Search Documents

By Maryam Sadeghi, Jonathan Roy, Claude Bazin

"The operation of mineral processing equipments is intimately related to the mineral composition of the ore. However unit performances are usually characterized in terms of metal contents or recoveries as this data is easier to obtain than the mineral contents. This paper describes a method that combines the operations of material balancing and estimation of the mineral contents of the ore. The estimated mineral contents can be used for process analysis and diagnosis of operating problems.IntroductionThe ore that is feeding a concentrator is made of minerals that condition the energy requirements for the ore comminution and the performances of the subsequent separation circuit. Indeed a change in the mineral composition of the ore may lead to lower grinding mill throughput as well as lower recovery or grade of the economical products. Despite this relationship is recognized the mineral composition of the ore is seldom measured or estimated to provide regular information for the diagnosis of operating problems. Some methods such as the QEM-SCAN (Whiten, 2008; Lamberg and Vianna, 2006) are available to measure the concentration of the minerals in ore samples but the method is time demanding and plant operators usually base their evaluation of the plant performances on chemical assays of metals or elements since this data is easier to obtain from ore samples.Usually samples of the streams of mineral processing plants are collected on a daily basis to be assayed for strategic elements. The obtained concentrations are balanced to produce coherent data with the material conservation constraint and then used to characterize the day to day operation of the plant in terms of recovery of valuable metals and grades of the marketable concentrates. The behavior of contaminant elements can also be monitored from this data allowing the operators to explain for instance a lower zinc concentrate grade by a more important contamination of iron. However such diagnosis is only partial as the contaminant element can be transported by different minerals. Indeed the iron contamination of a zinc sulfide concentrate may be caused by an inadequate depression of pyrite or due to another iron carrying mineral. A possible way to answer the question is to determine the concentrations of the various minerals in the ore and produced sealable concentrates. Since measuring the mineral contents of the ore could be a demanding task one should consider to estimate this data from the daily chemical assays of the sample collected on the main streams of the circuit. Some authors have already investigated the problem. Whiten(2008) described a method to estimate the mineral contents of an ore sample. Lamberg and Vianna(2006) proposed a method to do a sequential mineral reconstruction followed by a material balance. Few of these methods account for the mass conservation of the reconstructed mineral contents."

Jan 1, 2016

By R. H. Lien

The Bureau of Mines has conducted research on a flue gas desulfurization (FGD) process as part of its goal of minimizing the undesirable environmental impacts associated with sulfur dioxide (S02)-bearing waste gases. This FGD process, referred to as the modified citrate process, involves absorption of S02 in a buffered citric acid solution. The absorbed S02 is subsequently stripped from the solution using steam, which regenerates the solution and produces a wet S02 product. This product can be further processed to make sulfuric acid or liquid S02. Economic evaluations showed the process to be expensive when the stripper was operated at or near ambient pressures because of the large amounts of steam required for solution regeneration. Research was directed at reducing steam consumption in the stripper. The effect of stripper pressure on steam consumption was investigated. A process research unit (PRU) was operated with the stripper pressurized in the range of 5 to 150 psig. Test results showed that steam consumption decreased with increased stripper pressure. For example, when operating the PRU stripper at 150 psig, 4.1 grams of steam per gram of S02 was required to remove 90 pct of the S02 from a 1.0-vol-pct-S02 gas. This compares to 7.1 grams of steam per gram of S02 required for 90-pct S02 recovery at 5 psig.

Jan 1, 1982

By William F. Hahn

This report describes an illumination system suitable for use in a slope under construction, Simulator work was performed using actual lighting hardware to verify adequate light levels to meet MSHA proposed regulation (as published in the Federal Register, January 13, 1977). The sequence of operating activities for two different slope driving sites are discussed and lighting requirements are defined for each,

Jan 1, 1981

By Patrick J. Hannigan

The pile foundation designer typically performs a subsurface exploration program and static pile capacity calculations before selecting a pile foundation type, length, and capacity. During construction, a pile installation criterion must be established to meet these design requirements. This installation criterion usually consists of a minimum penetration resistance or blow count to confirm pile capacity and may also include a minimum embedment requirement. This text will focus on use of wave equation analysis and dynamic measurements to meet design requirements. BEFORE THE WAVE EQUATION Since the mid-1800s, over 450 dynamic formulas for pile driving control have proliferated. In their simplest form, these formulas relate hammer energy to the work of soil resistance, or simply: W ? h = R ? s (1) Where W = ram weight h = ram drop height or stroke R = pile capacity s = pile penetration per blow

