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By W. F. Riggs

INTRODUCTION Flotation equipment is becoming more definitive in design as well as greater in dimension. The last ten years have witnessed the implementation of large flotation cells ranging in size from 28 to 85 cubic meters. However, small plants still operate with cells as small as 3 cubic meters. These changes have increased the operational sensitivity of the flotation system to the chemical reagents used. No scientific study has been undertaken to develop the relationship between the size of equipment and the response of reagents in the flotation system. Hence, this article is an attempt to present several observations from past experience for the purpose of stimulating future research in an area previously ignored and perhaps subsequently not used to advantage. CONVENTIONAL FLOTATION Recent advances in conventional flotation cell design have been made in two areas: a. Flotation cells are becoming larger, and b. Basic design of flotation cells has changed. They can be classified into two types: deep cell and shallow draft cell. Size and design changes of flotation cells have a greater effect on frother performance than on the performance of other chemical reagents. Hence, the discussion in the following sections is restricted to the impact of frothers in the flotation system. Flotation Cell Size The advent of increasing flotation cell size has resulted in the increase of frother consumption. There appears to be a correlation between reduced horsepower (kilowatt) consumption and increased frother consumption per ton of ore processed in the circuit. This is more prevalent when the frother chemistry remains unchanged. Another reason for increased frother consumption is the increased distance between the rotating central shaft and the lip of the cell for larger flotation machines. Increasing this distance results in increased surface area corresponding to the larger cell size. Reduced power input per ton combined with the need for longer, stronger load support of the froth bubble as a result of increasing cell size has resulted in the development of a new series of stronger and more persistent frothers. By the same token, these newer, stronger frothers are difficult to control when applied to the smaller cells. This is true even at lower dosages because the break point between too much frother and not enough frother for optimum metallurgy is normally very narrow. This problem is often exaggerated when operators have established an optimum setting for pulp level and air for the particular frother in use. Generally, the tendency is to operate the flotation cells simply by adjusting frother dosage. The increase in frother strength to accommodate the large cells often results in the realization, after a retrofit, that the existing pump box or sump which is still handling the same volume of concentrate is no longer adequate in size. Flotation Cell Design The two most common flotation cell designs installed during the past ten years are the deep cell and the shallow draft cell. The deep cell provides for complete mixing of air and pulp at the bottom of the cell. The shallow draft cell does all the mixing/pumping in the bottom haft of the cell whereas the mixing of the air is performed further up the shaft and is brought into contact with the pulp midway up the vortex. There are many preferences for one or the other. It is the author's contention that both designs have very valid concepts and must simply be suited to the particular situation as required by the operator. The following comments are subjective observations which should be explored in greater detail. The deep cell mixes both air and pulp together at the bottom of the cell requiring a full depth ascending of the homogenized air to the surface to form the froth layer. This design, in combination with charged air, provides for good concentrate grade control under adverse conditions of selectivity, especially when faced with a fine grind and a slime-laden gangue. A selective frother can be applied without a competitive loss in recovery. One of the conditions for good selectivity in this environment is operating at medium pulp solids concentration in the range of twenty-six to thirty-four per cent (26-34%). When a higher solids concentration is used in combination with a coarse grind, it becomes difficult to maintain the same recovery with a selective frother due to higher pulp viscosity. This condition sometimes results in an unacceptable coalescence of the air bubbles as they ascend the full height of the deep cell. The increased pulp viscosity at higher solids concentration can also retard the flotation kinetics. The combination of decreased surface area of dispersed air and slower kinetics can result in reduced recovery causing coarse particles to continue to drop

