Search Documents

By S. J. Ripke

To pelletize fine moist magnetite concentrate, a 40% water slurry must be dewatered to about 10% by filtration, before it can be agglomerated into pellets. Slurry pH, typically ranging from 8 to 11, gives the magnetite particle surface a strong negative charge and thus causes two adverse effects. First, this negative charge attracts calcium and magnesium cations, which strongly retard the effectiveness of the bentonite clay binder added during agglomeration. Second, a repulsive force created by the negative charge functions as a dispersant that reduces filtering production rates. Tests were conducted to remove these cations during filtration, by rinsing the moisture remaining in the filter cake with a small amount of water adjusted to pH 6 with HCl. Laboratory work was also conducted at Michigan Technological University (MTU) and at Cliff’s Mining Services Company (CMSC) to corroborate the plant tests. In some cases HCl caused filter bag blinding, therefore CO2was investigated to reduce pH. The CMSC lab tests showed that using carbon dioxide to reduce slurry pH from 7.6 to 7.0 improved filtering production rates by 11%. Plant-scale filtering rates were improved by 23.7% when carbon dioxide addition reduced the slurry pH from 8.6 to 6.7.

Jan 1, 2004

By Craig Ammar

JAMIE DAVIS: Our next speaker is Craig Ammar. He's director of equipment management for Cyprus Climax Metals Company. He has, prior to this assignment, been responsible for maintenance at Bagdad Copper, Cyprus' Miami smelter, and Thompson Creek. Like Jerry, he's very shy and retiring, and doesn't have any strong opinions about maintenance. INTRODUCTION CRAIG AMMAR: The ultimate goal behind implementing a proactive equipment management process is to provide capacity assurance and ultimately increase an organization's ability to generate revenue while reducing operating costs. Targeting such lofty objectives has brought many an organization to its knees, utilizing new maintenance techniques, concepts, and technology aimed at making our lives better and more organized. The root cause of such frustration generally stems from a lack of understanding or support for the fundamentals of implementing a proactive equipment management process. There are just two types of maintenance programs, reactive and proactive. It's an established fact that you need a little of both to run an effective equipment management process, obviously more of one (proactive) than the other. Here are some telltale signs that your equipment management process is in trouble: -Maintenance is performed as a knee jerk reaction when equipment fails. -Repeated and frequent equipment failures occur, with no focus on eliminating the root cause. -Sketchy, inconsistent, unclear preventive maintenance is performed or there is no support for the preventive maintenance process. -No predictive maintenance technology process is in place, or little support for predictive maintenance exists. -Less than 50 percent of your work is generated by the maintenance group resulting from inspections.

Jan 1, 1998

By Lynne Chastain

The Eastern Shoshone and Northern Arapaho tribes of the Wind River Indian Reservation, Wyoming are interested in developing their industrial mineral resources. The U.S. Bureau of Indian Affairs (BIA), Division of Energy and Mineral Resources (DEMR) is assisting the tribes in evaluating the potential of their industrial mineral prospects for development. Gypsum occurs on both sides of the Owl Creek Mountains in the basal portion of the Jurassic Gypsum Springs Formation. The gypsum resources that are being evaluated crop out along the northern flank of the Owl Creek Mountains in the Sweetwater basin, a small topographic sub-basin of the Big Horn Basin. From October 1998, to April 1999, DEMR personnel mapped, sampled, and drilled the southcentral butte within the Sweetwater basin. Samples were analyzed for free and combined water, and major mineral oxides to determine gypsum purity. Gypsum purity averaged 93.6 percent for surface samples and 95.1 percent for drill core samples. The basal portion of the Gypsum Springs Formation is comprised of several beds of gypsum up to 9 feet (2.7 m) thick separated by 0.5 to 2.0 foot (0.15 to 0.61 m) thick lenses of siltstone and limestone. Overall gypsum in the formation ranges from 35 to 90 feet (11 to 27 m) in thickness. A resource of approximately 7 million short tons (st) (6.4 million metric tons [mt]) has been identified.

