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By K. N. Han, H. C. Cho, R. Kim

"A comprehensive analysis of the effect of OH- on various cations in hydrometallurgical systems has been investigated. Cations chosen for this analysis included groups 1A and 2A, rare-earth elements and other common transition metal ions such as Cu2+, Fe2+, Fe3+, Mn2+, Ni2+, Co2+, Ag+, Cd2+, U4+, UO2 2+, Hg2+, Al3+ and Zn2+. The Newton-Raphson technique was used to calculate and plot various metal species over a wide range of pH. This study has clearly shown that by adjusting the concentration of OH-, the separation of Fe from Mn, U from V, Ce and Eu from other rare-earth elements, and In from Sn is possible. The effects of hydrated metal ions on the separation and removal of various metals from each other under various conditions is discussed.IntroductionThe primary purpose of hydrometallurgical processing is to extract, remove and purify various metals from diverse sources. Hydrometallurgists are frequently preoccupied by the extraction of cations in metallic form, but overlook the important role anions play in such processes. A proper choice of anions can determine the fate of successful extraction, removal and purification of metals (Esmaeili et al., 2005; Brbooti et al., 2011; Wei et al., 2005; Jeppesen et al., 2005; Al-Tarazi et al., 2004), and also separation (Farha et al., 2011; Sevenich and Fritz, 1983; Rashid, 1974) of cations from various solutions.In this study, the authors have examined some of the effects that anions play in various solutions. The anion considered in this study was the first hydroxide, OH-. Other anions, such as Cl-, Br-, I-, and CN-, will be dealt with in the second part of the series of two papers."

Jan 1, 2015

By T. H. Eyde

Natural Zeolites are a less expensive and in certain applications a superior alternative to organic ion exchange resins. Mining and metallurgical waste streams are difficult to treat because the effluents which contain potentially valuable heavy metals such as copper, lead, and silver are often highly acidic and contain significant quantities of suspended solids. Under rigorous operational conditions, certain natural zeolites can remove the metals, which if desired can be recovered by either elution or conventional smelting techniques. There are significant differences in cation exchange rate, selectivity and capacity as well as resistance to either high or low pH, blocking cations and tolerance to elevated or depressed temperature and pressure not only between different zeolite minerals but between the same mineral from different deposits. Applying natural zeolites to the treatment of mining and metallurgical waste streams depends on matching the specific zeolite to the effluent by characterization of the zeolite minerals.

Jan 1, 1994

By J. Perlacia

Introduction The Bulk Handling Technology has already started its transformation to the Industry 4.0. Having some of the harshest working and environmental conditions of the industry, the possibility of remote analysis and maintenance of the components seems a perfect target to focus on. The most important and expensive tools have been adapted to the digital era during last years, from remotely controlled haul trucks to monitored conveyor belts. However, these big parts of the installations rely in smaller parts that have been left aside for a while, mainly due to the difficulty to adapt them to IoT (Internet of Things). The paradigmatic example is the lack of monitored rollers whereas all the other components of the conveyor belt installations (the belt itself, motors, drums etc.) were monitored some time ago. The main problem is that a failure of a single roller can cause the stop of the whole conveyor, due to the possible damages to the belt, thus the implementation of an integral monitoring system of all the components of the conveyor is a must. The R&D Department of ULMA Conveyor Components, has been working since early 2012 on the development of Monitored Rollers, facing all the problems until its final installation in very different demanding conveyors, from the Australian extreme heat to the freezing cold Norway. All the tests done under actual working conditions, in real installations, have given a valuable knowledge in the identification of problems, their solution and the final advantages of a roller monitoring system. Background and Current State The malfunction of a single roller in certain conveyor belts can suppose the standstill of the whole installation until its replacement, due to the risk of greater and more expensive failures like the rip of the belt. In the case of a bulk handling installation where a continuous supply of material is necessary, an unexpected stop of one hour could entail huge economical losses. What’s more, many conveyor belts are several kilometers long or the access to some parts of them is very complicated. Due to these difficulties the inspection and maintenance operations can become expensive and hard going, with staff going over the whole area checking the correct condition of the conveyor and rollers, which means a dangerous activity. As in many other industry products, the condition of rollers can be recognized measuring key parameters like the temperature of the bearings, the vibration level etc. The traditional way is to use the characteristic noise of a failing bearing, but this method usually implies to change several rollers because the maintenance team is not able to identify a single source of the noise. In recent years different attempts to measure the temperature of the bearings have been made, but the result is not accurate enough due to the proximity of the rollers in the idlers

