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By H. Yen, D. E. Walsh, H. K. Lin

"Comminution circuits are widely used in nonferrous and precious metals milling. Steel crushers, grinding mills and grinding media are typically used in comminution circuits. Comminution circuit wear products, in the form of metallic iron (steel) fines, are unavoidably produced and report to undersize products in the classification circuit, i.e., flotation or leach feed, while tramp grinding steel (TGS) reports to classification oversize products and returns to the grinding mill, building up in the circulating load. In laboratory studies, TGS reduced grinding efficiency significantly, the impact being dependent upon the size of the TGS present in the mill. Because iron fines adsorb flotation reagents effectively, iron fines increase reagent consumption and reduce flotation recovery. Iron fines are also capable of reducing gold recovery in cyanidation circuits via a cementation reaction. When using filtered gold solution from the cyanidation circuit of an Alaskan gold mine, the gold concentration in solution was reduced by 0.2 to 2.6% over various reaction periods when iron fines were present in the solution.IntroductionComminution circuits are widely used in copper, lead, zinc, nickel, cobalt, molybdenum and precious metal mills. Flotation and leaching processes are usually preceded by comminution (crushing and grinding) circuits in order to liberate valuable minerals for effective separation, concentration or dissolution by the subsequent flotation or leaching processes.Steel crushers, grinding mills and grinding media are typically used in comminution circuits. Comminution circuit wear products, in the form of metallic iron (steel) powder, are unavoidably produced and report to undersize products in the classification circuit (flotation or leach feed), while tramp grinding steel (TGS) reports to oversize productions during classification and returns to the grinding mill, building up in the circulating load. Variables affecting the amount of metallic iron powder and TGS produced in a comminution circuit include ore hardness, grinding mill operating conditions, comminution circuit design and the metallurgy of the steel used for manufacturing crusher liners, mill liners and grinding media. As one example, a comminution circuit product of 80% passing 200 mesh at the Pogo Mine, AK is estimated to contain approximately 2 kg/t of metallic iron. A finer grind will generally produce a comminution circuit product with higher metallic iron fines content."

Jan 1, 2015

By S. S. Sephton

The La Perla Mine, owned by Altos Hornos de Mexico, S.A., is located approximately 100 miles east of the City of Chihuahua in the State of Chihuahua, Mexico. The mine began operations in 1958. Existing ore beneficiating facilities, consisting of heavy media and jig plants, upgrade the ore prior to shipment by rail to the Altos Hornos steelmaking complex in Monclova. Sizable reserves of two distinct ore types, which were not amenable to treatment in the existing beneficiating plant, or usable in the blast furnaces, have been mined and stockpiled in order to uncover the treatable ores. One of these ore types has been labeled "Diseminado" ore, and is low grade containing approximately 42% Fe with sulphurs ranging from 1 to 2%. The other ore type has been labeled "Pulverulento" ore, and is high grade containing approximately 65% Fe and 0.1% S, but at 80% minus 325 mesh, is too fine grained for efficient sintering. Late in 1968, Arthur G. McKee & Company became involved with the problem of improving the above ores for their efficient and economical use in Altos Hornos' blast furnaces. Early in 1969 representative samples of Diseminado ore were obtained for laboratory bench-scale testing at the University of Minnesota, Mineral Resources Research Center. Concentration tests incorporating magnetic roasting, wet magnetic separation, high intensity separation, high tension magnetic separation, anionic flotation of apatite, cationic flotation of silica and oleic acid flotation of iron were performed. Laboratory testing was concurrently carried on at La Perla Laboratory, which resulted in plans to construct a 10 TPD pilot plant. The pilot plant was operational in September, 1969. Analyzing laboratory results as well as pilot plant results, Altos Hornos and Arthur G. McKee & Company metallurgists agreed that the most promising flowsheet for the low grade Diseminado ores entailed wet magnetic cobbing, desliming, and oleic acid flotation of the non-magnetic fraction. A combined concentrate of

Jan 1, 1972

By B. C. Flintoff

In general, process control systems in solid-solid separation have not evolved to the same level as in flotation circuit control. Perhaps one of the more significant contributing factors in this regard is the lack of suitable on-line analytical instrumentation. In spite of the obstacles, some interesting work has been done. This paper presents a review of current industrial control strategies in ore sorting, dense media separation, gravity separation and electrical and magnetic separation.