Jan 1, 1989

By Glen L. Black

Choosing a mining method for an underground orebody is a complicated and often iterative process. Advances in technology have given design teams an array of possibilities for methods and equip¬ment. Hecla Mining's discovery of the deep Gold Hunter ore body challenged the staff at the Lucky Friday Mine to determine the optimum mining method. Taking an ore body from prospect to production requires traditional resource characterization. This includes drilling, delineating and modeling. Developing the mining plan is an evolving process, changing with each new piece of in¬formation as the project progresses through exploration and development. The Gold Hunter deposit is a steeply dipping vein system in the Wallace Formation of Idaho's Coeur d'Alene mining district. Gold Hunter is a misleading name for the ore body. The vein is a silver-rich, lead-zinc deposit with only traces of gold. The Gold Hunter ore body is located about 1.6 km (1 mile) north to northeast of Mullan, ID. The ore body is mined from the Lucky Friday Mine, located 0.4 km (0.25 miles) east of Mullan. Mining began on the vein from an access drift driven from the Lucky Friday Mine's 4900 level. Production from the ore zone is projected to be 771 t/d (850 stpd). The Gold Hunter ore is combined with Lucky Friday ore and milled in the Lucky Friday mill. The combined ore boosted Lucky Friday's 1998 silver production from 62.2 t/a (2 million oz/year) to more than 124.4 t/a (4 million oz/year).

Jan 1, 1999

By M. E. Kuchta

LKAB's Kiruna mine, located above the Arctic Circle in northern Sweden, is one of the world's largest underground mines, and it is one of the most modern. The Kiruna orebody is a high-grade magnetite containing about 80% low-phosphorous iron ore and about 20% high-phosphorous iron ore in situ. The mining method used is large-scale sublevel caving. Due to the blending of high-phosphorous ore with low-phosphorous ore during the extraction process, only about 20% of the run-of-mine ore can be used for the mine's low-phosphorous product. The blending process is highly irregular and difficult for the mine-planning personnel to predict. An algorithm was developed that uses principles of gravity flow to predict the run-of-mine phosphorous grades from the in situ geologic block model. The model can be used for both long- and short-term predictions.

Jan 1, 2003

By Takaji Kusakawa

In Japan, almost no natural gypsum is mined for industrial uses of gypsum, and almost all gypsum is synthetic gypsum, that is desulphogypsum, produced by waste sulphur dioxide gas from metal smelters and power plants, and other industrial waste sources. The amount of such sythetic gypsum production has reached more than six million metric tons per year (1979). Major uses are for cements and building materials. Other uses are soil conditioner, investment casting mold, organic composite materials, etc and sulphur recovery by gypsum decomposition is being examined. This paper summarizes present Japanese production and uses of sythetic gypsun produced from industrial waste.

Jan 1, 1982

By A. T. Yu

As a nation, we have been known as perhaps the most wasteful in history. From the perspective of engineers and builders on the other hand, planned obsolescence and demolition did beneficially pave way for growth and provided environment for new businesses. Recent economic recession and intense competition from overseas, however, have drastically changed the economics. The high cost of capital and the demise of indiscriminate plant expansion have totally altered the way we conduct our business and run our operations. As a response to increasing demands for better efficiency with little or no funding available, everyone is forced to make do and do better with whatever little he has. Today it nay not be an exaggeration to state that modification of existing facilities may have finally emerged as a way of life. This paper will outline examples of how several companies have effectively modified existing facilities to do more and do it efficiently without having to demolish everything and/or to spend a fortune.

Jan 1, 1985

By D. A. Augenstein

Operators of coal preparation plants use equipment such as large-capacity dump trucks and bulldozers to haul, spread and compact refuse material to conform to federal and state regulations governing the disposal of solid waste. For example, federal regulations require that refuse be spread and compacted in layers not more than two feet thick. If the refuse layers or piles have poor load-bearing characteristics, movement of equipment over them becomes extremely difficult. The increasing cost and limited space for the construction of settling ponds extensively used for fine refuse disposal are leading to the growing practice of dewatering the fine refuse by means of vacuum disc filters and combining the resulting filter cake with coarse refuse for waste bank disposal. However, this filter cake usually contains more than 25% moisture. Therefore, when it is combined with coarse refuse, the moisture level of the total refuse may become high enough to impair the load-bearing strength of the refuse. Precisely this problem and the attendant difficulties of moving heavy equipment arose when vacuum disc filters were installed at a preparation plant in West Virginia. Combining the moist filter cake with the coarse refuse generally results in a 12% moisture level for the total refuse at this plant. At this moisture level, the refuse can still be handled with some difficulty by the equipment. However, the problem has frequently been compouned after rains.