Jan 1, 2019

By M. P. Miano

Matching the productivity gains of continuous mining machines with the ever increasing performance levels achieved by longwall units has required creative thinking to assure that development is completed in time for uninterrupted longwall production. By using management information systems to coordinate support operations, the most productive planning decisions can be made. This paper focuses on the role of computer technology tools in achieving improved productivity from both longwall and continuous miner sections. The primary emphasis is on the planning process and the methodology developed to guarantee the best allocation of management and manpower resources.

Jan 1, 1993

By T. Schrauf, J. Scott

"INTRODUCTION Cyanide heap leaching of gold ores in areas with extremely low winter temperatures requires special considerations to prevent freezing of the leach solution. Factors that impact the solution temperature include ore temperature at the time of stacking and during operation, burial of drip irrigation lines, use of geomembrane covers, and heating of the leach solution. Thermodynamic modeling was performed to simulate expected ore and solution temperatures under different operating strategies for Kaminak Gold’s Coffee Gold project in the Yukon Territory. Mean monthly temperatures at the site ranged from a low of -22.5oC to a high of 13.6oC, while in situ ore temperatures ranged from -0.5 to about -1.5oC. The modeling results were used to optimize the operational parameters and indicated that a combination of drip line burial and heating of the leach solution during the winter months was required to maintain solution temperatures above freezing during the initial years of stacking, although as the size of the heap increased, heating was no longer necessary. MODELING OBJECTIVES The successful operation of a cyanide heap leach under extremely cold winter temperatures requires the implementation of operational strategies to prevent freezing of the leach solution and the ore within the heap. Thermodynamic modeling of the heap provides the means to quantify the effectiveness of these different operational parameters on maintaining the required operating temperatures to avoid freezing within the heap. The operational parameters that were evaluated with the model included: • Burial depth of irrigation lines to prevent freezing during the winter months; • Variation in the temperature of the applied leach solution (to simulate heating of recirculated solution); • Variation in the rate of irrigation including seasonal variations between winter and summer months; • Seasonal versus year-round stacking of ore (to simulate the impact of the initial temperature of each ore layer as it is stacked); • Seasonal versus year-round crushing and stockpiling of ore, including the option to stockpile ore on the leach pad in the winter (i.e. stack but not leach fresh ore in winter); • Start date for seasonal stacking; • Variation of the heap geometry over time (both vertical and lateral expansion) and the associated heat storage within the heap; • Use of thermal covers (gravel or geomembrane) over the ore during the winter months; and • Effect of crush size on heat loss during crushing, stockpiling and stacking."

Jan 1, 2016

By Jack O?Hearn

A liquid and solid waste management plan for an operating uranium ore processing mill was developed to efficiently and effectively dispose of existing solid wastes and related, affected surface and ground water resources. The goal of this management plan was to achieve satisfactory clean up of these existing wastes ad their by-products as well as to prevent similar situations from occurring in the future. An existing, modern system of synthetically lined tailings ponds, constructed after many years of mill operations, now provides an approved site for the disposal and containment of waste streams currently generated by the mill. This system was thought to be readily adaptable to serve as a key element of the waste management plan. The potential presence of extra capacity in these ponds could eliminate or reduce expenditures for new facilities required solely for proper management of liquid and solid wastes generated by operations prior to construction of the modern tailings ponds as well as for a range of anticipated future operations.

