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By A. J. Neale

Much has been published lately about the application of advanced control strategies in the automatic control of autogenous and semi-autogenous grinding circuits. The application of adaptive control algorithms, self-tuning controllers, state estimation, and expert systems has been well documented. While these approaches can be very effective; experience has shown that quite often simply "fixing the fundamentals" can have a significant positive impact on overall grinding circuit performance. This paper will highlight the results of process optimization and process control work by the authors at a variety of autogenous and semi-autogenous installations. A review of one approach for quantifying the mill load/bearing pressure/power relationship is provided. Accurate monitoring of key mill process variables is a necessary prerequisite for both effective process analysis and process control. This paper discusses some of the concerns related to defining steady state operating conditions and the issues related to signal conditioning. The paper concludes with a discussion of an effective application of algorithmic constraint control which incorporates many of these considerations.

Jan 1, 1994

By K. T. Valsaraj, L. J. Thibodeaux

Solvent sublation, the separation process for the removal of two hydrophobic compounds (penta- and trichlorophenols) from the aqueous phase, is discussed, as is a steady-state mathematical model for fire process. Solvent Sublation "'as conducted in a continuous countercurrent mode. The underlying mechanisms, theory and experimental details on the effects of process variables on removal efficiency are reported.

Jan 1, 1994

By Frank R. Cappuccitti

This paper will deal with current market trends for sulfide mineral collectors in three distinct parts; the global market for sulfide collectors, collectors as tools to solve mineral processing problems and new collector Research in the 1990's. The global market and manufacturing of sulfide collectors will be detailed as well as the trend towards using increasing amounts of specialty products. The use of Total Quality Concepts for laboratory and plant evaluations of new products will also be discussed. Research in the 1990's for sulfide collectors will need to focus not on the development of new chemical species but on the application of the new technologies that have already been developed.

Jan 1, 1994

By A. M. Whiting

Competition for coal producers and their primary customers has constantly increased during recent years. The effects of the Clean Air Act Amendments of 1990 on the electric utility industry, coupled with the normal complexities of coal production, quality control, transportation and contracting techniques have spurred both buyers and sellers to increase their level of sophistication. This paper will review the basic aspects of the U.S. coal business and explore the commercial approaches which have proven to be most successful.

Jan 1, 1994

By F. Calizaya

This paper explains and discusses a computer program developed to determine the ventilation design parameters for complex auxiliary ventilation systems such as those found in the construction of long excavations with multiple headings. The program is based on the principle of partitioning the system into segments of finite length, and formulating and solving the resulting networks recursively. The application of the program is illustrated by the detailed solution of an auxiliary ventilation system proposed for the Exploratory Studies Facility (ESF) at the Yucca Mountain project, Nevada.

Jan 1, 1994

By G. S. Austin

New Mexico produced 83% of domestic potash and 27% of domestic consumption in 1992. The potash industry of New Mexico produces sylvite (KCI), langbeinite (K2SO4-2Mg(SO4)2), and artificial K2SO4. Average sylvite grade in New Mexico today is about 14%. The average grade of langbeinite is 8-10% Kp. Commercial potash occurs in the middle or McNutt Member of the Salado Formation (Upper Permian Ochoan Series). The 120-m-thick McNutt Member dips about 1° east and contains 11 of 12 potential ore zones in the Salado. The mineralogy and proportion of clay minerals, up to 7% of the ore, influence optimum milling procedures and ore grade cutoff.

Jan 1, 1994

By Richard M. Chamberlin

Perlite is an altered rhyolitic glass with 2 to 5 wt % water that expands or "pops" when heated quickly to plasticity while evolving steam to form lightweight, glass foam. Commercial perlite deposits in New Mexico are well-developed zones of chemical weathering (hydration) superimposed on highly permeable and thick glassy zones at the chilled upper surface and toes of high-silica-rhyolite lava flows and lava domes. The maximum tonnage of glass in these volcanoes was predetermined by their unique eruptive histories. New Mexico perlite production (80% of US production of 571,00 st) is mostly from the 3.9 Ma high-silica-rhyolite lava flows at the No Agua Peaks volcanic center. The primary vent at No Agua is defined by a 900 ft-high rubidium-rich composite lava dome, known as West Peak, that contains minor perlite reserves. Slightly less rubidium-rich lava squeezed out from under the west flank of the dome to form relatively thin (250 ft) but highly vesicular lobate flows that now consist of about 50 % recoverable perlite. Finally, rubidium-poor lavas were extruded from a radial dike on the northeast flank of the dome. These thicker (400 ft) flow lobes contain about 20 % recoverable perlite. The largest mass of lava does not always contain the most perlite. The thinner (west) flow at No Agua yields the largest perlite reserves rather than the large composite lava dome or thicker (east) flow.

