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By M. R. Yalamanchili, W. H. Jang, Y. Ye, J. D. Miller

Typically, rougher molybdenite flotation and recovery from bulk copper/molybdenum concentrates involves the use of alkalisulfides, Nokes reagents, cyanides, oxidants, and/or thermal treatment to depress copper sulfide minerals. The bulk copper/molybdenum feed generally varies from 0.2% Mo to 1.0% Mo, and with traditional reagents the single-stage rougher flotation recovery of molybdenite varies between 40% and 90% at a concentrate grade of 5% to 10% Mo. With ozone conditioning for copper depression, however, improved separations appear to be possible, as demonstrated by tests with Cu/Mo concentrates from both the Phelps Dodge Morenci Operations and the Kennecott Copperton Operations. Single-stage rougher flotation after ozone conditioning can provide a molybdenum concentrate at a recovery of more than 90% and a rougher concentrate grade higher than 20% Mo in some cases. Subsequent cleaner flotation with additional ozone conditioning resuIts in relatively copper-free molybdenum concentrates containing as much as 52% Mo. Preliminary analysis indicates that, with a multistage ozone conditioning/fotation strategy, the process is technically and economically viable and should be suitable for industrial ap¬plication.

Jan 1, 1991

By M. R. Fletcher

Slags generated by the ferrous metals industry can he used to produce high-value ceramic materials. The properties of these ceramics can be controlled by judicious choices of composition, additives, and processing parameters. Standard methods of materials handling, such as comminution and mixing, are as applicable to slag as to any other mineralogic raw material. In this study, foundry slag was ground, homogenized, melted, and, formed to produce a glass, and then heat treated to crystallize it into a high-strength glass-ceramic. The product shows promise as a low-cost, wear-resistant tile material that (-an he custom cast. This and similar materials made from slags and natural rocks are candidates for use as construction materials, acid-resistant piping, shock-resistant sheathing, rot-proof pilings, and, when foamed, even as pontoons.

Jan 1, 1990

By Frank F. Aplan, Edward C. Dowling, Richard R. Klimpel

Several series of time-instantaneous samples were taken on a cell-by-cell basis in the flotation circuits of the Pinto Valley, AZ copper concentrator. These samples were used to calculate mass flow rates throughout the circuit using standard, deterministic metallurgical formulae and also a variety of more statistically oriented techniques. Because of the magnitude of the errors associated with the individual cell samples, the standard metallurgical formulae are not sufficient. Consequently, it is necessary to utilize some type of statistical technique capable of distributing the individual cell sample errors in such a way so as to provide a physically useful mass balance for the entire circuit. This paper explores the use of linear and least squares programming as one technique to providing credible mass balance calculations. For linear programming this was done by distributing the error using two different criteria involving specific linear programming formulations: least absolute sum minimization (which assumes an underlying double exponential distribution error structure) and minimax (which minimizes the maximum absolute deviation and assumes an underlying rectangular distribution error structure). These results were then compared to the more standard formulation of minimization of the sum of least squares which assumes an underlying normal distribution error structure. The least absolute sum approach was particularly attractive due to its simplicity of use and the ease in which repetitive calculations can be done with no user intervention.

Jan 1, 1990

By Keith S. Liddell

Gold in many ores occurs in sulphides, which, if the gold is finely disseminated, renders the ore refractory and therefore not amenable to the simple process of milling and cyanidation. Traditional methods of treatment of these refractory ores is to produce a sulphidic flotation concentrate which is roasted to form a porous calcine from which the gold is recovered by cyanidation. The roasting process imposes a constraint of a minimum sulphur grade of the concentrate on the flotation plant, which may lead to a lower gold recovery being achieved in the flotation section. Thermal decomposition of the concentrate by roasting means that the sulphur contained therein has to be treated and disposed of in an environmentally acceptable manner; and, if arsenopyrite is present in the concentrate the environ- mental aspects will be worsened. It has long been recognized that finer milling of gold-bearing materials improves the liberation of gold, especially when the gold particles are very fine. After extensive laboratory and pilot plant investigations (Liddell, Patents), a suitable mill has been developed for the mining industry by Metprotech, which is capable of producing very fine grinds (down to 90 percent passing one m if necessary). In the course of the investigations it has been found that a large number of gold-bearing materials are amenable to fine milling. A specific advantage that fine milling of sulphidic materials has over oxidative processes such as roasting and bacterial leaching is that the sulphides are not decomposed and there is therefore not a sulphur disposal problem. Furthermore, the milled sulphides can become a future sulphur feed source, and can be reclaimed if necessary. A further feature of the Metprotech process is that it is possible to add cyanide to the mill feed