Jan 1, 1984

By T. Bednarski, T. McCallum

"Physical impurity transfer in solvent extraction (SX) has a significant impact on operating costs, electrowinning (EW) performance, and cathode quality. Some operations use a wash stage to limit impurity transfer by diluting the entrained pregnant leach solution (PLS) to prevent direct transfer to EW. Wash stage operating conditions vary impacting impurity transfer. A number of factors impact dilution efficiency including mixer continuity, wash aqueous acidity, and organic quality. The impact of these variables on dilution efficiency was studied and compared to current industry practice. INTRODUCTION With the exception of iron, impurity transfer in copper SX is due to PLS carryover in the loaded organic via aqueous entrainment and crud movement. The quantity of impurity transfer is influenced by many variables including operating set points, organic quality, and settler housekeeping. Crud management and treatment is a common practice aimed at minimizing transfer of impurities to EW. Crud is a complex solid-stabilized emulsion of aqueous and organic[9]. As such, it contains a large aqueous component and the associated impurities (from the PLS). A common practice is to remove interfacial crud to prevent movement. Additionally, mixer continuity can be altered to enable compaction and improve the efficiency of interfacial pumping[10]. Understanding the factors impacting aqueous entrainment and optimizing the available controls should be a key focus for any operation. Aqueous entrainment in the loaded organic can be impacted by: • Mixer continuity • Mixer organic/aqueous (O/A) ratio • Mixer speed and impeller type • Organic and aqueous depths • Specific settler flow • Use of settler internals (picket fences, coalescing packs) • Organic quality • Design and operation of loaded organic tanks Conventional thought is to run the E1 mixer in aqueous continuity to reduce aqueous entrainment. Generally, O/A ratios close to 1:1 result in improved metallurgical and physical performance. Mixer speeds should be chosen to achieve acceptable stage efficiencies while minimizing over-mixing. Organic depths can be increased in the E1 stage to increase retention time and minimize aqueous entrainment. Settler internals can also be used, but require maintenance to maintain effectiveness. The quality of the plant organic inventory will impact physical performance. Poor organic quality can lead to higher phase disengagement times increasing impurity transfer to the electrolyte. Additionally, the design and operation of the loaded organic tank can impact impurity transfer[8]. Despite the variables that can be used to reduce aqueous entrainment and crud movement, impurity transfer is still an issue in some operations. For these operations with high PLS impurity concentrations, a wash stage may be beneficial to manage impurity transfer. Understanding factors impacting wash stage performance is important to optimize performance and limit impurity transfer."

Jan 1, 2016

Selective Flocculation process development generally involves single mineral flocculation tests to identify the appropriate polymer and experimental conditions for achieving the desired selectivity. Invariably the selectivity predicted on the basis of such tests is not realized when mixed mineral tests are conducted. A systematic experimental investigation revealed that adsorption of the polymer on various substrates is critical to selecting the suitable flocculent. Simultaneously, a mathematical model was developed to predict the overall process efficiency with a given polymer. In this paper, results of these efforts to scientifically design a suitable selective flocculation process are presented.

Jan 1, 1991

By A. Mei, F. Amadini, F. Cernera, D. Baliani, A. Flor, M. La Morgia, F. Sassi

The risk of TBM jamming because of squeezing rock mass or excessive caving (instability of the cavity) conditions is always a focal point while boring long and deep tunnels with shielded TBMs. Mechanized excavation provides a large amount of real-time data, for each machine’s parameters. Several analyses have been executed to assess the correlations between different sets of TBM parameters for the exploratory tunnel. Instead of analyzing the full dataset, a different approach is proposed, with data processed sequentially to simulate the real excavation situation. The probability distributions are recalculated together with their statistical parameters while advancing. This approach is extended also to the training of a Machine Learning model able to foresee the behavior at future rings based on past rings (using a Recurrent Neural Network). The predictions show a promising first step toward creating practical tools that can assist contractors and designers to correlate and predict TBM excavation data. These tools will assist to predict and quantify high risk situations that could arise during excavation.

