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By J. Sikamo, A. Mwanza, C. Mweemba

"The Zambian copper mining industry as we know it today had its genesis in the 1920s. Consistent private sector-driven investment in the industry over a period of over 50 years in exploration, mine development and operation, development of minerals processing facilities, building of infrastructure for pyrometallurgical and hydrometallurgical processing, with attendant support facilities, including building of whole new towns, resulted in copper production rising to a peak of 769 000 t in 1969, providingover 62 000 direct jobs. The industry was nationalized in 1973 and remained in government hands for just over 24 years. During this period, the industry experienced a serious decline in production levels, reaching the lowest level in the year 2000 when production was 250 000 t. An average of just under 2000 jobs were lost every year in the 24-year period, reaching just over 22 000 direct jobs in 2000.Following the return of Zambian politics to pluralism and liberalized economic policies, the government decided to privatize the mining industry. The process started in 1996 and by the year 2000 all the mining assets had been privatized. The new investors embarked on serious investment to upgrade the assets and to develop greenfield mining projects. Fourteen years later and after more than US$12 billion investment, production levels increased year-on-year to a peak of 763 000 t in 2013 with direct jobs reaching 90 000.This paper discusses the impact of the mining industry in Zambia on the economy in areas such as employment, support for other industries, direct contribution to the national gross domestic product (GDP), foreign exchange earnings, and social amenities. The paper also focuses on the performance of the mines during these periods vis-à-vis mineral availability, mineral grades and complexity, new technologies, and human capital. This is looked at particularly in the light of current challenges the industry is facing. Suggestions are proposed on how the industry can be nurtured to continue being a major driver for the Zambian economy and a major player in the international copper mining business."

Jan 1, 2016

By F. Lowell Lawrance

JOHN SMITH, citizen of the U.S.A., has become so accustomed to reading that Congress has appropriated billions of dollars to pay war costs. that he no longer is impressed by relatively small figures, such as several hundred thousand or a few million, in connection with Government departments.

Jan 1, 1944

By M. W. BERNEWITZ

ALL live producers and manufacturers of metals and alloys are investigating new uses for their products. The tin and tin-plate industry is no exception. One-third of all the new tin mined and refined is consumed in making tin plate. Several billions of cans are each year made from tin plate for the preservation of nearly 200 kinds of food. There are more than 500 tin-plate mills or individual stacks in the United States, which country makes more tin plate than all other countries combined and exports large quantities. As much as 1,800,000 tons of till plate has been made in a year in this country, and 28.000 tons of tin has been used in this period for this purpose. In sonic years a third of the till is so consumed; in 1933 it was half of the supply.

Jan 1, 1935

By T. Mwanza, B. N. Belford, P. Conradie

"Metix has introduced a three-piece ’deep-cooled’ copper slag tapblock into a six in-line copper matte settling electric furnace. The tapblock was designed without any internal refractory; it relies purely on the development and maintenance of a freeze lining on its hot face and within the tapping channel to protect the copper and promote the integrity of the surrounding endwall refractory lining. In addition, the geometry of the tapblock further supports the sidewall refractories, reduces the impact of funnelling and, therefore, the need for premature rebuilding of the furnace endwall, and facilitates easy removal and replacement of the wear components even under ’hot’ furnace conditions. Eighteen thermocouples embedded in the copper components ensure full resolution of the copper condition, enabling plant personnel to identify wear rates, estimate freeze lining thickness and stability, and schedule replacement of spares and wear components well in advance.At the time of writing the tapblock had been in operation for 6 months with approximately 350 000 t of slag having been tapped through it. Every indication is that the design will limit the need for premature relining of the furnace endwall due to rapid deterioration of the tapblock and its surrounding refractories. IntroductionNonferrous furnaces rely heavily on the maximization of refractory campaign life to increase profitability and reduce planned downtime. In large electric copper slag-cleaning furnaces utilizing insulating linings, campaign lives of six or more years are realistic if consideration is given to each aspect that can degrade the refractory lining during the campaign. An area that is particularly vulnerable is the slag tap-hole and the local surrounding refractory. To avoid premature relining of the furnace walls, every effort should be made to consider not only the tap-hole design itself, but also the selection of the sidewall refractory material and its construction immediately adjacent to the tap-hole, and furthermore the interplay between the tapblock and this adjacent refractory. A holistic approach to the design that considers these interdependent features in the slag tapping area can reduce the incidence of accelerated refractory wear (‘funnelling’), support the surrounding refractories to prevent their collapse, introduce easily replaceable wear components that can be exchanged with the furnace still ‘hot’, and encourage and maintain a stable freeze lining at the refractory hot face that maximizes the tapblock and refractory lifetime."

