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By Romeo Jurani, Ralph Dresel, Fred Kissell, Charles Parker

This report describes actions taken to control silica dust at the Yucca Mountain Exploratory Studies Facility (ESF), a tunnel located in Southern Nevada that is part of a scientific program to determine site suitability for a potential nuclear waste repository. The rock is a volcanic tuff containing significant percentages of both quartz and cristobalite. Water use for dust control was limited because of scientific test requirements. A major dust reduction was achieved with an intermediate air cleaning station located on a rear deck of the TBM trailing gear.

Jan 1, 1999

By R. H. Grau

The National Institute for Occupational Safety and Health's Pittsburgh Research Laboratory is now involved in research to identify silica dust generation in underground metal/nonmetal mines. The ultimate goal of this research is to develop control technologies to reduce worker exposure to respirable silica dust. Commodities and job classifications with the highest silica dust exposure have been identified through analysis of the Mine Safety and Health Administration's compliance dust-sampling database. Dust surveys were conducted in an underground limestone and gold mine to investigate silica dust sources, generation levels and the controls being used. A summary of the mining operations, sampling procedures, resulting data and suggested methods to improve dust control are provided.

Jan 1, 2003

By R. H. Grau

NIOSH’s Pittsburgh Research Laboratory is currently involved in research to identify silica dust generation in underground metal/nonmetal mines. The ultimate goal of this research is to develop control technologies to reduce worker exposure to respirable silica dust. Commodities and job classifications with the highest silica dust exposure have been identified through analysis of the Mine Safety and Health Administration (MSHA) compliance dust sampling database. Dust surveys were conducted in an underground limestone and gold mine to investigate silica dust sources, generation levels, and controls being used. A summary of the mining operations, sampling procedures, resulting data, and suggested methods to improve the dust control will be provided.

Jan 1, 2002

By Alan T. Nelson, Ronald D. Mariani

The Tilden concentrator was originally constructed in 1974 for the processing of low grade hematite. Flotation is a key concentrating process in the operation, and therefore flotation optimization has been a major concern since the plant startup. This paper will discuss some of the modifications made in the process to achieve optimization. The conversion that now enables the plant to process magnetite as well as hematite also will be discussed. INTRODUCTION The Tilden Mine, located in Ishpeming, Michigan, is managed by Cleveland-Cliffs Iron Company and is owned by Cleveland-Cliffs and two Canadian steel makers. It was constructed and started production in 1974 and expanded in 1979 for processing a low grade, fine-grained hematite iron formation for which there was previously no technology available. Several papers have been written describing the unique character of the concentrating operation. The hematite plant consists of 12 grinding and concentrating lines, which utilize two stages of autogenous grinding with crushing of an intermediate sized product. The ground product is deslimed in a highly dispersed alkaline environment to reject silica. Corn starch, the flocculant, has a high affinity for iron at the operating pH range of 10.5 to 11.0. The ore is upgraded from 35% to 45% iron in the desliming step. The deslime thickener underflow is the feed to flotation. Each flotation line consists of a bank of 10 rougher cells, followed by four scavenging banks incorporating 5, 4, 3, and 3 cells each. The Wemco flotation cells are each 14.1 cubic meters (500 cubic feet) in volume. A total of 12 flotation lines are available. [ ] A reverse flotation process is employed, using a straight-chain, 8 to 10 carbon primary ether amine silica collector. At the levels used in the circuit, the amine also serves as a frother. A final concentrate is produced in the rougher cells. The concentrates from the four scavenging steps are combined and recirculated to the feed end of the roughers, with the fourth scavenger froth being discarded as a final tailing. Upgrading to about 65% iron is achieved, with control of the circuit based on final concentrate silica grade. Starch is again used, this time as a depressant for iron. During the years of operation, several key areas of the flotation process have been targeted for optimization. The most significant improvements have been realized in the following areas: *Grade Control Automation *Control of Water System Chemistry *Flotation Spray Water This paper will focus on these areas, but other minor improvements also will be briefly discussed.