Jan 1, 1986

By John C. Kleiber

From time to time since the initial installation of an experimental flotation section in 1940 (reference A), Permanente Cement Company has made efforts to beneficiate the low-grade limestone fraction which occurs in its deposit at Permanente, California, The encouraging results outlined in this paper are the result of Permanente's latest effort. This paper discusses the factors governing the selection of the flowsheet with particular reference to marketability of the sand tailing by-product. The process flow is outlined in detail, and operating statistics of the plant are presented. Finally, the problems encountered in the operation of Permanente's beneficiation plant are discussed as well as solutions sought and found.

Jan 1, 1964

By R. L. Loofbourow

The Sunro Copper Mine is near the south coast of Vancouver Island about 35 miles west of Victoria. Failure of the roof of a large open stope let a good sized mountain stream into the mine. Broken are, boulders and sand were washed into the underground mill and out through a 7 800-foot adit. The adit became plugged; water burst out an a ridge above the adit, washing out the portal and o trestle by which it was reached, Rock and ore are strong but several systems of steep, pronounced but generally tight fractures are found on and parallel to the walls of the orebody. The stope was started from a slusher drift 390 feet below the bed of the River and brought up to an elevation 155 feet below the River by blasting vertical and horizontal rings of longholes in the nearly vertical orebody. Mining was stopped there and five months were given to grouting and bolting the pillar under the bed of the River, During this time and for several months thereafter sloughing increased the width, length and height of the stope. At the last known observation the stope was 77 to 96 feet wide, 185 feet long and the highest point of the domed back was only 55 feet below the River. The flooding took no lives. In other respects, however, it might be difficult to find in mining lore o more savage example of the application of "Murphy's Laws".

Jan 1, 1968

By Regina N. Tempel, Mae S. Gustin, Mark A. Engle

This study characterizes the hydrogeochemistry of groundwaters near opalite-hosted epithermal hot-spring type mercury deposits in the Ivanhoe mining district, Elko County, Nevada. Local groundwaters generally range from Ca-HCO3 to Ca-Mg-Na-SO4 type waters with background mercury concentrations ranging from 0.014 to 0.32 ug/l. Leaching experiments conducted on mineralized rocks, using typical water chemistries to represent local groundwaters, yield total mercury concentrations ranging from 6.3 ug/l to 27.4 ug/l after one year of reaction. Geochemical modeling indicates dissolved mercury is dominated by HgO(,) and that precipitation of quicksilver controls mercury concentrations to an upper limit of 63 ug/l.

Jan 1, 2000

By Walid M. Abdellah, Soliman Abu Elatta A. Mahmoud, Hanaa A. Abu Khoziem

The high-grade Th-U-Y zone is one of the numerous mineralized zones found in the El Garra El Hamra hydrothermally altered syenites in southwestern Egypt. It is characterized by the thorium minerals thorite and thorogummite, which are closely associated with xenotime-(Y). This zone of mineralization is localized in the eastern part of the El Garra El Hamra hydrothermally altered syenites. This zone does not relate to the first phase of syenites that appeared on the surface but is linked to the other, hidden phase of the syenitic body. Additionally, the fluids responsible for the mineralization of this zone belong to the late-stage hydrothermal event as well as the fault action due to the fact that it had continued reactivations for a long period of time. The studied mineralized zone also contains ceriopyrochlore-(Ce),(Ce,Ca,)2 (Nb,Ta)2O6 (OH), fluorite (CaF2) and barite (BaSO4), which are found in considerable amounts, whereas apatite (Ca5(PO4)3F) and chromite (FeCr2O4) are rarely found together with Fe-oxi-hydroxides (hematite and goethite) with a minor amount of jarosite (KFe33+(OH)6(SO4)2). Finally, the main constituent mineral in the zone is the pseudomorph perthite in addition to quartz, which is found as deformed crystals. A technological sample was collected from this zone and was found to assay 4.62 weight percent thorium (Th), 0.37 weight percent uranium (U) and 3.12 weight percent rare earth elements (REEs). From the chemical and mineralogical composition of the studied technological sample, the leachabilities of Th, U and REEs were investigated using sulfuric acid (H2SO4) agitation leaching and pug leaching methods. The latter was found to be preferred under the conditions of 0.54 ton H2SO4 per ton of altered syenite at 110 °C for two hours.