Jan 1, 2001

By J. D. Miller

Fluid flow phenomena and therefore the flotation efficiency of air-sparged hydrocyclone (ASH) flotation are strongly dependent on operating and design variables such as air and slurry flow rates, underflow and overflow opening areas, percent solids of the feed, reagent levels, particle size and ASH length. Time-averaged multiphase flow characteristics, as determined by X-ray CT (described in a previous publication), are used to understand and explain the steady-state ASH flotation of quartz. A detailed parametric study of quartz flotation by a nominal 2in. diam. air-sparged hydrocyclone (ASH-2C) revealed the influence of these variables on the flotation response, which is discussed in terms of the multiphase flow characteristics. Thus, a phenomenological description of quartz flotation has been established to assist in the further development and utilization of the ASH technology.

Jan 1, 1996

By A. Casuge, D. Lee, J. A. Finch, C. C. Sui

The adsorption of copper and lead und their subsequent xanthate uptake were compared at pH 3.0, 6.0 and 9.2 on both fresh and oxidized sphalerite. The extent of adsorption and the rate of adsorption were strongly dependent on pH, with the highest adsorption of Cu and Pb being at pH 9.2. In the presence of both Cu and Pb, Cu adsorption was enhanced and Pb adsorption was suppressed. The adsorption kinetics of Cu and Pb were characterized by two- and three-stage adsorption processes, respectively. The exchange ratio of Cu to Zn was about one and that of Ph to Zn was greater than one and varied with pH. The uptake of xarlthate on "activated" sphalerite was dependent on pH. The rnaximum uptake was found to be at pH 6.0 for Cu-activated sphalerite artd at pH 9.2 for Pb-activated sphalerite. A measure of "activation strength" based on inetal ion adsorption and xanthate uptake was introduced. The activation strength of Cu to Pb was about one at acidic pH, but it was higher at neutral (pH -6) and alkaline (pH -3) conditions. The oxidation of sphalerite decreased Pb and, especially, Cu adsorption and decreased xanthate uptake.

Jan 1, 2000

By Andrew Neale

ERIC GUTIERREZ: With that, we'll go ahead with the final speaker of the day, Andrew Neale. Andrew has a master's of science degree in mineral processing from the University of Alberta. He worked at the Falconbridge in Sudbury area, also at Brenda Mines, and then he became part of the Brenda Process Technology group in British Columbia. He joined Freeport in late 1993 in Indonesia, and was involved in process control and automation. He is now the senior manager of metallurgy in New Orleans. He's responsible for designing Freeport's new 100,000-ton-per-day expansion concentrator, which is currently being commissioned. Please welcome Andrew. ANDREW NEALE: With the ongoing explosion in digital computing power, there seems to be no limit to what can be modeled, simulated, and controlled in the mineral processing plant. However, at each stage of development of a control system, it is necessary to complete a cost-benefit analysis for justifying the move to a higher level of control. Incremental improvements in plant performance, while often significant, must be weighed against the costs of implementation and long-term maintenance. This presentation will provide examples of what the author believes are misplaced or misguided process control efforts and make a case for the KISS principle as applied to process control.

Jan 1, 1998

By Gerald L. Finfinger, Michael A. Trevits

Since 1964, the US Bureau of Mines has been conducting a comprehensive program of research on the origin and control of coal bed gas. Several extensive databases have been developed during the work representing information from every major coal producing region in the United States. Gas content measurements have been made on 885 coal samples from 15 states representing 221 coal beds. Records indicate that the range of gas content varies from zero to over 640 ft3 per ton (20 cm3 per gm). During the conduct of the research program, several drilling and completion techniques have been developed or refined to divert and collect coal bed gas before it enters the mine environment. Such techniques include horizontal, cross-measure and vertical boreholes. Samples of gas collected from boreholes drilled under the program indicate that the primary gas constituent is methane which comprises 97 pct, the remaining hydrocarbons make up approximately 0.2 pct. Nitrogen and carbon dioxide account for the majority of the remaining gases at average concentrations of 1 pct each. Surveys have been made on the total daily gas emissions from underground coal mines. In fact, the most recent survey indicates that 180 mines had emissions in excess of 100 Mft3 per day (2.8 Mm3 per day). Furthermore, total mine emissions were in excess of 300 MMft3 per day (8493 Mm3 per day). An analysis of the data showed that there appears to be no relationship between in-place gas content and coal bed gas composition. Furthermore, no correlation was observed between in- place gas content and daily mine emissions. In a general sense, the higher the gas content the higher the relative gas emissions. Perhaps a more direct relationship would be observed if more complete emissions information (including gob gas borehole production) was available.