Jan 1, 1988

By John O. Marsden

Technology development has played a crucial role in the minerals industry throughout history. The development of new technology allows mankind to produce metals and minerals at progressively lower cost of production in real terms, and therefore at progressively lower prices, improving their availability, accessibility and utilization worldwide. However, the developers of such technology are not guaranteed to reap the benefits from this effort: There is an expectation that technology developers will gain an advantage over their competitors. Is this a short-term benefit that results from a temporary cost or efficiency improvement, or is it a sustainable longer term "edge" that prevails even after metal or mineral price has been eroded by the implementation of a major step change technology? This issue is examined by reference to several case study examples in the copper industry. BACKGROUND The development and adoption of new technology has played a crucial role in the commodity minerals industry throughout history. As new, cost-efficient technologies are commercialized, the cost of production decreases, and this enables lower grade ore to be processed profitably. This in turn increases the availability and supply of the metal or mineral of interest, and ultimately (in a free market environment where the supply- demand balance determines price) inevitably decreases the metal or mineral price. This leads to the question: Why should mining companies invest in (new) technology development if the result is a decrease in the product price? The answer is to achieve competitive advantage, where the application of new technology enables one or more

Jan 1, 2004

By Brian W. Hester

Ore was first discovered at the Kidd Creek mine site during the first few days of December 1963 when a diamond drill hole there cut sulfide mineralization. This event marked the end of the search started 11 years earlier with the conception of a geological idea. Economic forces provided the stimulus needed for the application of this idea but other-events, and legal considerations, also played arole in delaying the ultimate discovery. The location of Kidd Creek is shown in Fig. 1. Management of the then Texas Gulf Sulphur Co. had become concerned in 1951 at the company's declining reserves of native sulfur in Texas. This problem was to be alleviated by new discoveries and development of methods to recover sulfur from sour gas. At the time, however, the solution appeared to lie in the recovery of sulfur from pyritic ores. Canada was chosen as the best country in which to find these ores. Walter Holyk was hired in 1951 to conduct the search. By 1952, he was working in the area near Sherbrooke, Quebec, known as the "Eastern Townships" where mineralization consisting of base metal sulfides in volcanic rocks has long been known. His observations here led him to the then revolutionary conclusion that such mineralization could have formed as part of the volcanic process and not, as was generally supposed at the time, by replacement. On learning of the discovery of similar mineralization near Bathurst, NB, he moved there in the spring of 1953. He was able to utilize his new concept and found the Half-Mile Lake sulfide deposit.

Jan 1, 1991

By A. D. Davis

A ground-water flow model was developed to simulate the post-mining recharge rate at the Belle Ayr surface coal mine in the Powder River Basin near Gillette, Wyoming. State regulations of Wyoming require that reclaimed lands should provide a rate of recharge that approximates the pre-mining rate. Steady-state calibration and transient simulations showed that the post-mining recharge rate in backfill is at least five centimeters per year, exceeding the original infiltration rate of 0.4 centimeters per year to shallow, overburden aquifers. Major reasons for the increase include the flat topography of reclaimed areas and decreased spoil density. It is expected that the backfill will disaggregate and settle over time, eventually resulting in a nearly constant recharge rate less than five centimeters per year but somewhat greater than the pre-mining rate.