Jan 1, 1993

By Paul Mitchell, Amy Wheaton, James Rybock

Acid rock drainage (ARD) represents one of the most intractable problems faced by the non-ferrous metal and coal mining sectors, and the creation in the recent past of a number of high-level national and international initiatives reflects the growing concerns of industry, government and other stakeholder groups. ARD is certainly considered one of the most serious environmental impacts caused by mining and the industry's greatest environment-related technical challenge. Additionally, the global depletion of non-acid generating oxide ore deposits and the increasing dominance of sulphide ores means that the potential for ARD incidents will continue to increase. Once initiated, the cycle of chemically and biologically mediated and catalysed reactions leading to ARD generation is difficult to stop. While there is evidence to suggest that the degree of contamination of ARD will decrease rapidly within a relatively short timeframe (Wood et al., 1999), experience in historic mining regions of the world indicates that the problem may persist for centuries at certain sites. Current best practice in dealing with ARD puts the emphasis on prediction and prevention, planned from the outset of the operation and integrated with each phase of the mine site life cycle. The elements that constitute best practice are becoming more clearly defined and as this process of clarification continues industry will undoubtedly accelerate the process of best practice implementation, burying at last the image of mining as a despoiler and polluter of landscapes, an image based on past, rather than current, practices. However, it is equally clear that despite the best efforts of industry and regulators, many sites will continue to generate ARD during operation and following closure - in many cases, a legacy of ARD has been derived from operational and strategic decisions made decades ago, before the risks and impacts of the self-sustaining cycle of ARD generation were properly understood. Add to this ARD generation from poorly managed operations and from historic and abandoned sites, and it becomes clear that the treatment of ARD will be required for the foreseeable future to protect water quality, and ecosystem and human health.

Jan 1, 1999

By A. L. Anderson, J. T. Rybock

KEECO has developed the Silica Micro Encapsulation (SME) technology for the treatment of acidic, metal-laden waters. Utilizing a silica-based chemical formulation that entails chemisorption and micro-encapsulation of heavy metals in a permanent silica matrix, encapsulated particles settle quickly and are effectively isolated from the surrounding environment, producing a stable sludge that is characteristically non-hazardous. In a number of independently-verified pilot and full-scale applications (including the Bunker Hill Mine, Leviathan Mine, Wheal Jane Mine, and Meldon Quarry), SME has been proven highly effective. The technology has been featured in a number of mining publications and selected for innovative technology awards.

Jan 1, 2000

By L. C. Morales

Mexico has an area of about 2 million km2 (772,260 sq miles), with volcanic activity, large shores and mountainous areas reaching as high as 6000 m (19,680 ft) above sea level. These conditions are favorable for most mineral deposits, some of commercial value and others as a source of mineral samples. In addition to its vast mineral wealth, Mexico has another valuable asset in its people. Even before the discovery of America, natives were successfully mining metals. During the colonial days, the mineral deposits were mined to increase the wealth of Spain. All this experience was passed from generation to generation. It created a tradition of mining and minerals processing engineers that currently accounts for about 182,000 people supported by mining-related activities. Nonmetallic minerals in Mexico have been mined by natives since the early days. They knew the value of kaolin clays for pottery, as evidenced by archeological findings. This experience was also passed from generation to generation and has become recognized worldwide as ceramic wares of high quality. The Talavera ceramic from Puebla is an example of family traditions many generations old.

Jan 1, 1994

By L. C. Morales

During my College days in Mexico City, my Mineralogy Professor used to say "Mexico is the Horn of Plenty, rich in minerals, and it is easier to say which minerals are not found instead of stating all that exist. He said that the only ones missing are bauxite, diamonds and titanium ores." Today, twenty years later, a rutile mine in Oaxaca is in successful operation. Mexico has an area of approximately two million square kilometers, with volcanic activity, large shores and mountainous areas reaching as high as 6,000 meters above sea level. These conditions are favourable for most mineral deposits, some -of commercial value and others as a source of mineral samples only. (fig. No.1) In addition to vast mineral wealth, Mexico has -another valuable asset in .his people. Even before the discovery of America, natives were successfully mining metals, and during the Colonial --days, the mineral deposits were mined to increase the wealth of Spain, and it increased the --knowledge of mining. All this experience was passed along from generation to generation, and created a tradition of mining and minerals processing engineers, that currently account for approximately 182,000 persons supported by mining related activities.

