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By D. E. Traut

A fluidized countercurrent ion-exchange system was developed, operated, and evaluated by the Bureau of Mines. The system consisted of integrated multiple-compartment absorption and elution columns in which the solution flows are continuous except for short periods when resin increments are withdrawn. The exchange of uranyl sulfate between a simulated acid leach uranium solution and a strong-base, ion-exchange resin together with the subsequent elution with an acidified sodium chloride solution was studied. The effects of the number of sections, section heights, amount of resin withdrawal, and solution flow rates were investigated. Also examined were the kinetic and equilibrium relationships for the absorption step. The experimental data indicate a strong interdependence between variables. Solution retention time appears to be a major limiting variable. The column was efficient over a range of conditions, but close control was needed for optimum operation.

Jan 1, 1975

By R. R. Givler

Since the 1860's the good ole days, oil has been nozzle fed to burners under pressure atomizing the oil into droplets -- 1960's has produced vaporized oil that burns oil with the flame color and consistancy of gas -- If you can tell the difference by looking at the flame, gas or oil I?ll buy the lunch. First, we must ask, "Why all the excitement about Blue Flame?" This question is best answered by you after you have studied the principle of operation and see the result. I will attempt to explain both of these so that you can draw your own conclusions.

Jan 1, 1975

By B. Salopek

The greatest part of crushed stone, gravel and sand production is extracted through open pit operations, whereas gravel and sand are also partially extracted from riverbeds. Its obvious that such a mining activity provokes some changes in the configuration and environmental characteristics of the region, in the temporary or permament disapperance of vegetable or animal species and in the creation of noise, dust and waste water. However, the above-mentioned mining operations shouldn not have only negative effects on the landscape and land potential, but they can discover and predetermine the potential of the exploited areas for various communal purposes after exploitation (eg. sports and recreation centers, campsites, resorts, fish-farms, etc.). In this paper, the production of construction aggregates in plants located in the vicinity of Zagreb, the capital of Croatia is presented. The advantages and disadvantages of aggregates? production in urban areas in the spirit of sustainable development are discussed.

Jan 1, 2003

By John K. Hammes

This paper has been written as one of a group of papers dealing with the subject "Cost Elements in Mining". What are cost elements in mining? The mine operator thinks of direct mining costs in terms of labor, materials, supplies and power, and we might define cost more generally as the price paid to acquire or produce something. Economic theory also has its concepts of cost. From one point of view, that of the consumer, the cost of mineral commodities might be viewed as the total price industry pays for mine output. Similarly, the mining company engaged in the on-going business of finding, developing and operating new mines is concerned very much today with the distribution of all the revenue paid for mine output and not just with its direct or controllable cash costs. In other words, what will the labor force, the supplier of energy, explosives, and reagents, and the supplier of government services, management, capital and the ore reserves receive for their contribution to production.

Jan 1, 1974

By J. R. Knudson

A major contribution to the art of blasting was made at the Cleveland- Cliffs Iron Company?s Hawkins Mine in Cashwauk, Minnesota during April of 1956. It was here that the first experiments with fertilizer grade ammonium nitrate were conducted-experiments which led to the development of the ammonium nitrate and fuel oil method of blasting which has been eagerly adopted by open pit and quarry operators throughout the United States. While this new blasting agent was a more or less natural outgrowth of the Akremite Process devised by Maumee Colleries of Terre Haute, Indiana; no one, to our knowledge, had used this particular combination of ingredients prior to this time. Certainly this was a "break-through" as far as the Lake Superior District was concerned. Akremite consists of a mechanical mixture of grained ammonium nitrate and a solid carbonaceous material packed in a plastic bag. At the time of its introduction to the Mesaba Range, Akremite sold for 10.5 cents a pound as compared to the 18 cent powder previously used in both wet and dry large hole blasting. The discovery of this agent was indeed a remarkable achievement, one that afforded a substantial reduction in blasting costs. However, Akremite proved to be only an intermediate step in the evolution of our present low cost explosives. Cleveland-Cliffs utilized prilled ammonium nitrate and fuel oil and then eliminated the mixing and packaging plant entirely by combining the two raw materials in the field at the drill hole collar or in the hole itself. Thus we have approached the ultimate in simplicity, for the blaster and his helper now manufacture their own explosives not only as they are needed but where they are needed, and at a cost of under 4 cents a pound. This two-man crew may charge and explode as much as 8 tons of ammonium nitrate in an eight-hour shift and in so doing break some 65,000 tons of ore.