Jan 1, 1995

By James D. Bennett

During the past decade many U.S. industries have realized the importance of a total loss control program; the bituminous coal mining industry is no exception to this trend. Oftentimes, we realize that the circumstances surrounding a "near miss" (an incident which does not result in personal injury or property damage) are practically identical to those associated with a fatality, disabling injury, or major property damage. And, many organizations suffer enormous financial losses in cases where no one is injured or property damaged but costly delays in production result. Detailed analyses of both injury and non-injury cases can provide valuable input into those engineering, behavioral, and management controls that are necessary to prevent their recurrence. The purpose of this paper is to describe a comprehensive loss control surveillance system (LCSS) that will enhance management control in preventing personnel, property, and production losses, thereby, maximizing profit. The next section describes the components of this LCSS. Then, we present one practical example of how this valuable management tool can be used to minimize loss through safety and training programs.

Jan 1, 1985

By N. L. Piret, R. J. Wesely, A. E. Melin, A. D. Zunkel

At the end of the sixties new iron precipitation techniques as jarosite, goethite or hematite brought about the new generation of electrolytic zinc plants, thereby terminating the multitude of existing neutral leach residue treatment schemes. Since the eighties, increasing environmental impact considerations urge the conversion of these contaminated waste generating precipitation processes to techniques which either produce environmentally acceptable residues or minimize their formation thereby generating iron-bearing byproducts. Technologies identified and economically assessed include the hematite process either suitably improved or with subsequent upgrading, the iron extraction process and the direct smelting of neutral leach residue to slag and fumed zinc oxide.

Jan 1, 1993

By C. A. Pickles, D. Mallette

Silicon nitride (Si3N4 ) is an advanced structural ceramic materia1 which is presently being considered for a number of potential engineering applications, particularly in heat engines, gas turbines, and electronics. With respect to other structural ceramics, silicon nitride has relatively low thermal conductivity and thermal expansion coefficients and a moderate elastic modulus. Thus, during thermal cycling the stresses developed in this material are lower than in other structural ceramics. At the present time silicon nitride is produced via three main processes: thermal decomposition of silicon imide or amide, treatment of silicon tetrachloride or silane vapour with ammonia and nitriding of silicon powder. These three methods of production are discussed with particular attention to the effect of morphology and phase content on the properties of the final product. In this work carbothermal production of silicon nitride has been studied in a high temperature resistance furnace. Compacted briquettes of silica and carbon were produced which were reacted in a nitrogen atmosphere. The optimum reaction temperature and the carbon to silica ratio were found to be 1425OC and ten to one, respectively. The presence of large amounts of ash in the reductant promoted the formation of silicon nitride. The specific surface area of the briquettes did not have a large effect over the range studied in the present work. Briquette seeding with small amounts of Si3N4 was effective in increasing the reaction rates.

Jan 1, 1990

The 70th Annual Meeting of the Minnesota Section of SME and the 58th Annual University of Minnesota Mining Symposium were held April 22-24, 1997, in Duluth, MN. About 450 attended both. The Fifth Annual Trade Expo, held during the meeting, was attended by a record 80 exhibitors. An SME short course on materials handling preceded the meeting. Iron-mining and the steel industries highlighted the meetings. Specific topics in the keynote addresses and technical sessions primarily concerned iron mining, iron- ore processing, product (taconite pellet) transportation and the steel market. Although the iron mining industry held center stage, several papers outside of iron mining were also presented. Iron mining in Minnesota contributes $1 billion to Minnesota's economy. According to the Iron Mining Association of Minnesota, more than 20,000 state jobs rely on the industry. Minnesota's iron mining industry came through tough times in the early 1980s, mostly because of worldwide competition. However, the industry has shown significant improvement in the last 15 years. A large share of the steel industry's competitiveness in the late 1990s is due to cost and quality improvements in the taconite mines. The taconite industry has become more productive, largely through the application of new technology. Since the early 1980s, Minnesota's taconite mines have nearly doubled the number of tons per worker-hour. Most of the taconite reserves in the United States are located in Minnesota's Mesabi, Vermilion and Cuyuna iron ranges. The Mesabi range alone contains an estimated 24. Gt (23.6 billion long tons) of mag- netic taconite. Since the 1950s, when taconite production first began, 1 Gt