Jun 1, 2019

By Steve Wilson, Bern Klein, Jeff Drozdiak, Stefan Nadolski, Andrew Bamber

"In the adaptation of high pressure grinding rolls (HPGRs) to hard-rock mining applications, circuit development has mainly focused on placing HPGRs in the role of tertiary crusher in the preparation of ball mill feed. In order to take advantage of the potential energy benefits associated with HPGR and stirred mill grinding technologies, work was done to investigate the potential of and resultant energy benefits of placing the HPGR in series with a high speed stirred mill in replacement of the conventional cone crusher / ball mill arrangement. The proposed circuit was designed to operate with two stages of HPGR grinding followed by high speed stirred milling.Using a pilot-scale HPGR unit inline with a 20 liter stirred mill, the design criteria, circuit arrangement and consequent comminution energy requirements for a circuit processing copper sulphide ore from Teck Resources’s Mesaba Copper project were determined. These results were then compared to two other circuits, an HPGR / ball mill circuit and a conventional crusher / ball mill circuit processing the same ore.The testwork indicated at a proof-of-concept level that the HPGR / stirred mill circuit could potentially be appropriate for this duty and further work on the concept is merited. While the results indicate that the HPGR component of the circuit was more energy efficient than conventional cone crushing, the energy efficiency of the stirred mill was found to be lower than that of a comparable ball mill undertaking the same duty. However, increased energy efficiency of the stirred mill portion of the circuit is possible with further optimization and further work on the concept is indicated."

Jan 1, 2010

By J. R. Koehler

Although two-entry yield pillar-based gate roads supported by wooden cribs have been commonly used throughout longwalling in the Wasatch PlateadRoan Cliffs coalfield of central Utah, a three-entry yield-abutment gate road configuration was recently trialed in the Hiawatha Seam at the Genwal Resources (GRI) Crandall Canyon No. 1 Mine, near Huntington, UT. Pillar, entry, and cable bolt performance were monitored through second panel mining using a fairly extensive array of geomechanical instruments installed over a span of four crosscuts. Ground pressure and entry closure measurements confirmed that the 9.1-m-wide (30-ft) yield pillar was partially shielded from first panel longwall loads by the 36.6-m-wide (120-ft) abutment pillar, and consequently, experienced only minor yielding until the approach of the second panel face. Complete yielding of the 9. I-m-wide (30-ft) pillar occurred when the second panel was approximately 6.1 m (20 ft) inby the instrumentation site. Average cable bolt loads and differential roof sag remained low through second panel mining and tailgate entry ground conditions were excellent; however, very high ground pressures in the abutment and yield pillars, and second panel rib strongly suggest a high potential for coal bumps utilizing this gate road configuration at mining cover depths in excess of 396 to 457 m (1300 to 1500 ft). This conclusion is supported by the suspected occurrence of small coal bumps along the abutment pillar ribs, observed indirectly as fresh debris in the middle entry just behind the second face. This paper presents a case history developed from the geotechnical measurements and on-site observations of this unique application of a yield-abutment gate road configuration and cable support system in the Hiawatha Seam.