Jun 13, 2023

By L. Yuan, C. Brown, N. Rayyan, J. Soles, T. H. Dubaniewicz

As lithium-ion batteries (LIBs) become more prevalent in the mining industry, new hazards of battery fire and explosion are emerging. Efforts must be taken to ensure that workers are safe from these new hazards, such as batteries undergoing thermal runaway in underground areas that may have explosive methane-air mixtures. Researchers at the National Institute for Occupational Safety and Health (NIOSH) investigated overpressures generated within a sealed battery enclosure filled with an explosive methane-air mixture and a single cell lithium-ion battery driven into thermal runaway using an accelerating rate calorimeter (ARC). For both iron phosphate (LFP) and nickel manganese cobalt (NMC) lithium-ion cells, the explosion overpressures remained unchanged with varying percentages of methane concentration in the atmosphere surrounding the cell. It’s likely that the gases released from the battery undergoing thermal runaway caused an inert atmosphere within the sealed canister. The results from this study will help mining equipment manufacturers develop proper measures to keep miners safe while working with lithium-ion batteries in underground gassy mines

Mar 2, 2022

By A. Newman, A. Brickey

Although some of the prevalence of openpit production scheduling software can be explained by the predominance of openpit mining throughout the world, other factors have led to a lag in corresponding underground software. We explain mathematically why underground production scheduling is more difficult than its openpit counterpart and provide directions for research in the underground scheduling arena.

Jan 1, 2014

By A. Newman, A. Brickey

A pesar de que parte del predominio de software de programación de producción a cielo abierto se puede explicar por la preponderancia de la minería a cielo abierto en todo el mundo, hay otros factores que han dado lugar a un retraso en el software subterráneo correspondiente. Explicamos por qué matemáticamente la programación de la producción subterránea es más difícil que su contraparte a cielo abierto y daremos pautas para la investigación en el campo de la programación subterránea.

Jan 1, 2014

By G. A. Kordosky

The literature contains several references to the influence of copper solvent extraction reagents on crud formation, but, there is disagreement as to whether the reagent has an influence on crud generation. The results of three pilot plant campaigns, where crud generation was studied as a function of the copper solvent extraction reagent, are reported. These pilot plants were run at operating copper solvent extraction plants using the aqueous solutions being treated by the commercial copper solvent extraction plants. Two of the pilot plant studies showed that the copper solvent extraction reagent had a significant influence on the extent of crud formation while the other pilot plant study indicated the copper solvent extraction reagent had a lesser influence on crud generation.

Jan 1, 1996

By F. Calizaya

This study summarizes the ventilation requirements for a highly mechanized P.T.Freeport Indonesia's underground mine operation in Irian Jaya, Indonesia. The Deep Ore Zone (DOZ) is a copper-gold deposit being developed underneath the current Intermediate Ore Zone (IOZ) mine. One of company's current plans is to prepare this mine for a steady oreflow of 25,000 tpd by year 2003. This study includes the estimation of airflow requirements for various mining activities, the design of major intakes and returns, the determination of airway resistances and specifications of fan duties. It also includes the results of air pressure/quantity measurements in existing airways and the standards stated by the current Indonesian mining law.

Jan 1, 1998

By João F. C. L. Costa, Vanessa C. Koppe, Clayton V. Deutsch, Marcel A. A. Bassani, Pedro H. A. Campos

Blending inevitably occurs to some degree during mining and mineral processing operations. Traditional mine scheduling assumes that all variables average linearly, which allows the calculation of the blended material properties as a linear weighted average. However, metallurgical properties such as metal recovery and Bond Work Index (BWI) are known to average nonlinearly. The nonlinear properties of the blended material can be calculated using nonlinear blending models. A simulated annealing algorithm is developed and applied to a short‐term mining face optimization problem to maximize the total metal recovered considering nonlinear blending. Compared to a standard schedule plan, the optimized one shows relevant improvements in synergistic and antagonistic blending behaviors.

