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By Frank E. Dalton

The Metropolitan Sanitary District of Greater Chicago (MSDGC) serves an area of approximately 860 square miles and collects and processes used water from the city of Chicago and 116 surrounding communities. As a public agency, the MSDGC -Serves a population equivalent to 10 million people which is composed of 5.5 million people and an industrial wasteload equivalent to an additional 4-1/2 million people. -Provides 400 miles of intercepting sewers and tunnels ranging in diameter from 12 inches to 24 feet. -Operates 71 miles of navigable waterways and channels conncecting the Atlantic Ocean and the Great Lakes with the Gulf of Mexico and 6,000 miles of inland waterways. -Maintains the largest water reclamation plant in the world. -Processes 1,380,000,000 of used water daily and removes approximately 1,000 dry tons of organic solids each day. -Has spent approximately 700 million dollars in capital improvements to date, and will require expenditures in excess of 3 billion dollars (including over one-half billion dollars in tunnels) to meet existing federal and state water quality standards.

Jan 1, 1974

By S. J. Jung

In recent years, the use of shotcrete, a practice familiar to the mining industry, has been on the increase. This research has come about because of the recognized need for a safe, easy way to line small diameter bored raises (less then 150cm). Up until now, an operator has gone down the raise and applied the concrete lining manually, using the shotcrete method of application. With an automated system, there would be no man positioned in the bore itself. All control functions could be commanded from a central location. Shotcreting in the confined space of a small diameter bored raise presents problems that can be overcome by the application of shotcrete using a remote system.

Jan 1, 1994

By Stanley R. Riggs

Extensive phosphate resources occur within the Miocene Hawthorn and Pungo River Formations which have not been considered in the past since they were poorly known and were not available to conventional mining. These resources include 1) deep phosphates that occur below 75 meters of overburden within major sediment basins throughout the southeastern coastal plain, and 2) offshore phosphates that occur on the continental shelf and within the U.S. Exclusive Economic Zone (EEZ). The future potential of these two vast resources will be realized with development of new mining technologies such as hydraulic slurry mining and integrated with advanced technolgy already being utilized in the offshore petroleum industry.

Jan 1, 1986

By J. Stachurski, N. A. Abdel-Khalek

The objective of this investigation was to compare the results of countercurrent, column cell flotation vs. conventional (mechanical) cell flotation for the cleaning of a sulfur ore (-0.5 mm, 27.43% S) and its discrete size fractions. The tests were carried out using diesel oil as a collector and alcohol as a frother. Generally, column flotation produced concentrates of higher grade. For example, column cell flotation produced a nonwashed concentrate of 65.3% S with a recovery of 84.1%. However, conventional cell flotation produced a rougher concentrate of lower grade (57.0% S) and higher recovery (92.5%). At a superficial-wash water velocity of 0.265 cm/sec, the column product grade increased to 76.4% S, with a slightly lower recovery (80.3%). However, a concentrate with a similar recovery but a lower grade (74% S) than that of the washed product was obtained after three cleaning stages with the conventional cell. The column gave superior results for the flotation of fine and ultrafine particles.