Jan 1, 1990

By J. C. Engel

Recent innovations in mine safety include the use of mercury vapor lamps for mine vehicle illumination. Such lamps, however, extinguish whenever the line voltage at the machine momentarily sags or is interrupted. The lamps must then cool for several minutes before they will restart. By supplying reduced high frequency power to the lamps from an auxiliary source, it is possible to maintain ionization in the arc tubes preventing the lamps from extinguishing. Essentially an auxiliary high frequency supply, the keep alive system provides additional power to the lamps automatically whenever the lamps are in danger of dropping out. The system can also provide the operator with the ability to dim the lamps at will for periods of up to three minutes by simply interrupting the 60 Hz power to the conventional ballasts. Each unit, housed in a steel explosion proof enclosure with a volume of approximately 0.6 ft3, is capable of servicing up to six 175 watt H-39 mercury lamps and two 100 watt H-75 reflector flood lamps. A total of 16 units were produced for the USBM under this contract and its extension.

Jan 1, 1979

By M. Zanotto

[ ] A period of heavy rains caused the river Adda to flood parts of the Valtellina, one of the Alpine valleys of Northern Italy. The exceptionally high waters put under considerable strain the whole system of embankments and levees controlling the river and protecting the adjacent towns and lands. In some places the water breached and washed away the embankments, submerging large tracts of cultivated land, buildings, roads and railway tracks. The town of Talamona, in the lower Valtellina, was hit particularly hard: in its proximity the river overrun and then washed away 300 m (1,000 ft) of embankment (see vicinity map, fig. 2), depositing large amounts of riverbed debris onto over 400 hectares (1,000 acres) of fertile land.

Jan 1, 1992

By E Ah Mu and C R Lilley, A D. Campbell

Cave propagation is a complex process due to interacting variables such as mine geometry, rock mass heterogeneity and complex structural networks and stress fields. The Ernest Henry sublevel cave (SLC) is directly below an open pit, which provided an opportunity to observe and measure rock mass failure as the cave initiated and propagated through the pit wall. This paper describes interaction between the open pit and SLC as well as rock mass failure mechanisms observed from the start of the SLC to surface breakthrough.Cave propagation and slope failure mechanisms were found to be governed by intermediate structures, while the cave shape was largely controlled by cave-scale faults. The open pit, production-level geometry and production draw strategy were also important factors for cave and subsidence growth. Cave propagation was episodic and asymmetric in shape due to the orientation and relative position of geological structures, combined with the effects of the increasing SLC geometry and drawdown from the underlying production levels. The precursors and failure mechanism of a 2.5 Mt wall collapse are also reviewed in detail.Cave growth was simulated using a 3D, non-linear, discontinuum finite element model coupled with Newtonian Cellular Automata. Model results are compared to field observations and monitoring data to determine the accuracy of forecasts and compared models versus actual rock mass response during cave propagation.CITATION:Campbell, A D, Ah Mu, E and Lilley, C R, 2016. Cave propagation and open pit interaction at the Ernest Henry Mine, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 311–318 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

Development of Process for Beneficiation of Low-Grade Iron Ore Samples from Orissa, India The paper deals with the results of characterisation and beneficiations studies undertaken on two low-grade Indian iron ore samples (IO-1 and IO-2) with a view to develop process for beneficiation of composite of the two samples to a high-grade concentrate, suitable for iron making through pelletisation. Indian iron ores contain relatively high iron but cost effective reduction of alumina within the specified limits has been a challenging task. Characterisation of the samples revealed the ore to be laminated and fine grained with hematite as the major mineral. Clay is the dominating gangue in most of the ore pieces followed by silica. Occasionally goethite and quartz/jasper were recorded. Clay occurs either as patches within the hematite mass or as cavity/fracture fillings. Liberation studies on the representative samples crushed to 2 mm indicated that around 95 per cent of the grains are liberated below 105 micron. Beneficiation of the two individual samples and their composite based on gravity and magnetic separation techniques resulted in products with varying yield and grade of the products. The effects of various process parameters were studied. Granulometry of the feed was observed to be important for improving quality of concentrate. The results of bench-scale studies were validated through pilot-scale continuous trials. Based on the studies undertaken a suitable process was developed for beneficiation of the composite sample, comprising 60 per cent IO-1 and 40 per cent IO-2, to a high-grade product assaying over 65 per cent Fe and material balance was computed. A commercial plant for beneficiation of low-grade iron ore to produce DRI pellet grade concentrate is proposed to be installed.