Jan 1, 1989

At first glance the staid Joralemon background does not seem to equate with the life of adventure that irresistibly called me for over 70 years. But my ancestors had their adventures too. My father's family were Dutch Reformed Protestants who had energy or daring enough to come to America to escape the Catholic persecution that followed the Massacre of St. Bartholemew. The first Joralemon came from Friesland to New Amsterdam m 1636, just after Peter Stuyvesant. My father's mother's family, the Berdans, were French Huguenots who came to northern New Jersey only a little later to escape the Catholic domination in France. Some say that the first Berdan to come to America was given all the land between the Passaic and the Hacken-sack Rivers by King James. Whatever, the Berdan family settled there and was able to make a scanty living by farming and selling their produce in Manhattan. The spirit of adventure in my mother's family was just as tenuous. Gamaliel Beaman was pastor of a shipload of Puritans who came to Massachusetts in 1636. Gamaliel's descendents were peaceful farmers and some ministers in New England and later New York State. They had got all of the adventure out of their systems in the long and dangerous voyage across the Atlantic to escape religious persecution. The Joralemons and the Berdans married into families that had been in America almost as long as they had. On my father's side the Berdans, Doremus, DeGreys, Vanderbeeks, and Varicks showed by their names their Dutch or French Huguenot stock. The only one who achieved any fame was Peter Varick, who was George Washington's military secretary during the American Revolution. After this he was nine times mayor of New York and was one of the founders of Kings College, later Columbia University. He was responsible for one of my few ancestral claims to distinction. When the Marquis de Lafayette made a fare-

Jan 1, 1976

By Gregory Witte

This paper will explore the technology behind and applications of smart motor control centers (MCCs) being used today in mineral processing facilities. The two technologies to be discussed are solid-state motor controllers that can be installed in MCCs and the complementary digital communication networks that can transmit operational parameters of the solid-state devices to the supervisory system. The toughness and reliability of solid-state technologies have led to a dramatic increase in their usage throughout the mining industry. Products such as solid-state motor protectors, controllers, and variable frequency drives have demonstrated greater flexibility and performance in a variety of applications than their electromechanical and mechanical counterparts. The three key trends apparent in the solid-state devices are: 1. A shift to smaller, smarter, more integrated devices, which allows a single solid-state device to serve the purpose of multiple electromechanical devices but in a much smaller form factor. 2. Distribution of control logic in motor control devices rather than conveyed through a hard wired connection to a central automation system. 3. Embedded network communication that allows supervisory systems to have an expanded view into critical loads and sensors. In applications, the use of smart actuators and sensors with integral local intelligence and communication allow a supervisory controller to send high level commands and let the smart device coordinate its own work The ability of smart field devices to return noncontrolled, nonpoled information opens a whole array of new capabilities for preventive maintenance and diagnostics and forms the basis for an effective motor management program. The smart motor control devices this paper will explore are the smart motor protectors (SMP), smart motor controllers (SMC), and variable frequency drives (VFD).

Jan 1, 2000

By W. H. Schiffbauer

The U.S. National Institute for Occupational Safety and Health (NIOSH) developed an active proximity warning system called hazardous area signaling and ranging device (HASARD) for warning workers as they approach known dangerous areas around heavy mining equipment and other dangerous work zones. HASARD is composed of a transmitter and a receiver. The transmitter generates a 60-kHz magnetic field using one or more wire loop antennas. Each antenna is adjusted to establish a magnetic field pattern for each hazardous area. The receiver, which is worn by the worker, is a magnetic field strength meter. The received signal is compared against preset levels that are calibrated to identify levels of danger. The receiver outputs can include visual, audible and vibratory indicators, and it can also be made to disable machine functions. HASARD was field tested on a Joy 12 continuous miner, a Komatsu 210 M Haulpak and on a high wall launch vehicle. Slight modifications were made for each application. HASARD provided warnings as designed, and it proved to be rugged enough to withstand the harshest of production environments.

