties, and other properties that result from the essentially two dimensional morphology of the individual clay mineral platelets. Because of their basic relationships to the chemical and physical properties of clays, the chemical and mineralogical content have been the subject of continuous studies over the past few decades. Advances in knowledge about the chemical, mineralogical, and physical properties of clays are responsible for most of the advances in processing. The need to remove off-colored contaminants, minerals with low melting points, and soluble salts has resulted in beneficiation by wet processing methods such as water washing. Water washing is restricted to kaolins, although low cost methods of water washing have been extended more recently to ball clays in Europe. High intensity magnetic filtration and flotation technologies have noticeably improved the quality of kaolins and broadly expanded their use in the ceramics industry. In addition to products for construction (e.g., brick, tile, sewer pipe, field drain pipe, cement, fiberglass, roof granules, and paint) and manufacturing (e.g., refractories, kiln furniture, sanitary ware, pottery, and dinnerware), clays are used in calcined form as ceramic fillers, carriers, extenders, and grogs. Ceramics suppliers are under economic pressure in several of these product areas. Manufacture of refractories in America has declined as steel production has decreased. Similarly, dinnerware and tile production have declined because of foreign competition. Fortunately, new uses for clays,

Jan 1, 1994

By Jerry Dolph

Hecla Mining's Lucky Friday Mine, located beneath the town of Mullan, ID, has been shaken since the 1960s by many deep underground rock bursts. The largest rock burst carried a magnitude of 3.5 on the Richter Scale. It occurred in 1969 when all of the stopes on a level approached an upper level at the same elevation. After that, a stair-step pattern was used to give the mine's levels more of an "arch." The article is an account of one of the more ferocious bursts to hit the miners of the Lucky Friday. I say "miners" instead of "mine" because I was there and it was a very personal experience for me. I had been working at the Lucky Friday for six years. During that time, I had heard and felt thousands of air blasts. In fact, in the early spring of 1986, the mine was experiencing as many as 1000 air blasts an hour, of different intensi¬ties, of course. Most of them sounded like popcorn popping. There were also a few bumps and occasionally a real boomer. That day did not seem any different

Jan 1, 1994

By D. Panda, P. K. Sahoo, A. S. Rao

The waste phosphogypsum produced by Paradeep Phosphate Limited (PPL) at Paradeep (Cuttack, Orissa, India) consists primarily of calcium sulfate with small amounts of phosphoric acid, calcium fluoride and other harmful components. Presently these are dumped as waste. In this work, laboratory trials have been made to utilize the calcium sulfate present in the phosphogypsum to prepare usable products like ammonium sulfate, calcium carbonate and magnesium sulfate.

Jan 1, 1994

Laboratory tests were conducted in a full-scale continuous miner test gallery to evaluate resulting dust levels for changes in face airflow, spray water quantity and pressure, and mining height. The minimum and maximum values tested for each parameter were as follows: airflows between 1.42 and 6.14 m3/sec, water flows between 56.8 and 132.5 lpm, nozzles pressures between 413 and 1379 kPa, and mining heights between 1.52 and 2.74 m. Each of these parameters were evaluated for four common spray system designs. Respirable dust samples were collected in the operator's cab on the miner and in the immediate return. Second-order polynomial models were used to represent expected dust levels and multiple stepwise regression was used to identify significant control parameters for inclusion in the models. Separate models were developed for dust levels at the operator and return locations and for each individual spray system. Interaction between control parameters and curvature effects were found in most models. The analysis indicated that at the operator location, airflow and mining height had the most significant impact on respirable dust levels. In the return, airflow and water pressure were typically the most significant parameters. The models developed for each spray system design can be used by mine operators to guide application of control parameters for a variety of operating conditions and mining heights.

