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By H. L. Ames, P. H. Jennings, R. W. Stanley

A process has been developed for leaching copper, lead and calcium from molybdenite concentrate. The leachant is a solution containing an oxidizing chloride (e. g., CuC12, FeC13) and an alkaline earth metal chloride (e. g., CaC12). Cupric chloride and ferric chloride, in the presence of 20-30% calcium chloride, are effective oxidants for chalcopyrite and galena. Calcium chloride, in addition to promoting the rate of leaching, serves to lower the solution pH and raise the boiling point. Leaching for two hours at 110'~ with a 1 % CuC12-10% FeC13- 30% CaC12 solution results in the extraction of up to 98% of the copper in molybdenite, 98% of the lead, and 79% of the calcium. Less than 0. 5% of the molybdenum is dissolved. The leach solution can be rapidly and effectively regenerated with gaseous chlorine and recycled. Build-up of copper and lead in the leach solution is controlled by discarding about 30% of the leach solution each cycle.

Jan 1, 1973

By J. F. Boux

"The study of the total utilization of fly ash has involved all of the known technology in the processing of this waste material into useful products. In addition, a complete knowledge of all the possible uses of fly ash and its products in the market area was probably the most important factor in evaluating the theory and practical feasibility of the total utilization of fly ash from a single large supplyLaboratory tests carried out on the separation of fly ash into different fractions were shown to improve its value and utilization. Four main fractions were studied: a fine pozzolanic low-carbon fraction; a coarse fraction for light-weight aggregate production by pelletizing and sintering; a high-iron fraction; and a carbon-rich fraction. The term ""beneficiation"" here refers to a process of separating fly ash into more useful components.Laboratory and pilot sinter strand tests were employed to optimize the sintering capability and the quality of the heat-hardened pellets through a study of the agglomeration cycle in four principal heat zones, under controlled conditions of air flow, temperature and atmosphere, and including the controlled sizing of pellets.The suitability of the heat-hardened pellets as light-weight aggregate was evaluated in test batches of concrete, which were compared with concrete containing commercial lightweight aggregate of established quality.A study of beneficiated fly ash pozzolan as a partial cementitious binder component in normal and high-temperature cured concrete was reported in a paper at the re-cent Second International Fly Ash Symposium.Samples of raw and beneficiated Lakeview ash were compared with samples of other established high-quality fly ash pozzolans. The evaluation indicated the usefulness of beneficiated Lakeview ash as a pozzolan. Economic studies indicated that to accomplish the primary objective of total utilization of any single source of fly ash (in this case. fly ash from the Lakeview Generating Station, producing approximately 400,000 tons per year), a broad knowledge of the technology of various mineral processes was essential.The design of the fly ash processing plant had to be based on the disposal of all the raw fly ash produced by the generating station. This is contrary to the normal design of a processing plant in which raw materials are supplied and produced according to product demand. The design, therefore, had to be of such flexibility as to pro-duce as wide a variety of products as possible, and the ability to market them had to be well researched and understood."

Jan 1, 1970

By T. Hofbauer, M. J. Dry, G. B. Harris, C. W. White

"Urban Mining is a term that is increasingly being used, and represents an appreciable source of secondary materials for the metals extraction industry, a source that does not incur mining costs, but does, at present, incur considerable disposal costs. Electric Arc Furnace Dust (EAFD) is probably the most common of these materials, with an estimated global production of 8 million tonnes annually, of which 1 million tonnes is generated in North America. The contained annual metal value in EAFD at current prices is of the order of $6 billion, yet, apart from the zinc, virtually none of this is recovered.Despite many attempts over the years, with pyrometallurgical, hydrometallurgical or hybrid processes, currently the only commercially viable method of treating these materials is smelting in a Waelz Kiln (or a Rotary Hearth Furnace), which essentially recovers only the zinc, in an impure oxide form, and generates a secondary slag waste, which is still toxic and requires disposal. This paper describes the development of a chloride-based treatment process to recover all components of the EAFD in a marketable form, which centres around the novel hydrochloric acid recovery and recycle operation. Laboratory, miniplant and pilot plant data are presented, leading to the definition of a viable process flowsheet enabling the recovery of pure iron and zinc products (the principal components of EAFD), together with secondary products such as copper, silver, lead, cadmium, magnesium and manganese. A rigorous mass-energy balance is used to examine the preliminary economics involved."