By Michael P. Connor, O&apos

The Wing Hill Garnet Deposit, located near Rangeley, Maine, forsed through assimilation of Early Paleozoic metasediments by an intrusive Devonian gabbro. The resulting ore body is exceptionally large and high-grade, consisting of 50-70% almandine garnet. Following open-pit quarrying, the ore is trucked to Industrial Garnet Extractives' mill in West Paris for final processing. Two grades of abrasive are produced - a pure, premium grade INDUSTRIAL GARNET and the Lower grade co-product IGE UTILITY GRIT, both of which are available in a variety of sizes. INDUSTRIAL GARNET is marketed world- wide into a diverse marketplace including both loose grain and bonded applications.

Jan 1, 1985

By T. W. Martin

The use of conveyors in large, open pit mines and their drawbacks are discussed. Technological developments such as long distance conveyors capable of handling large rocks are explored. The development and testing by the Bureau of Mines of a prototype crib and cable conveyor for handling large rocks are discussed, and possible modifications of the concept for a production model are examined.

Jan 1, 1984

By K. Biswas

In general, it cannot be assumed that the strength of coal pillars remains constant over long time periods. Field observations indicate that a coal seam, especially when it contains a parting layer, deteriorates over time, reducing load-bearing capacity of the pillars. This paper discusses a unique approach to determine the time dependent strength of coal pillars in the field. Three coal pillars that were developed 5, 15 and 50 years ago were chosen for the study. Holes were drilled in coal and parting layers in each pillar and the strength profiles were determined for each hole using the Borehole Penetrometer. The strength data were treated statistically to establish time dependent strength equations for different layers. The results can be used to help estimate the loss of pillar capacity over time.

Jan 1, 1999

By Steve Kral

As the mining industry watches commodity prices continue to soar, the question on most everyone’s mind is how long will this upcycle last. The con-census among speakers and attendees at the SME Annual Meeting and Exhibit is that this cycle is sustainable. The buzz at the meeting was, of course, the current boom cycle the industry is in. Most agree that China’s huge appetite for mineral commodities is part of the force driving the upturn. But the improving economies of other developing nations also plays a role. However, along with the good times come challenges. Speakers at the keynote session addressed some of the challenges and offered their opinions on the sustainability of the boom.

Jan 1, 2006

By A. J. Lynch, M. J. Lees

Introduction The design of wet grinding circuits may vary considerably according to the duty which is to be performed. Grinding machines which are commonly used in these circuits are rod mills, ball mills, autoge¬nous mills, and pebble mills while size separation machines commonly used are vibrating and wedge-wire screens, hydrocyclones, and rake classifiers. In some circuits, such as those producing feed to cement kilns, all the ore entering the circuit is discharged in a single product stream. In others, such as those operating on magnetite-taconite ores, the feed entering the circuit leaves in two or more streams. Grinding circuits in flotation plants normally include sections in which either the concentrate or the tailings from the primary flotation circuit is reground and these additional sections should be regarded as an inte¬gral part of the grinding circuit. A typical circuit is shown in Fig. 18. Problems in achieving maximum efficiency may occur at three stages: 1) At the design stage when the optimum size reduction flow¬sheet must be selected with respect to the types, numbers, and sizes of processing units. 2) At the operating stage when the correct selection of values must be made for those variables which may be altered while the circuit is off-line but which are constant while the circuit is on-line, for instance the vortex finder diameter of the cyclones. 3) Under conditions of continuous operation when changes in the circuit feed or in the mechanical operation of the circuit may cause undesirable changes in the circuit product. The first two prob¬lems are concerned with optimization, that is, with making the best choice from many possibilities, and the last with control. Optimization Problems. The main purpose of a wet grinding circuit is to produce particles with a sizing distribution which will ensure optimum performance of the later chemical reaction or physical concentration circuits, because it is on the efficiency of these later circuits that the economics of the total mineral treatment process depend. The size distribution of the product from a grinding circuit may be affected by many variables, some concerned with the arrange¬ment and operation of the machines and some concerned with the ore characteristics, and it is important that these should be recognized in the design and operation of the circuit. For instance, in a simple ball mill-cyclone circuit the variables which affect the product size even for constant feed characteristics are shown in Fig. 19. In addition, the rate, size, hardness, and mineralogical composition of the feed will affect the performance of the circuit and the product size. When the circuit contains more than one mill, both the number of choices available and the complexity of the problem are increased consider¬ably. Consequently, one type of problem which is to be solved if an optimum product is to be obtained from an existing grinding circuit is that of circuit design, and this includes arrangement of processing units and selection of those operating conditions which cannot be altered when the circuit is operating, such as mill speed and cyclone inlet and outlet dimensions. The other major problem in optimization is encountered at the design stage when a choice must be made about the type, number, and size of processing units. For instance, for a typical high-capacity size reduction operation, should two circuits each containing one rod mill and two ball mills or three circuits each containing one rod mill and one ball mill be used? Alternatively, should ball mills only be used and if so, how many, what size, and what arrangement?