Jan 1, 2003

By Karel SPIRKO

The one-dimensional mathematical model of unsteady-state heat conduct ion through multilayer (wall and floor of airway consist of several layers of material and rock) and two-surface (dry and wet surfaces) airway wall and airway floor with convective heat and moisture transfer between their surfaces and mine air with time dependent changes of temperature and humidity has been developed on the basis of introduction of acceptable simplifications of description of heat and moisture transfer between rock mass and mine air. The analytical solutions for calculation of the surface temperature of any type of surface of airway wall/floor and for calculation of water vapour pressure near the wet surfaces at given time are obtained by means of the model presented. These solutions are illustrated for the case of general harmonic course of air temperature and humidity. Balance of heat and moisture transfer between surfaces of airway wall and floor and mine air is solved by an iterative method in the partial sections of airway. The temperature and the humidity of mine air on the outlet of each partial section of airway at given time are its resolutions and they are the input data for following partial section. By this way it is possible to solve complicated dynamic changes of mine air temperature and humidity in an air way system by relatively simple mathematical apparat.

Jan 1, 1991

By A. C. Noble, D. E. Ranta, J. W. Mustard

Skarn deposits present many unique problems in estimating ore reserves, including difficulties arising from the complex character of the mineralization and intricate ore body shapes resulting from structural complexity. Mineralization within skarns occurs in metasomatically altered carbonate horizons produced by magmatic hydrothermal fluids emanating from intrusive stocks. Deposit formation is controlled by both the presence of favorable host rocks and by proximity of these host rocks to a mineralizing intrusion. Ore controls must be defined to account for abrupt changes in grade that occur between miner- alized and unmineralized horizons. Gradational grade changes within the mineralized zones must also be defined in terms of skarn type and included barren rock to assist in reserve estimation. Defining mineralized limits can be further complicated by faulted, rotated, or folded strata affecting the morphology of an ore body. The MacTung copper-tungsten exoskarn deposit, located along the Yukon-Northwest Territories border in Northwestern Canada exhibits a number of unique properties that preclude a simple mathematical approach to ore re- serve estimation. This deposit is used to demonstrate methods for modeling geologic controls and geostatistical properties for a skarn deposit.

Jan 1, 1992

By E. T. Sugar

English China Clays, the world's largest producer of China Clay, has its main production capacity in the South-West of England, where a complex of pits, refining plants, dryers and ports covers an area of approximately 100 square kilometres. The possibility of a computerised information network was first considered in 1980. The system was required to provide information at the central level and also at local plant level to improve co-ordination and control. Immediate access by any authorised user, and flexibility of interrogation were important aims. A small micro-based prototype system was implemented in 1981, and later that year development of the mainframe system commenced. This latter system will provide at least one terminal in every works location and will allow inter-communication of laboratory test data as well as detailed stock levels and production data. An integrated system for order processing will allow stock levels to be monitored in relation to anticipated requirements. The system has been developed by the Data Processing Department using the IDMS database package running on an ICL ME29 mainframe. It was decided to use microcomputers as terminals, which although more complicated because of protocol emulation allows stand-alone applications to be run on the same equipment. Those applications concerning Production Planning are outlined in the paper. Communication on the network is by synchronous transmission over dedicated lines. All data is stored on the central database with terminals accessing it in a star configuration. The system is currently partially implemented with 30 available screens at 18 separate worksites.

Jan 1, 1986

By J. A. Organiscak

Two types of airflow splitting methods for improving longwall dust control were investigated by the National Institute for Occupational Safety and Health's Pittsburgh Research Laboratory. Investigated were a translucent mesh barrier and a staged spray barrier system to confine the shearer-generated dust to the coal-extraction side of the longwall face while maintaining a cleaner split of airflow on the opposing worker walkway side of the longwall face. In laboratory experiments and in a longwall field evaluation, the translucent mesh barrier was shown to provide notable dust-control effectiveness for a distance of up to 60 m downstream of the shearer, provided that the mesh barrier remained relatively parallel to the airflow. The staged spray barrier system showed marginal dust-control effectiveness in the laboratory and, therefore, was not field tested.