Jan 1, 1996

By C. Pelley, A. Piche

"The Canadian mining industry faces the prospects of a severe shortage of graduate mining engineers over the next decade. This arises from three factors: first, a growth in industrial activity; second, the average age of company engineering and management staff; and third, the reduced number of students in engineering faculties around the world. This paper aims to identify the critical factors underlying the trend of inadequate recruitment into higher education for mining and to examine means of alleviating the problem.This paper is based upon surveys of potential and current students and graduate mining engineers from four mining schools. An attempt is made to understand institutional and industrial images, career prospects and what is required to attract enough high-calibre young people into mining education over the next decade.IntroductionThe mining industry has started to experience a severe shortage of graduate mining engineers which is likely to persist and even worsen in the short- to medium-term.This arise s from three principal factors:1. a recent and strong growth in mining activity, which surpasses that experienced through the 70s, before the recent international industrial recession; .2. an increasingly older average age of mine engineering employees, at least in the industry's larger companies; and3. problems associated with maintaining adequate mining undergraduate recruitment levels ."

Jan 1, 1989

By G. Lyle

Since its inception CEMI (Centre for Excellence in Mining Innovation) has focused on facilitating innovative solutions to the mining industry in six strategic research areas; GeoRisk, ConstructMine, ValueMine, FindMine, SustainMine and MineTech (visit www.miningexcellence.ca for details). This paper focuses on CEMI?s largest project to date, Ventilation on Demand (VOD). Energy consumption in mines can account for upwards of 40% of a mines operating cost, with a significant portion of this been consumed by the ventilation requirements. VOD provides a significant opportunity to reduce overall mine ventilation requirements and subsequently energy costs, while potentially increasing mine productivity. CEMI is currently in year 2 of an assessment of VOD, focusing on the financial, physical and equipment viability of utilizing such systems in both new and existing mines. This two year program, to be completed by March 31, 2011, is designed to systematically assess such a system to determine if and when it could effectively be applied in underground mines. The paper will describe the process by which the project was initiated, the demonstration projects established to capture data, the means to interpret the data and the modelling developed to calibrate and predict ventilation system requirements.

Oct 1, 2010

A composite iron ore-reductant pellet is a mixture of fine iron ore and fines of coal/char/coke, bonded at essentially room temperature with sufficient green strength for subsequent handling. In ironmaking, these pellets offer the advantage of fast reduction, utilisation of fines, non-coking coal and coke breeze. The composite pellet-based alternative ironmaking processes constitute a promising route for ironmaking in future. The present paper is a brief review of kinetics and mechanism of reduction of iron oxides into iron and other associated reactions, when these pellets are heated to high temperature. It would draw significantly from investigations conducted by the author and his co-workers.

Jan 1, 1999

By Grant R. Brown

This report presents the results of a study examining the relationship between supervisor characteristics and performance in underground coal mines, The specific objectives of the research include; document tasks performed by first-line supervisors during a normal shift; explain why supervisors carry out their duties as they do: identify salient characteristics of effective first-line supervisors; and formulate criteria for selecting and developing candidate supervisors. To accomplish the study objectives, on-site observation and data collection was carried out at 13 underground mines in Illinois, Ohio, and Pennsylvania. One hundred thirty-eight first-line supervisors were observed during a full work-shift and discussions with the supervisors and the mine superintendent were held during the course of the visit. The observational data from the study provide a detailed description of what supervisors to during their shift. The report begins with an introduction discussing the problem being studied and objectives of the research. The literature related to supervisor selection is then reviewed. The following section describes the research design including data collection procedures and statistical methodology used in the study. The next sections present the analysis of mine, section, crew, and supervisor characteristics. The report concludes with a discussion of the results of the study and recommendations concerning supervisor selection and development.

Jan 1, 1987

By D. M. Doyle

A study of the various components contributing to energy costs and their relationships to generally trended operating data, such as tonnage, operating costs, etc., over progressively shorter time periods provides information for an energy audit. A study of annual data gives some insight into the importance of various energy components. As the time frame of the study progresses through monthly, daily and, finally, into quarter hourly data, the variations become more evident and, most important, strategies develop to minimize energy costs. The results of an audit conducted during the summer of 1978 at Wesfrob Mines Limited are reported to illustrate this important phase, prerequisite to a meaningful energy cost avoidance program. The balance of the paper deals with the energy conservation program at Falconbridge Nickel Mines Limited's Sudbury operations, the metering and control equipment, the commitment, the new energy accounting practices and, lastly, the policies. Examples of successful energy conservation endeavours include automatic peak electrical load control, waste heat recovery from mine air and compressor cooling water, energy reductions resulting from lower building temperatures and curtailment of idling loads. The use of pulse meters to measure the flow of gas, steam, compressed air and electrical energy, with their signals interfaced to process computers, allows monthly, daily and, if necessary, immediate reporting of energy and energy per unit of production information The program so reported at Falconbridge's Sudbury Operations is credited with an annual cost avoidance of .9 million dollars in a 14.0-million-dollar annual energy account