Jan 1, 1959

By John F. Slonaker

This report is a review of current research being conducted in the United States which is intended to increase the utilization of coal ash. In order that this report be as timely as possible, the majority of information was obtained by direct comunication with the people listed in the references. Due to the magnitude of the flyash research program, some projects may be inadvertently omitted. Field research on flyash for use as an agricultural fertilizer is being monitored at Virginia Polytechnic Institute and State University.1 This research is directed at determining the plant nutrients that are available in flyash as well as the quantities of flyash that can be applied to agricultural soil without adversely affecting plant growth, Coal mine spoil and refuse bank reclamation with power plant flyash is being demonstrated by United States Bureau of Mines, Morgantown, West Virginia.2 Numerous highly visible coal refuse piles and strip mine spoil banks contribute to air, water, and land environmental problems. Revegetation of several experimental sites with flyash from bituminous coal-fired power plants was undertaken in West Virginia and Pennsylvania. Conventional farm equipment was used at some of the sites while large earthmovers were required at others. The flyash served as a neutralizing agent, dilutent, and soil amendment to provide some nutrients which enhanced vegetation of the barren areas, Estimated cost of reclamation by this method is $300.00 per acre of previously leveled area. This figure can vary considerably depending upon the topography of the site, haul distance, quality of the soil and quality of flyash.

Jan 1, 1974

By Immo H. Redeker

Tile Asheville Minerals Research Laboratory is a member of the Engineering Research Department of North Carolina State University. The Laboratory is engaged mainly in applied nonmetallic mineral processing research to assist the North Carolina mining industry. A few out of state projects are handled at times. The Laboratory helped to bring the flotation process to North Carolina feldspar, spodumene, mica and phosphate producers and maintains versatile batch and pilot plant facilities at Asheville. It is of interest that North Carolina has now one of the newest and largest flotation plants at Lee Creek where Texas Gulf Sulphur Company produces 10,000 tons of phosphate concentrate per day, and one of the smallest flotation plants at Pittsburgh Plate Glass Company's fiberglass plant in Shelby, North Carolina where $50,000 per year of platinum-rhodium metal is reclaimed from wasted fiberglass furnace refractories in a tiny flotation operation of pilot plant size. The conservation of mineral resources through improved processing methods has been the object of most of the Laboratory's projects. This work has been extremely interesting and rewarding in many instances. Or, the example of projects for Kings Mountain Mica Company it will be demonstrated how waste could be reduced step by step from 20 tons of waste per ton of product to LO tons of product per ton of waste by improved processing methods. Brick, high grade potash feldspar, and silica sand are now produced from formerly wasted materials. AL this time Laboratory work sponsored by three feldspar companies, the State of North Carolina, and the U. S. Bureau of Mines, is aimed at reducing the amounts of feldspar tailings in the Spruce Pine area. Mineral dressing techniques are applied to reclaim saleable mineral products such as feldspar, mica quartz, and to make more uniform material for possible ceramic and other applications. Processes to produce new products such as sand-lime brick, and lightweight foamed autoclaved calcium silicate building products will be tested.

Jan 1, 1969

By I. H. Warren, F. A. Forward, D. E. Pickett, Ernest Peters, Alvin H. Ross, I. M. Masters, N. P. Finkelstein, R. Derry, A. W. Fletcher

In this section the chemical, physical, and mechanical principles of hydrometallurgical processes are developed and reviewed. Plant practice is not discussed other than to note the metals which are processed using the various systems that are available. These notations will permit the reader to refer to the appropriate section in Part II of the Handbook for specific details on a particular metal or mineral. The equipment used to accomplish the desired unit operation is de¬scribed. Comparative data are presented to illustrate performance characteristics of unit operations, process, and equipment. The economic efficiency of individual processes is outlined. Some of the chapters contain material that is covered in detail in other sections of the Handbook Such chapters are developed only sufficiently to indicate the specific application of the techniques to hydrometallurgical processes. In this section considerable cross-referencing to the other related sections has been done.

Jan 1, 1985

By Frank C. Schora

The Institute of Gas Technology for many years has dedicated a large portion of its research effort to the development of a practical solid-fuel-based gasification process to produce a synthetic natural gas equivalent. The work is being done to prepare for the day when supplemental gas will be needed. This program, initially supported by the American Gas Association, and now by both the Department of Interior's Office of Coal Research and the American Gas Association, has developed the IGT Hydrogasification Process. This process, now entering the pilot plant stage, is based on the high-temperature, high- pressure hydrogenation of coal with a hydrogen-steam bearing gas. Product gas from this step is cleaned and catalytically methanated to produce a high-Btu gas. Estimated production costs indicate the process will be competitive with natural gas in certain areas of the country when required.