Jan 1, 2014

By Douglas J. Robinson

A pilot scale process has been developed to separate mercury, tin, silver, and copper from dental amalgam scrap. Laboratory research led to a process which was operated in 55 gallon drum sized reactors to treat 2000 Tr oz charges of scrap per day. This paper discusses the development work, presents a flowsheet and gives an indication of the equipment necessary to carry out the process on a commercial scale.

Jan 1, 1984

By P. T. O'Kane

The PLATSOL® process, initially developed for the treatment of the NorthMet Cu/Ni/PGM concentrate, has seen over the recent years its applicability extended to include numerous other Cu/Ni concentrates of the same type, as well as other precious metals-containing feedstocks. However, several concentrates were found refractory to the typical PLATSOL® conditions, more particularly so the platinum. Attempts to extend those conditions, such as higher temperatures (250°C), longer retention time, increased oxidation conditions, higher chloride additions, were not successful. Detailed mineralogical investigation of those PLATSOL® leach residues indicated the main refractory mineral to be cooperite (PtS). Further metallurgical investigations showed that a thermal pre-treatment of the concentrate effectively unlocked the refractory platinum minerals for the subsequent leach. Temperatures between 400 and 750°C were tested, with the optimum being found around 650°C. The kinetics of the pre-treatment process were fast, and one hour at temperature proved sufficient. Under those conditions, PLATSOL® extractions were re-established around 95% for both platinum and palladium. From a mineralogical examination of the calcine, it was shown that the effect of the pre-treatment was to transform the cooperite and other refractory sulphides into metallic platinum and alloys, amenable to the PLATSOL®. The implications of the pre¬treatment step for the processing of PGM concentrates arc briefly discussed.

Jan 1, 2004

By Takashi Furuyama, Sukeyuki Mori, Tetsuo Ikejiri, Abel Bissombolo, Yoshitsugu Koga, Masamichi Hata

In Japan, the increasing number of automobiles newly put into circulation is followed by a larger amount of end-of-life vehicles from which valuable metals are being recovered in shredder and related plants. Nevertheless, the processing of these scrapped automobiles which has reach a recycling rate of about 75%, generates a huge volume of waste, locally known as .shredder dust., which is commonly dumped on landfills. The saturation and depletion of valuable disposal sites in the near future, as well as the social and environmental problems related to the accumulation of these residues disposals are a major challenge for the automobile shredding industry. To promote an alternative way for the management of these disposals, the authors have initiated and developed a system for their processing, on the basis that more than 90% of these residues are combustible materials that could be used as refuses derived fuel. The developed processing system points out the mechanical/physical separation of shredded automobiles residues into two streams by means of an ascending airflow passing through a vertical zigzag separator and, the compaction of the light-density fraction of materials (that is about 60% of auto shredder residue recovered as float products and mainly composed of cotton, sponges and light plastics) to form a refuse derived fuel (RDF), the density, calorific value and ignition loss of which are 1.19 g/cm3, 4470 kcal/kg and 60.7%, respectively.

Jan 1, 2003

By Takashi Furuyama, Sukeyuki Mori, Ltd. Kyushu Metal Industry Co., Abel Bissombolo, Yoshitsugu Koga, Masamichi Hata