Jan 1, 1994

By G. K. Hoffman

Humate, defined as weathered coal or mud-stone rich in humic acid (HA) and fulvic acid (FA) have been mined, primarily as soil amendments or drilling mud additives, in New Mexico for 15-20 years. The New Mexico humate resource is estimated to be 11 Gt, including weathered coal and organic mudstone. The HA and FA content determines the end-use, therefore a simple and consistent method of measuring organic-acid content was developed. The New Mexico Bureau of Mines and Mineral Resources method is based on repeated alkali leaching and acid precipitation. Precipitates of humate are ashed, with mass balance of solids maintained, to correct for material added during alkali-acid treatment. Analyses of upper coal member, Cleary Coal Member (Menefee Formation) and Fruitland Formation samples from the southeast San Juan Basin show ashing to be important in accurate analysis of FA content. Ash in the total FA fraction averages 70% compared to 2% in HA. The FA in weathered coal and organic mudstone are similar, although HA is significantly higher in the former. As weathering progresses, the FA content of weathered coal increases faster than in organic mudstone because of the greater total organic material in coal.

Jan 1, 1994

By J. R. Koehler

Mining practices at the Sunnyside Mines, Sunnyside Coal Company, Sunnyside, UT, have been documented by U.S. Bureau of Mines researchers to preserve the extensive history of yield pillar-based longwall gateroad system evolution on the property. An overview of the historical mining conditions, practices, and innovations that resulted in the evolution of the two-entry yield pillar gateroad system currently employed at Sunnyside was developed from interviews of 30 long-time Sunnyside employees. Employing yielding chain pillars at Sunnyside virtually eliminates tailgate pillar bumps and contributes to reducing face bumps. Limiting the overall width of the gateroad system benefits bump control and especially, roof and floor stability.

Jan 1, 1994

By M. Yekeler

The critical surface tension of wetting values (Ye) of realgar (AsS), talc [Mg3si401o (OH) 2]' stibnite (Sb2S3), and sulfur (S) were determined by flotation in the absence of conventional flotation collectors as 38.7, 38.0, 35.5, and 30.0 dyne/cm, respectively. The surface tensions of flotation media were arranged by methanol. Separation of binary mixtures of these minerals was performed exploiting their Ye differences-which form the basis of the "ganuna flotation process". One step flotation test showed that sulfur floats preferentially from its mixtures with realgar and stibnite at recoveries of 73.6 and 70.7 % and grades of 81.7 and 91.2 %, respectively. The separation of stibnite from realgar gave a recovery of 4.1 % and a grade of 41.2 % for stibnite, indicate that a minimal Ye difference of 3.6±0.2 dyne/cm is essential for such separation when conventional flotation reagents are not used. This paper presents data and describes the approach employed in these separations.

Jan 1, 1994

By James A. Madonna

Several universities and colleges in Australia, Canada and the United States, recognized the need to establish or reorganize geoscience programs at the vocational and two-year technical levels. To accomplish this, a cooperative study with industry in one state or province from each country was initiated. These include Tasmania in Australia, British Columbia in Canada and Alaska in the United States. The objective of this work was to develop a diversified geoscience educational model at the two-year technical, vocational and continuing education level that provides the source from which any nation can draw the proper educational tools to create a new geoscience program, modernize an existing program or strengthen a weak program. More than 100 mineral industry organizations provided information regarding their specific training needs for support personnel. The data gathered have been used to identify training areas for semi-skilled, skilled and technical personnel in geochemical mineral exploration. These included geological, geochemical, environmental and computer skills. With the areas of major educational need defined for geochemical exploration, an educational field skills model was developed for the three levels of training. The international need for a study of this type was recognized as early as 1980, following numerous contacts from domestic and foreign geoscience educators regarding the structure and success of training within the University of Alaska Fairbanks Mining Extension program, located in Fairbanks. Contacts, correspondence and visits included educators from Australia, Brazil, Canada, Mozambique and the conterminous United States. The need was magnified between 1985 and 1989 at the University of Alaska Fairbanks, when an attempt failed at initiating and developing a two-year geoscience vocational-technology program leading to an Associate of Science degree.