Jan 1, 1985

By L. Whitby-Costescu

The Shebandowan mine and concentrator, with a capacity of 9072 t/week (10,000 st per week), was opened in 1972 after several years of environmental study and planning. The mine is located in a popular vacation cottage .area about 96 km (60 miles) west of Thunder Bay, Ontario. Undertaken before environmental assessment procedures had become an established requirement, Shebandowan is one of the first Canadian examples of effectively integrating environmental work into overall planning. Although it is an underground mine, many of the environmental considerations are common to open-pit operations, and hence, it provides a case history for the use of all mine planners. Computers can play a part in such studies by simulating the annual production of mine wastes, by on-line polling of environmental sensors and by processing sensor data. Early attention was focused on establishing base-line conditions in a two-year water quality monitoring program. Since production began, water quality monitoring has shown that mining has not caused any significant changes. However, mine drainage disposal arrangements had to be modified in the light of operating experience. There is no townsite associated with the mine, and workers commute from established municipalities. Harmonious relations have been achieved with local cottage residents after their initial fears were dispelled. Plans are ready to begin revegetating the tailings when a sufficient area of dry elevated tailings has been accumulated. Rehabilitation of the land disturbed during development was begun before start-up and was completed during initial operations.

Jan 1, 1979

By J. Raatikainen, I. Auranen

"INTRODUCTION Sorting technology has advanced rapidly recently. Of the two possibilities particle sorting has advanced especially in introducing new sensors and the use of multiple sensors. The analyzing and computing lead times have also shortened. This has made it a viable technology option for many applications but not for the most important sorting task at a mine; the run-of mine ore. Bulk sorting, however, has advanced in smaller steps, even if the technology has the capability to tackle the run-of-mine ore and offers a high potential to bring mines substantial economic benefits. The sensors, which are useful are restricted by the difficult operating conditions or by the ore characteristics. One of the important features of run-of-mine sorting technology is the major material handling infrastructure required. The capital expenditure can be substantial requiring good understanding of the sortability curve (grade-recovery curve) behavior of the ore. This paper discusses one industrial case, where substantial amount of data measured from the ore feed belt has been obtained. This data was then analyzed for the grade recovery curves obtainable from that ore with sorting. EXPERIMENTAL The XRF measurement used was the FCA device from IMA Engineering (Fig.1). It is a specially built version of XRF designed to operate with coarse material. The measurement was situated at the main belt conveyor taking ore from the primary crusher to the stockpile. The crushed ore was about 80% -300 mm at a capacity of 1100-1200 tph (Fig.2). Measurement times were varied from 30 seconds to a minute. Measurements were obtained over several months.As the XRF is a surface distribution measuring technique, the measurement was first tested upon accuracy and reproducibility against plant daily wet chemical assays and against on-line Courier feed analysis. As there is a varying delay in the ore stockpile, the delay time was used as a variant in the validation. Different measurement times were tested for accuracy. A one minute measurement time gave a total measurement relative standard error, which was both for Cu and Ni below 3%. The results showed also very robust correlations; for Cu, the correlation coefficient was R > 0,94 for one minute measurements over three months and R > 0,86 for Ni respectively. Fig 3. Shows a measurement period of two hours showing substantial feed grade variations (given as relative value; 1.0 represents the mean value during the measurement month)."