Jan 1, 1994

By B. L. Gibbs

Computers have been used in the minerals industry for about 30 years and, in a few cases, longer. With the explosion of microcomputing during the past 10 years, computers have changed how many minerals producers go about their work. What computer usage trends are active in the minerals industry today, and what can we expect in the future? In general, computer usage is accelerating. Engineers and geologists are becoming increasingly "application literate." Soft¬ware is increasingly oriented to how people work. User interfaces have improved, so most users need to know only a mini¬mum of system commands and structure to work with a computer. Most industry professionals know how to use word processing and spreadsheet pro¬grams. AutoCAD appears to be the drawing program of choice. One reason is availability of training and add-on programs for earthwork, mapping, contouring, etc. Another frequently cited reason for using CAD is the ability to quickly make changes to a map or design, as compared to hand methods. Management is moving toward greater acceptance of computer usage. Computers do not need workman's compensation ... even though they may get sick and take a few days off! Computer hardware used in most minerals-producing companies is strongly personal-computer based and likely to remain so. The 486 personal computers are inexpensive as compared to workstations and provide the power and speed to run most applications in minerals industry engineering offices.

Jan 1, 1994

By R. W. Smith, J. Dubel, M. Misra

The bacterium Mycobacterium phlei is highly hydrophobic and negatively charged. It has specificity for selective adhesion to fine coal particles, mainly due to hydrophobic interaction. However, it does not attach to pyrite and ash forming minerals present in the coal matrix. Results have shown that this bacterium is an excellent flocculant for fine coal. Not only, are the coal particles visibly aggregated, but the optical micrograph has shown that the coal particles are held in the aggregate by adhesion and bacterial bridging. With Mycobacterium phlei, the flocculation characteristic of coal is markedly different from that usually observed with synthetic polymeric flocculants. In particular, the entwining characteristics of the long chain molecules of synthetic flocculants are absent in the case of Mycobacterium phlei. Since the hydrophobic interactions between the adhering particles are of greater importance in the formation of particle aggregation, the flocculation process is very selective.

Jan 1, 1994

By J. G. Groppo, B. K. Parekh

Column flotation testing was conducted on the flotation feed slurry obtained from a preparation plant located in the Southern Illinois coal basin. The column flotation tests were conducted using three different bubble generating devices: a static sparger, a gas saver and a foam jet. Each of these devices was tested with three different types of frother and various column operating variables to provide maximum combustible recovery, minimum product ash and maximum pyrite rejection. The results show that column flotation provided improved flotation performance, in terms of combustible recovery as well as ash and pyrite rejection, for each of the bubble generating devices. However, the effectiveness of each bubble generating device was dependent on the type of frother used. Alcohol frothers were most effective for use with the static sparger, somewhat less effective for the foam jet and ineffective for the gas saver. Glycol frothers were effective for all three bubble generating systems, providing high combustible recovery (>90%); low clean-coal ash (4-6% ash) and high pyrite rejection (70-80%).

Jan 1, 1994

By M. E. Poad

In 1986, a cooperative effort by the Homestake Mining company, the U.S. Bureau of Mines and the University of Utah was initiated to determine shaft stability while recovering high grade ore in a nearby pillar. Premining finite element simulations indicated the shaft would remain in elastic ground. Six years have elapsed and, despite some initial concern during the first lifts, it appears that the bulk of the original reserve will be safely and profitably recovered. An integrated application of rock mechanics tools from laboratory testing through numerical modelling to mine measurements and observations contributed substantially to the operational success of the project.

Jan 1, 1994

By B. W. Cavender

Innovative mining and metallurgical operating techniques or processes can be identified and developed by systematically analyzing change as it occurs within the mine, plant, technology, or industry. Sources of change to be monitored for innovative opportunities include unexpected successes or failures, incongruities between perceived and actual events, process needs, changes in perceptions, and the development of new knowledge. Innovation can be effectively organized, practiced, and managed. The perception of change as an opportunity rather than a threat is mandatory, as is the systematic measurement of innovative performance. Innovation is enhanced by specifically-designed policies regarding organizational structure and staffing, daily management practices, and compensation and incentives.