Jan 1, 1977

By H. J. Chen

In recent years, it has been recognized that the high horizontal stress is an important factor that contributes to a cutter roof. When the immediate roof is thinly bedded, the presence of a high horizontal stress may first cause failure on the bedding planes or weak planes, and then a cutter roof develops as the individual stratum crushes and buckles progressively layer by layer. In this study, the stress distributions in the bedding planes of the immediate roof are analyzed for an entry-pillar system in the multiple longwall panels by using the finite element method. Then the roof failure is analyzed based on the rock failure criterion and the stress distributions.

Jan 1, 1998

By R. D. Hutchinson

I consider it an honour to be the opening speaker in this afternoon's session on "Canadian Exploration". I also think it most appropriate that this joint meeting of the MMIJ and AIME should consider this subject, because Canada is a major exporter of mineral products and Japan and the United States are our two largest customers. Clearly, therefore, both countries have a valid interest in developments on the Canadian minerals scene. I represent the Mineral Development Sector of the Canadian Department of Energy, Mines and Resources. I will therefore speak from the point of view of the Federal Government. At this point I would like to acknowledge the help and constructive criticism I have received from several of my colleagues in Mineral Development Sector in the preparation of this paper. In any discussion of exploration in Canada, it is essential to emphasize at the outset that Canada has a federal system of government, with powers shared between Ottawa and the provinces. Under our constitution, the federal government has jurisdiction over the north, and over offshore areas, while the provinces own the natural resources within their boundaries. They control the systems of land acquisition for exploration and the terns under which mining titles are issued, and are therefore able to determine the rate and conditions of exploration and development of these resources. It follows that the Federal Government can influence the exploration and development of the provincial resources only indirectly by consultation with provincial authorities. However, once the resources are developed and begin to flow to market, the Federal Government can exert a much stronger influence because of its constitutional right to control both inter-provincial and international trade, as well as through its general fiscal and tax powers.

Jan 1, 1976

By S. K. Palm

Volatility is a fact of life in the mining industry. Prices of and demand for mineral products are among the most volatile of those for any product. The volatility of these markets wreaks havoc on both corporate management and the personal lives of mining people. Yet, until recently, it has been difficult to assess the impact of volatility on business strategy. This paper discusses how mining firms can profit from market volatility through an operations strategy that stresses operating flexibility. The foundation for our strategy analysis is the observation that a mine is analogous to a stock option. Techniques based on those developed to value stock options have recently been extended to the field of mine valuation. The insights provided by option pricing are very valuable in the development of mine operating strategy.

Jan 1, 1986

By R. Pinksen

The IOC Mining and Operations Departments expressed an interest in reducing the amount of oversize material (>1.0 m x 1.0 m x 1.0 m; 39 inches x 39 inches x 39 inches) being produced and its subsequent downstream effects including in-pit sorting and reduction, damage to mobile equipment, and significant delays in the loading pockets and the primary crushers. To achieve this goal an oversize reduction project was undertaken by the mine and to date has significantly improved upon baseline measures. One key approach used to reduce the amount of oversize was the implementation of thicker emulsion. The introduction of a thicker emulsion provided more resistance to the forces created by dynamic water and reduces the infiltration of the emulsion into the cracks and fissures of the rockmass. Reduced amounts of oversize and more consistent fragmentation throughout the muckpiles has been a result. Additionally, a significant reduction in nitrates leached into the mine water discharge has been realized. To determine the effectiveness of the oversize reduction project, IOC used a of first-of-kind technology to assess fragmentation presented to the shovel at the digging face. A Digital Vision System (DVS) was installed on one of the shovels to capture images that were stamped with GPS locations. A large population of digital images were analysed to produce a robust fragmentation distribution baseline that was used as one of the mine key performance indicators (KPI). Changes to blasting practice were subsequently measured against the baseline KPI to assess effectiveness.

Jan 1, 2011

By G. H. Gronhovd

The U.S. Geological Survey estimate of the total remaining reserves of lignite in this country as of Jan. 1, 1967 was about 448 billion tons. This represents 27 percent of the total coal reserves on a tonnage basis and about 17 percent on a thermal basis. Approximately 98 percent of these reserves are in a vast lignite field located in western North Dakota and eastern Montana. This field also extends north into the Canadian province of Saskatchewan. Despite these large reserves and relative ease of mining by stripping operations, lignite production historically has accounted for less than 1 percent of the national total. This is largely due to the fact that the lignite deposits are located in an area that has no large centers of population and the economical radius of transportation is limited by its relatively high moisture and low heating value. Commercial utilization of North Dakota lignite for power production became firmly established in the mid-1920's with the development of the first successful lignite-burning equipment. Most of the early lignite-fired boilers were equipped with spreader stokers, but as the size of the plants increased, pulverized-coal firing became the more popular method, and with few exceptions, the plants built during the past 15 years are pc-fired.