Jan 1, 1979

By R. Sweennen, A. Vervoort, J. Caers

A case study is presented of the mechanical behaviour of fractures in the Westphalian A and B siliciclastic succession of mud-, silt- and sandstones with intercalating coal layers in the Campine basin of northeast Belgium. Mining ceased in the area in 1992 and a pilot well was drilled to assess the feasibility of methane extraction by hydraulic fracturing. Work was carried out to study the influence of types of cement fill in fractures on the shear behaviour of the rocks by comparison with that of the coal seams. X-ray computerised tomography was used for visual appraisal and selection of jointed rocks before destructive shear testing was carried out. Two major type of veins were found to be present, one cemented with carbonate and the other with kaolinite or kaolinite/carbonate. Uniaxial compressive strength and shear tests showed that differentiation of the two types of veins was vital in evaluating the strength of the sandstones, as cementing of the fractures by rigid carbonate minerals can reinstate the strength of the rock masses to that of the intact material. Kaolinite was more susceptible to plastic deformation than carbonates

Jun 19, 1905

By David E. Thompson, Andrew F. McKown, Herbert H. Einstein, Amr S. Azzouz

INTRODUCTION Design of supports for underground chambers in rock has undergone considerable development. This becomes evident when comparing support dimensions of subway station caverns built in the U.S. over the past fifteen years. The Porter Square Station cavern, which is a part of the Massachusetts Bay Transportation Authority (MBTA) Red Line extension, is the latest in this series. It is approximately 168 m (550 ft) long, 21 m (70 ft) wide, and 14 m (45 ft) high, and has a permanent support of light steel ribs imbedded in a 0.4 m nominal (15 in) shotcrete lining. An extensive construction control instrumentation program made it possible to evaluate the performance of the cavern and its support. This evaluation, which is presented in this paper, was the objective of a research project sponsored by the Urban Mass Transportation Administration (UMTA) and jointly conducted by Haley and Aldrich, and MIT. The actually used design procedure was compared with other approaches, notably procedures based on Finite Element analyses and empirical rock mass classification methods. Support dimensions predicted with all these approaches were compared to the actual support and its performance.

Jan 1, 1983

By Peter B. Lilly

Thank you, Syd, for the kind introduction and for inviting me to give the Keynote Address at this very prestigious gathering of some of the finest intellect and talent in the domestic and international coal industry. CONSOL Energy has been a part of this conference for its entire 24-year existence. We have presented 27 papers over that time. CONSOL employees have also been members of the planning committee for the conference, and we have been pleased to support the event both financially and with many participants. So I am honored to be here with all of you this morning, especially during such a positive period for coal. You can just feel the enthusiasm in this room for our industry, and for this conference. I can tell you, there?s also a lot of enthusiasm and excitement in CONSOL Energy?s boardroom. And our enthusiasm is mirrored on Wall Street. But there remains an ironic twist to all of this attention. Even when times are good, the coal industry seems to go largely unnoticed by the mainstream. Outside of West Virginia and other coal-producing regions, the industry still seems to lack influence and support, at least here in America. As an example, last month, an ABC News crew visited our Blacksville 2 Mine, near here, to do a feature story on increased employment in the coal industry.

Jan 1, 2006

By K. Morsi

The interest in spark plasma sintering has been growing considerable over the past few years. This has been brought about by the unique advantages of the process, which include reduced sintering temperatures and times and the production of materials with unique microstructures and properties. Despite its current reputation as an outstanding process that has solved major problems such as nano-powder consolidation, it has so far been largely limited to the manufacture of simple shapes, due to its inherent geometric configuration. In this paper we present preliminary results on spark plasma "extrusion" that can allow the production of extended geometries via electric-current processing. Preliminary results on the processing and microstructure of spark plasma extruded aluminum are discussed.