Jan 1, 1994

By Robert C. Freas

The summer joint meeting of the East Tennessee and Carolinas Sections of SME was held in Morristown, TN, on July 29 and 30, 1994. The Friday portion of the meeting began with a field trip to Asarco Inc.'s Young Mine and Mill, one of four mines operated by the company in the Mascot-Jefferson City district. The Young Mill processes ore from two other mines as well as its own, first by heavy media separation and then by standard flotation processes. Zinc concentrates are shipped by truck and barge to an electrolytic refinery in Clarksville, TN. The heavy media rejects and the dolomitic limestone tailings are sold through Asarco subsidiary American Limestone Co. Saturday's technical session, organized by Program Chairman Bob Fulweiler of the Tennessee Division of Geology, provided a review and status report of the zinc industry in Tennessee. This article summarizes papers presented, including one on recent developments in underground blasting.

Jan 1, 1994

By S. K. Kawatra, T. C. Eisele

Pyrite depression is of great interest in sulfide mineral flotation, where pyrite is a common gangue mineral. Since the floatability of pyrite is a function of the pH and a variety of other chemical factors, pH control is a critical part of sulfide flotation circuits. A wide variety of pyrite-depressing chemicals have been studied and used in sulfide- mineral processing, with considerable success. However, there are certain applications where there are still no satisfactory pyrite depressants, and even when suitable depressants are available, there is always a need for less-expensive reagents. Microorganisms, such as the bacteria Thiobacillus ferrooxidans, are known to depress pyrite flotation. However, the dependence of the depression on the type of organism or on suspension pH is still being determined. In this study, the relative effectiveness of various microorganisms, and the effect of pH, has been examined. Screening tests using microflotation showed that every microorganism tested was capable of depressing naturally hydrophobic pyrite at acidic pH. Larger-scale experiments with two of the screened organisms and two different pyrites showed that microorganisms are very effective depressants at acid pH, but are largely ineffective at neutral and alkaline pH where the pyrite surface is not naturally hydrophobic.

Jan 1, 1994

By Michael A. Linkous, Mark J. Zdunczyk

Silica in the form of sand and sandstone is one of the most common, and at the same time, unique industrial minerals. Found in every rock type of every geologic age and virtually everywhere in the world, silica is used in products that touch just about every aspect of daily life. Imagine a world in the 1990s without computer chips, fiber optics, or glass, and you have just begun to understand how important silica is to the quality of life we enjoy. The elements silicon (Si) and oxygen (0) comprise roughly 60% of the earth's lithosphere to a depth of about 16 km. The crystal structure of silicon dioxide consists of one atom of silicon bonded to four surrounding atoms of oxygen to form a three-dimensional network of SiO, tetrahedra. This network makes up the mineral quartz (Murphy and Henderson, 1983), the most common detrital mineral in most sandstones. Quartz is also a major constituent of many igneous and metamorphic rocks and is widespread as a siliceous cementing agent in various rock types. Although quartz is common, sandstones, quartzites, and pegmatites and the unconsolidated sediments derived from them that have a silica content high enough and pure enough to meet today's market demands for quality and consistency are not common. USES AND SPECIFICATIONS Silica sand that is mined and processed for industrial uses must conform to the chemical and physical specifications set by customers. In the United States almost half of the silica sand produced is used in the manufacture of glass. Other important products include foundry sand, ground silica, blasting sand, and fracturing sand. Glass Sand Silica is the principal glass-forming oxide in a glass batch. Glass manufacturers develop model specifications for each source of silica sand used. These specifications broadly define the limits and ranges for chemical and physical properties of the sand and are used by the manufacturer in calculating the desired batch mix or formula. Some specifications may be critical to a glassmaker and require very stringent limits on the quantity of impurities in the sand. For example, the total iron oxide content of a batch is extremely crucial when making white or flint glasses (Mills, 1983). Iron is present in almost every raw material used in a glass batch and must be carefully controlled in order to obtain a consistent color in the finished product. It is difficult, however, for a raw material supplier to tightly control the chemistry of a naturally occurring material such as silica sand. To a great extent the commercial quality of a sand is determined by its geologic history. Realizing this, glass producers tailor their model specifications to each source of approved material. In general, a glass company is concerned most about the consistency of raw materials on a day-to-day basis. Soda-lime-silica glass was the earliest type of manmade glass (Baker-Can, 1967) and still accounts for most of the glass manufactured for commercial use today (Mills, 1983). It is relatively easy to melt and shape and is less expensive per ton to produce than most other types of glass (Baker-Can, 1967). Soda-lime-silica glass is used in fabricating containers, flat glass products, incandescent and fluorescent lamps, glass fiber, and many other products. Heavy minerals such as ilmenite, leucoxene, kyanite, and zircon are impurities on which strict limits are placed for a glass batch. Because of their refractory nature they either do not melt or only partially melt, which results in stones or feathers in finished glass. Aluminosilicates such as kyanite also contribute unwanted alumina to the batch as they partially melt. Limits are especially rigid for refractory mineral grains coarser than 0.60 to 0.425 mm (30 to 40 mesh). [Tables 1 and 2] present typical specifications for silica sand used in flat glass and container glass products. The percentages shown represent an average of many companies7 specifications.