Jan 1, 1997

By Terry Ramsey, N. Finkelstein

INTRODUCTION The Cyprus Pima Mine is located 20 miles southwest of Tucson, Arizona and about fifty miles north of the Mexican border. The Cyprus Pima orebody was discovered in 1950. Feasibility studies were begun in 1952 employing underground development. Economic studies showed open pit operations to be feasible and stripping of overburden was begun in late 1955. The first ore was reached in October of 1956. A 3,000 tpd (tons per day) concentrator was completed and began operation January 1, 1957. From these beginnings, Cyprus Pima Mining Company has expanded into a plant processing approximately 54,000 to 56,000 tpd. Four expansions were required to bring the plant up to its present capacity. Each expansion incorporated what had been learned in previous operation of the plant. The first expansion was completed in August of 1963 doubling design capacity to 6,000 tpd. In reality, because of softer than average ore, capacity was closer to 8,000 tpd. Expansion I1 was completed in July 1966 bringing design capacity to 18,000 tpd. Expansion I11 followed immediately. Completed in the summer of 1967, this expansion increased the design capacity to 30,000 tpd. The actual dry tonnage of this portion of the operation in 1974 averaged 38,400 tpd, again, primarily as the result of treating softer than average ore. The latest expansion (Expansion IV), completed in December 1971 and utilizing a semi-autogenous grinding circuit, is located in a separate building (Mill 11) approximately 200 yards southeast of the original mill (Mill I). Expansion IV was designed for 14,000 tpd, but after circuit modifications, averaged 16,500 tpd in 1974.

Jan 1, 1976

By Jack W. Eloranta, Michael J. T. Orobona, Peter R. VanDelinder

Ore blending for process optimization is becoming an increasing factor for managing cost and productivity. Economic mining and processing a very low value ore in an extremely competitive market results in constant cost-cummng initiatives. The inherent conflict between the lowest possible mining cost and the lowest possible milling cost is reviewed here in the context of blasting for autogenous mills. Iron ore blending focuses on a number of properties-liberation values, weight recovery and concentrate silica being the most important. Other chemical and metallurgical factors are also commonly controlled. Recent research has fueled an emerging interest in blending on physical ore properties as well. Fully autogenous mills rely on the large, competent fraction of crushed feed to act as grinding media. Previous test work indicated that Hibtac mills require specific amounts of 6- to 10-inch ore. High recirculating loads require a steady influx of large rock fragments. Blast designs, therefore, are presently characterized by wide patterns and low powder factors. Current efforts are aimed at improving mill throughput while reducing overall energy costs. Based on research and published case studies and the advent of optical measuring devices, Hibbing Taconite Company has embarked on a blast optimization program to identify optimum mill feed and to design blast fragmentation goals for each geological unit and each mining area. This paper outlines the preliminary findings of an ongoing, broad-based team effort which requires close cooperation of geologists, mine engineers, crushing and milling personnel. Three specific areas of investigation are reviewed: I) Historical relationships between powder factor and mill performance, 2) Blast fragmentation modeling using the Kuz-Ram model, and 3) Drill

Jan 1, 2004

By Carl E. Nelson

Shallow epithermal stockworks hosted by maar eruption craters contain over ninety percent of the bulk mineable gold identified to date in the Circum-Caribbean region. Pueblo Viejo (Dominican Republic) and Santa Rosa (Panama) contain combined gold reserves of over 600 tonnes. Bulk mineable gold deposits are also being discovered in and around veins that were formerly mined underground. Bellavista, El Recio and San Martin (Costa Rica) contain combined announced gold reserves of over 50 tonnes. Representative rock suites collected at 8 bulk mineable gold deposits include 291 samples of veins and vein stockworks, hydrothermal eruption breccias, sinter, variably altered host, unaltered host, nearby intrusive rocks and basement. Analyses completed to date show that Circum-Caribbean epithermal ores are enriched in arsenic, mercury and antimony as well as gold and silver. Exploration efforts in the region naturally focus on districts with past production. However, an order of magnitude more bulk mineable gold has been discovered in shallow epithermal stockworks outside of the old bonanza vein camps. Exploration guides include basal island arc volcanic sequences, hydrothermal and hydrovolcanic (maar) eruption breccias, thinly-bedded carbonaceous maar sediments, and hot spring-related silicification and argillic alteration.