Jan 1, 2009

By Phillip Cancilla, Daniel Roy, Frank Rosenblum

"The manual moisture determination methods employed today by mineral processing plants falls short in providing timely information required for automation control. The costs associated with transporting and handling concentrates still represent a major portion of the overall treatment price. When considering the cash flow of a mining operation, that is governed by both the smelter contract, with moisture penalties and the quantity and quality of the concentrates shipped, an efficient method of on-line moisture content would be a welcome tool.A novel on-line determination system for ore concentrate moisture content would replace the normally tedious classic manual procedure. Since the introduction of microelectronic-based control systems, operators have strived to reduce the treatment costs to the minimum therefore a representative and timely determination of on-line moisture content becomes vital for control set points and timely feedback. Reliable sensors have long been on the “wish list” of mineral processors since the problem has always been that you can only control what you can measure. Today, the task of moisture determination is still done in the classical technique of loss in weight by uncontrolled procedures. These same methods were introduced in the earliest base metal concentrators. Generally, it is acceptable to have ore concentrate moisture content vary within a range of 7 to 9%. Many times, delays in manually achieving reliable feedback on the moisture content results in the moisture varying from 5 to 12% before corrective actions can be made.This paper first reviews the traditional and widely available methods for determining moisture content in granular materials by applying physical principals and properties to measure moisture content. All methods are in some form affected when employed on mineral ore concentrates. This paper describes a unique and promising on-line moisture sensor in two mineral processing applications, which not only automates the tedious tasks but also results in reliable moisture feedback that can be used in the optimization of the de-watering process equipment such as pressure or vacuum filters and fuel-fired driers. Finally, two measurement applications will be presented to indicate the usefulness and to summarize the measurement requirements for the proposed method of employing drag force and mechanical properties of the material itself to determine the moisture content."

Jan 1, 2001

By Zuhair A. Nawab, Muhammad A. Al-Marhqun, Mehmet Guney

"The Atlantis-Il-Deep is a stratified metalliferous deposit located along the median valley of the Red Sea at a water depth of about 2200 m. The metal-bearing mud contains sulphides of zinc, copper and iron with significant amounts of silver, gold and cobalt. A variety of oxide, siliceous and carbonaceous gangue material is also present. Long sediment cores indicate that the thickness of the deposit may reach 25 m, but the average kriged thickness of metal-rich sediments is about 11 m.Mining geostatistics was applied to estimate the Red Sea offshore mineral resources. Experimental semi-variograms were computed along 0 ± 180 degrees and then models were fitted to analyze the mineralization phenomenon. Kriging estimates indicate that 696.330 million t of bulk sediments contain 1.891 million t of zinc, 0.425 million t of copper and 3. 75 thousand t of silver. Gold and cobalt contents were calculated from the analysis of solids in flotation concentrates as 47 t and 5368 t respectively. The significant outcome of implementing geostatistics to the Red Sea brine precipitates is not only for the evaluation of metal resources, but it also provides a useful tool in the optimization of selective dredging of appropriate areas to be mined. IntroductionThe discovery and extensive exploration of hot brines and hydrothermal sediments in the Red Sea median valley revealed the fact that the Atlantis-II-Deep is a potentially exploitable metalliferous mud in the economic sense. Sediments in the mineralized deep are composed mainly of oxides, various types of silicates and sulphides with considerable concentrations of zinc, copper, cadmium, silver and gold. The mineral-rich deposit, located at a mean water depth of about 2000 m, has an average thickness of 11 m, and is covered by a brine layer having a temperature of 60°C."