Jun 25, 2023

By E. Jong, E. Watkins

"The application of passive tracer gas sources in underground mines is particularly useful for long-term tracer studies as well as for studies conducted in permissible areas of underground coal mines. The use of passive perfluoromethylcyclohexane (PMCH) sources has been previously demonstrated in underground mines, but this new work details the testing of multiple, distinct tracer compounds compatible with passive sources. A description of their potential application in mine ventilation systems is also provided. Three tracer compounds are detailed: (1) PMCH, (2) perfluoroethylcyclohexane (PECH) and perfluoromethylcyclopentane (PMCP). The release rates of these tracers were examined over a 180-day period at multiple temperatures. The advantages and disadvantages of these sources are presented, along with potential applications in characterizing ventilation circuits, flow through gob and leakage. IntroductionThe use of tracer gases for ventilation applications is an established practice, with various past research projects conducted using sulfur hexafluoride (SF6). Tracer gas techniques have been applied to assess flow rates, dilutions rates and auxiliary ventilation system efficiencies with quick, reliable and accurate results (Suglo and Frimpong, 2002). Perfluorocarbon tracer (PFT) compounds are a new introduction to ventilation and air modeling applications in terms of ventilation flow characterization (Watson et al., 2007).PFTs are liquids that are characterized by low background presence in air, low reactivity, high detectability and low toxicity. A design was proposed, called a permeation plug release vessel (PPRV), to convert PFTs from a liquid to a gas and then release the gaseous tracer in a controlled manner. The initial concept was originally introduced by Brookhaven National Laboratory and refined later to become the PPRV. The PPRV functions by allowing the volatile PFT liquid to become a vapor in a controlled manner. The vapor diffuses through a permeable silicone stopper at a predictable rate proportional to temperature (Zhang and Cloud, 2006)."

Jan 2, 2018

By S. S. Klima, D. E. Pollock, J. A. Organiscak

"Airborne respirable coal dust capture by water sprays or wet scrubbers has been studied and developed over many decades as an engineering control to reduce dust exposure in coal mines and combat coal worker pneumoconiosis. Empirical relationships and deterministic models for particular dust capture experiments have previously been devised to show the key parameters involved in airborne coal dust capture. Many of the results from these models show that the significant parameters related to airborne dust capture are water spray pressure, water quantity, water droplet size, relative water droplet-to-dust particle velocity, and total operating air pressure of the scrubber. However, many airborne dust capture efficiency relationships and models developed for particular experiments cannot be readily applied to forecast the dust collection efficiency of different spray and scrubber design configurations, which rely on several key dimensional engineering measures. This study examines engineering measures from previous water spray and wet scrubber experiments conducted by the U.S. National Institute for Occupational Safety and Health (NIOSH) and the U.S. Bureau of Mines (USBM) to develop empirical models for wet collection of airborne dusts. A dimensionless empirical model developed for predicting airborne dust capture efficiency of water sprays and wet scrubbers is presented. IntroductionWater sprays have been one of the earliest mainstay engineering controls used to suppress respirable dust in underground coal mines. Some of the earliest reports of water spray usage on continuous mining machines indicated respirable coal mine dust reductions of 20 to 60 percent (Kobrick, 1970). Not long after the enactment of the 1969 Coal Mine Health and Safety Act, the U.S. Bureau of Mines (USBM) and others conducted extensive research into water spray and wet scrubber systems to control respirable dust in coal mines. The primary aspects of water spray dust control included prewetting for dust prevention, localized ventilation redirection and airborne dust capture, which are summarized in handbooks or best-practices guides (Kost, Yingling and Mondics, 1981; Kissell, 2003; Colinet et al., 2010). Initially, underground studies were conducted to identify the primary sources of dust during the mining processes and effective dust controls (Courtney, Jayaraman and Behum, 1978; Jankowski and Organiscak, 1983). Laboratory research systematically studied ventilation and airborne dust capture effects of water sprays and scrubbers to improve their application in underground coal mines (Tomb, Emmerling and Kellner, 1972; Divers and Janosik, 1978, 1980; Grigal et al., 1982; Ruggieri et al., 1983; Jayaraman, Jankowski and Kissell, 1985; Volkwein, Ruggieri et al., 1985; Jayaraman, Schroeder and Kissell, 1986; Divers, Jankowski and Kelly, 1987; Jones and James, 1987)."