Jan 1, 1994

By Greg Beckstrom

On Oct. 1-3, SME?s Twin Cities chapter (SME TC), in cooperation with the University of Minnesota ? Duluth?s Precambrian Research Center (UMD-PRC), cohosted a symposium on silica sand mining and processing. The conference was held at the Earle Brown Heritage Center near Minneapolis. The symposium was followed by a day-long field trip to operating mines, processing plants and loading facilities located in southwestern Wisconsin. Speakers and attendees at the symposium included university professors, industry experts, regulators, mining company representatives, equipment suppliers, consulting engineers and service companies. Approximately 320 people attended the conference. In addition, about 50 people who oppose mine development and the oil and gas industry showed up to voice their displeasure with the event and those companies that operate in this space.

Jan 1, 2012

By M. J. Zdunczyk

The final 1995 figures on industrial sand and gravel have not yet been compiled by the US Geological Survey (USGS). There is usually about a nine-month lag time in receiving and compiling this information. However, USGS estimates that domestic production of industrial sand and gravel will increase about 4% to 28.2 Mt(31 million st). The average unit price is expected to increase as well. The top five producers during 1995 were Unimin, US Silica, Fairmount Minerals, Oglebay Norton and Morie Co. Glass manufacturing for containers, automobiles and buildings was mixed during 1995. Containers, the largest consumer of silica sand, remained steady, with regional increases. However, silica use in glass containers face increased competition from plastic and recycled glass (cullet). It was reported that the Pepsi Cola announced plans to replace glass containers with plastic during 1996.

Jan 1, 1996

By Rudolph K. Hoagberg

Silica sands, primarily in coarse size ranges, are used to prop open fissures or voids created in the bedrock by hydraulic fracturing. This procedure increases the flow of gas or oil or other fluids through the bedrock. The sands used must meet various specifications relating to their physical and chemical characteristics; these characteristics are in turn related to the geologic provenance of the sand deposit. The Jordan Sandstone, a Cambrian formation which is exposed in Minnesota and Wisconsin, meets the specifications of a proppant sand by virtue of its depositional history and its sedimentary properties.

Jan 1, 1980

By Kostas Fytas, Pierre Bousquet, Bill Evanelou

Acid mine drainage (AMD) is a serious environmental problem that preoccupies the Canadian Mining Industry. Considerable amounts of money are spent every year in an effort to prevent or reduce the acid mine drainage phenomenon. AMD occurs when sulphide minerals (ex. pyrite) contained in rock are exposed to air and water and subsequently oxidise to produce low pH water. This acid effluent has the potential to mobilise any heavy metals contained in the rock. Coating the sulphide minerals with silicates is a new promising technology to reduce AMD. Pynte is treated with a solution containing H2O2, sodium silicate and a buffering agent. H2O2 oxidises a small part of pyrite producing ferric iron (Fe3+) ions. These ions subsequently react with the silicate ions to produce ferric hydroxide-silica that precipitates on the pyrite surface producing a passive coating. This silicate coating can protect the grains of pyrite from oxidation. This paper presents a series of experiments that confirm that silicate coating can considerably reduce AMD.

Jan 1, 2000

By R. Bruce Tippin

The silicates represent the largest and most common group of minerals on earth. Yet in spite of the chemical similarities, numerous mineral processing plants worldwide are operating successfully to yield varied commercial products for numerous uses. The silicates that are commercially produced in the United States by flotation include quartz, feldspar, mica, spodumene, talc, kaolin, and wollastonite. The operation of several plants and the conditions affecting mineral separation by flotation are described. Because the process is usually dictated by the desired market, specifications for the most common products are provided. Potash is a basic fertilizer component, along with phosphate and nitrogen. Potash is typically produced from underground evaporite beds or recovered from natural brine solutions. Flotation of potash is unique in that it is processed in a saturated salt solution. The potash flotation process is outlined and several commercial operations are described.

