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By J. Hanna, H. R. Gonzalez

Four Ca-bentonitic clays from Alabama were evaluated for use in diammonium phosphate (DAP) or urea ammonium nitrate (UAN) fertilizer suspensions. The viscosity and gel strength of suspensions prepared with different proportions of a Western bentonite clay and sodium-exchanged Alabama clays were measured as a function of clay content and dispersant concentration. The results obtained suggested that three of the Alabama Ca-bentonites would replace about 40% of the more expensive Western bentonite in UAN and DAP fertilizer suspensions. The performance of the Nu-modified clays, prepared according to the Tennessee Valley Authority soda ash method, was as good or even better than those observed for the Mg-, NaIMg- or K-modified clays. The TVA clay modification procedure appears to be reliable and cost effective.

Jan 1, 1991

By N. Edmonson

An examination of the statistics of the world phosphate fertilizer industry since 1980 reveals an increasing tendency for fertilizer manufacturing activity to concentrate in phosphate rock mining areas. The economic justification for this resource-oriented strategy is clear. The choice between shipping phosphate rock, a comparatively low-value product, and shipping more valuable finished fertilizers will always be resolved in favor of the latter if cost considerations control the decision. The historical existence of substantial phosphate fertilizer manufacturing capacity oriented toward fertilizer-consuming activities and dependent on imported phosphate rock shows that narrow cost considerations have not always determined the industry's location. One is entitled to ask what conditions have changed to precipitate the observed relocations, and how permanent these changes are. These questions are the subject of this investigation.

Jan 1, 1995

By Daniel McNamee, Wern-ping N. Chen

The Amtrak East River Tunnels include four tunnels, Line 1 to Line 4, which extend from New York Penn Station in Manhattan, under the East River to Sunnyside Yard in Long Island City. Since fall 2015, Amtrak has initiated a program to repair and reconstruct the century-old tunnels, including structural repairs of all the tunnels and reconstruction of the Line 1 and Line 2 tunnels. The reconstruction includes bench wall demolition and replacing and installing the following elements in the tunnels: direct fixation track, traction power, signal, communication, and tunnel fire/life/safety components. This paper provides design and site investigation challenges and knowledge gained from this program.

Dec 1, 2022

By Jeff Fontana, Daniel Ebin, Eric Westergren, William Currier

The PMott MacDonaldlane Train Tunnel West Extension (PTTWE) Project at HartsfieldJackson Atlanta International Airport includes the extension of the existing automated people mover system and terminal renovations at the baggage claim station. To assist with design, pricing, and assessment of risk on this progressive design-build project, 3D design models were prepared to increase visibility into realities of construction. This paper will focus on the original intent of the models and explore the additional, unforeseen value they provided throughout the design and construction process.

Dec 1, 2022

By Robin Dill, Julian Prada, Kathryn Kelly, Brian Hann, Todd Moline

Narragansett Bay Commission’s (NBC) Pawtucket Tunnel Project includes construction of the 11,600-ft long, 30-ft ID, deep rock tunnel. This paper presents insight into the features and benefits of lump-sum, design-build that led NBC to select it as the project delivery method. The use of a design-build contracting process that included proprietary meetings to discuss and obtain feedback on Alternative Technical Concepts as well as to facilitate reaching consensus on modifications to the GBR-B is also described. The discussion includes features and benefits of design-build process that not only addressed NBC’s desired outcomes, but also allowed the Design-Builder to propose several innovative changes to the Base Technical Concepts included in the bid documents, and to develop a GBR-C that was compatible with their proposed means and methods of construction and addressed what they believed to be the more significant subsurface risks on the project.

Jun 13, 2023

By Earl Gardiner, Michael Grenier, Stephen Hardcastle, John Vergunst

A prototype, self-contained mine refuge station air supply sys- tem was tested in an underground metal mine to verify it's ability to keep oxygen and catbon dioxide levels at acceptable concentrations in an emergency situation. In this test, 25 volunteers were assembled and sealed in a functional underground refuge station for a period of 24 hours, without the benefit of the standard com- pressed air supply. The prototype system was designed to: 1) operate on a self-contained power supply for a period of at least 27 hours; 2) supply oxygen at a metered rate; and 3) remove car- bon dioxide by re-circulating refuge station air through soda lime scrubbing beds. During the test period, the catbon dioxide concentration remained at an average of 2500ppm and oxygen concentration stayed between 20.2% and 20.6%. The volunteers found the prototype easy to use and seemed confident in its ability to provide a safe atmosphere. The test showed that this technology could become part of an underground mine's refuge station emergency equipment.