Jan 1, 2018

By P. J. Hyde

Cyanide is a significant contributor to the cost of producing gold. Any reduction in consumption that can be achieved through more reliable measurement and/or more efficient management of dosing rates can have a significant financial impact. An automated analyser, by its mechanical nature, is not prone to the variations of human operators, particularly notice­able from shift to shift. Reducing the standard deviation of the measurement (ie, reducing noise ), the automated measurement will give the metallurgist a truer picture of the underlying patterns of usage. The combination of automated analysis with on-line operation and a control loop provides timely information that is efficiently utilised in the management of the plant. Until the release of the Chemtronics On-Line Cyanide Analyser (OTA3000) about 12 months ago, the Australian experience with automated analysers (especially on-line) had been substantially negative. Since its release, the Chemtronics instrument has outperformed both manual titrations and other automated instruments, gaining an enviable reputation for accuracy and reliability in the process. The instrument is built around the technique ofpotentiomet­ric titrations, in which the potential of an indicator electrode is measured as a function of the volume oftitrant that is added to the sample. As the cyanide in the sample is depleted, the potential on the indicator electrode changes rapidly, producing a typical sigmoidal curve. The OTA3000 takes the first differ­ential of the curve, identifies the apex of the peak as the endpoint and reports the result in parts per million of sodium cyanide. The OTA3000 accepts the peak as valid only if it exceeds a certain minimum height. That minimum height is a programma­ble parameter and is used to optimise the relationship between sensitivity and the rejection of spurious peaks. The instrument will track cyanide trends through both positive and negative slopes of any magnitude, but it will provide a warning if it the slope becomes excessive, not because it affects the instrument but because it means that something unusual is occurring in the tanks. There are a limited number of conditions under which the instrument will produce a result of zero. In these cases the OTA3000 holds any output lines at the last valid result while it repeats the titration. This feature was incorporated for reasons of stability in a feedback loop.

Jan 1, 1995

By Abegail Endraca, Allan Sebastian, Andrew Raine, Allan Patdu

The project involves the construction of a new aqueduct tunnel by an Earth Pressure Balance TBM tunnel for the Novaliches-Balara Aqueduct No 4 (NBAQ4) project in Metro Manila. It comprises a 7.3 km long and 3.1 m internal diameter tunnel that can deliver up to 1,000 MLD of raw water and the tunnel passes under urban residential and urban populated areas adjacent to and along Commonwealth Avenue. A new reservoir intake structure was constructed in the La Mesa reservoir by a cofferdam and the TBM breakthrough connected the reservoir to the outlet surge shaft structure and the downstream pipe network system connecting to the Balara Water Treatment Plant. The TBM incorporated a double articulated head configuration to allow tight 80 m radius curves to navigate some of the difficult alignment considerations. The alignment passed very close to some existing foundations for MRT7 and needed to clear several tight curves to remain within government land ownership. The project excavated through the local Guadalupe weak rock formations and there was minimal ground movements observed as a result of the work.

Jun 13, 2023

By Benoit Gagnon

Mining of the Schefferville iron deposits began in 1954 on completion of the 574 km railway linking the mines and the St-Lawrence river port of Sept-Iles. Apart from crushing, no treatment of these ores was required before smelting. In the late 1950's, testwork began at Schefferville to develop a process for upgrading the extensive lower grade deposits containing 5l% iron with 15% silica (natural analysis). Engineering for 6.1 million tons per year Beneficiation Plant using cationic silica flotation and the A-C Grate kiln began in 1970 and the first pellets were produced in mid 1973. Production requirements and operating difficulties have restricted capacity to approximately 85% of design but ongoing improvements are being made continuously to attain design capacity.

