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By H. Simpson

Middelburg mine is an opencast export mine operating in the Eastern Transvaal Coalfields of the Republic of South Africa (Figure 1). The mine was commissioned in 1983, to its original design capacity of 4.25 million sales tonnes which was subsequently raised to 5.5 million sales tonnes in 1989. This increase in export tonnage was brought about through an increase in the mines export allocation and the revision of management strategies. The maintenance of this increased tonnage with minimal additional capital has been achieved through improved operational efficiencies and the upgrading of planning operations through the purchase of an Enhanced Mine Scheduling Software Package (EMSSP/MINESTAR). Simultaneously with this requirement were additional factors that contributed to the implementation of the EMSSP. The mine was owned by a joint venture of two partners and is operated by Middelburg Mine services (Rand Mines Pty. Ltd) (Figure 2). This structure of ownership required the evaluation of numerous planning options to be under-taken concurrently and hence the need for an efficient streamlined scheduling pack-age that could fulfill this requirement. Compounding the EMSSP needs further, were the problems experienced in the export market, these being the external pressure from current and new suppliers in the market place which obliged management to provide solutions to rapidly changing market conditions. These fluctuating market conditions have had a direct effect upon the mine's planning strategies because of the large percentage of the mine?s sales sold on the international spot market. The sanction factor for all South African exporters has had a negative effect upon price and this was compounded further through internal competition in 1987 via suppliers attempting to maintain the market position.

Jan 1, 1991

By C. D. Anderson

A variety of processing technologies exist for recovery from both primary and secondary sources of rhenium. Currently, there are no known primary rhenium deposits, thus, the method in which primary rhenium is produced is dependent on the commodity of which it is a byproduct, e.g., copper, molybdenum, uranium, etc. In addition, focus on the recovery of rhenium from secondary sources, such as alloy scraps and catalysts, is continually growing. This paper presents a review of both primary and secondary processing technologies for the recovery of rhenium. Key Words: Rhenium, Ammonium Perrhenate, Extractive Metallurgy

Feb 27, 2013

By Peter G. Chamberlain

The Bureau of Mines is conducting research to boost domestic production of manganese. Virtually no mining exists in the low grade and/or small deposits that occur in this Country. One large, low-grade manganese deposit located in westcentral Arizona--The Artillery Peak district--was extensively studied and sporadically mined during the 1940's and 1950's. Although manganese mining in the district has been long dormant, recent studies indicate that the deposits may be amenable to economical production by heap and/or in situ leaching methods. A conceptual design for an in situ leaching system features undercutting and blasting a block of ore, leaching with SO2, and extracting the manganese as a sulfate or oxide. Possible applications to other manganese deposits depend upon formation permeability and specific manganese mineralogy.

Jan 1, 1981

Heap leaching has become one of the prime technologies used for the recovery of precious metals from low-grade ores over the past ten years. The recovery process involves mining and stacking the ore on engineered leach pads, with or without crushing and/or agglomeration, followed by leaching with a low concentration sodium cyanide solution. The metal-bearing, pregnant solution is then processed by zinc precipitation or activated carbon absorption to extract the precious metals. The leaching process continues until all economic metal values are removed at which time the spent heap leach pads, the leached materials and excess process solutions require decommissioning. The management of these solutions may present a potential challenge for successful and environmentally sound decommissioning due to their composition, volume or continuity of generation from the spent ore even though active leaching has been terminated. The principal objectives of solution management in decommissioning spent heap leach pads are to meet all operative environmental regulations in a cost-effective manner and to leave the pads in a condition where they do not present a long-term liability either to the operator or to the environment. This involves the reduction in volume of the residual process solutions and/or treatment of these solutions to where they meet applicable water quality criteria. In the past, the environmental and economic aspects of decommissioning and solution management have been overlooked or under-estimated during the planning of mining operations. As a result, there is a potential for long-term liabilities and costs to be recognized only at the end of active leaching, a time at which operating revenues and cash-flow are minimal. Therefore, the decommissioning process requires addressing at the mine planning stage and agencies now require that a plan for solution management after the cessation of operations be submitted prior to initiation of mining. This paper discusses aspects of process solution management during decommissioning, both in terms of quantity and quality, and how potential issues may be recognized and planned for in the initial stages of heap leach design.