"Actually, the recovery of valuable metals such as iron, aluminium and copper is a nowadays practice in factories dealing with the processing of scrapped automobiles (Harder (WERG); Koga et al., 1997). This process has reach a recycling rate of about 75%, and generates a huge volume of waste (including cottons, sponge, plastics, rubber, etc…), locally known as “shredder dust”, which is commonly dumped on landfills; its recycling is either unsatisfactorily or not yet performed (Keller and Schebdat, 2000).The saturation and depletion of valuable disposal sites in the not-so-distant future, as well as the social and environmental problems related to the accumulation of these residues disposals are a major challenge for the automobile shredding industry.To promote an alternative way for the management of these disposals, the authors have initiated and developed a system for their processing, on the basis that more than 90% of these residues are combustible materials that could be used as refuses derived fuel. The developed processing system points out the mechanical/physical separation of a calibrated (–80+5mm) shredded automobiles residues into two streams by means of an ascending airflow passing through a vertical zigzag separator and, the compaction of the light-weight materials (that is about 60% of auto shredder residue recovered as float products and mainly composed of cotton, sponges and light plastics) to form a refuse derived fuel (RDF), the density, calorific value and ignition loss of which are 1.19 g/cm3, 4470 kcal/kg and 60.7%, respectively. A sedimentation tank is used to recover the light-weight materials deported in the heavy fraction stream."

Jan 1, 2003

By H. J. Handewith, W. D. Coski

This paper describes the development and testing of the RAMEX excavation system. Incorporating a synergy of low velocity, high energy impact and kerf cutting, this machine offers a competitive alternative to drilling and blasting in hard rock. It is a boom mining machine that incorporates the features of a lightweight roadheader and it can mine nearly any shape opening in hard rock. The RAMEX Tunneler has been developed to satisfy industry demands for a non-explosive, flexible, continuous and rapid underground rock excavation system. It will produce minimum ground vibration in the urban environment and allow the flexibility necessary for thin seam mining conditions. It will also reduce initial ground support costs and has a minimum impact on rock integrity. Developed by RAMEX Systems with cooperative research provided by the U.S. Bureau of Mines, this system, could produce the next step in the continuing evolution of mechanical mining systems.

Jan 1, 1989

By S. Shamaila

The design and efficient operation of density-based mineral processing units requires regular densimetric analysis to be carried out on the various associated process streams. The results obtained from such analyses can have wide application, including the generation of washability and partition curves, which are critical for process design, control, and simulation. This paper describes some of the collaborative efforts that Kumba Iron Ore, in partnership with Springer New Technology and Anglo Technical Solutions Research, is pursuing in developing a novel density determination technique exploiting X-ray transmission (XRT) and optical imaging. This technique is being developed with the aim to determine sample density distributions that apply to washability characterisation of ores. This technique is aimed to be an alternative to the traditional sink and float method. For certain applications sink and float has required the use of tetrabromoethane (TBE) solution?a chemical that has been classified as harmful and environmentally unfriendly. This paper therefore presents some achievements in developing this novel technique which seems to be very promising.

Jan 1, 2012

By D R. Seaman, Y Peng, F Burns, D J. Bradshaw

Telfer Gold Mine is a gold-copper mine in the eastern Pilbara of Western Australia, owned and operated by Newcrest Mining Limited. TelferÆs ores are processed by a dual train, 21 Mt/a, concentrator where gold is primarily recovered by gravity concentration and the flotation of a gold-bearing copper concentrate. A minor portion of TelferÆs gold is also recovered to a pyrite concentrate that undergoes treatment via carbon-in-leach (CIL) cyanidation. The gold recovery of the CIL circuit is below the industry standard and operates with a high reagent consumption rate.With a new fine-grinding facility, the Telfer process plant will have the ability to liberate copper and gold from the pyrite concentrate and recover these by flotation prior to the existing leaching circuit. This process will improve overall gold and copper extraction, while reducing reagent consumption in the CIL circuit.This article is an overview of the development of this methodology. Size-by-size analysis and mineralogical studies of monthly composites identified factors limiting the CIL gold recovery and the causes of high reagent consumption. Laboratory studies confirmed a relationship between the regrind product size and gold leach recovery. The addition of an intermediate flotation stage ensured that the regrind circuit will improve overall recovery while at the same time reducing operating costs. Without the addition of a flotation stage, the additional reagent consumption from regrinding alone would be prohibitive towards increasing recovery. Pilot scale studies confirmed the conditions required to selectively recover gold and copper from the pyrite concentrate as well as establishing the full scale regrinding energy requirements. Construction of this facility at Telfer is currently underway.CITATION:Burns, F, Seaman, D R, Peng, Y and Bradshaw, D J, 2012. Development of a pyrite regrind circuit at Telfer Gold Mine, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 45-52 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By B. Ni, J. D. Robertson