Jan 1, 1994

By R. A. Holmes

Although manganese is a metallic element and is widely dispersed in nature, it never occurs except as a compound in combi¬nation with other elements. Use of such compounds in the production of glass is known to have occurred in early Egypt. The dioxide of manganese was considered a compound of iron until 1774 when C.W. Schule first recognized it as an element. In the same year, a Swedish mining engineer, J.G. Gahn, became the first to isolate manganese. In 1856 development of the Bessemer process of steelmaking gave economic importance to manganese, and later, in 1882 Robert Hadfield discovered the benefits of high manganese steels. GEOLOGY Physical Properties Elemental manganese is a silver-gray metal, resembling iron but harder and more brittle and used primarily in alloys (both ferrous and non-ferrous) and a wide variety of chemical compounds. Some of the physical properties of manganese include: melting point¬1 245°C; boiling point-2 150°C; density at 20°C-7.43 g/cm3; specific heat at 25.2°C-O.115 cal/g; latent heat of fusion-63.7 cal/g; hardness on Mohs scale-5.0; linear coefficient of thermal expansion from 0 to 100°C-22 x 10-6. Mineralogy There are over one hundred minerals that contain manganese. These minerals vary from those with compositions that are pre¬dominantly manganese to those having only minor percentages of manganese. Distribution of Deposits Manganese ore deposits are found worldwide and were formed in various geological environments, but only a rather limited num¬ber of deposits have high grade manganese ore in sufficient quan¬tities to be mined and utilized economically on an industrial scale. It is worth noting the fact that almost all of the significant deposits can be classified into two types of deposits: marine chemical sed¬imentary deposits, and residual (secondary) enrichment deposits. There are, however, a much larger number of geological types but these are not of commercial significance at this time. Sedimentary deposits are the most common and are usually stratiform or lenticular. Manganese minerals were formed by a chemical process during the deposition of marine sediments. They usually contain manganese oxides and carbonate minerals, some¬times interbedded together or with other sedimentary rocks such as limestone or shale. Examples of this type of deposit are the Russian ore bodies of Nikopol and Tchiatoura, as well as the Kalahari deposits in South Africa and deposits of Groote Elyandt in Aus¬tralia. Residual deposits were formed in a different way: by alteration of existing manganese deposits or by concentration of the manga¬nese minerals when other minerals were washed away by weath¬ering or ground water processes. The Nsuta deposit in Ghana, the Amapa deposit in Brazil, the Moanda deposit in Gabon, and nodules in the residual clays of the US Southern Appalachians are examples of this type of geological process. In the case of the Ghana and the Amapa deposits, this is only true for the outer layers of the deposit containing oxide minerals, the inner part being comprised of car¬bonate minerals including manganese carbonate, probably from marine origin. Some sedimentary and residual-type deposits have been metamorphosed, giving rise to small high grade ore bodies. These deposits are regionally metamorphosed, occurring in mar¬bles, slates, quartzites, schists, and gneisses. Some of these deposits, such as the Franklin, NJ, deposit are rich enough to be commercial without secondary enrichment; however, most of the exploitable deposits have been secondarily enriched. Due to the diversity and complexity of manganese deposits, both with respect to deposition and chemistry, a wide range of impurities are almost invariably present in the ores. Table 1 shows that the reserves (i.e., a measured resource that can be economically and legally extracted) are estimated at 814 x 106 tons of contained Mn, which equates to more than a 100 year supply at the current level of production. The reserve base is made up of the marginally economic reserves and sub-economic re¬sources and are some 4.5 times greater than the proven reserves. Also apparent from study of Table I is the fact that some 75% of manganese reserves are found in two countries, the USSR and South Africa. On the other hand, North America (i.e., the United States and Canada) have few significant deposits. The largest deposit, or at least one of the largest, in the United States is located at Chamberlain, SD. This deposit is sedimentary

Jan 1, 1994

By H. Saito

To Japan, which is scarce in natural resources, limestone is the only mineral resource comparatively rich in ore reserves and having broadly recognized outstanding quality. Distribution of the limestone deposits extends from Hokkaido in the north to Kyushu and Okinawa in the south, and the deposits are located in a manner of framework formation of the Islands of Japan. Studies of the geological ages of these ore deposits reveals that almost all of the main ore deposits west of Kanto Area belong to the Carboniferous Period - Permian Period of the Paleozoic Era. Also in the east of Kanto Area, deposits belonging to the Paleozoic Era constitute the main part, although recently there are increasing examples of reclassifying the geological age of the deposits heretofore considered as Paleozoic Era to the Triassic Period of the Mesozoic Era by the recent discoveries of the fossils of conodont, etc. Large ore deposits and main ore deposit groups are given in the Figure 1, which shows that the deposits are roughly found well distributed throughout the country.

Jan 1, 1982

By S. Gupta

Froth flotation is a process commonly employed for the selective separation of phosphate from unwanted mineral. Column flotation has become widely accepted in the mineral processing industry, including phosphate industries, due to its ability to improve selectivity, lower operating cost, lower capital cost, and superior control. In this work, a hybrid model is developed that combines a physicochemical model with artificial neural networks. The physicochemical model is based on axial dispersion with first order collection rates. A new approach, in which both frankolite (the desired mineral containing phosphate) and gangue (undesired product) are modeled, enables prediction of grade of the recovered product. Thus, two basic parameters are required in this model: flotation rate constants for frankolite and gangue. Artificial neural networks are used to predict flotation rate constants. The model also takes into account the particle size distribution and predicts grade and recovery for each particle size range. The model then combines grade and recovery for each particle size range to determine the overall grade and recovery of the column. The model is validated against laboratory column data.

Jan 1, 1998

By George W. Land

For the year 1985, the U.S. coal industry produced 881 million tons of bituminous coal and lignite. Domestic consumption amounted to 814 million tons. The electric utilities consumed 689 million tons, almost 85 percent of total consumption, over 78 percent of production. In May, 1986, the NCA forecast that with moderate growth rate averaging 1.9% per year from 1985 through the year 2000, production could reach 1,176 billion tons and domestic consumption 1079 billion. The estimate for electric utilities indicate 924 million tons for the year of 2000, about the same percentage of production and consumption as now experienced. Before we consider the main topic of this paper, the cost of using high sulfur coal, let us examine the coal use patterns of the last 25 years, the changes in those patterns and consider the reasons for those changes. Table I shows those changes.