Jan 1, 1992

By Horry Parker Jr, Jason Gillespie, Justin Kolster, Stephen O’Connell

Construction of the 5,932-ft Reedy River Basin Sewer Tunnel in Greenville, SC was marked by a critical transition from drill-and-blast mining in mixed-face conditions to TBM excavation with limited rock coverage. In this paper, we discuss the geological, geotechnical, and risk management considerations for transitioning to TBM operations in variably weathered gneissic bedrock. After construction of an unexpected 230-ft starter tunnel due to differing site conditions, the 11-ft diameter TBM was successfully launched in December 2019 without significant ground support issues. This project highlights the effectiveness of extensive rock probing to fully characterize bedrock topography prior to the TBM launch.

Jun 13, 2021

By Elimame Elaloui, Kais Elghniji, Constantin Virlan, Aurel Pui, Chaima Ouled Amor

Separation and identification of minerals composing the Tunisian silica sands have been conducted by acid etching and hot filtration/sedimentation (HFS) without affecting the quartz component. It was found that the hot acid etching process is an effective method to separate quartz and clay minerals in the silica sand. The SEM micrographs of the silica sand show rough surface and some cracks with irregular shapes. The surface becomes clean and smooth after acid etching process. After chemical dissolution, the clay minerals were recovered by hot filtration following by sedimentation at low temperature. FT-IR, EDS maps, and secondary electron (SE) analyses of separated clay minerals reveal the presence of Fe2O3, montmorillonite, and kaolinite minerals. The LIBS analysis of clay minerals shows the presence of Al, Fe, Ca, Al, and Mg. The sequential etching process can be introduced in the purification methods as an effective way to separate quartz from clay minerals.

Jul 29, 2020

By B. Qiu, Y. Luo

The design of the predriven recovery room is not an easy task, because the stress distribution in the barrier pillar, standing supports, fender pillar and the immediate roof is changing as the longwall face approaches the predriven recovery room. An analytical approach is proposed to determine the stress distribution in the barrier pillars, fender pillars, standing supports and immediate roof of the recovery room based on the fracture mechanics approach. Based on the developed mathematical model, a stand-alone computer program has been developed to facilitate the required computations. The parameters such as overburden depth, recovery room width, mining height, shield and standing support capacities are incorporated into this program to access the feasibilities of predriven recovery room designs. Compared to the finite element method previously employed, this analytical approach offers the same, if not better, accuracy without requiring expensive computer hardware and software or specialized expertise.

Jan 1, 2012

By Matthew Goff, Russell Lutch

The Great Lakes Water Authority (GLWA) operates the largest regional water authority in the State of Michigan. Two of the tunnels supplying raw water to the system from the Detroit River are the Springwells and Northeast Tunnels. The existing 70- to 90-year old concrete lined tunnels have experienced distress and cracking over their life requiring non-structural repairs to sections of the tunnels. For the repair, an interior stainless-steel segmental liner plate system has been designed to restore the watertight capacity of the tunnel liner and resist the exterior hydrostatic groundwater pressure in a dewatered condition. The team is utilizing a “wet repair” approach to perform the necessary repairs while the tunnel remains fully flooded and operational. To test and validate the tunnel repair approach, a full-scale mock-up of the proposed repair has been performed using underwater equipment and divers.

Dec 1, 2022

By Paul R. Smith

The theoretical requirements for the flotation d large particles are discussed. A flotation machine is described which has components which meet many of the theoretical requirements for the flotation of large particles. The machine's salient features include multiple fine-bubble attachment, froth level feeding, quiescence, shallow depth, and short flotation time. Test conditions and results are presented for the laboratory flotation of 10 mesh phosphate, 4 mesh potash, and 1/2 inch coal. In addition, test conditions and results of pilot plant flotation of minus 14 plus 35 mesh phosphate and minus 14 plus 150 mesh phosphate are also presented.

Jan 1, 1969

By S. Bargigli, S. Ulgiati, M. Raugei, F. Cherubini

Metallic magnesium is mostly used in lightweight alloys in order to decrease fuel consumption in automotive applications. Several different production processes are currently used worldwide, and the magnesium production scenario is changing rapidly, with Chinese production increasingly dominating the world market. For the purpose of this paper, a novel approach to Life Cycle Assessment was applied, in which Material Flow Accounting and energy-based methods (Embodied Energy, Exergy and Emergy Analyses) are integrated and complemented, with a detailed description of the environmental hazards associated with emissions from all the different processes.