Jan 1, 1990

By D. P. Plute

The mechanization of the materials management function must contribute to the overall goal of optimization of profits. A computerized system contributes to the profitability of the company by saving more than it costs to operate. Design and implementation of the sys- tem must respond to the needs of users, the operating environment of the property, and must support the objectives of materials management. Three basic functions interact within the scope of materials management. They are inventory control, purchasing, and warehousing which have the following objectives: 1) Inventory control-to request materials in a timely manner and in quantities that provide the best level of support to users at the lowest cost. 2) Purchasing-to purchase requested materials and services at the required time and at the lowest cost. 3) Warehousing-to efficiently receive, store, and issue materials and to prepare accurate transaction documents for the activities. The development of the mechanized materials management system will require a plan and objective analysis by management and system users of system requirements. A typical plan would include: 1) System Design Objectives-the development of objectives that support mechanization of the materials management function. 2) System Characteristics and Concepts- the development of key system concepts and characteristics, which identify the needs of materials management. 3) System Inventory Item Classification- development and assignment of inventory category codes to inventory items. 4) System Order Decision Rules-the development of decision rules and forecasting techniques to minimize the inventory investment and to provide acceptable support levels. 5) System Report Structure-the development of a report structure to support the goals and objectives of materials management. 6) System Report Design-the development and design of reports for effective utilization of the mechanized system.

Jan 1, 1979

By Stephen G. Hardcastle

CANMET has developed a simple yet very effective tracer gas method to test the efficiency of stench gas emergency warning systems which can easily be performed by mine personnel. This test method uses sulphur hexafluoride (SF,) as a surrogate for such stench gases as ethyl mercaptan. The test has many advantages: it is non-disruptive to production because SF, is odourless, colourless; it is safe to use as it is inert and only a small volume, insufficient to reduce oxygen levels, is necessary to dope the air with a measurable concentration; and most importantly it provides definitive results to assess the adequacy of the warning system. Specific findings of these tests have included, over doping sections of the mine and subsequent production loss due to sickness, the warning being ignored, the injection period being too short, excessive dispersion, and inadequate notification times. The simple test protocol involves releasing a known volume of the SF, under similar circumstances to those of the stench gas, and then sampling for its presence downstream. These samples are collected in air-tight syringes which are then analyzed in a laboratory with a gas chromatograph. By direct proportion, between the size of the stench and tracer gas releases, it is possible to convert the SF, concentration into equivalent stench gas concentrations profiles. From these, it is possible to define, the initial arrival time of the gas, the time it takes to reach a "target" notification concentration, whether the gas peak will exceed TWAEV, STEV and CEV exposure limits, and the duration of the peak above these levels. Since 1993, this test protocol has been employed a total of eight times on four different Canadian mine properties and the results are being used to optimize the stench gas release system with respect to volume of gas used, duration of injection, and number of injection locations.

Jan 1, 1997

By S. Chander

The use of various electrochemical techniques to study mechanisms of sulfide mineral- flotation reagent interactions is briefly reviewed in this paper. Prior to such studies it is desirable to thermodynamically determine solution conditions favorable for formation of hydrophobic species deemed to be responsible for flotation. The thermodynamic equilibrium involving both the stable and metastable species can be conveniently represented by an Eh-pH diagram. Thermodynamics can also be used to predict conditions where a mineral might not float if depressants are present. Under favorable conditions of flotation there is competition between reactions leading to formation of hydrophobic species with reactions that lead to formation of hydrophilic species. Due to the sluggish nature of the reactions involving sulfide minerals, a knowledge of the kinetic behavior of the system is necessary. Electrochemical methods of investigation are wed in laboratory studies to (1) control the state of oxidation, (2) determine the type and amount of electroactive species present at the mineral surface, and (3) study kinetics of electrode processes. By combining electrochemical techniques and wetting measurements the identification of hydrophobic species that might be present at the mineral surface could be achieved. Both contact angle measurements at mineral electrodes or flotation in a cell equipped with a particulate bed electrode can be used for the wetting measurements.