A new radioactive tracer method for the measurement of airflow in inaccessible airways was developed. The method can be used in situations where studies of the mine-ventilation system are not possible using conventional flowmeters (anemometers). The method was tested in the ventilation laboratory at the University of Kentucky and in the US Bureau of Mines Experimental Underground Coal Mine and was utilized in leakage, dilution and flow-velocity measurements.

Jan 1, 1998

By A.M. Wala

A new radioactive tracer method to measure airflow in inaccessible airways has been developed for situations when studies of the mine ventilation system are not possible using conventional flowmeters (anemometers). The new method has been tested in the ventilation laboratory at the University of Kentucky and in the Experimental Underground Coal Mine at the U.S. Bureau of Mines. This new tracer method has been utilized in leakage, dilution and flow velocity measurements in laboratory and field (mine) experiments.

Jan 1, 1996

By P. O. Rag, Daniel E. Walsh

"Gravity concentrators are evaluated either in closed or open circuit. The process developed by MIRL employs the use of neutron activated gold (/98Au) and radiation detection circuits which monitor the concentrator's product pulp streams. Concentrator recovery is determined from the ratio of the number of gold particles detected as passing into the concentrate to the total number of gold particles detected over all monitored pulp streams. This system eliminates the experimental errors introduced by sampling, sample reduction, and assaying and allows recovery to be evaluated for gold particles of specific sizes, shapes, and flatness. In addition to allowing for a more accurate and detailed recovery analysis, this process significantly reduces the time and cost required for unit evaluation when compared to other gold recovery analysis procedures. This system enjoys its greatest utility where a large number of tests are to be run in order to evaluate a concentrator over a variety of operational settings, i.e. factorial designs, and allows accurate testing of concentrators operated in closed circuit systems.IntroductionThe surge in gold prices of the late 1970s and early 1980s was followed closely by a renewed interest in gravity concentration processes, especially in concentrators claiming efficient recovery of fine placer gold. Cones, spirals, spinning bowls, jigs and cyclones are all considered potential fine gold concentrators. Fine gold, in this context, is defined as not only that gold finer than 250 um (60 mesh""), but also coarser gold, whose low shape factor may decrease its recovery by conventional, large-scale sluicing operations.Adoption of fine gold concentrators by the Alaskan placer milling industry was retarded by the lack of reliable, accurate, and reproducible data on concentrator efficiency with respect to fine placer gold recovery. In most cases, concentrator performance was based on a limited number of tests run on placer material, about which only slight knowledge of gold size and shape characteristics existed. In order to be prepared for the resurgence of interest in fine gold concentrators, which will follow the next upturn in gold prices, a detailed study of the fine gold recovery characteristics of gravity concentrators needs to be conducted."

Jan 1, 1986

By M Carr, C Wheeler, M Lurie, B Chen

The demand for steel products in modern society is prompting the iron ore industry to optimise their operations to ensure sustainability of fines and lump products. One of the key components in the iron ore transportation chain are belt conveyors. The energy consumption of modern belt conveyor systems has reduced considerably over the past few decades, however, there is still significant scope for further reductions, especially when heavily loaded long overland belt conveyors are considered. A new rail based continuous bulk material transportation system has been developed by researchers at the University of Newcastle to reduce the energy consumption of heavily loaded and long overland conveyors. The Rail-Running Belt Conveyor technology is a state-of-the-art continuous belt conveying technology which provides an innovative and novel departure from conventional continuous bulk material transportation systems with significant energy and economic benefits. This paper presents an overview of a Rail-Running Belt Conveyor variant which considers an enclosed belt. Enclosed belt conveying has the benefits of encapsulating the bulk material, and thereby reducing dust emissions and moisture ingress, in addition to being able to negotiate smaller radius horizontal and vertical curves leading to greater flexibility. To quantify the primary differences between conventional conveying technologies, the Denver office of thyssenkrupp Industrial Solutions (USA) developed a case study for an 11 km long conveyor. The conveyor design throughput was 2750 t/h and included a small net elevation loss of 10 m. When considering CAPEX the Rail-Running Pipe Conveyor equipment supply cost is approximately 45 per cent of the cost of a conventional pipe conveyor, while savings upwards of US$50M emerge for CAPEX combined with five years of OPEX. The savings vary with the topography and density of the bulk commodity, with iron ore generally showing increased savings because the high bulk density increases rubber losses in conventional conveyors.