Jan 1, 1997

By Peter Hornby, Maurice Craig, Franklin G. Horowitz, Don Bone

We have developed a high-performance, flexible scheme for interpolating multi-dimensional data. The technique can reproduce exactly the results obtained, for example, from Ordinary Kriging and related techniques in 3D, or from Thin-Plate Splines (Briggs' minimum-cuwature algorithm) in 2D. Moreover, com- pared to traditional implementations of these algorithms, our method enjoys large computational-cost savings. The new approach produces an interpolation that obeys a Partial Differential Equation (PDE). The PDE may arise from physically based arguments, but its form can vary widely. It might be specified only implicitly (as through a Model Variogram), or be nonlinear (although a performance penalty could then apply). While a formal equivalence between Kriging and Splines has been known for some time (Matheron, 1980), the present derivation, from radial basis functions, further illuminates this connection. Thus, for example, we can make explicit the PDEs that underlie some of the Model Variograms most often used in Geostatistics. Besides its practical utility, the work thereby ac- quires a theoretical interest.

Jan 1, 1996

Sandvik built its first stone crusher in 1896 and has since grown to become a world leader in mining equipment. ?We are the best in the world, and we can now be even better at making our cone and jaw crushers in different models,? Olle Lundberg, production engineer at the Sandvik Mining factory in Svedala, Sweden told freelance journalist U. Samuelsson, of mekpoint.com. As a specialty manufacturing business under the umbrella of the Sandvik Group, Sandvik Mining is a leading global supplier of equipment, tools, services and technical solutions for the mining industry. Its expertise covers the areas of rock drilling, cutting and crushing, as well as loading, hauling and the handling of materials. Lundberg, along with five colleagues, will write CNC programs for the lathes and machining centers that manufacture Sandvik?s specially constructed casting. In 1999, Sandvik chose ESPRIT computer-aided-manufacturing (CAM) software by DP Technology to program its array of machine tools, and has worked with ESPRIT reseller Holotech, based in Örebro, since 2003.

Jan 1, 2014

By B. K. Mishra, A. Datta

Estimating the power draw of a ball mill is of great importance from both operational and control standpoints. There are many factors that affect the power draw, and its prediction is particularly difficult in an operating plant. The important factors that affect power draw are the mill dimensions and operating parameters. Although mill dimensions remain the same for any given mill, the operational factors, such as ball load, mill filling and mill speed, may vary. This makes the modeling effort extremely cumbersome. It is for this reason that an artificial neural network is considered for the development of a black-box-type model to predict power draw. In this work, a total of 48 sets of plant data are used. Using these data, a neural network is built and trained. The trained network is used to predict power that is found to be in good agreement with operating mill power for many situations. In addition, the results of simulations are also com- pared to those obtained from a discrete-element method- based power-draw model.

Jan 1, 2000

By L. Cheng

Almost all modern cutting bits use a cemented tungsten carbide tip to provide adequate hit life against wear. Laboratory tests by the US Bureau of Mines have indicated that the number of strikes for ignition increased by a factor of three with a new non-rotating bit impacting a sandstone block when the clearance angle was increased by 10°, and that carbide-tipped bits allowed more strikes before ignition than steel-tipped bits by a factor of 7 to 10. Recent field tests in an operating coal mine indicate a dramatic reduction in the frequency of frictional ignitions and improvement in hit life by using a mushroom-shaped hit cap and a larger initial clearance angle. The latter was achieved by increasing the hit attack angle. Improved hit performance through selection of the grade of tungsten-carbide is a com¬promise between fracture resistance and wear resistance. A large clearance angle should he maintained by various techniques, such as a variable attack angle holder, or a reusable hit that can he reground.