Jan 1, 2005

By Gerald W. Elger

Research at the Albany Metallurgy Research Center has shown that high-purity rutile can be produced from relatively low-grade ilmenite obtained from a massive rock deposit. Ilmenite is first smelted in an electric-arc furnace to separate the iron and produce a slag enriched in titanium dioxide. Titania slag mixed with a phosphate flux is then oxidized to synthesize rutile and form a phosphate-glass matrix which contains the impurities. Attrition scrubbing the treated slag in dilute solutions of phosphoric or sulfuric acid liberates the rutile, which is concentrated by physical methods. Tests show that synthesized rutile containing 95 to 97 pct titania responds to chlorination at the same rate as natural rutile.

Jan 1, 1973

By S. M. Hossaini, M. Ataei, H. Moosavi

The abstract highlights the importance of pillar stability in underground coal mines and the influence of rock mass strength and joint orientation on pillar behavior. The study employs numerical modeling using the distinct element code (UDEC) to investigate the impact of these factors on pillar stability. The research considers different joint orientations and varying rock mass strengths, analyzing parameters like stress distribution, displacement, and failure patterns. The findings reveal that both joint orientation and rock mass strength significantly affect pillar stability, with specific combinations leading to reduced safety factors and increased deformation. The study concludes by emphasizing the importance of considering these factors in pillar design for safe and efficient mining operations.

Apr 4, 2022

By Allan G. Provost

Shaft construction is assuming ever increasing importance when new mining enterprises are considered. The reasons for this increased emphasis is the much greater depths at which many new ore-bodies are being developed and the rapid depletion of near surface reserves requiring mines to go to greater depths on existing deposits. These greater depths increase the probability of exposure to unfavorable geologic conditions and it is more likely that high ground and/or water pressures will be experienced at these depths. The large capital costs involved and the critical position of a shaft in the overall mining program necessitate that this element of project development be given careful and critical consideration. The Henderson No. 2 Shaft is located in the Rocky Mountains of north central Colorado (See Figure I), about 55 miles west of Denver, near the community of Empire in Clear Creek County. At the 10, 442 foot collar elevation, winter arrives in late September and brings snow to contend with until May. The labor force for Shaft No. 2 is approximately 90 men. They are provided access to the project via all-weather U. S. Highway 40. SHAFT DESIGN The Henderson No. 2 Shaft is a 28-foot I. D. circular, concrete lined (1 foot thick) vertical shaft. The final depth will be approximately 3100 feet

Jan 1, 1972

By A. Bascetin

It was recently proposed to use the pastefill technology as a surface tailings management method. Surface paste is an economic and safe storage method that respects current environmental regulations. There are many problems related to accidents that occur in conventional tailings damps. In this study, the applicability of the surface paste disposal (SPD) method for a Pb-Zn mine in western Turkey was examined. Density was 3.084 and specific surface area was 0.899 m2/g. The mill tailings have very low plasticity and show characteristics of clays and silts in terms of the Unified Soil Classification System. The particle size distribution of the tailings was 39.2% particles finer than 20 µm. The results of this study showed that the physical and chemical properties of mill tailings make them suitable for SPD.

Feb 23, 2014

By Dan B. Kivari

One of the key operations in any milling circuit is grinding. Over the last two decades, large diameter Semi-Autogenous Grinding (SAG) mills have become the preferred primary grinding mills. The drive systems became more complex as the size of the mills became larger, during which time operating and design experience for SAG mill accumulated. Considerable reliance is now placed in power electronics to provide flexibility in SAG mill operation to meet the demands of lower operating costs. Whereas earlier most SAG mills were designed to operate at fixed speeds, present day SAG mills can operate at a fixed speed or variable speed through the use of an AC synchronous motor or DC motor. However, this flexibility comes with an increase in capital and operating costs. Since the capital and operating costs of a project directly affect the project's rate of return, the selection of a SAG mill and its drive system should depend, in part, on the impact that the extra cost makes on the project. This impact can be measured by performing an economic analysis based on Net Present Cost (NPC) calculations. Although the NPC calculation is an important factor in the grinding mill selection, other factors such as reliability of mill drives and power source are important elements in the decision making process. This paper examines how the NPC calculation, plus reliability and power source, influence SAG mill selection.