Jan 1, 1994

By Kenneth S. Johnson

Iodine, a grayish-black nonmetallic element, with a density of 4.9 g/cm3, is a solid at ordinary temperatures. It is a member of the halogen family, along with fluorine, chlorine, bromine, and astatine. Iodine melts at 114°C. and at 184°C it is volatilized to a blue-violet gas that has an irritating odor. It does not occur as an element in nature, but occurs as iodates, iodides, or other combined forms. It is the 47th most abundant element in the earth's crust. Iodine was discovered by Bernard Courtois in 1811. He observed an unknown substance in the crude soda ash that results from the burning of seaweed. Samples of this unknown substance were identified to be a new element, and in 1813 Gay-Lussac named the substance iode, from the Greek word for violet color. The world production during 1989 and 1990 [(Table 1)] is estimated to be about 16 million kg per year (Lyday, 1991), of which about 30% is consumed in the United States. GEOLOGY AND MINERALOGY Compounds of iodine are minor constituents in seawater and brines, in certain marine organisms, and in minerals of the Chilean nitrate deposits. Seawater contains approximately 0.05 ppm iodine, and certain marine organisms, such as seaweed, sponges, fish, and some brown algae, are able to further concentrate iodine (Lyday, 1989a). Some seaweed can extract and accumulate iodine up to 0.45% of their weight, on a dry basis. The northern Chilean nitrate deposits, in the Atacama Desert, contain the following iodine minerals: lautarite, Ca(I03), (calcium iodate); dietzeite, CaJIO,), (CrO,) (calcium iodate-chromate); and bruggenite, Ca(I03), . H20 (Erickson, 1981). Various subsurface brines also contain iodine compounds. Some gas-field brines in the United States and Japan locally contain 30 to 1 300 ppm iodine. Several coals in Germany also contain iodine compounds. Iodine has been recovered from brines mainly in Japan and the United States, but also in Java, Indonesia, Italy, England, and the former USSR. Iodine has also been recovered from seaweed in Ireland, Scotland, France, Japan, Norway, and the USSR. Seaweed was a major source of iodine for the world in the first half of this century, and it remains as a large resource. The reserves and future resources of iodine are large, even excluding the resources in seaweed and seawater, and are shown in [Table 1]. Analysis Iodine as the free element can be detected by the characteristic blue color it gives to a starch solution. Quantitatively it is determined as the free element by titration with standard thiosulfate solutions using starch as an indicator. Colorimetric methods are also applicable. PRINCIPAL PRODUCING COUNTRIES Major iodine-producing nations are Japan, Chile, the USSR, and the United States, with lesser amounts being produced in China and Indonesia ([Fig. 1; Table 1]). Annual world production in 1989 and 1990, respectively, is estimated at 15.6 and 16 million kg. In Japan and Chile, the production of iodine depends on production of other materials, such as natural gas or nitrates, respectively, whereas in US operations (in Oklahoma) iodine is the major product recovered from natural brines. Chile was for a long time the principal world producer of iodine from its nitrate-fertilizer operations, but in recent years Japan has become the world leader with increased production of natural gas and associated iodine-rich brines.

Jan 1, 1994

By R. E. Gertsch

Mechanical mining holds great promise for the mining industry. Realizing this promise depends on giving mine operators the capability to evaluate the higher production, the lower costs, and safety enhancement that comes with mechanical mining. The opportunities for low cost and high production must outset the high capital costs associated with mechanical excavation. Giving the mining industry the tools to effectively evaluate and successfully implement mechanical methods defines the challenges and directions of the mechanical mining industry.

Jan 1, 1994

By Deborah A. Kramer

Although beryllium was initially discovered in 1797, it was not until 1916 that the first significant quantity of beryllium metal ingot was produced in the United States. Before 1940, most of the small quantity of beryllium metal used in the United States was supplied by Germany. Beryllium was not used in its metallic form; it was used as an alloying addition to other metals, mainly copper and nickel. World consumption of beryllium at that time was estimated to be a few hundred kilograms annually. Because of increased tensions in Europe before World War II, imports of metal from Germany ceased in 1940, and domestic production was required to meet the needs of the military. As a result, by 1946, the United States became the principal supplier of beryllium products for the world, a condition that prevails today. Because of beryllium's high strength, light weight, and high thermal conductivity, it has been used in a large number of industrial and defense applications as a metal, alloy, and oxide. The United States is the only country other than China and the former USSR currently producing beryllium products from beryllium ores and concentrates. Bertrandite, mined in Utah, is the principal ore source of domestically produced products. Imported ore, mainly from Brazil, supplements domestic ore supplies. Production and consumption data for the United States is shown in [Figs. 1 and 2]. Production data for 1969-1979 is withheld to avoid disclosing company proprietary data.

