Intro To Mineral Processing

OSWER
May 2012
Mining is a complex long term activity.

The basic elements of environmental risk at mining sites
has not changed: mines have large pits and generate large
amounts of tailings and waste rock.
Modern mining often resembles a complex chemical plant
rather than a quarry due to the reliance on acids and
cyanides.
Environmental management of mining requires attention
from the very beginning of mine design throughout the
life of the mine until closure.
Environmental compliance requires a robust monitoring
program which provides data to the public on a regular
basis.
Reclamation and closure planning begin at the start of

mining and are refined throughout the life of the mine.
Environmental modeling of mine waters is extremely
complex. The reliability of modeling is at best
questionable. Modeling must be confirmed with life of
mine monitoring.
Environmental impacts may not become apparent until
years after closure and may occur despite the best
designs.
Mines should be required to obtain financial assurance
to cover the costs of remediation by a third party.
The
industry includes exploration, extraction, and beneficiation.
Typically
located in rural areas and may vary in size exceeding

10,000 acres.
About
25 large mining companies dominate the industry.

Ownership structures are complex, with individual mining
operations separately incorporated, potentially shielding parent
corporations from future liabilities.
Many
of the mines are sited on a mix of public and private lands

that often involve multiple ownerships including BLM, FS,
National Park Service, Tribal, State, and private lands.
Approximately 1200 active extraction and beneficiation hardrock mining sites

operating
Gold mines in NV, CO, AK, with prospects in SC
Copper mines in AZ & NM, w/new copper/gold mines potential in MI, MN and WI
Lead mining takes place in MO
Zinc mining occurs in TN
Phosphate mining takes place in FL and ID
Iron ore mining occurs in MN and MI
Uranium mining is taking place in NM & Colorado w/new exploration throughout
the US.
Approximately 500 mineral processing facilities located throughout the US.
Chemical use in mining has changed dramatically over the last 20 years (e.g.,
cyanide heap leaching of gold has become widespread), creating new
environmental and human health challenges and leading to a resurgence of mining
activities in many areas of the country.
Copper and gold mines comprise 80% of the facilities in the United States.
Nevada is the most active with approximately 150 gold mines.
What is Mining?
Extractionremoval of overburden and ore from
the ground
Underground and surface mining methods
In-situ miningpump solution into ore from
surface wells
Underground Mining
Use of shafts and tunnels to access ore
Pumping out mine water
Bring ore to the surface for additional handling
Surface Mining
Open pit--Cheapest method to access ore
Causes greatest potential environmental impacts
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Ore Concentration
Crushing, grinding in ball mills, then froth floatation

Final product looks like dark sand which goes to smelting
Cyanide Heap/Tank Leaching
Concern about leakage into ground and surface water

Concern about releases of mercury
Hydrometallurgical Processing
Ore is leached with chemicals and then a liquid/liquid

chemistry to create a metal rich solution which is then
electrowinning produces solid metal plates with out
smelting
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In a general sense, Extraction is the initial removal of

ore from the earth.
In a general sense, Beneficiation is the initial attempt at
liberating and concentrating the valuable mineral from
the extracted ore. This is typically performed by
employing various crushing, grinding and froth flotation
techniques. The remaining material is often physically
and chemically similar to the material (ore or mineral)
that entered the operation, except that particle size
reduction has often occurred.
Mineral processing is generally viewed as smelting but
the term encompasses a wide variety of
processes. Primary smelters covered under this Rule.
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Open Pit
Underground
Strip/Ridge Top
Placer
In-Situ Leaching (uranium)
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15
16
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18
BERKELEY
BERKELEY PIT
PIT
1.5 mi
1 mi
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Shaft - vertical
opening to the
surface
Adit - horizontal
opening to the
surface
Stope - opening
along the vein or
ore deposit
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21
22
23
24
Crushing/Grinding in Ball mills
Froth floatation
Cyanide Heap Leach
Copper (SX/EW) solvent extraction/electrowinning
25
Large rotating mills

use metal balls or
rods to grind the
ore
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A concentration
process commonly
used for sulfide
ores of copper,
lead, and zinc is
flotation .
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28
29
30
31
Waste Rock
Tailings
Tailings Impoundment disposal

Dry stack disposal
Disposal in lake impoundment
Heap Leach/Dump Leach
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SOURCE: Teck 1999 annual report
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35
36
ATSDR- Agency for Toxic Substances and Disease
http://www.nunat.net/atsdr.pdf http://www.nunat.net/iris.pdf
Cleaning up Abandoned Mines in the West CU
EPA and Hardrock Mining: A Source Book for Industry in the Northwest and Alaska
http://yosemite.epa.gov/r10/water.nsf/59f3b8c4fc8c923988256b5800
60f5d9/e4ba15715e97ef2188256d2c00783a8e?OpenDocument
EPA Framework for Metals Risk Assessment 2007 www.epa.gov/
osa/metalsframework/pdfs/metals-risk-assessment-final-3-8-07.pdf
EPA National Hardrock Mining Framework (EPA 1997
EPA Mining Waste http://www.epa.gov/epaoswer/other/mining/index.htm
Inactive Mine Site Characterization and Cleanup Handbook (EPA 2000)
Mining 101 Training: Introduction to Non-Coal Mining Operations
Mining Engineering Handbook SME
Paul W. Thrush, 1968, A Dictionary of Mining, Mineral, and Related Terms, US Bureau of Mines,
USEPA R10 Mining Financial Assurance Strategy (PDF)
The Process and Requirements for Large Mine Permit Applications in Alaska. State of Alaska Large Mine Team presentation.
(See pages 5-8 for Mining 101 information.)
http://www.dnr.state.ak.us/mlw/mining/largemine/lmpt.pdf
US Geological Survey Investigations of Watershed Contamination from Mining http://toxics.usgs.gov/bib/bib-Mining.html
37

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OSWER

Mining is a complex long term activity.

Reclamation and closure planning begin at the start of

industry includes exploration, extraction, and beneficiation.

located in rural areas and may vary in size exceeding

25 large mining companies dominate the industry.

of the mines are sited on a mix of public and private lands

Approximately 1200 active extraction and beneficiation hardrock mining sites

Nevada is the most active with approximately 150 gold mines.

Crushing, grinding in ball mills, then froth floatation

Cyanide Heap/Tank Leaching

Concern about leakage into ground and surface water

Ore is leached with chemicals and then a liquid/liquid

In a general sense, Extraction is the initial removal of

Crushing/Grinding in Ball mills

Cyanide Heap Leach

Copper (SX/EW) solvent extraction/electrowinning

Large rotating mills

Tailings Impoundment disposal

Heap Leach/Dump Leach

SOURCE: Teck 1999 annual report

ATSDR- Agency for Toxic Substances and Disease

Cleaning up Abandoned Mines in the West CU

EPA Framework for Metals Risk Assessment 2007 www.epa.gov/

EPA National Hardrock Mining Framework (EPA 1997

EPA Mining Waste http://www.epa.gov/epaoswer/other/mining/index.htm

Inactive Mine Site Characterization and Cleanup Handbook (EPA 2000)

Mining 101 Training: Introduction to Non-Coal Mining Operations

Mining Engineering Handbook SME

USEPA R10 Mining Financial Assurance Strategy (PDF)

(See pages 5-8 for Mining 101 information.)

US Geological Survey Investigations of Watershed Contamination from Mining http://toxics.usgs.gov/bib/bib-Mining.html

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