Jan 1, 1990

By Susan T. Bagley, Kenneth L. Rubow, David H. Carlson, Bruce K. Cantrell, Winthrop F. Watts

Permissible exposure limits (PELs) have been established for gaseous pollutants, carbon monoxide (CO), carbon dioxide (CO2), nitric oxide (NO), nitrogen dioxide (NO2), and some gas-phase hydrocarbons emitted in diesel exhaust. There is, as yet, no PEL recommended for diesel exhaust aerosol (DEA), nor is there a standard method for sampling this aerosol. The University of Minnesota and the U.S. Bureau of Mines have collaborated to develop a personal diesel exhaust aerosol sampler (PDEAS) which utilizes size-selective inertial impaction and gravimetric analysis. During the field tests of this sampler, numerous air quality measurements were made in underground coal mines that use diesel equipment. The mine mean DEA concentrations for the five mines surveyed, determined with the PDEAS in the haulageway, was 0.89 mg/m3 with a standard deviation of 0.44 mg/m3. DEA contributed 52 % of the respirable aerosol at this location. In three of the mines filter samples were collected for DEAassociated polynuclear aromatic hydrocarbons (PAHs) and biological activity determinations. Two of the mines were also monitored for the major gaseous constituents found in diesel exhaust. In general, the PAH and biological activity levels were similar for all three mines, and indicate that up to 25 % of the haulageway concentrations may be contributed by outby diesel vehicles. Measured concentrations of CO, C02, NO, NO2, and SO2, were well below regulated levels. INTRODUCTION Diesel exhaust contains pollutant gases, such as carbon monoxide, carbon dioxide, nitric oxide, nitrogen dioxide, and gas-phase hydrocarbons, as well as DEA. Much of the health-related concern focuses on DEA and associated organic compounds (Watts, 1992a). A wide variety of these PAHs have been identified and some are known carcinogens and/or mutagens. The U.S. Mine Safety and Health Administration (MSHA) has proposed new PELs for these and other contaminants (MSHA, 1989). MSHA has also published an advance notice of proposed rulemaking to establish a separate PEL for diesel particulate (MSHA, 1992). The U.S. Bureau of Mines has collaborated with the University of Minnesota to develop and field test a PDEAS. The PDEAS is a three stage sampler based on the MSA' personal respirable dust sampler. It utilizes a respirable cyclone preclassifier followed by a 0.8 µm cut point impactor and afterfilter operating at a flow rate of 2 L/min. Respirable aerosol greater than 0.8, µm in size is collected by the impactor while DEA, less than 0.8 µm in size, is collected by the afterfilter. Hence, gravimetric analysis of the afterfilter permits measurement of DEA concentrations. This development and laboratory evaluation of the PDEAS were described previously by Cantrell (1990) and Rubow (1990). During field tests of the sampler, numerous air quality measurements were made in continuous miner sections of five underground coal mines that use diesel haulage equipment. These air quality measurements included levels of selected PAH and biological activity associated with DEA collected in the intake and haulageway areas of three of the five underground mines, and CO, CO2, NO, and NO2 in two of the mines. The objectives of this paper are to present the DEA and associated pollutant concentrations measured in these mines and to assess the impact of diesel face-haulage equipment on underground mine air quality. MINE DESCRIPTIONS The mines used for the PDEAS evaluation were designated J, K, L, N, and 0. Mines K, N, and 0 are located in the Western United States, while mines J and L are located in the East. Each mine produces high volatile, bituminous coal with shift production levels varying from 500 to 2000 tons/section. Seam heights varied from 1.5 to 3.0 m. Mines K and N use continuous mining to develop longwall panels. The others are strictly room-and-pillar operations using continuous miners. The number and types of diesel-powered vehicles used at these mines were described by Watts (1992b). Mines J, K, N, and 0 use diesel power to assist in a wide range of activities in addition to coal haulage. These included road maintenance, personnel and materials transport, lubrication, and welding. Mine L used only three diesel-powered shuttle cars to haul coal. SAMPLING AND ANALYSIS METHODS Aerosol Measurements Aerosol samples were collected in the mine portal area, the clean air intake to the continuous miner section, the haulageway one crosscut inby from the feeder breaker and belt, in the return airway, and on selected personnel. The haulageway sampling site was located near the point where the diesel-powered shuttle cars turn around to dump their loads. Additional respirable and DEA samples were collected and have been reported by Haney (1990).