Jan 10, 2018

By S. C. Schmelter

The destabilizing effect of water pressure on rock mass stability is examined quantitatively by the finite element method. A coupled code that accounts for the simultaneous effects of rock mass deformation and transient fluid flow is used for this purpose. The traditional soil mechanics assumption of an incompressible fluid is shown to be untenable for the analysis of porous, fractured rock slopes. A Mandel-Cryer effect, a transitory but elevated and potentially destabilizing water pressure following a cut, was not observed.

Jan 1, 1997

By S. Renslow, G. Wang, L. R. Moore, Y. Xiong, J. Gu

"Clays are known to contribute to a wide range of mineral processing challenges. These challenges can haunt a plant from the pit, through the beneficiation plant and even to the tailings pond and process water. Each step that the clay is present potentially experiences significant and costly impacts to the process efficiencies. The effect of clay minerals on the performance of phosphate flotation was investigated. The investigation led to an understanding of the movement of clay through the beneficiation plant, the impact on reagent usage, and the overall flotation performance. INTRODUCTION With the decline in mineral feed grades, mineral processing will continue to face challenges. One significant challenge would be obtaining high recoveries of industry specified quality mineral concentrates with lower quality raw minerals. Other challenges may be the handling of the excess tails and process water being produced to maintain a mill’s production volumes. For example, increased levels of clay have been, and will continue to be, a topic of concern for many mines. Some of these concerns include environmental regulations associated with water storage and discharge, as well as beneficiation. Gonglun Chen reported that clays produced in the phosphate industry are generally colloidal and fine (90% < 45 µm) (Chen, 2006). As such, these clays can take 20-30 years to settle, in the absence of polymeric assistance. The settling of these clays is essential as an accidental discharge can lead to substantial impacts to the wildlife and ecosystem. The Environmental Protection Agency (EPA) has referenced cases where the discharge of water can result in fines in the tens of millions of dollars, and at times causing the processing plants shut down, depending on the volume and quality of this discharged water (EPA, 1997). The turbidity discharge criteria will vary from state to state. Florida’s Department of Environmental Protection has listed a turbidity maximum of 29 NTUs, or 60 mg/L total suspended solids, above the natural background condition (Florida Department of Environmental Protection, 2016). A lot of the literature has been focused on the impact of high levels of clay (>10%) on mineral processing. Farrokhpay has reported the significant impact of clay minerals on froth stability in copper flotation (Farrokhpay, 2012). He reported that clays can form a hydrophobic slime coating on the surface of bubbles, which can yield an increase in froth stability. Clay concentrations as low as 5% can have significant impacts on the rheological properties or slurry viscosities. Increased slurry viscosities can lead to either elevated pumping/processing energies being required, decrease in flotation efficiencies due to a decrease in bubble mobility through the pulp, or decreased throughput to manage these viscosities (Tu, 2005; Farrokhpay, 2013; Burdukova, 2014)."

Jan 1, 2017

By D. Gove

All mining operations using trucks have a common need to properly match the number and size of hauling units (trucks. wagons. scrapers. etc.) to a loading unit (wheel loader. hydraulic shovel/excavator, cable shovel. push tractor. etc.) to provide the best possible fleet match. Optimizing fleet match minimizes the cost per unit of material moved by that fleet. As haul conditions change (haul length. grade. or rolling resistance), there may be need to adjust the number of trucks to maintain the optimum fleet match. Fleet Production and Cost is a tool which, among other things, can be used to optimize the truck-loader match.

Jan 1, 1994