Jan 1, 1999

By Lee S. Richardson

Silicon is usually considered to be a useful metallic alloying element. To be more truthful, it is not a metal at all, but a semiconductor, whose electrical resistance (when pure) is high and decreases with temperature. We will join the metallurgists, at least for this paper, and refer to it as a metal. In its commercially available form, silicon is metallic in appearance, brittle, with a density of 2.33, less than that of aluminum. Silicon dioxide or quartz has a high heat of formation, which not only makes the metal a useful reductant for other materials, but also makes it difficult to reduce from its ore. The melting point is 1412°C, slightly less than steel, but substantially higher than aluminum or cast iron. The alloys of silicon with iron, usually called ferrosilicons, have some unique advantages. The melting points of most alloys are substantially below those of iron or silicon (Fig. 1). The two major compounds formed (FeSi and FeSi2) help somewhat in the reduction of silicon by their energies of formation, but the influence of these phases on the mechanical properties is more important. Four major groups of alloys are made -- silicon metal (>95% silicon), 75-85% ferrosilicon, 50% ferrosilicon, and silvery pig iron (12-22% silicon). The alloys between 50 and 65% silicon and between 25 and 40% silicon are normally avoided because of structural instabilities, presumably of the two compounds, leading to disintegration of the alloys on cooling.

Jan 1, 1974

By R. C. Burtan

Long before recorded history, man began to dig into the earth's crust in a never ending search for useful materials. It is well known that more than half of the earth's crust is composed of silicon dioxide (SiO2), also known as silica. Silica and silica-containing material have a great many uses in modern society. This material, however, is potentially an extreme health hazard. Silicosis: Not a New Disease Centuries before the Christian Era, Hippocrates wrote of a lung disease common to those who mined in hard rock. He was obviously describing silicosis. It is also apparent from ancient writings that the Egyptians were aware of this malady. Dioscorides also wrote on this subject in the fifth century B.C. It is undoubtedly the oldest and best studied of the occupational lung diseases. Silicosis was certainly described by Agricola in his De Re Metallica published in 1556. Here he described lung disease among hard-rock miners. The original document was written in Latin and then translated in 1912 by Hoover and Hoover. One of these translators was Herbert L. Hoover, a former US president who once made his living as a mining engineer. More recently, there are numerous references in medical literature in the 19th and 20th centuries relating silica exposure to silicosis. There are specific references to mining in hard rock, as well as to sandblasting and a host of other industrial exposures. In 1919, Winslow described standards for measuring the efficiency of exhaust systems in polishing shops using sandblasting. These standards were equally applicable in the mining industry. As early as 1920, Winslow explored the efficiency of certain devices used to protect sand-blasters against the dust hazard. These devices were equally applicable in the hard-rock mining industry. The medical community recognized the silica health hazard in the early 1900s. Middleton described the illness in the British Medical Journal in 1929. He noted the danger to health at that time. D. Hunter mentions in his book, The Diseases of Occupations (1969), the monumental work of Merryweather in 1936, in which he surveyed the silicosis risk in Great Britain. He showed statistically that the average employment length of sandblasters who ultimately died of silicosis was 10.3 years, compared to 40.1 years for all fatal cases, irrespective of occupation. Sandblasting and hard-rock mining and drilling, obviously, are very hazardous occupations. Weil and Zisking of Tulane University wrote in 1975 that "it was known as early as 1935 that the course of silicosis is much more rapid in sandblasters than in miners or foundry workers. This can be explained by the fact that sandblasters are exposed to an almost pure siliceous dust containing high concentrations of respirable particles within the range of 1 to 3 micron size." Protecting the Worker The medical community recognized in the early 1900s the need for proper protective equipment for all of those who worked with siliceous materials. Middleton, writing in 1929, said: "The worker is then protected by a close fitting helmet with an air feed, much as in the case of an underwater diver. In spite of these precautions, cases of silicosis among sandblasters are being met with today. It is a matter for serious consideration whether a substitute, such as steel or iron grit, could not be used to replace the siliceous grit as the abrading material." C. E. A. Winslow, a professor of public health at Yale School of Medicine, and others wrote of the need to protect sandblasters by

Jan 7, 1984

By R. C. Burtan

Long before the dawn of recorded history, man began to dig into the earth's crust in a never ending search for useful materials. It has been well established that prehistoric man discovered flint. "The Flintstones" were aptly named. The flintknappers of southern England and Wales still exist today in ever dwindling numbers as they seek out chunks of flint. It is a well known fact that more than half of the earth's crust is composed of silicon dioxide (SiO2), also known as silica. Silica and silica containing materials have a great many uses in modern society. However, this material is potentially extremely hazardous to our health. Centuries before the Christian Era, Hippocrates wrote of a lung disease common to those who mined in hard rock. It is obvious to us that he was describing silicosis. It is also apparent from ancient writings, that the Egyptians were aware of this malady. Dioscorides also wrote on this subject in the fifth century, B.C. It is undoubtedly the oldest and best studied of the occupational lung diseases. It was certainly described by Agricola in his "De Re Metallica" published in 1556, in which he described lung disease among hard rock miners. This publication, I'm sure, is of special interest and perhaps known to many of you in the mining community. The original document was written in Latin and was translated in 1912 by two gentlemen, Hoover and Hoover. One of these translators was Herbert L. Hoover, a former president of the United States, who made his living before his presidency as a mining engineer.