Jan 1, 1993

By R. Poulin, R. Pakalnis, D. Peterson

Introduction A comprehensive project has been completed at the University of British Columbia that focused on the development of a commercially competitive composite cable bolt. Laboratory evaluation consisted of pull tests, preliminary shear tests, grout column testing and scanning electron microscope evaluation of the composite cable bolt. Field implementation at five underground mines throughout Canada were completed for technical and overall performance evaluation of the new product. The project began in 1989 under the sponsorship of HDRK Ltd., a consortium of mining companies including Inco, Noranda and Falconbridge Ltd. The objective was to develop a cuttable cable bolt that would serve as support for a continuous miner within a hardrock environment (Mah, 1994). The bolt was required to be cuttable by a continuous roadheader without adverse effects to equipment, personnel and the milling process. From the beginning, the focus was to employ existing cable bolt installation technology (Goris et al., 1994) whereby the cable bolts are grouted within a 4.8-cm-diam (1.08-in.diam) or larger employing a portland cement grout having a water: cement ratio between 0.35:1 to 0.4:1. The prototype, developed from Phase I, was technically comparable to that of conventional steel cable bolts. However, high cost and limited accessibility hindered its commercial acceptance. The second phase of the project was sponsored by the British Columbia Science Council and Pacific Pultrusions Ltd. of British Columbia to locally develop a glass fiber cable bolt. This phase of the project has resulted in the DAPPAM cable bolt (Pakalnis et al., 1994). DAPPAM Cable bolts are the second most used support method in Canadian underground mines after mechanical rock bolts. It is projected that 870,000 m (2.9 million ft) of cable bolts are installed annually in Canada (Poulin et al, 1994). The objective of the research program was to develop a glass fiber cable bolt with similar pullout strengths to the conventional steel cable bolts (267 kN - 60,000 lbf). More than 200 laboratory pull tests were conducted employing standard cable bolt test procedures, as outlined by the US Bureau of Mines (Goris, 1994), to assess optimum rod and surface composition, geometry, number required, pullout and shear characteristics, among others. This resulted in the DAPPAM cable bolt (Fig. 1). It consists of 10 individual 0.6cm-diam (0.25-in.-diam) rods enveloping a 2.2-cm (0.8-in.) outside diameter, high-density polyvinyl grout tube. The composite used in the construction of the rods is comprised of about 65% glass fiber within a 35% polyester resin matrix (by volume). Through pultrusion (a continuous fabrication technique), the fibers and resin are combined into a composite material. The strength of the overall composite is largely governed by the material properties, the alignment [ ] of the fibers relative to the applied load and the density and interaction of the overall components within the composite. A further modification to the composite was the addition of a sand grit to the surface of the individual rod. This increased the overall bond strength between the rod and the cement-based grout, used to solidify the cable bolt to the rock mass. The grout tube has an inside diameter of 1.9 cm (0.75 in.) and is rated at a pressure of 1.72 MPa (250 psi). During installation, the grout is pumped through the annulus of the grout tube thereby filling the hole from toe to collar. Laboratory and field trials concluded that a minimum drill hole diameter of 4.8 cm (1.08 in.) be used to ensure optimum grout coverage. Table 1 compares the design strengths (as tested) for DAPPAM vs. the ultimate strengths for a conventional 1.6cm (0.6-in.) steel cable bolt. The characteristics for the steel cable have been derived directly or indirectly by Goris et al. (1994). A design tensile strength of 289 kN (65,000 lbf) was proposed for the composite developed. However, recent tests have indicated maximum breaking strengths of more than 400 kN (90,000 lbf) (Fig. 2). Figure 2 shows the load vs. displacement pull out curves for steel and DAPPAM cable bolts. The methods of testing were standardized so as to be able to compare the results directly. The shear strength of the fiberglass cable is largely a function of the surface area sheared. Shear strengths of 89 kN (20,045 lbf) were obtained for the configuration shown in Fig. 1 when sheared normal to the axis of the cable. The testing procedure was similar to the shear tests performed on steel by Goris (1993). It is important to reinforce the implication that critical bond strength has on the success of an overall support system.