Jan 1, 1994

By Steve Van Kouteren

Filters and absorbents purify, clarify, and clean many types of liquids by removing solid particles. In addition, absorbents provide a convenient way to handle liquids and to clean up liquid wastes or spills. Filtration or absorptive processes are accomplished either in a mechanical way, as in absorption and filtration, or in a chemical way, as in adsorption. In filtration, minerals and rocks used as filter mediums are extensively utilized in applications requiring the filtration of high volumes of liquids. End use applications include liquid food products, waste waters, petroleum and chemicals, and drugs and pharmaceuticals. Upon closer examination of all of the materials used as filters and absorbents, industrial minerals and rocks represent only a small proportion of the total amount, as shown in [Fig. 1] (Rees, 1991). Given all the industries that use these minerals, most of the volume is concentrated in a few major end-use markets. Within these major end-use markets, a handful of minerals account for most of the total volume and value. The focus for this chapter will be to discuss the industrial minerals and rocks used as filters and absorbents in the most important markets. The selection of the minerals and markets to review is solely based on the total volume of material used and in special cases, those where the value of the market and material is high. The major materials include diatomite, perlite, sand, gravel, and such specialty clays as montmorillonite and attapulgite. These materials are mainly used for the filtration of food, chemical, and petroleum products. In addition, they are used as absorbents for pet litter and oil and grease spills, and as carriers for pesticides and fertilizers.

Jan 1, 1994

By G. Vallebuona

Currently, empirical models are used for predicting the hydrocyclone performance in terms of capacity, cut size (d50,c), water split and partition curve. These models, for example those of Lynch and Plitt, have been developed and checked for hydro cyclones with diameters larger than four inches. For smaller diameter hydrocyclones little empirical modelling has been done. This paper reports extended experimental research on small hydrocyclones. For these cyclones, the suitability of existing empirical models has been checked and their accuracy compared. Modifications of the existing models equations are proposed, improving their predictive capability for the small cyclones performance.

Jan 1, 1994

The most important event affecting the United States coal industry in 1993 was the strike by the United Mine Workers of America (UMWA). This was a series of selective strikes, beginning with a strike against four Peabody Holding affiliates on Feb. 2, following unsuccessful contract negotiations between the UMWA and the Bituminous Coal Operators' Association (BCOA). Although that strike ended on March 3, the failure to reach a new contract agreement led to walkouts at several Midwestern mines on May 10. During the summer, the strike expanded to include mines of 13 companies in seven states including Ohio, Pennsylvania, Illinois, Indiana, Kentucky, Virginia and West Virginia. About 17,000 miners were idled during the strike. As the prospects for a settlement diminished, the Secretary of Labor appointed a federal mediator. The mediation resulted in a five-year contract. In addition to increases in wages and pensions, it was agreed that 60% of new job openings would be filled by laid off and active UMWA miners. In return, companies won the right to establish more flexible work rules and scheduling of miners. While some health care benefits were expanded, the agreement established a new health care system that was designed to reduce costs. Preliminary Energy Information Administration (EIA) data indicate that US coal production fell by 5% in 1993, to 859 Mt (947 million st) (Table 1). The strike was one of the primary causes of the decline in production. Another significant cause was a 27% decline in coal exports. Also, a very small displacement of domestic coal production resulted from a rise in coal imports.