Jan 1, 1980

By Patricia Pride, Mike Robison, Jon Bergenthal, Wojciech Klecan

"The Lower and Middle River Des Peres (LMRDP) CSO Storage Tunnel is the largest single component of Metropolitan St. Louis Sewer District’s (MSD) CSO control system improvements planned to meet consent decree requirements for MSD’s Lemay Service Area. The 13.7-km (8.5-mile) long, deep, hard rock tunnel will have a finished diameter of 9.1 m (30 ft). Beginning at the Lemay Wastewater Treatment Plant (WWTP), the alignment follows the channelized River Des Peres to the outfall of the existing Forest Park tubes, as indicated in Fig. 1.The project includes three construction shafts, 34 intakes and a deep, cavern-style pump station located adjacent to the WWTP. The tunnel will be driven from the Defense Mapping shaft to the Macklind shaft. Another shaft is located near the midpoint at the tunnel in River Des Peres Park.The Forest Park intake, located at the upstream end of the tunnel just beyond the Macklind shaft, is a large, tangential vortex intake structure. With a peak flow rate of 170 m3/s (6,000 cfs), it will have a 6.1-m (20-ft) diameter dropshaft to transfer flow into the tunnel.The project includes another three large tangential vortex-flow intake structures with peak flow rates ranging from 28 to 44.5 m3/s (990 to 1,570 cfs). These large intakes are located at points where three large sewers (formerly creeks) enter the River Des Peres. Dropshaft diameters for these intakes range from 3 to 3.7 m (10 to 12 ft) in diameter. The 30 remaining intakes are smaller tangential vortex-style, with dropshafts in the range of 0.8 to 1.7 m (30 to 66 in.) in diameter.Each intake structure drops flow into a deaeration chamber constructed adjacent to the tunnel at tunnel depth. Intake tunnels transfer flow from the deaeration chambers to the main tunnel. Most of the intake tunnels are short. However, two are long. The Glaise Creek tunnel will extend 762 m (2,500 ft) from the main tunnel to the Alaska Park intake, while the Rock Creek tunnel will extend 823 m (2,700 ft) from the main tunnel to the Rock Creek intake. The dewatering pump station, located at the downstream end of the tunnel, will be built inside a large, horseshoe-shaped cavern with two access shafts. Excavation of the cavern and its access shafts will be performed by the tunnel contractor. Build-out of the dewatering pump station will be performed under separate contract."

Jun 1, 2019

By S. J. Lefond

Most people, when Borates are mentioned, mentally visualize the famous twenty mule team (really eighteen mules and two horses), trudging across the Mojave Desert or "she burns green Rosie, we are rich." Actually, however, the first use of borax was prior to Babylonian times. Their emissaries had orders to bring borax Iron the Gobi desert for use as a flux by the Babylonian goldsmiths. The borate mineral imported for this is not known but probably was borax. The ancient Persians and Arabians knew about borax and the Arabic word "Baurach" appears in a two thousand year old manuscript. The Sanscrit word for borax was tincana which has been corrupted to tincal. The Chinese were using borax as a glaze in three-hundred B.C. Marco Polo brought the first borax, along with gunpowder and spaghetti, from Mongolia to Europe in the late 1300's. Borax from Tibet was imported to Europe for nearly 500 years. In 1772 boric acid (sassolite) was discovered around Tuscany, Italy as a precipitant from volcanic steam vents. Production of boric acid started there about 1815 and provided the sole competition to the borax from Tibet. Borate deposits in Turkey have been known and exploited on a small scale since the 13th century. It is only recently that the operations are being modernized and production increased. About 1836, borax minerals were found in Chile and Argentina with borax production starting in 1852 in Chile and in Argentina in 1886. During the latter half of the 19th Century, Chile was the principle world producer of borax.

Jan 1, 1980

By R. Owen

An overwhelming amount of data can be collected around the blasting process. This information can include blasting product, pattern design, blast results, and routing. It is only when these data sources are combined in a concise and accurate form that they are of real use in determining the safety and economic implications of each parameter. Two key technological aspects of blasting are drill fleet management (DFM) and size fraction analysis (SFA). As these technologies are integrated as near-real-time measurement and QA/QC tools, the resolution and realization of blasting parameters is significantly increased. The Freeport-McMoRan Morenci Mine has integrated these technologies along with other existing database structures to create a responsive and sustainable tool for reconciliation, forecasting and parameter matching. This ability allows Morenci to customize blast patterns to meet the criteria most critical to each shot, whether the impact is influenced by routing and recovery, equipment maintenance or safety concerns. DRILL FLEET MANAGEMENT The current DFM was stabilized in its current form in mid 2009 after database and hardware maintenance met stability requirements. Currently the system is running on 12 production drills. The system receives pattern layout and is capable of semi-autonomous drilling over the entire district. The fleet is capable of drilling in highly altered intrusive units and hard granites through the range of sedimentary and volcanic units that comprise the Morenci District. The system brings a level of accuracy not achievable with earlier paint-marked patterns. Depth control is also increased along with more consistent wear and maintenance patterns due to semi-autonomous drilling.

Jan 1, 2011