Jan 1, 1995

By Meghan Murphy, Yiming Sun, Kush Chohan

DTX is a 1.3-mile-long rail extension being constructed by Transbay Joint Powers Authority to extend Caltrain rail service and future California High Speed Rail service to downtown San Francisco. It includes a 3,352-foot-long mined tunnel with a cross section varying from 50 to 60 feet wide and 43 feet high to accommodate two- and three-rail tracks. DTX will be excavated in mixed-face and Franciscan Formation with ground cover ranging from 40 to 85 feet. This paper discusses how mined tunnel design has evolved since the initial preliminary design phase over 10 years ago. The current design concept for tunnel construction is also discussed.

Jun 13, 2023

By P. T. Bissert, T. J. Lutz, J. A. Yonkey, G. T. Homce

"The U.S. National Institute for Occupational Safety and Health (NIOSH) has been researching refuge alternatives (RAs) since 2007. RAs typically have built-in pressure relief valves (PRVs) to prevent the unit from reaching unsafe pressures. The U.S. Mine Safety and Health Administration requires that these valves vent the chamber at a maximum pressure of 1.25 kPa (0.18 psi, 5.0 in. H2O), or as specified by the manufacturer, above mine atmospheric pressure in the RA. To facilitate PRV testing, an instrumented benchtop test fixture was developed using an off-the-shelf centrifugal blower and ductwork. Relief pressures and flow characteristics were measured for three units: (1) a modified polyvinyl chloride check valve, (2) an off-the-shelf brass/cast-iron butterfly check valve and (3) a commercially available valve that was designed specifically for one manufacturer’s steel prefabricated RAs and had been adapted for use in one mine operator’s built-in-place RA. PRVs used in tent-style RAs were not investigated. The units were tested with different modifications and configurations in order to check compliance with Title 30 Code of Federal Regulations, or 30 CFR, regulations. The commercially available relief valve did not meet the 30 CFR relief pressure specification but may meet the manufacturer’s specification. Alternative valve designs were modified to meet the 30 CFR relief pressure specification, but all valve designs will need further design research to examine survivability in the event of a 103 kPa (15.0 psi) impulse overpressure during a disaster. BackgroundThe Mine Improvement and New Emergency Response Act of 2006, known as the Miner Act (U.S. Department of Labor, 2006), was enacted in the wake of three mine accidents involving explosions or fire that claimed 19 lives that year. Intended to help improve underground coal mine accident preparedness, the Miner Act includes provisions that target mine safety issues in areas such as emergency response planning; adoption of new technology; training and education; and mine safety standards enforcement. Section 13 of the Miner Act specifically directed the U.S. National Institute for Occupational Safety and Health (NIOSH) to provide for research into the effectiveness and viability of refuge alternatives (RAs) for underground coal mines, and the U.S. Department of Labor to act on the results of such research, as appropriate. These mandates culminated in the 2009 adoption of changes to the Title 30 Code of Federal Regulations, or 30 CFR, mining health and safety regulations (U.S. Department of Labor, 2008), requiring underground coal mines to supply mine emergency RAs and associated components so as to provide a life-sustaining environment for persons trapped underground. Such RAs can be either selfcontained mobile units or built-in-place facilities. The regulatory changes also include provisions establishing requirements for the approval of RAs and their components by the U.S. Mine Safety and Health Administration (MSHA), among which are numerous criteria for providing a safe breathable atmosphere under positive pressure within the RAs. One criterion for maintaining a safe RA atmosphere is the inclusion of an air pressure relief valve that will activate at a maximum of 1.25 kPa (specified as 0.18 psi, or approximately 5.0 in. H2O), or as specified by the RA manufacturer, above mine atmospheric pressure in the RA (U.S. Department of Labor, 2008)."