Jan 1, 1994

By S. A. Richards

Business planning in the coal' industry revolves around the production and quality forecast. It is difficult to accurately estimate costs and revenues until the production forecast is made. At mines where production comes from multiple sections, quality is tied to each section's production. Blending becomes a part of the planning process. In order to respond to rapidly changing business climate, a reliable program is needed to accurately forecast the effects of changes in key parameters affecting the production. This paper discusses an efficient, intuitive, and economical approach to underground coal mine planning program which uses a PC-based relational database as the programming platform to forecast production and quality. The program was developed at a major coal company. The relational nature of the production planning data, the programming algorithm, and the underlying principles are discussed in this paper.

Jan 1, 1994

By John E. Tilton

Looking back on the second half of the 20th century, future historians, I believe, will be fascinated by two major political upheavals. The first is the environmental revolution in the 1960s. It erupted in the United States and parts of Western Europe and then swept across the rest of the globe like a wild fire. The second event is the collapse of the Soviet Union. It was the last of the world's great imperial empires. With its demise went central planning as a viable economic system. History, I suspect, will see this second revolution as an offspring of the first. This is because economic and environmental issues were largely responsible for the unraveling of the Soviet Union.

Jan 1, 1994

By M. T. Ityokumbul

The liquid phase mixing in Western Research Centre (WRC) pilot plant flotation column with diameter of 0.76 m has been characterized using a salt tracer. The process variables studied were gas and liquid flow rates. The response of the column to a tracer pulse input was monitored at three axial and two radial locations. For all the experimental conditions investigated in the present study, radial and axial concentration gradients were not observed. It is thus concluded that the 2 tph flotation column is behaving as a well mixed tank. This finding is consistent with the observed poor recoveries of coarse fractions in the column flotation circuit. Based on the findings of this report, it is recommended that several schemes of reducing the backmixing be implemented and evaluated for their effectiveness in improving the column recoveries.

Jan 1, 1994

By M. D. Bath

Minproc Engineers Inc. (Minproc) recently completed the construction and start-up of a process facility to treat 14,000 t/d of gold-silver ore at Kori Kollo, Bolivia. The comminution circuit consists of crushing and SAG-ball mill grinding. Breakage characteristics of the ore were determined and a circuit model developed. This enabled variations of the circuit to be simulated, and evaluated in terms of predicted performance to provide the criteria for final engineering design. Subsequently, analysis of the operating circuit provided data for circuit model-fitting. The validity of the original model and circuit performance predictions are discussed.

Jan 1, 1994