Jan 1, 1994

By James R. Hindman

Vermiculite is the mineralogical name generally applied to a group of hydrated, trioctahedral ferromagnesian aluminum platty or micaceous silicate minerals. In microscopic particles the mineral as mineral is differentiated from montmorillonite by a higher Si:AI ratio of approximately 3:l and a higher layer charge and higher cation exchange capacities. Commercial vermiculite, the vermiculite which is mined, beneficiated, and discussed in this chapter, is an important industrial mineral which is formed by the alteration of macroscopic particles of biotite and iron-bearing phlogopite. In natural form it has the size and shape of mica, while possessing the ion exchangeable properties of zeolites and some clays. Within the internal structure of vermiculite lie water molecules, which when rapidly heated to high temperature, transform into steam causing the vermiculite particles to increase in volume. This process of thermal exfoliation produces a lightweight product which finds use in various construction products, agriculture, horticulture, and other industrial applications. In exfoliated form it has the low density and biological inertness of expanded perlite, while maintaining a chemically active surface. Most of the uses of vermiculite are for the thermally exfoliated material. In addition, the cation exchange potential of vermiculite and its layer-silicate structure are properties which can be used as the basis for numerous products including intumescent coatings and gaskets, inorganic films, and the treatment of nuclear and other toxic waste. When chemically and physically modified, it possesses some properties common to organoclays and synthetic compounds. In high purity concentrates and manufactured products, these properties can be altered and optimized in applications to produce superior performance. GEOLOGY Mineralogy Vermiculite was first described as a mineral by Thomas H. Webb in 1824. Webb believed vermiculite to be a variety of talc and described its diagnostic property of thermal exfoliation thusly: "If subjected to the flame of a blowpipe, or that of a common lamp, it expands and shoots out into a variety of fanciful forms, resembling most generally small worms having the vermicular motion exact." Observing that with one exception, all commercial vermiculite has formed by the alteration of iron-bearing phlogopite, a simple definition of vermiculite might be the alteration product of trioctahedral micas, macroscopic particles of which display marked exfoliation when heated rapidly to temperatures above 374°C (the critical temperature of water). The first vermiculite described was found near Worcester, MA, but it was later pointed out by Brush (1866) that vermiculite had been known for some time in Japan as a children's novelty. Because the techniques for mineral analysis were somewhat primitive com- pared to those routinely available today, and because the structure and crystal chemistry of the micas and related minerals were not widely understood, the early literature generated at least 20 "new" minerals which were nothing more than variations in the color and chemistry displayed by vermiculite. Trade names such as Dugarlite, Mandolitem, Strong-LiteTM, and Zonolitem are sometimes used to denote commercial vermiculite, thermally exfoliated vermiculite and their products. Vermiculite particles resemble mica and vary in color from colorless through tan and green to black, depending on the chemical composition. Most physical and optical properties are close to those of biotite, with perfect basal cleavage, hardness between 1.5 and 2.5 Mohs, and specific gravity between 2.2 to 2.8. Fine-sized particles will feel talcose, especially when wet. However, for commercial vermiculite the diagnostic test is that of thermal exfoliation. Vermiculite can display a wide range of compositions, depending on the composition of the original mica and the change of chemistry during weathering and ion exchange. Chemical data for some commercial vermiculites are given in [Table 1]. There are numerous analyses for vermiculite given in the literature, and the analyses of vermiculites from commercial deposits will fall within the range indicated by the average analysis in the table. Many analyses separate the adsorbed water (H2OP) from crystalline water and water as hydroxyl (H20+). The basis of separation of adsorbed water is generally considered to be 100°C. However, hydrate water within the vermiculite interlayer begins to be lost at 75°C and lower. Therefore, measured water content and loss on ignition are combined in the table as H20[total].

Jan 1, 1994

By Robert C. Freas

Over the past twenty years people throughout the world, but particularly in the United States, have been taking an increasing interest in the environment, sources and causes of pollution, and pollution abatement. Air quality in the United States has been and continues to be an area of primary emphasis. In 1970, the US Congress passed the Clean Air Act and subsequently revised and strengthened it in 1977 with the issuance of the New Source Performance Standards. The Act has been further strengthened with the passage of the 1990 Amendments. By far the largest single source of sulfur dioxide (SO,) pollutants are coal fued electric generating power stations. Hence, a substantial portion of the flue gas desulfurization (FGD) research and equipment installation has been geared to the utility industry. Several competing FGD technologies were touted during the period 1970 to 1990 with varying degrees of success. Subsequently, the more successful technologies have been accepted, revised, and improved to the point that by 1991 third and fourth generation technology is available. A second area of emphasis for FGD has been coal fired industrial boilers. While individually they are much smaller than any electric utility generating station, they do represent a significant source of sulfur pollution. However, due to the size of industrial boilers and their location within industrial and educational complexes, the wet scrubber technology being employed by the utilities is not appropriate for these applications. Hence, fluidized bed combustion (FBC) technology has been developed for the industrial boilers. Since the installation of the first full scale test unit at Georgetown University, several equipment vendors have come forward with an increasing array of more sophisticated FBC units. Currently, FBC technology has matured to the point that the Tennessee Valley Authority (TVA), in cooperation with the Electric Power Research Institute (EPRI), has installed an FBC system on a 250 MW test unit at the Shawnee Power Station in Kentucky.

Jan 1, 1994

By W. A. Rickelton

The first commercial use of phosphine derivatives as solvent extraction reagents began in the mid 1970's with the construction of several plants to recover uranium from wet process phosphoric acid. The process eventually adopted by all of these plants used the well known trioctylphosphine oxide (TOPO) in synergic combination with D2EHPA to extract U(6+). This prompted the development of other phosphine - based reagents and led to the discovery of a variety of interesting commercial and potential applications which are summarized in this paper. The applications include cobalt-nickel and niobium-tantalum separation and the selective recovery of silver and zinc.

Jan 1, 1994