Oct 1, 2016

By Yiming Sun, John Stolz, Jakob Walter, Drew Mason

The Courthouse Commons SEM Tunnel was excavated within 6 feet of cover beneath two buildings in downtown San Diego utilizing high-precision geotechnical instrumentation. The excavated dimensions are approximately 25 feet in diameter and 328 feet in length connecting two in-service detentionlevel security buildings. Presupport includes large-diameter grouted canopy pipes and smaller pipe spiles. Initial support consists of fiber-reinforced shotcrete with lattice girders. This paper presents observed ground and structure behavior and lessons learned. During construction an unanticipated brick structure was encountered, and methods were developed to improve adhesion of shotcrete to sandy soil and to reduce rebound

Dec 1, 2022

By M. H. Col

Within the last few years, there have been numerous techno-logical advancements within material handling due, in part, to the introduction of conveying systems and mobile material handling systems to the industry. Although the traditional material handling methods are still commonly used, the introduction of conveyors to the industry has provided companies with some very efficient and economical options. These "new" systems change with the industry to accommodate rigorous demands, ease of operation, and low operating cost requirements. The number of mobile material handling systems utilized in mining operations is increasing, especially in heap leaching applications. Ten years ago, mobile material handling systems like Mobile Stacking Conveyors (MSC) were considered a novelty. There were two (2) MSC's in actual operation and only one of those in a heap leaching application. Today there are numerous proven systems operating at mine sites around the world-La Coipa, Zaldivar, Florida Canyon, Cananea, El Abra, Chuquicamata, and Radomiro Tomic. The popularity of mobile systems is due to the benefits realized by individual projects. As technology advances, so do the concepts behind mobile material handling systems. Implementing self leveling mechanisms, Programmable Logic Controllers, and Global Positioning Systems to control the equipment are just a few of the recent advances that will be discussed in this paper. We will also discuss current proven systems, and touch on what we see as some of the future advances.

Jan 1, 1998

By John J. Reed

The 1945 fire at the Braden (El Teniente) Copper Mine in Chile took 354 lives, and ranks as the most lethal metal mine fire in history. The mine was developed in the wall of a canyon over 900 m (3,000 ft) deep. Principal entrance was through a main haulage adit at the canyon bottom, and up through two internal shafts. Mining was by block caving from the top of the orebody with most of about 900 men on shift working in three production areas. Ore was transferred by gravity to the haulage level through a complex system of ore passes with associated ladderways. Normal mine ventilation was incast through numerous level portals and up- cast through the shafts and raises. The fire was confined to a maintenance shop just inside the portal of the lower production level. Smoke, gases and flammable vapors were drawn into the mine, and a subsequent explosion of the gases destroyed an air door and injected carbon monoxide into the workings. Falling water in a drainage raise near the fire made it downcast, which carried gases down to all the lower levels where they were drawn into the levels and then up connecting raises. Miners attempting to escape by climbing down the ladderways from the production levels were met and killed by the rising gases.

Jan 1, 1989

By Ch. R. V. S. Nagesh, Ramesh Naidu Mandapati, Venkata Swamy Nalajala, Tondepu Subbaiah, Naga Jyothi Kothamasu

Leaching studies of magnesite obtained from Tamilnadu Magnesite Limited, Salem, have been carried out using hydrochloric acid leaching and percentage of magnesium chloride recovered was estimated. The variables considered in this study were the following: duration of leaching, volume percentage of hydrochloric acid, temperature, and pulp density. Percentage recovery of magnesium chloride increased with duration of the leaching, volume % of concentrated hydrochloric acid, and temperature. Percentage recovery of magnesium chloride decreased with increase of pulp density. The optimum conditions found to be pulp density (10%), hydrochloric acid concentration (30%), duration of leaching (2 h), and temperature (348.15 K). Iron was removed by treating the leach liquor with hydrogen peroxide and by raising the pH to 3.5–4. The purified leach liquor was subjected to spray drying for producing high pure magnesium chloride.