Jan 1, 1969

By Daniel C. McLean

Chemistry plays a more important role in milling operations than is generally recognized, particularly in fluid- solid separation processes. Chemical aspects are also very important insofar as plant water quality is concerned, and in the manner in which this water quality effects plant design and operation. Aside from the inherent chemical characteristics of plant water, the mineral preparation industry is becoming increasingly more dependent on the use of mining chemical reagents--relatively new to the coal industry, but items of I standard usage in complex metal recovery plants. These chemicals have many useful properties and can produce significant improvements in operations and metallurgical efficiencies when used properly and intelligently. They can produce poor results and sometimes severe losses when used improperly. Most reagents are relatively expensive on a per pound basis, hence costs can be excessive if they are used wastefully or inefficiently.

Jan 1, 1968

The Bagdad mill, built in 1977, was de-signed for a mill capacity of 36,300 tpd. An ABC (Autogenous Mill-Ball Mill-Crusher) grinding circuit was chosen. The original mill contained three completely independent grinding circuits, each containing one 9.75 m diameter by 3.96 m long fixed speed autogenous mill, one 4.72 m diameter by 6.71 m long ball mill and one 2.13 m diameter short-head cone crusher. Total installed power per grinding circuit was 8,464 kw with 5,966 kw in the autogenous mill, 2,237 kw in the ball mill and 261 kw in the crusher. (See FIGURE I--Major Equipment Flow Diagram.) The autogenous mills were designed to be able to operate semi-autogenously but were never converted to SAG. As a result of this design, only about 4,100 kw of the designed power is utilized in the autogenous mills. The grinding circuits are closed with 2.44 m by 6.10 m double deck vibrating screens. Screen oversize is returned, by a series of conveyors, underneath the mill coarse ore stockpile to feed the crushers. Variable speed belts feed the crushers and control power draw. Crusher product reports directly to the tail end of the autogenous mill feed belt. (See FIGURE 2--Typical Crusher Feed and Product Size Distributions.) Tramp iron in the autogenous mill-crusher circuit is handled in a unique way. A magnetic sensor detects the metal. This closes a gate which directs the crusher feed onto a separate belt which bypasses the crusher and returns the material to the autogenous mill feed belt.

Jan 1, 1992

By Richard W. Patton

With the advent of the Clean Air Act and the installation of flue gas desulfurization (FGD) equipment (scrubbers) on coal fired power plants, the management of solid wastes has taken on added importance. Aside from the large amounts of fly ash and bottom ash usually generated, large quantities of liquids in the form of scrubber sludge are also produced. These wastes must be disposed of within the constraints of land and water quality regulations. This paper describes the practices adopted by the electric utility industry in denting with this problem, including methods of generation and treatment, quantities and characteristics of the materials, and transportation and disposal practices. The paper also briefly describes final product characteristics and several applications for commercial utilization and land reclamation.

Jan 1, 1983

By Karl S. Vorres

Coal my not seem like it, but it is a perishable commodity. The basic coal scientist cannot always replicate earlier experiments with a given sample because of changes that have taken place in the sample. This has led to a stated need for stable samples Coal looks like a uniform black solid to many people, but it does vary in its composition from state to state and mine to mine it also can be shown to vary significantly within a mine or seam. These variations have led to a stated need for consistent samples.

Jan 1, 1985

By U. S. Sawant

During the last few years, Process Machinery Division, Rexnord, has conducted extensive research on the effects of cone crusher variables such as speed, throw and cavity design on the productivity of the crushers. Simultaneously, Rexnord's engineers have developed advanced design and testing techniques and criteria that assure efficient and reliable crusher designs. The combination of these two has resulted in a design of the 2390 Omnicone (1000 hp) crusher which fits on an existing 7 ft. Symons foundation and yet is capable of producing twice the tonnage compared to our 7 ft. super heavy duty (500 hp) crusher. Both speed and throw can be varied to give a wide application flexibility from making twice the tonnage to the finest product. The 2390 Omnicone also incorporates innovative features such as full balance, cavity clearing, adjusting under load with automation capability, maintenance-free seals, one head for all cavities, ease of maintenance and servicing, etc.