Jan 1, 1987

By R. Norman Holme

Sulfonate promoters and collectors were originally developed as relatively inexpensive anionic collectors to selectively concentrate the iron-bearing minerals in low grade iron ores and to remove iron and other mineral contaminants by flotation in the processing of glass sands, feldspar and other ceramic raw materials. The first reagents produced were effective collectors for such iron oxide minerals as goethite, hematite, limonite, magnetite and siderite. Further development has resulted in additional reagents with a broadened application to the selective flotation of a variety of nonsulfide and nonmetallic minerals. The products in this group are anionic sulfonate-type promoters, natural petroleum sulfonates, and synthetic modified sulfonates. Beyond their applications to iron-bearing minerals, the sulfonate collectors have gained commercial use in the flotation treatment of barite, celestite, fluorite, apatite, chromite, industrial garnet, kyanite, mica, rhodochrosite and cassiterite. in addition, extensive laboratory studies indicate their potential suitability for flotation of the following minerals: Anatase Anhydrite Bauxite Beryl Calcite Chlorite Some Copper Carbonates Corundum Dolomite Hornblende Huebnerite Ilmenite Lepidolite Magnesite Phosphate Minerals Rutile Scheelite Spodumene Sillimanite Talc Tourmaline Wolframite Zircon Sulfonate promoters are water soluble or dispersible liquids, syrups or pastes of varying viscosity with colors ranging from dark blackish-brown to clear. Customarily, they are fed to the conditioner or flotation as 5% to 30% water solutions or dispersions. In addition to their normal collector activity, certain of these products display notable frothing characteristics. Improved collector efficiency and adequate froth control can frequently be obtained by employing mixtures of sulfonate reagents, of ten with results quite markedly superior to those achieved with equivalent dosages of the individual promoter alone. Reagent requirements will vary with the type of mineral being treated; however, a general overall range of 0.13 to 2.0 kg/metric ton (0.25 to 4.0 lb/ton) of feed should cover most applications.

Jan 1, 1986

By Ignacio González, Marcos Monroy, Valerie Bertrand, Roel Cruz

Results of an electrochemical study using carbon paste electrodes of pyrite and pyrrhotite samples suggest that the mineralogical impurities associated with these minerals are the determinant factor on their reactivity under alteration systems. These results were supported by mineralogical and leachate chemistry data from leach cell tests run on these samples. Pyrite reactivity decreases in the presence of associated impurities due to a galvanic effect whereas pyrrhotite reactivity appears to be controlled by the formation of a passivating layer, which overcome impurities effect. Electrochemical responses of sulfide-bearing samples provided valuable information on the prediction of ARD generation.

Jan 1, 2000

By John C. Edwards, F. Friel, John J. Opferman, Robert A. Franks

A series of diesel fuel fire experiments were conducted in the Pittsburgh Research Center's Safety Research Coal Mine (SRCM) to determine products-of combustion (POC) spread rates along a single entry under zero imposed airflow conditions. Six experiments with an average fire intensity of 330 kW and three experiments with an average fire intensity of 30 kW were con- ducted in a 180 m long entry which had an average 2 m height and 4 m width. POC spread rates were measured by the response time of diffusion type CO detectors, positioned at 30 m intervals, to CO concentrations 5 ppm above ambient. For the 330 kW fires, average POC spread rates of 0.22, 0.1 3, and 0.06 m/s were determined at 30, 60, and 90 m distances from the fire. For the 30 kW fires these average spread rates were reduced to 0.08, 0.04, and 0.04 m/s. The measured maximum roof layer temperature 30 m from two of the 330 kW fire was 30 and 36"C, which is less than the 57°C alarm point of a typical mine thermal sensor. It was determined that smoke detectors can be more effective for mine fire detection than CO detectors. The experimentally determined POC spread rates can be used to provide guidance for specification of sensor spacing to improve early fire detection at zero or very low air flows.

Jan 1, 1997