Jan 1, 1968

By R. Bishop, J. Baggett, J. Monsalve, J. Hole, N. Ripepi, A. Abassi

This work focuses on the operational and safety issues associated with karst voids in large opening underground mines. Issues include water inrush, structural instability, and engineering uncertainty in these environments. Coupled with the fracturing prevalent in folded sedimentary rocks, karsts are complex and challenging ground control risks. Traditional methods of predicting karst locations, such as probe drilling, are impeded by the inconsistent spatial distribution and variable sizes of the features. Ground penetrating radar (GPR) is a geophysical technique that transmits radio waves into a medium and subsequently detects reflected waves via a receiver. The travel time and energy of received signals are then processed and interpreted. The difference in material properties between limestone and open karsts causes strong reflections. GPR is frequently used as a geophysical surveying technique in several industries, however there is a lack of published research on underground mining GPR applications. The purpose of this work is to prove the viability of GPR in underground stone mines for karst detection, and to discuss the importance of karst detection ahead of mining. INTRODUCTION The Mine Safety and Health Administration (MSHA) currently lists 116 active underground stone mines in the United States, the vast majority of which extract limestone for crushed stone products. These limestone mines have the potential to encounter karst voids at some point in their operation, as most karstic regions of the United States develop in limestone rock masses (Kuniansky, Weary, & Kaufmann, 2016). Karsts, the cavities formed by the dissolution of carbonate rock, have long plagued the mining and tunneling industries, as well as been a hindrance on the Earth’s surface, producing sinkholes and ruining otherwise valuable land for construction and public use. The impact of karsts on the Gavarres tunnel in Spain is well documented by Alija et al; constant instability conditions, material spills into the tunnel, and unexpected cavities seriously delayed the project deadlines and “were not foreseen in the design” (Alija, Torrijo, & Qunita-Ferreira, 2013). At the water supply project in Sohngua River, China, Bin et al detail the presence of both water and sediment filled karsts which are sources of disastrous conditions at this tunnel (Bin, et al., 2017). A hydrological tunnel in Lebanon encountered numerous massive karsts in the tunneling path which required remediation via friction anchors, rockbolts, welded wire fabric, channel steel arch segments, invert steel beams, and shotcrete (Leech, Jaoude, & Ghanem, 2008). From a design standpoint, rock mass classification schemes, such as the RMR from Bieniawski and the Q-system from Barton, are not able to represent the true nature of a karstified carbonate rock mass, and therefore complex case-by-case analyses of underground conditions are necessary (Andriani & Parise, 2017).