Jan 1, 1984

By A. P. Grobbelaar

Andalusite is a member of the sillimanite group of minerals consisting of andalusite, kyanite, and sillimanite. These minerals are the structural polymorphs of Al,Si05 (the anhydrous silicate of aluminium) and although chemically similar, they differ in physical properties due to their different crystal structures. For further information on the sillimanite group, see the chapter on Kyanite and Related Minerals that follows. The minerals are generally the products of the metamorphism of alumina-rich sediments and are found in schists, gneisses, or hornfelses, which have undergone either regional or thermal metamorphism from their original form. Sedimentary deposits may also form since the minerals are chemically and physically resistant to breakdown. When heated to a sufficiently high temperature the sillimanite group minerals convert to mullite with a resultant volume expansion and the liberation of silica. Due to the stability of the mullite formed, its high hot strength and resistance to chemical and physical erosion, they are widely used in the manufacture of refractories and special ceramics (Table 1). The reaction can be represented as follows: [ ] The worldwide use of these minerals depends to a large degree on their availability (Fig. 1). Andalusite, with its lower conversion temperature and the lowest volume expansion on being heated is the natural choice as a raw material to produce energy-saving refractories without prior calcination. The Republic of South Africa holds by far the largest minable andalusite deposits of the world, estimated at some 70 Mt of known in situ reserves. The only other large commercial production of andalusite comes from France, with known reserves of about 5 Mt. Potential new deposits are known from China, Ireland, Australia, and South America. World consumption of andalusite in special performance refractories has risen from less than 10 ktpy in 1960 to nearly 300 ktpy in 1990, which is due to cost effectiveness in many industrial applications compared to other conventional refractory products. Andalusite-based refractories have traditionally been used in Europe, South Africa, and the Far East; usage in America was limited in the past due to relatively high delivery costs and availability of other local refractory minerals. However, there is a significant trend towards greater use of andalusite in North America, thus opening new markets and replacing other traditional refractory raw materials. GEOLOGY Andalusite occurs in metamorphosed rocks of clay-like com- position, as in the andalusite-hornfelses in thermal aureoles (contact metamorphism), formed under conditions of high temperatures and low stress, and in regional metamorphic rocks, such as the andalusite-schists. These schists are mostly unconnected with definite igneous intrusions but were presumably also formed at high temperatures and under low stress. Andalusite can also appear in alluvial deposits associated with the primary deposits. At depths of 10 to 20 km, temperatures of up to 450°C might be expected. Another result of increasing depth is an increase of pressure due to the load of the rock cover. The load stresses involved in metamorphism is generally believed to lie in the range 0 to 10 000 bars. During contact metamorphism the increase in temperature is brought about by the injection of magma. The temperature reached in the country rock at some distance from the igneous body will always be less than the initial temperature of the intrusion, which is presumably less than 1 200°C, and will vary with time and distance from the contact. A simple metamorphic reaction involving dehydration of an aluminous sediment can be: [ ] At higher temperatures sillimanite would form at the expense of andalusite, while kyanite would be the mineral formed at higher pressures, as can be seen in the phase diagram of A12Si05 (Fig. 2).