Sep 13, 2010

By Michael J. Beus

This Bureau of Mines report describes the development of load cells for measuring compressive loads in timber and lock-bolt support systems commonly used in. coal; metal, and nonmetal mines Design and evaluation is covered in detail to insure a reliable, accurate, and practical instrumentation scheme. The load cells are relatively inexpensive and adaptable to various size support systems. User-oriented procedures are emphasized, and design equations were reduced to a series of nomographs. Laboratory evaluation, destructive testing, environmental testing, and tests to determine the effect of extraneous loads were conducted. Field performance was evaluated in conjunction with ongoing Bureau projects at a metal mine in North Idaho and a coal mine in Utah. Load cells utilizing a titanium alloy as the cell body and weldable strain gages as the strain-sensing components satisfied the basic design and performance criteria, and with minor design modifications, the load cells can be adapted to many mining applications.

Jan 1, 1974

By Richard L. Sanford

This report summarizes the results of the development of a Directory of Computer Programs Applicable to U.S. Mining Practices and Problems. The Directory includes a sampling of computer usage in operating and manufacturing companies, consulting firms, computer companies, research organizations, universities, and various U.S. government agencies. References to computer applications throughout the mining industry are presented as well as comments on the availability of programs to interested organizations or individuals.

Jan 1, 1977

By J. Kunze, R. Degal

During the last 100 years, the submerged arc furnace has been one of the most amazing diversified melting units. These furnaces have found their application in more than 20 different main industrial areas such as iron, ferro alloy, chemical industry, lead, zinc, copper, refractory, titanium oxide, recycling, phosphorus etc. Such an evolution was only possible because of tremendous efforts in research and development and due to the large range of design solutions. The worldwide strong competition also forced the industry and plant suppliers to develop highly efficient, economically balanced units in optimized sizes and with long lifetimes, to adapt to the market conditions. Regarding the environment, the plants improved significantly in terms of water treatment plants and off-gas treatments as well as on site recycling units. This paper will give a short overview regarding the history of the furnace and the latest developments in today?s main application fields: ferro alloys, non-ferrous, special application and recycling. In addition new activities in research and developments are briefly discussed.

Jan 1, 2004

By M. K. Roberts

The approximately 2800 Ma old Ventersdorp Contact Reef is a unique Witwatersrand orebody, from which about 6% of the world?s gold production is derived. A major portion of this production is mined at depths exceeding 2500 m and deepest levels of mining are at about 3600 m. The orebody?s hangingwall consists of volcanic rocks. This differs from the older Witwatersrand orebodies, which have quartzitic hangingwalls. The thickness of the Ventersdorp Contact Reef is generally about 1.20 m, but is highly variable, at an average dip of about 18°. A pronounced unconformity beneath this orebody is also expressed by varying footwall rock type characteristics and frequent rolling of the reef plane. These rolls follow topographic variations of the palaeo-surface. More geological than rock mechanics studies were performed on the Ventersdorp Contact Reef prior to 1992. Recently, however, a multidisciplinary team comprising various rock engineering and geological disciplines has delineated geotechnical areas by a novel technique. Geotechnical areas are defined by distinct footwall/hangingwall rock assemblages. The presence of three footwall and two hangingwall rock types results in the definition of six geotechnical areas across a distance exceeding 60 km, including about 10 gold mines. Distinct rock mass behaviour has been documented in three of the six geotechnically defined areas. Different rock mass behaviour is expressed by features such as mining-induced fracturing, closure rates, fall of ground characteristics and seismic character. Some geological features override the rock mass behaviour as defined for the individual geotechnical areas. These are undulations of the orebody or the frequency, characteristics and attitude of major discontinuities. It is concluded that the concept of geotechnically subdividing orebodies is not only important for facies delineation and the associated grade, but also needs to be considered for safety aspects, in determining factors such as the appropriate support to be employed.

Jan 1, 1999

By Thomas P. Mucho, Dennis Dolinar, Christopher Mark

Horizontal stresses are caused by global plate tectonic forces. During 1995 alone, they were largely responsible for closing two U.S. longwall mines. This paper presents six case histories from Pennsylvania. West Virginia, Kentucky and Alabama. In each case history, a mine encountered roof falls or difficult ground conditions in the headgate, caused by horizontal stress concentrations. The problems are detailed and the control measures adopted are described. In most cases, nearby longwall panels without stress concentrations were trouble-free. The paper also discusses detailed measurements made at two adjacent Pennsylvania longwalls. One headgate was oriented to avoid a horizontal stress concentration, and the other was not. Eliminating the stress concentration dramatically reduced roof support loads and roof deformation. The paper concludes that proper panel orientation and sequence is the key to maintaining headgate ground control. The optimum orientation is not parallel with the maximum horizontal stress, as previously thought but rather 200 in the stress shadow of the gob. Other stress control techniques, including artificial support, are briefly discussed.