Jan 1, 1986

By J. E. House

Creative ideas and endeavors require imaginative and positive responses, if they are to be reduced to practices. This lecture will define the plurastic roles of various technical disciplines which were important in the development of the LIX reagents. Specific personalities, facts, and events will be used to trace the development from an idea, to the exciting acceptance and practice of the technology. An objective analysis of the entire LIX reagent development, spanning twenty-five years experience of the author, will be given, these will be used as a basis for critical examination of how the various technical disciplines could improve their effectiveness in advancing future technologies.

Jan 1, 1990

By K. M. Atencio, T. Pike, S. Forrest

We will introduce the Small Business Liability Relief and Brownfields Revitalization Act, which is an amendment to CERCLA and the types of sites it includes and excludes, especially as related to mine-scarred land. We will also describe the types of available funds, whether they are competitive or not, what entities are eligible to receive them, and how to access them. We will introduce the legislation’s liability provisions; for example, the recently issued interim guidance clarifying some of the conditions that contiguous property owners, bona fide prospective purchasers, or innocent landowners must meet to qualify for the liability limitations provided in the Brownfields Law.

Jan 1, 2004

By Y. C. Guan

The dissolution behavior of silver and copper form their elemental states and Ag/Cu alloys in ammoniacal solutions has been studied using rotating disc electrodes. The variables studied included concentration of ammonia, oxygen partial pressure and rotating speed of the disc. The results have been interpreted in terms of the mixed potential theory. The effect of local current resistance on the overall current has also been examined as a part of the governing theory of the dissolution. It was observed that the dissolution potential and the rate of dissolution were very much affected by the composition of the alloys.

Jan 1, 1995

By HASAN SERKAN GOKCEN, SERKAN CAYIRLI

Manufacturers have improved various stirred mill types to be well adapted to fine and ultrafine grinding applications. These stirred mills, which are operated in wet or dry conditions, may be classified as horizontal — such as AHM-horizontal agitated media mill, IsaMill and Drais mill — or vertical — such as tower mill, Vertimill, Maxmill, Stirred Media Detritor and ATR vertical agitated media mill. The main difference between vertical and horizontal structures is in their operational variations. Additionally, the scaling-up of mills is also an important parameter for selecting the suitable orientation [1]. The purpose of this study was to investigate the dry grindability of calcite powders in a vertically and horizontally orientable laboratory batch-type stirred mill. The experimental results were evaluated using stress intensity analysis. The results showed that the d50 values decreased with increasing stress energy down to a certain point and then increased for both milling orientations. Even though the optimum stress energies for both vertical and horizontal orientations were in the range of 1 × 10−3 to 5 × 10−3 Nm at 750 and 1,500 kJ/kg energy consumption, the product size was finer for the horizontal orientation at the same stress energy value.

By Richard C. Corson

Modern microprocessor systems make it possible to use several variables to anticipate changes in the process and to react with responses before upsets can be magnified by the process or by control action. Through tighter control, "insurance" can be eliminated from process set points without affecting product quality. In actual operation with a traveling grate furnace this control philosophy has produced savings of up to 20% in fuel consumption and 8% in fan power usage while producing a more consistent quality product.

Jan 1, 1982

By V. K. Gupta

A detailed laboratory study was carried out to investigate the effect of the particle size distribution on the grinding rate parameters, Si, for the dry ball milling of quartz and limestone. Contrary to the present belief, the Si values were found to vary strongly with the particle size distribution. In particular it was observed that: (i) the Si values increased with the fineness of the particulate charge - the increase being more pronounced in the case of the coarser sizes, (ii) the next finer size class had the maximum effect on the breakage of the particles of a given size class, while the coarser size classes had only a slight effect, (iii) the effect of two or more size classes was non-additive, and significant higher order inter-size interactions were indicated. The importance of these results in the context of the analysis, design and scale-up of the comminution systems is discussed.

Jan 1, 1987

By B. Nyman

A lot of work is in progress to improve copper recovery by leaching-solvent extraction-electrowinning (L-SX-EW). At Outokumpu the focus of attention is on SX equipment development as a result of which a new mixing-settling technology, the Vertical Smooth Flow (VSF) has been introduced. Using helical stirrers in the VSF mixers a more gentle and uniform contacting can be obtained than in the mixing compartments of the low-profile design. The benefits of Outokumpu's new approach are an essential decrease in organic losses and in aqueous in organic entrainments. Separate pumping using a smoothly pre-contacting "Dispersion Overflow Pump" (DOP) is a key feature of the VSF design. The scale-up of this pump as well as the VSF mixers are shown to follow simple mathematical relationships which also have been confirmed by full scale experiments.