Jan 1, 2000

By D. M. Bodily, M. D. Deo, E. M. Whitney

Field data from coalbed methane wells indicate a significant variation in composition as a function of flow rate and time. In particular, San Juan Basin wells have displayed an increase in C02 concentration over time. Prediction of gas quality is critical to the economic evaluation of any coalbed project. Previous models have forecast only pressure and production profiles, ignoring compositional variations. In this study a multicomponent model that incorporates binary isotherms for methane and carbon dioxide has been developed. An extended Langmuir isotherm is used for the adsorption representation and a constant separation factor (similar to relative volatilities in distillation) describes the phase distribution of the species. This separation factor depends both on the surface characteristics of the coal and on the adsorbing species. The chromatographic separation equations have been superimposed on Darcy's law flow. The formulation allows decoupling of the pressure and compositional partial differential equations. The equations have been cast in dimensionless form and solved for pressures and compositions. It is observed that the composition of the preferentially adsorbed C02 increases at the wellbore as a function of dimensionless time. The dimensionless time is directly proportional to the real time and coalbed permeability and is inversely proportional to the gas viscosity, coal porosity and the square of the length of the reservoir. As the separation factor increases, the compositional variation increases. This variation in produced C02 concentration is also greater when the initial C02 concentration in the reservoir is higher. A sensitivity study has been performed to identify the effects of important parameters such as isotherm variables and reservoir characteristics on pressure and composition profiles.

Jan 1, 1993

By F. M. Doyle, Jun Li, Milton E. Wadsworth, Ximeng Zhu, E. Peters

The electrochemical behavior of pyrite in borate/sulfate solutions was investigated using cyclic voltammetry. Three anodic peaks at approximately -0.8 V, -0.1 V and +0.5 V (SCE) were detected along with their corresponding reduction peaks. The first two peaks correspond to the oxidation of surface products. The third peak corresponds to the direct oxidation of pyrite with reaction products FeO oxides. sulfate ion and partially oxidized sulfur intermediates present as a surface film of polysulfides and So. The Few oxides and sulfur intermediates were reduced to ferrous hydroxide and HS during the negative-going scan. The HS interacted preferentially with Fe(OH), on the surface to form FeS. Excess fenous hydroxide continued to reduce to metallic iron. During the return positive-going scan, metallic iron was oxidized to ferrous hydroxide and FeS was oxidized to pyrite. These reactions are characterized by a unique double peak observed in the region -0.8 to -0.65 V. The growth kinetics of the surface sulfur film formed during anodic oxidation were studied using chronoarnperomeay. Potentiostatic measurements were well correlated by a paralinear rate equation, suggesting the formation of an intermediate passive film, associated with the simultaneous dissolution of the outer layer of the film. The reaction rates were affected by applied potential, solution pH and temperature, but were independent of electrode rotation speed. A reaction kinetics model which fitted well with experimental results, was developed.

Jan 1, 1993

By J. W. III Leonard, T. E. Wilson

In addition to coalbed thickness and basic coal quality data, coal drill cores can produce design data for coal beneficiation processes. To generate design data, a coal drill core should be reduced from its original cylindrical form to a particle size distribution and composition that represents (with the possible exception of top size) a raw coal process stream. Reducing a coal core with a crushing machine rarely accomplishes this representation. This investigation employs drop-shatter impact breakage followed by dry batch tumbling in a steel cylinder rotated about its transverse axis to characterize the core in terms of first-order and zeroth-order break- age rate constants, which are indices of the propensity of the coal to degrade during handling. To reduce composition variables and conserve difficult-to-obtain coal cores, the initial drop-shatter and dry-tumbling tests were done with synthetic cores. Then, cores from three coal beds, Illinois No. 6, Upper Freeport and Pocahontas No. 5, were tested. Comparison of a crushed drill core and a drill core prepared by drop-shatter and tumbling indicated that the size distribution and size fraction composition of the drop-shattered/tumbled core more closely resembled the plant feed.