Jan 1, 2019

By I. Iwasaki

There are many reasons why the US mineral and primary metals industry is in its present state. Undoubtedly, a flood of imported goods in all sectors is playing a major role in the plight of our raw materials industry. Domestic industry is becoming increasingly aware of the importance of its international competitiveness. And we are beginning to wonder what is happening to our technological edge. A number of factors affect the international competitiveness. Engineers cannot do much about some of these factors - labor costs, tax policy, government relations, interest rates, dollar strength, and labor-management relations. Something can be done about technology, however. Some say technology is so easily transferable today. But I would like to believe that we have the ability to apply it better than others. Not too many years ago, "made in Japan" meant cheap and shoddy products. Today, Japan has completely changed its image. The US is beginning to feel the threat from Japan's low-cost, defect-free products with dependable delivery. With worldwide recession and the strength of the dollar, we were shocked at the sudden weakness that developed in America's industries, not only in the international market, but domestically as well. What went wrong and what can we do about it? Senior executives from 300 large American manufacturing companies were surveyed. These executives believe US companies must: • invest in more efficient plants and equipment (27%); • invest in more research and development (23%); • improve the quality of service to customers (23%); and • adopt more aggressive marketing tactics and strategies (14%). Are we not doing enough research? The US has nearly four times as many people engaged in research and spends four times as much for research as Japan (Fig. 1). There is little doubt about the excellence of the US performance in basic science as indicated by the number of Nobel prize recipients. Japan has produced only four winners since World War II. Look at technology trade of five countries (Fig. 2). Again, US performance has been remarkable. An interesting observation here, is that the United Kingdom, another country with economic woes, is also in the black, West Germany and Japan, both with trade surpluses, are net technology importers. It is apparent that the US' performance in the commercialization of new knowledge is much more in question. Japan had $50 billion of trade surpluses with the US last year, which led to some friction between Washington, DC and Tokyo. Comparing the technology trade of Japan and the US in more detail, Japan imports disproportionately large amounts of technology from the US and Europe. This data is rather old, 1978, but the general trend is not too different even today. It is generally believed that scientific research leads to innovative technology, then to economic payoff. But, after seeing the current technological challenge by Japan, we are forced to change this traditional view. Investment in research may eventually lead to economic payoff, but not directly. There is a middle ground between new knowledge and its commercialization. This is an area where the Japanese have been successful. Until the 1970s, many western companies licensed patents to Japan for quick profits. But, in recent years, these companies have become more discrete about the terms of technological transfer. As a result, a number of scientists and engineers are expressing deep concern over the future of technological developments in Japan. A survey was conducted on 450 research managers of private industries in Japan on how they viewed the level of breakthroughtype original research in Japan as

Jan 6, 1986

By Timothy P. Smirnoff, Anthony Stirbys, Amanda Elioff

The construction of the continuing expansion of the Los Angeles Metro System has required the construction of eight new station structures. One contractor proposed, as a construction alternative for the support of excavation of the Hollywood/Vine Station, the use of soil-mix walls instead of the conventional soldier piles and wood lagging. Soldier piles and shotcrete or wood lagging support systems had been generally used on the other sub-way station excavations constructed to date throughout the system. Immediately east of that station and in almost exactly the same geology, the Hollywood/Western Station was being excavated at the same time using a conventional support system. This paper com-pares the performance of these two support systems in the alluvial soils of the Los Angeles Basin.

Jan 1, 1997

By Odin Wilhelmy

Agriculture in the United States today is becoming more and more a business, rather than a way of life. In the light of this, it behooves the farm-supply industries that provide the American farmer with his tools of production--feed, fertilizer, machinery, and the like--to give even greater attention than they have in the past to meeting the needs of the farmer-businessmen they are serving. Increasing competition among the companies that make up these industries merely accentuates this need for better service. An opportunity for such improved service, not yet fully realized, exists in the fertilizer industry today. That opportunity lies in the increased transportation of fertilizer ingredients by water. However, before the benefits inherent in this increased water movement of fertilizers can be fully realized, certain obstacles must be met and overcome. It is the purpose of this paper to outline the nature and magnitude of this opportunity, to point out some of the roadblocks and the steps that can be, or are being, taken to remove them, and to indicate some of the rewards that would logically stem from success in these efforts.

Jan 1, 1961

By S. D. F. Rocha

The influence of surfactants on the crystallization of calcium sulfate was investigated in both hatch and continuous systems. The investigation was per formed at the following conditions. 343 °K, 28% P205 and with a sulfate level of 2.0%. At concentrations of 5 and 200 µgig, respectively, dodecylbenzene sulfonic acid (DBSH) and sodium diisooctil sulosuccinate (SSNa) promoted both an increase in the size and a reduction in the length/width (L/W) ratio of the calcium sulfate hydrates produced in the hatch and continuous crystallizers. Unique effects were observed in the batch system at higher DBSH concentrations. At 10 µg/g, the precipitation of hemihydrate crystals with a distinct morphology and texture occurred under conditions where dihydrate precipitation was expected. Above 50 µg/g, the precipitation of calcium sulfate hydrates was completely inhibited.

Jan 1, 1996

By D. C. Seidel, W. K. Tolley

Supercritical water alters the structure of common sulfide minerals by partially removing sulfur from the mineral structure. This discovery has been applied to the treatment of pyritic gold ores to improve precious metal recovery without generating or utilizing environmentally sensitive products such as S02, chlorine, or cyanide. Pretreating pyrite concentrates in supercritical water under mildly oxidizing conditions provided by certain metal oxides or oxygen improved gold leaching using thiourea. The pretreatment differs from chlorination or roast pretreatments in that elemental sulfur rather than sulfuric acid is the major product. A pyritic ore containing 58 g/mt Au was pretreated with oxygenated supercritical water at 24 MPa and 400°C, then leached with 20 g/L thiourea. With pretreatment, gold recovery was 90%; by contrast, gold recovery was below 10% without pretreatment.