Nov 8, 2021

By J. D. McAuliffe

The Homer-Wauseca Mine is operated by the Hanna Mining Company, three miles north of Iron River, Michigan on the Menominee Iron Range. The mine produces 5,300 tons of direct shipping iron ore daily. The present main producing level is at a depth of 1,500 feet below the collar. The ore body continues to a depth of 2,700 feet below the collar, to which depth the modern circular concrete shaft has been completed. A view of the property is shown in Figure #1. This paper is a report on the development of large underground boreholes used initially to conduct stope filling material into inaccessible, mined-out stopes. Later holes were drilled for ventilation raises, for mine drainage, for passageway for power cable, also for the primary breaking point for long hole stoping. Some, which were drilled as ventilation raises, were later stripped to a suitable size for a manway or ladder road. The holes varied in size from 6" to 30" with the present popular, economical working size being 16 1/4", used as a stope fill passage in mined out areas and for ventilation in deeper development. Foremost has been the desire to develop equipment suitable for drilling raises large enough for manways.

Jan 1, 1963

By R B. Wanty

Historically, most investigations of biogeochemical cycling in acid rock drainage systems involved synoptic sampling over longer time periods (one sample per week or month) or intensive time series studies over a few hours or days. However, many important episodic loading events, such as seasonal meltwater and storm events occur on timescales that are rarely observed by these traditional sampling approaches. Monitoring these transient processes, which may contribute the bulk of the annual metal loading, is essential for accurate assessment in acid rock drainage areas. Recent work also has demonstrated dramatic diel (24 hour cycle) variations in trace metal concentrations in response to diel changes in temperature, pH, oxygen, and photochemical cycling (Brick and Moore, 1996; Nimick et al, in prep). To characterise a system that may respond to diel, seasonal, and episodic events, a monitoring program must sample at a frequency that captures the details of these major forcing events. We developed two novel instruments, the Zn-DigiScan and the DigiSampler to examine low and high frequency temporal changes in acid rock drainage areas. The Zn-DigiScan is a battery powered real time in situ chemical analyser designed for long-term deployments with hourly analyses of Zn. Stream physical parameters (temperature, conductivity, dissolved oxygen, pH, turbidity, etc) were measured every 15 minutes with a water quality sonde. The DigiSampler was developed for the long-term daily sampling of biogeochemically active elements and can take either discrete samples or samples integrated over 24 hours. The DigiSampler collects 2 ml samples in a Teflon coil which are separated by 0.2 ml nitrogen bubbles. The sample coil is returned to lab and the 2 ml samples are diluted 1:10 and analysed for trace metals by ICP-MS. Initial results from a three-day deployment at Fisher Creek, MT, USA have successfully demonstrated the ability of the Zn-DigiScan to record Zn concentrations at levels below 100 ¦g/L. Zinc concentrations measured at 30 minute intervals in Fisher Creek showed a diel cycle with low values of ~25 ¦g/L in the late afternoon and increasing to ~60 ¦g/L by early morning. Zn concentrations were inversely related to temperature and pH, suggesting that temperature and pH dependent adsorption was the main factor controlling diel Zn fluctuations. Initial deployment of the DigiSampler also was successful, revealing diel cycles in Zn, Cu, and Mn. Comparison of trace metal samples collected by the DigiSampler showed good agreement with samples collected by an Isco automated water sampler, demonstrating that the DigiSampler can collect clean samples for trace metal analysis at the low ¦g/L range.