Jan 1, 1994

By Palmer C. Sweet

Kyanite. andalusite, and sillimanite are anhydrous aluminum silicate minerals, and they have the same chemical formula, Al2SiO3. Dumortierite and topaz are also classified as aluminum silicates although they contain boron and fluorine respectively. Mullite (a rare mineral named for its discovery site, the Scottish island of Mull) is produced when kyanite, andalusite, or sillimanite are heated. Synthetic mullite, also classified as an aluminum silicate, is formed by melting alumina and silica, bauxite, and kaolin or alumina, kaolin, and kyanite, depending on the type of synthetic mullite desired. These materials are either sintered in rotary, periodic, or tunnel kilns, or fused in an electric arc furnace. The world's largest producer of kyanite is the United States. Domestic kyanite is presently produced from one company at two sites in Virginia; Kyanite Mining Corporation mines kyanite from Willis Mountain and adjacent East Ridge in Buckingham County in the central Piedmont province of Virginia. Internationally, kymite is produced in Australia, Brazil, India, Kenya, Sweden, and Zimbabwe; the former USSR also produces kyanite (Fig. 1). Andalusite is produced by Piedmont Minerals Company, Inc. in the Piedmont province near Hillsborough, NC. Andalusite is also produced in France, India, the Republic of South Africa, and Spain (Fig. 1). Sillimanite is produced in Australia, Brazil, India, Spain, and the Republic of South Africa; the former USSR is also thought to be a major producer (Fig. 1). Some of the countries produce only for domestic use. Synthetic mullite, made by sintering and by electric arc fusion, is produced by Mulcoa (Mullite Company of America) in Andersonville, GA, and by Washington Mills Electro Minerals Corporation in Niagara Falls, NY. Annual world production of kyanite, andalusite, sillimanite, and synthetic mullite is approximately 672 727 tons (Potter, 1988). GEOLOGY Mineralogy Kyanite is a blue to light-green, triclinic mineral that occurs in long, thin-bladed crystals and crystalline aggregates in gneiss, schist, and pegmatites. The mineral has a hardness of 5 parallel to the long axis of the crystal and a hardness of 7 across the crystal. Andalusite is a yellow, brown, green, or red orthorhombic mineral that occurs in thick, almost square prisms in schist, gneiss, and hornfels. Gem quality andalusite exhibits a strong pleochroism; brownish-green in one direction and brownish-red perpendicular to it. Andalusite also occurs in placer concentrations where it has weathered out of rock. Sillimanite is a brown, pale-green, gray, or white orthorhombic mineral that occurs in long, slender, needlelike crystals in schist and gneiss. Chemical and Physical Properties Chemical and physical properties of kyanite, andalusite, and sillimanite are noted in Table 1. Kyanite is the only mineral that irreversibly expands when heated (calcined to produce mullite) and may offset the shrinkage of most ceramic or refractory ingredients when heated.

Jan 1, 1994

By H. Colijn

The trend in the coal industry for many years has been to make everything "bigger and faster" This also held true for loading and storage facilities. Where once a million ton per year mine was rare, three to five million ton per year mines are not uncommon today in the bituminous industry. This greatly increased production, made possible through mechanization, required greatly improved loading facilities just to get the coal away from the mine. Also, there is a trend toward combining production from more than one mine and cleaning it in a single preparation plant. In addition to increased loading capacity, this frequently necessitates raw coal storage and blending facilities. The development of the unit train, more than any other factor, has contributed to the widespread construction of storage and high-speed loading facilities for clean coal. In the export market, the construction of ever larger coal bulk carriers has contributed to a need for faster and larger loading facilities at ports. The present engineering and construction cost of these larger facilities make it essential that the flow and handling properties of the particular coals are fully known. These properties can be measured well in advance and the proper design criteria established. This eliminates costly surprises later on during start-up and operations. This paper will review coal and coal refuse properties, such as shear strength, cohesion, friability, and the flowability of coal and how they affect the design criteria of storage silos.

Jan 1, 1979

By Larry A. Enloe

The 16-to-1 milling operation is Sunshine Mining Company's first new silver and gold producing facility. The 16-to-1 underground mine and mill are located approximately 64 km (40 miles) southwest of Tonopah, Nevada. Ore re- serves in the epithermal vein deposit are estimated at 0.91 Mt (one million st) of ore, at an average silver grade of 206 to 240 g/t (6 to 7 oz/st) and an average gold grade of 1.2 g/t (0.035 oz/st). The underground mine uses a large diameter blasthole stoping system of mining using highly mechanized rubber-tired equipment. The mill uses conventional cyanide leaching with countercurrent decantation and Merrill-Crowe precipitation. The mill start-up was in February 1982 resulting in the first pour of dore' in March 1982. The mill's present annual production is approximately 31.1 t (1.0 million oz) of silver and 264 kg (8500 oz) of gold.

Jan 1, 1984