Jan 1, 1990

By Sepp A. Kutschera

are gaining increased interest for over­burden removal and ore production at large open cast mines. The application of bucket wheel excavators is still tied to soft un­consolidated rocks and soils, while belt conveyors can cope with all kind of matri­als restricted only by the top grain _ size. Therefore, mode of transport and the re­quirement of down stream ore processing de­fine the materials size distribution. These requirements are usually met by primary crushing or scalping. The paper discusses general applica­ tion criteria of bucket wheel excavator with systems primary for in-pit overburden crusher removal. and It _indeapits scalper units and discusses their technical and operational features. It further com­pares the capital and operating cost struc­ture relative to the syste

Jan 1, 1992

By John K. Hammes

This paper has been written as one of a group of papers dealing with the subject "Cost Elements in Mining". What are cost elements in mining? The mine operator thinks of direct mining costs in terms of labor, materials, supplies and power, and we might define cost more generally as the price paid to acquire or produce something. Economic theory also has its concepts of cost. From one point of view, that of the consumer, the cost of mineral commodities might be viewed as the total price industry pays for mine output. Similarly, the mining company engaged in the on-going business of finding, developing and operating new mines is concerned very much today with the distribution of all the revenue paid for mine output and not just with its direct or controllable cash costs. In other words, what will the labor force, the supplier of energy, explosives, and reagents, and the supplier of government services, management, capital and the ore reserves receive for their contribution to production.

Jan 1, 1974

By S. K. Jena, S. Singh, B. Das, N. Dhawan, P. K. Misra, D. S. Rao

"Iron as an impurity in pyrophyllite ore affects pottery, ceramics and tile quality. We carried out the characterization of a pyrophyllite ore sample using optical microscopy, scanning electron microscopy, X-ray diffraction, Fourier transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA) and wet chemical analysis. The study revealed the presence of 2.15% iron oxide (Fe2O3 ) along with silica and alumina as the major components, which constituted around 90% of the total sample. We carried out the removal of iron from the pyrophyllite using magnetic separation and acid leaching and found that wet high-intensity magnetic separation (WHIMS) could remove 28% of iron values while oxalic acid leaching could remove up to 99.3%. The leaching kinetics of iron removal and the effects of pulp density, acid concentration, leaching time and temperature were also investigated. The optimum conditions for leaching were found to be leaching time of 60 minutes, temperature of 90°C, pulp density of 5%, oxalic acid concentration of 0.3 M, and particle size below 100 microns. Iron dissolution from the pyrophyllite sample can be best described by the diffusion of ions through the product layer of constant-size spherical particles. The breakdown of the pyrophyllite structure was evident from the FTIR and TGA studies. The activation energy of the leaching process over the temperature range was calculated to be 43.47 kJ/mol. IntroductionPyrophyllite is a naturally occurring phyllosilicate mineral composed of aluminum silicate hydroxide [Al2Si4O10(OH)2] as the major component and often associated with other minerals such as kaolinite, mica, quartz, rutile and epidote. It occurs in fine-grained sericite schist that is quarried as pyrophyllite (Pandit et al., 2008). In India, pyrophyllite occurs mainly in Madhya Pradesh state, Uttar Pradesh state and the Keonjhar district of Odisha state (Harpavat, 1995). Pure pyrophyllite is a highly desirable material for various applications due to its unique properties. It exhibits high refractive behavior, low thermalelectrical conductivity, low expansion coefficient, low hot-load deformation, low bulk density and high corrosion resistance to molten metal and basic slag (Rieger, 1997). It is used in the ceramics, refractory, foundry, electrical-insulation, sanitary-ware, glassmaking, pesticide and rubber fields. Compared with clay, it has lower thermal conductivity and coefficient of expansion, making it more suitable for refractory applications (Harben, 2002; The Minerals Yearbook, 2011)."

Jan 1, 2015