Jan 1, 1988

By R. H. Fernald, C. D. Smith

When the United States Geological Survey began operations at the coal-testing plant erected at the Louisiana Purchase Exposition at St. Louis, Mo., in 1904, it had already outlined a comprehensive plan for the systematic study of coals, lignites, and other mineral fuels with reference to their suitability for particular purposes and the methods by which they could be utilized most efficiently. Recognizing the need of information on the relative economy of producer gas as compared with steam for power purposes and the lack of comparable tests of American coals in the gas producer, the Geological Survey undertook investigations of the merits of different coals as producer fuel for the purpose of promoting efficiency in the utilization of the nation's fuel supplies. These investigations were carried on at St. Louis, Mo., and, later, at Norfolk, Va., and Pittsburg, Pa. The aet of Congress approved May 16, 1910, transferred the fueltesting work being carried on by the Geological Survey to the Bureau of Mines. This bureau is conducting producer-gas tests at P~ttsburg, Pa., and is publishing and distributing reports relating to all the fuel tests made by the Survey. These investigations into the possibility of generating producer gas in a commercial way for power purposes from the various fuels of the country have been associated with steaming, briquetting, coking, and other tests, all of which supplemented an examination into the nature, extent, and distribution of the fuels. The tests have all been made with carefully selected representative samples and carload lots of materials procured specially for the purpose by experienced collectors.

Jan 1, 1911

The research described in this report was conducted under a cooperative research agreement between the U.S Bureau of Mines Twin Cities Research Center (TCRC), Cleveland-Cliffs Inc. (CCI), and three operations in Northern Michigan managed by CCI: the Empire and Tilden surface taconite mining operations, and the Central Shops maintenance facility. All of these operations are in or near Ishpeming, MI. The Human Factors Research Group at TCRC is responsible for designing, planning, and conducting the research, and reporting on the findings. This project was carried out in order to investigate the high prevalence of back injuries being experienced by workers employed at the three CCI Northern Michigan sites, In an analysis of Company accident records for workers employed at these sites, it was determined that back injury problems confronting the CCI sites mirror those confronting the entire mining industry.

Jan 1, 1994

By R. W. Stahl

Employees and dollars are necessary to all enterprises and any force, such as fire, which destroys either, can bring very serious consequences, including business failure. Since everyone acknowledges the necessity of conserving human life, we will devote most of our paper to the economic factors involved. A coal-mine fire is considerably more difficult to combat than a fire in a surface building because of the combustible surroundings in the mine, the explosive gases emitted from the coal, the suspension of explosive dust when mine timbers burn and the unsupported roof falls, the limited space in which approach to the fire can be made, and the limited avenues of escape. A survey of coal-mine-fire protection indicated that a rather low value was being placed on property and equipment. This prompted comparison with other industries. The comments made in this comparison are not intended as an indictment of the coal industry, since we do have mines that are well protected against fire, but the comments on conditions at the mines visited are factual and may help others to improve similar conditions. SURVEY PROCEDURES Plants of the steel, aluminum, rubber, chemical, and petroleum industries were surveyed, and all facets of the fire-protection scheme were covered. The industrial plant invariably had four times as much water readily available for instant use than the mine. In many mines where water is available, no equipment for applying it is provided, such as hose, nozzles, and adapters, so that time is lost in collecting this equipment. (See Table I.) EXTINGUISHERS Many more and generally larger portable extinpishers are available at the plant as compared to the mine. The extinguishers are generally placed nearer to sources of danger. In addition, respiratory protective equipment is always available at strategic points in plants but only in a few mines. (See Figs. 1 and Table 11) INSPECTING AND TESTING EQUIPMENT Plant water facilities are checked weekly and flushed at 6-month intervals, and hose is pressure-tested at least yearly; some mines check water yearly, but hose is not tested unless used. Fire extinguishers are inspected weekly in plants and completely overhauled yearly; one mine had monthly checks and overhauls only after use. FIRE BRIGADES AND TRAINING Every plant had designated fire-fighters and some complete full-time brigades; at one mine a chief mechanic was designated as being in charge of fires, and other depended entirely upon officials who might not be familiar with the equipment. COST OF FIRES AND PERCENTAGE OF CAPITAL INVESTMENT IN FIRE PROTECTION The direct cost of recent mine fires ranged from $128,000 to $240,000; indirect costs, such as lost tonnage, idled equipment, lost orders, and the like might run the cost to over $500,000. (See Figs. 2 and 3).

Jan 1, 1961