Jan 1, 2000

By H. Wilcox, M. Prichard, Y. P. Chugh

Environmental considerations related to the disposal of coal combustion byproducts (CCBs) and the impacts of deforestation associated with the harvesting of timber for utilization as roof supports in mines should become more severe in the future, as landfill space and suitable timber reserves become more scarce. To help address these concerns, lightweight artificial supports, such as post and crib elements, that use large percentages of coal combustion byproducts as aggregate have been developed for use in underground mines. These structural products show equal or better engineering characteristics than timber, and they have the potential to replace timber support in underground mines. CCB-based ultralight structural material (ULSM) has also been developed and commercialized for use in the construction of ventilation stoppings in underground mines. The bulk densities of these blocks range from 0.40 to 0.64 g/cm3 (25 to 40 lb per cu ft) with more than 75% CCBs. Efforts are also given to develop and demonstrate large volume CCB-based subgrade improvement technique for road construction. Soil treated with SIUC fluidized-bed combustion (FBC) fly ash developed an immediate bearing value exceeding 25% with a swelling strain of less than I %, which is greater than untreated soils, and met Illinois Department of Transportation (IDOT) standard specifications. In this paper, development procedures, engineering characteristics and beneficial uses of CCB-based structural products are given.

Jan 1, 2002

By G. A. Rowell, T. M. Barczak, J. C. Zelanko

The US Bureau of Mines conducted a multifaceted geomechanics research project at a bump-prone longwall coal mine in eastern Kentucky. This mine presented a unique opportunity to study coal mine bumps because the problem appeared to be confined to areas beneath a sandstone channel of limited areal extent. The Bureau's research plan sought to exploit the uniqueness of the site by monitoring strata behavior and longwall support reactions as the longwall face approached and passed beneath a sandstone channel. The study incorporated static pillar stress and strata deformation measurements, shield support leg pressure measurements and microseismic monitoring, as well as geologic mapping and the collection of observational data. Data collection was underway when a major coal bump occurred on the longwall face at the mine. Pillar behavior (load and deformation), shield loading and microseismic activity were monitored prior to, during and after the bump. Observations in the tailgate indicated that these pillars were failing prior to and following the face bump. Shield load data, evaluated in an effort to identify trends that could be used to forecast coal bumps, appear to provide a measure of the effectiveness of destressing operations conducted on the face (e.g. shot firing). Analyses of microseismic data revealed anomalous values associated with microseismic "energy" prior to the face bump. In addition, microseismic source-location data and underground observations provided some insight as to the sequence of pillar and face bumps.

Jan 1, 1992

By B. Pollack, L. G. Stevens

INTRODUCTION In other chapters of this volume many of the important technical aspects in the design of concentration and dewatering circuits have been discussed. This chapter will deal with the steps necessary to bring that information together in order to produce the specifications necessary to purchase the equipment and complete the design. It deals with the plant as a whole rather than just concentration and dewatering, since the steps are essentially the same. Prerequisites to Engineering Design Feasibility studies will have been completed and design parameters established prior to the start of the engineering design stages for a metallurgical plant. The data base for the feasibility studies will have included laboratory and/or pilot plant test work, historical data, proposed plant site data such as climatology, topographic mapping, geological and geotechnical information. These studies will have established the general project design criteria as well as the process design criteria leading to the preparation of preliminary flowsheet ( s) and/or alternative process flowsheets. These will have incorporated metallurgical and material balances, allowing identification of major equipment items, and development of preliminary plant site plot plans. Preliminary technical and economic assessments and recommendations will have been prepared during this phase for Owner's review and evaluation of the technical, physical, and cost effectiveness of the overall project and its component process, process facilities, and supporting facilities elements. After Ownert s approval and decision to proceed, the engineering design can be initiated, using the above information as the basis. Engineering Design Phase The engineering design of metallurgical plants and their elements are generally developed in two sequential stages, namely: (1) Basic ("Front end") Engineering Design (2) Detail Engineering Design Figure 1 relates these engineering stages to the entire program from feasibility through construction.

Jan 1, 1986