Jan 1, 1987

By L. Michael Kaas

In recent years a number of data processing and analytical techniques have proven to be useful to engineers and geologists in various segments of the mineral industries. Petroleum companies were among the first to utilize the computer to store well data files and to analyze that data for exploration purposes. A few years later, metal mining companies began to apply the same basic computer methods to problems in mineral exploration, ore reserve evaluation, and open pit mine planning. Because of the increasing complexity of planning for coal mines and land reclamation, a case study was undertaken to evaluate the usefulness of computer techniques to assist mining engineers and geologists in mapping coal deposits, evaluating coal reserves, strip mine planning and land management. The data used in the study was provided by the Illinois State Geologic Survey. This paper describes some of the results of that study. First, considerations for the development of a computer data base for coal deposits are presented. Next, a series of analytical techniques for processing the data is described. Finally, the case study is presented to illustrate how the coal data base and the analytical techniques could be used in actual practice.

Jan 1, 1973

By William N. Poundstone

Since World War II, when off-track mining became popular, mining machinery has undergone much change. However, the change has been basically to make the machines more powerful, more productive and more reliable. Little change has been made, in this period, in the basic mining system. While steady improvement was made in productivity until the passage of the new Federal Coal Mine Health & Safety Act, I believe that the cost Co benefit ratio of further improvement from this basic approach of improving the existing extractive tool is not as promising as I believe may be obtained from a new approach. Consequently, six years ago Conoco and Consol undertook a comprehensive long-range R&D program to see if improvements of a more basic nature could be made in underground mining. We concluded early in our program that while many things currently limit the rate of production such as the rate at which roof can be supported, time needed to advance ventilation systems, time required to clean up and rock dust, time required to maintain and service equipment as well as time lost due to haulage deficiencies, that the key to improvement was a truly flexible continuous high capacity haulage. With face equipment in use today, mining rates can be increased with such a haulage system where the ability to support the roof exceeds the ability of conventional haulage equipment to remove the coal. More importantly, if we could develop such a system, it would set the stage for development of far more sophisticated methods of mining at the face than exist today, and as new and more dependable mining machines and methods are developed, continuous transportation will enable the gains envisaged in production to be realized.

Jan 1, 1974

By J. B. Mitchell

Comminution methods for base metal and precious metal ores have had considerable attention from mine operators, equipment suppliers and design engineers for many years and much of their work has been well reported. This interest derives from a healthy concern with the costs of comminution, often the largest single cost factor in ore dressing of hard ores. Many imaginative innovations have resulted. One notices a trend toward autogenous and semi-autogenous methods, combined with a trend toward very large equipment. Unfortunately, there has been less obvious cost incentive to experiment with softer ores. This is unfortunate because the consequences of inappropriate comminution methods can have an important effect on overall economics by influencing down stream processing and salability of final products. This paper concerns some of the factors to be considered in the selection of comminution methods for potash ores, and gives some specific examples to illustrate some of the principles involved.

Jan 1, 1969

By Robert A. Westin

Polychlorinated biphenyls (PCBs) are a group of chlorinated chemicals that were used in many different fire resistant hydraulic fluids, heat transfer fluids, and in electrical equipment as dielectric liquids. PCBs were manufactured primarily by Monsanto Chemical Company under the tradename Aroclor, and were used by many different electrical equipment manufacturers. PCBs are noted chiefly for their extreme chemical inertness. This resulted in exceptional fire resistance and long life in applications involving exposure to high temperatures and intense electrical fields. This combination of properties resulted in PCBs being widely used in electrical equipment used in mines, including transformers, capacitors, and some electric motors. PCBs were also used as working fluids in some heat transfer and hydraulic sys terns. The same chemical resistance that gave PCBs long life in industrial applications give PCBs essantially eternal life when they are released into the environment. PCBs are not highly toxic in the sense that exposure does not cause immediate health problems. However, PCBs accumulate in the human body and neither degrade nor are eliminated from the body, and long-term exposure to PCBs can result in changes in liver function which may increase susceptibility to the carcinogenic effects of other chemicals. PCBs also accumulate in the food chain; the concentration of PCBs in fresh water fish may be several hundred thousand times as high as in the water the fish are taken from.

Jan 1, 1981

By A. M. Gaudin

In a recent paper we have reviewed principles and applications of measurement methods for contact angles and their hysteresis (22). In this paper we apply these methods to a system consisting of rutile, an organic liquid (benzene, decane, or dodecane) and water. Surfactant (dodecylamine hydrochloride) was used at various concentrations and various pH values.

Jan 1, 1964

By James P. Bowersox

Modem mineral processing plants handle large amounts of ore and produce large tailing streams. Plant performance can be optimized when the water is quickly recovered with a thickener. The caisson thickener was developed to overcome process and mechanical problems with the conventional traction and center column units. The caisson is a hollow center column that serves as a pump house. The rake arm structure is supported by a hydrostatic bearing which sits on top of the caisson. The caisson thickener with a hydrostatic bearing has operated for many years in several mineral processing applications.

Jan 1, 1981