Jan 1, 1995

The need for an integrated approach to optimization of unit operations in both the pit and the mill has long been recognized, but the complexity and nature of the overall problem has up to now resisted solution. This paper reports on a modeling methodology which couples symbolic and numeric computing to unify operations in both the pit and mill. The ultimate goal of this work is to optimize all operations that are influenced by blasting. Blasting plays a key role in all facets of operations. Obviously, drilling and blasting costs are determined by blast design, but the down-stream costs that are closely related to blasting results are often treated as separate functions: loading, hauling, cleanup, and crushing and grinding are all heavily influenced. Diggablilty and bucket fill factor are a function of fragmentation, the condition of the floor and uniformity in the shape of the muck pile. Likewise, cycle times and loading delays partially determine haul cycles, while fragmentation distribution and size determines the efficiency of truck loading. Removal and breakage of oversize causes loading delays and increases cleanup costs. The influence of blasting doesn't stop at the crusher. Mill productivity, power consumption, and maintenance are a function of the feed. Even at the SAG mill a reduction of a critical particle size during blasting can increase throughput. Thus, a bottle-neck for production far removed from unit operations in the pit can be alleviated by a modification in blast design. The question is: how do we optimize blasting with respect not only to itself but to al\ related mining and milling operations? For that matter, how do we even model blasting so that we can control the results of a blast?

Jan 1, 1991

In May 1993, SME contracted with The Dolecek Companies of Denver, CO to conduct a salary survey and a study of Mining Engineering. A written, four-page survey was sent to a random select sample of 1897 current SME members from the United States and Puerto Rico and to 40 current SME members from Canada. A total of 621 survey responses were input and analyzed, to guarantee the validity of the survey findings. The findings are representative of the entire SME membership. And the survey is within a statistical range of accuracy of plus or minus 5%. Salary survey SME members currently earn an average of approximately $60,000 a year. Some 45% earn less than $60,000 and 49% earn more than that. About 24% of all SME members earn $80,000 or more each year and 13% earn $100,000 or more. Not surprisingly, a statistically greater number of owners (27.5%) and those in senior management (30%) have a current income or salary of $100,000+ a year.

Jan 1, 1993

By Randy Clarkson

Sluiceboxes which are designed and operated as recommended from our recent research can provide much higher concentration ratios than most other gravity concentrators (up to 50,000: 1) at very high overall placer gold recoveries (95-99%). They are also very reliable, inexpensive and simple to operate. A sluice­box is a rectangular flume containing riffles on matting, through which a dilute slurry of water and gravel flows. However, sluiceboxes operating under ideal conditions are actually cen­trifugal concentrators whose riffles overturn ribbons of slurry to form vortices. At the bottom of these vortices, centrifugal and gravitational forces combine to drive gold particles into matting (figure 1).

Jan 1, 1996

The role of ZnSO4 in activation of sphalerite (ZnS) and deactivation of lead-activated sphalerite has been investigated. Adsorption of metallic ions at the solid-solution interface, electrokinetic results for sphalerite under different chemical conditions, and thermodynamic calculations were used to elucidate the mechanisms involved. It is shown that flotation response of sphalerite in absence of activators is rather weak and that adsorption of ethyl xanthate on the mineral mainly electrostatic in nature. Zinc sulfate is found to activate the mineral but only in a narrow acidic pH range. This is attributed to the increase of zeta potential as well as the possible increase in amount of negatively charged bulk precipitated zinc xanthate. Lead ions activate sphalerite in a wide pH range and the lead activated mineral assumes a flotation behavior similar to that of galena (PbS). However, addition of ZnSO4 depresses the lead-activated sphalerite by replacing lead ions at the mineral/solution interface.

Jan 1, 1999

By Steven A. Elmquist

INTRODUCTION R&D activities are needed, at a minimum, for a company's competitive survival followed in importance by the growth and diversification of the company. For most industrial companies, however, R&D is the business area that has been the most difficult relative to confident long-range financial commitments and effective control and relative to its value as a long-term investment. Investors look not only at the current profitability of the company but increasingly at the plans, actions, and quality of the personnel in position to improve the market position and profitability of an organization. "The strongest predictor of investment value is the degree of innovation of the 'company.' I believe this is true of both strategic planning and R&D activities." R&D is the lifeblood of a company's future. If this basic premise-R&D for survival and growth-is believed to be true, why is it necessary to "Sell R&D in your organization? My personal experience, in a number of organizations, is that R&D budget is perceived as a business element area that could be delayed or reduced to improve the bottom line during difficult business conditions. I believe the following quote speaks volumes about this subject-"There is only one thing I know for certain about research, and that is it costs money-lots of it." -Unnamed, Hard- headed Financial Executive. A business must make money and be profitable in order to maintain and create jobs, pay taxes, cover working capital and costs of goods sold, and most importantly, create value for its shareholders. The foremost element of selling R&D, therefore, is to consistently demonstrate the R&D group's contribution to the bottom line.

Jan 1, 2004