Jan 1, 1991

By A. Jennings, J. Cornet, P. Perrone

Controlling long overland conveyors with multiple drive stations is a complex problem. The methods for controlling these belts in a steady state are well-covered in existing literature, but a discussion of starting and stopping strategies is absent. This paper outlines different control strategies for starting, stopping and running conveyors with multiple drive stations. To illustrate the benefits of applying the methods described in this paper, the authors show how their adoption corrected many of the control system problems at Essroc Cement’s overland conveyor, which features three drive stations separated from each other by long lengths of continuous conveyor belt.

Jan 1, 2013

By William C. McBee

A sulfur concrete technology has been developed by the U.S. Department of the Interior, Bureau of Mines, in which chemically modified sulfur is utilized with suitable mineral aggregates to produce construction materials which are resistant to corrosion by acids and salts. This report presents a summary of the basic technology and results of testing the materials under actual operating conditions in 50 corrosive environments in 40 commercial plants. After 4 years of testing, there was essentially no evidence of material degradation or loss of strength. Regular concrete materials were attacked and in some cases completely destroyed under the same conditions. Testing is continuing to establish ultimate longevity and durability of the sulfur concretes. The materials are finding widespread applications in metallurgical, chemical, and fertilizer processing plants.

Jan 1, 1983

By E. A. Wieselmann

In 1970 Texasgulf (Australia) introduced natural gamma radiation logging of drill holes for exploration in the Hamersley Iron Province of Western Australia. Drill hole logs have allowed positive stratigraphic and structural correlations within complexly folded secondary hematite ore deposits and between individual iron ore deposits separated by distances in excess of seventy-five miles. A Neltronics model KPD logging system and gamma-ray sonde are being used to measure the natural gamma radiation of the enriched Brockman and Marra Mamba banded iron formations. The parent banded iron formations are composed of thick, chemically precipitated iron oxide, chert, iron silicate, and carbonate with thin intro-formational clastic horizons. These clastic horizons give a greater natural gamma radiation than the banded iron horizon, and each clastic horizon has a characteristic radiation profile related to its composition and thickness. Because the natural gamma-radiation profile is unchanged during secondary enrichment of the iron formation, the present stratigraphic position of each drill hole can be established and complex folding can be accurately traced in the sub-surface. Gamma ray logging of percussion drill holes has made feasible a significant reduction in diamond core drilling without loss of accuracy. At the same time, it has provided a means of rapid evaluation of complexly folded iron ore deposits.

Jan 1, 1975

By Peter G. Chamberlain

Domestic mining will not produce a significant portion of the manganese consumed in the United States unless new mining and processing techniques are implemented that will enable domestic lean ores to economically compete with rich foreign ores. One mining-processing technique that appears promising for certain deposits is in situ and/or heap leaching with aqueous SO2. Since leaching offers economic advantages of low capital costs, low operating costs, and short start-up times as well as environmental and safety improvements over conventional mining-processing, the Bureau of Mines studied the leachability of manganese deposits from several districts. Manganese oxides, hydroxides, and carbonates were leached to 80 to 90 pct recovery in 7 to 40 days of leaching with a solution containing 5 pct SO2 in column leaching tests. Preliminary cost analyses of surface mining-heap leaching, block caving-in situ leaching, and shrinkage stoping-in situ leaching indicate that the products of manganese leaching may be economically produced for the chemical and electrolytic manganese industries. The easiest marketable product to obtain would be a manganese sulfate commonly used as a fertilizer amendment. Manganese carbonates and hydroxides could also be precipitated from the pregnant leach solutions.

Jan 1, 1983

By Paul Soros

Lord Robens, Chairman of the National Coal Board of England announced recently to the world press plans for construction of the largest bulk terminal in Western Europe. This should result in annual freight savings of 22.4 million dollars and between 150 and 190 million dollars of new export business. These are rather substantial amounts for any mining enterprise. Or to put it another way, opportunities to make substantial savings in the delivered price of a highly competitive commodity such as coal are few and far between. One area where such opportunities still exist is in the economical; movement of bulk materials between producer and consumer.

Jan 1, 1966