Feb 24, 1997

By Graham Davis

The future of the world's minerals industries is often painted as bleak. Peter Drucker has repeatedly proposed that the demand for minerals has become "uncoupled" from world economic growth.' This implies that, while mineral demand was in the past linked to the growing demand for and consumption of goods and services, further world development will not require substantial mineral inputs. Lester Thurow noted that for these reasons the US minerals industry is diminishing in scale and economic importance.2 There is some documented evidence of such uncoupling, and the demand for minerals may indeed diminish in the future. But such announcements are, to this point, no more than speculation. For instance, is it not just as likely that renewed environmental concerns will cause increased demand for the relatively innocuous environmental properties of metals, replacing plastics? And even if the prophesied demand decreases do occur, a sufficient fall in metal prices due to technological advances could increase the quantity of minerals demanded above current levels, in spite of leftward shifting demand curves. Thus, worldwide mineral production activity may increase or decrease in the future and no one can say whether more or fewer of the earth's citizens will become involved in the extraction and processing of minerals.

Jan 1, 1994

By H. K. Lin

Deepwater discharges of sulfide flotation tailings have been practiced for several decades. Oxygen penetration and organic matter content in such environments are the two major factors that determine their reduction-oxidation condition and hence the rate of sulfide mineral dissolution under such discharge environments. In this study, the effects of solution redox potential and pH on the dissolution of some heavy metals from sulfide flotation tailings were examined. Zn, Pb and Cu concentrations in solution were all higher at a higher redox potential and lower pH. Dissolved Zn concentrations reached 100 ppm even at a low redox potential of 105 mV and near neutral pH after 33 days. Pb concentrations were below 2 ppm at 105 mV and near neutral pH after 165 days. At 105 mV, the Cu concentrations were below 0.2 ppm at near neutral pH after 165 days. At pH 2.3, the Fe concentrations were higher at 420 mV than at 105 mV. But at pH 6.8, the Fe concentrations were lower at 420 mV than at 105 mV, due to the oxidation of Fe2+ to Fe3+ and the subsequent precipitation of ferric hydroxide. Arsenic concentrations in solution were all less than 0.002 ppm. For Zn, Cu and Fe, no significant differences were observed between the tests in solutions prepared using seawater and those using distilled water. However, Pb concentrations reached higher levels in solutions prepared using seawater.

Jan 1, 2009

By M. G. Irish, E. E. Vidal, M. J. Jahraus, P. R. Taylor

An experimental system has been designed to monitor on-line variations of leaching parameters in a closed circuit of cyanide leaching solutions and gold bearing ores. Experiments performed to deter-mine variations in some important leaching parameters of the solution: pH, dissolved oxygen, free cyanide, oxidation/reduction potential, gold content, temperature, pressure and solution chemistry. By comparing results obtained when the leaching solution is allowed to become acid or kept basic, it was possible to infer the chemical reactions that occurred between the solution and the ores.

Jan 1, 2004

The principal activities of the Bureau of Mines Explosives Research Center from July 1, 1962, to June 30, 1963, are described briefly in part 1. Part 2 gives short abstracts of publications that appeared during fiscal year 1963; in general, the research reported in these publications antedates the report period.

Jan 1, 1965

By Edmund S. Leaver, R. S. Dean, T. L. Joseph

The metallurgy of manganese has developed along the lines of iron metal¬ lurgy. Enough high-grade ore has Been available so that by reduction with carbon it could be turned into an iron-ma.nga.nese alloy and a slag containing some 9 to 15 percent manganese. More siliceous ores have been smelted in the blast furnace to form iron-silicon-manganese alloys called spiegel. When lower-grade ores came in for serious consideration, which lias only been since l°l4, two types of processes received the most consideration — hydrometallurgical processes to produce a concentrate which could be smelted like the higher-grade ore and processes involving concentration of the manga¬ nese from manganiferous iron ores by preferential reduction of the iron (184)1. Special chapters in this bulletin are devoted to the production of ferro¬ manganese from ore, the hydrometallurgy cf manganese, and the Bureau of Mines modification of the preferential reduction process. Other methods of producing manganese alloys from low-grade or refractory ores have been suggested and may find future application. Manganese has a very high affinity for sulphur and is particularly adaptable to concentration by matte smelting. According to Betts (26), manganese silicate may be smelted with pyrite to give manganese sulphide and iron silicate. This method would be applicable to concentration of either the silicate or carbonate ores. The sulphide, once obtained, could be roasted to oxide and reduced in the usual way. Another possibility for the production of manganese from silicate ores involves their reduction by silicon or manganese silicides. Swedish Patent 52290, February 25, 1925. covers the reduction of a slag rich in manganese by silicon-manganese alloy containing more than 10 percent silicon, Joseph H. Brennan (38.) describes the concentration of manganese iron ores by partial reduction with silicon. Beckett (7,4,19) describes the reduction of manganese dioxide with a manganese silicide for the production of standard ferromanganese. Beckett gives as a typical alloy, manganese 64.4, silicon 24.6, and as a typi¬ cal ore, 5S.5O manganese as MnO^. The product of the reaction between these two is 80.11 percent manganese and 1.22 percent silicon.