Jun 7, 2022

By Kathleen A. Altman

INTRODUCTION The basic premise of the ideas presented in this paper are as follows: Engineers believe that "theoretically" it will work. Operators ask what they must do to make it work. And, people can screw it up. r Today the challenges conf onted during the engineering, startup and operation of mines are becoming more complex. As mining and processing professionals, we are called upon to trav­el all over the world, are subjected to a wide variety of climates and must deal with a numerous cultures and people. Historically, for the majority of the people working in the mining industry, the primary challenges related to projects have focused on the differing perspectives of the disciplines involved. For example, geologists focus on resources and reserves, mining engineers relate to tons or tonnes, metallurgists count ounces or pounds or kilograms of product, mechanics emphasize availabil­ity, human resources personnel deal with absentee rates and turnover and accountants watch the bottom line ($$'s). As the world has become "smaller" and the mining industry has become more globalized, the puzzle is becoming increasingly difficult. Even the most experienced in the crowd of mining profes­sionals are oftentimes surprised by the types of problems that are encountered. Try as we may, we cannot anticipate the complex­ity of dealing with the human side of an operation.

Jan 1, 1998

By G. E. Karantzavelos

Introduction Pure alunite (KAl3 (SO4 )3 (OH)6 ) contains 37% A1203. In the alunite ore found on Milos Island, Greece, opal is the principal gangue while some aluminum, iron, and titanium oxides are also present. Processing of alunite ore leads to the recovery of potassium sulfate, alusil (alumina-silica mixture), and sulfur dioxide. An interesting process has been developed in Greece (Svoronos, 1977) consisting mainly of roasting the alunite ore mixed with KCl to disrupt the mineral lattice in preparation for separating its components. The thermal decomposition of alunite at approximately 600°C occurs by the reaction: KAl3 (SO4)3 (OH)6 + nSiO2 + 6KC1 - 4 K2SO4 + 3 A1203 . nSiO2 + 6 HCl + 3H20 According to the process pure alunite mixed with 543 kg KCl, 840 kg K2SO4, 370 kg alusil, 264 kg HCl, and 65 kg H2O are produced. The roasted calcine is leached in hot water. The potassium sulfate leach slurry is then thickened and washed to obtain a solid residue (alusil) plus a solution rich in potassium sulfate. Assuming the alunite ore feed consists of 50% to 60% alunite, the solid residue might consist of approximately 22% to 27% A1203, silica, iron, and titanium oxides. This leach residue could be digested in a hot sodium hydroxide solution to dissolve alumina. An amount of the alumina (approximately 10%) would not dissolve. In addition, part of the silica would dissolve requiring removal from the solution in a subsequent desilication operation. The same leach residue could be attacked by mineral acids such as a diluted hydrochloric acid to extract aluminum chloride (Sawyer et al., 1983). Alumina and aluminum are presently produced from bauxite of which Greece has important reserves. If this aluminous material (alusil) could be beneficiated by any physical process, then it would be considered as a raw material for the production of fire-clay refractories instead of an alternate source of alumina. Experimental procedure Extensive laboratory work (mineralogical and chemical analyses) indicates that alusil is a mixture of liberated (mostly) alumina and silica particles, not a natural silicate mineral. Table 1 shows the chemical assays of two alusil samples that were obtained from a roasted alunite ore leaching pilot plant. The samples used for the experiments were a very fine alusil powder (K80 = 400 mesh, 38 µm). These were pulped in tap water. Desliming of the pulp before each flotation test was ineffective. Flotation tests were performed in a 2000 ml Denver cell. A standard 500-g sample was first conditioned at a pulp density 50% solids for 5 min with hydrofluoric (HF) acid solution (40%). The temperature of the conditioned pulp was measured and kept nearly constant at 50°C. The pH of the conditioned pulp was also regulated to 2.5-3 with HF solution. Then ARMAC C solution (2%) as well as two drops of fuel oil and one drop of AEROFROTH 65 were added and the pulp was reconditioned for 2 min. After conditioning, the viscous pulp was transfered to the flotation cell. It was then diluted with warm water to about 15% solids and floated to separate silica from alumina particles. A rougher froth product that was cleaned and recleaned was obtained from the flotation tests.

Jan 1, 1987