Jan 1, 2003

By W. P. Arnott, P. Nascimento, X. L. Wang, K. C. Kocsis, S. J. Taylor, H. Firouzkouhi

We report the first spectral photoacoustic measurements of silica, coal, and kaolinite dust absorption coefficients from 11 to 13 μm at 5 nm resolution made with a tunable quantum cascade laser. This is important because airborne silica dust and coal dust within mining environments continue to be a problem for mine workers and staff due to their severe health effects on the respiratory system, while other dust types are potentially interferents to their detection. Our real-time spectra compare favorably with the non-real-time filter-based Fourier transform infrared spectrometer (FTIR) spectra obtained using the sampling system developed by NIOSH for their end-of-shift method to determine silica dust concentrations using a portable FTIR. We discuss our new dust generation system and instrument testing chamber. We also show that our PM4 silica mass concentration measurements by a low-cost air quality sensor (SPS30) are in good agreement with the TSI Aerosol Particle Sizer instrument, the NIOSH end of shift method, gravimetric mass, and correlate well with photoacoustic light absorption measurements at a wavelength where silica absorbs strongly.

Aug 20, 2022

By David Bigby

A remote reading dual height telltale system has been developed to provide mine management with early warning of impending roof failure. This system is a logical development from the visual dual height and triple height telltales which are increasingly being used worldwide for routine monitoring of mine roof. The paper describes the principles and history of telltales from their origins in France, their refinement and routine use in the UK and their subsequent spread around the world. They are now being used in various forms in USA, Canada, Germany, Spitzbergen (Norway), Poland, Ukraine, Russia, Australia, South Africa, Mexico, India, Egypt and China. The remote reading telltale system has coal mine intrinsic safety approval in Europe and the United States (MSHA) and the first commercial system was installed in a German colliery at the beginning of the year. Up to 100 dual height telltales can be connected, in a simple "daisy chain" configuration, to each of 4 underground interrogation units. These are connected through a twisted pair link to a surface computer which displays the readings, updates the database, generates warnings and provides the user interface. The paper describes the features and principles of operation of the system which differs considerably from conventional mine-wide monitoring systems. A European Community funded research programme is currently underway with the aim of developing improved alarm generating algorithms including evaluation of interfacing a neural network to the system. The paper concludes by exploring other potential applications of the system for ground control monitoring currently in development, including extensometry, stope closure monitoring and support load measurement.

Jan 1, 2001

By J. A. Hillier

The staff of the Hudson Bay Mining and Smelting concentrator have developed a new type of reagent feeder. Several factors encouraged the development of such a system: varying heads caused by the mixing of ores from several mines, the increasing number of flotation circuits operated and reagent feeding stations remote from the flotation operator's work area. The reagent feeders also had to be compatible with future plans for reagent control from an on-stream X-ray analyzer and computer system. The new feeder is a positive-displacement pump set to deliver a constant volume per stroke. At a remote panel, the feed rate is altered by changing the time between strokes. The feeders have been found to be reasonably trouble-free and accurate to less than 2 per cent error.

Jan 1, 1973

By H Lemos, E Nunes, D Jacobson, R Costa, L Ono, A Alves, H Delboni Jr

Oversize rock breaking and metal tramp removal are key issues for reducing primary crusher downtime, as well as improving the safety associated with its operation. Remote operation of such tasks would thus not only increase productivity, but also reduce the risks related to work in confined spaces, fall risks, and overhead hazards. These issues are particularly relevant in high-capacity operations such as iron ore mining, where large machines are in continuous operation. This article describes the architecture, construction and advanced testing of a novel remotely operated robotic mechanism for assessment and removal of metal tramp from primary crusher chambers. The system essentially includes a robotic-arm equipped with a hydraulic clamp tool for handling oversize material, as well as an oxy-flame module for cutting metal pieces entrapped within the primary crusher cavity. The first industrial unit was delivered to a large iron ore mine in Brazil, where the installation and testing is scheduled within the coming months.

Nov 8, 2021