May 1, 1934

By D. K. Steele

An 18-in-diam column water elutriator was designed, tested, and operated by the Bureau of Mines for recovering nonferrous mixed metals from automobile shredder rejects. The waver elutriator separated metals from nonmetals contained in shredded nonmagnetic rejects. The unit was constructed and integrated into a local automobile shredding operation. Nonmagnetic rejects from the automobile shredder were fed onto the surface of a column of rising water. Dense materials fell through the rising water and were collected as a sink product at the bottom of the column; medium-density materials were removed as an intermediate product in a water flow through a discharge port located between the overflow and sink; and light materials were immediately carried out in the overflowing water at the top of the column as a float product. Nearly 99 pct of the mixed metals were recovered from the nonmagnetic rejects as a 70-pct-metal concentrate. Other operating conditions yielded a 93.7-pct-pure-metal product resulting in a 93.1-pct metal recovery. Float rejects are combustibles, light plastics, foam rubber, and minimal amounts of coated and uncoated copper wire. The middling discharge contained mainly medium-density rubber, plastics, glass, rock, coated and uncoated copper wire, and frequently some thin-sheet stainless steel and wrought aluminum. Maximum metal recovery in the operating program was achieved using a water velocity of 52 fpm (650 gpm). Maximum purity was obtained with a velocity of 88 fpm (1,100 gpm). .Water was recycled through a 12,000-gal baffled clarifying tank. Entrainment water losses with the float and middling rejects averaged 50 gpt of reject feed. Records maintained by the shredder operator show a 34-pct increase in nonmagnetic metals recovery during a 1-yr operation of the water elutriator as compared to recoveries from a previously used air classification system.

Jan 1, 1983

By K. E. Brown, J. P. Brill, A. R. Hagedorn, T. C. Doerr

A recent correlation for multiphase vertical flow by Hagedorn and Brown1,7 has been used to examine the effect of numerous variables such as pipe size, gas-liquid ratio, liquid flow rate, liquid viscosity, liquid surface tension, oil API gravity, water cut, etc., on flowing pressure gradients. Most previous correlations were derived by using a form of the general energy equation which assumed negligible changes in kinetic energy. Under certain flow conditions this can lead to serious errors in predicting pressure traverses. Examples of traverses calculated both with and without the kinetic energy term are included here. The Chew and Connully correlation for calculating changes in viscosity with changing pressure and temperature has been extended so that the effect of a changing viscosity with depth on pressure gradients can also be predicted. Examples illustrating the effect of tubing size show the importance of this correlation in determining pipe sizes for initial well completions. Limitations on production rates in small pipe sizes from excessive friction losses can be predicted with greater accuracy. The combined use of a vertical-flow correlation with a horizontal-flow correlation provides a method for determining the maximum flow rate possible from both flowing and gas-lift wells. Examples are included to illustrate application of the combined use of vertical and horizontal-flow correlations in optimizing production rates and minimizing excessive costs from over injection of gas in gas-lift wells. INTRODUCTION The problems of multiphase vertical and horizontal flow are immediately encountered in any producing well. Fig. 1' shows three stages of production: flow in porous medium, vertical flow and horizontal flow. All three stages affect the production rate from a well. If we are confronted with a particular well and consider only the variables involved in the vertical and horizontal stages of Fig. 1, we should be capable of calculating the flowing bottom-hole pressure necessary to produce a particular flow rate. A change in any of the variables results in a new solution to the problem. Recent approaches in developing horizontal and vertical-flow correlations have improved to the extent that the solution can now be obtained with more confidence than previously. VERTICAL AND HORIZONTAL FLOW CORRELATIONS Since Poettmann and Carpenter's' original work in multiphase vertical flow, there have been many additional vertical-flow correlations developed which have greatly improved the accuracy of pressure-loss calculations. These

Jan 1, 1967