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By Veerendra Singh, NILAMADHABA SAHU, ARIJIT BISWAS

Manganese alloys are important raw materials for steelmaking. However, selective mining of high-grade manganese ore resources has resulted in a scarcity of these high-grade Mn ores (Mn: >42; Mn/Fe: >5). The present research work is carried out to explore a new smelting reduction process to produce high-Mn/Fe syntheticMn ore from low-grade ferruginous manganese ores. Representative samples of low-grade ores (Mn: 25–30%; Mn/Fe: ~1) were collected and smelting reduction studies were carried out using variable smelting power (20–30 kWh), carbon rate (10–20% of ore) and slag basicity (0.1–0.3) to produce high-MnO slag and manganese pig iron. Studies have shown that different-grade high-MnO slags (MnO: 38.57–58.24%; Mn/Fe: >15) and manganese pigs (Mn: 5.16–24%) can be produced at optimum process conditions. The high-MnO slag can be used as synthetic ore for the ferroalloy production process. The developed process is capable to effectively segregate the iron and manganese in the metal and slag, respectively. The optimum Mn and Fe separation (>95%) was achieved by smelting of 10 kg Mn ore batch in a 50-kVA electric arc furnace using 30 kWh smelting power and 0.16 kg of coke. The slag basicity was maintained at 0.3 and the optimum slag SiO2 was ~30%. The studies indicated that the upgrading of low-grade ferruginous manganese ores is a promising solution for achieving high-Mn/Fe-ratio synthetic ores for ferroalloy production. It can help the manganese alloy industry to overcome challenges associated with the scarcity of high-Mn/Fe-ratio Mn ores and efficient utilization of low-grade resources.

Aug 3, 2020

By Mark E. Schlesinger

Engineering design follows a six–step sequence. Demonstration of this sequence in materials engineering is less common. A case study is presented, using the 1989 paper by Gafner on the development of 990 gold-titanium alloy. This paper identifies a need, develops the problem, identifies alternatives, demonstrates the use of metallurgical principles to identify alternative responses, and shows how more favorable options are selected. The paper can also be used to illustrate engineering design as an iterative process. The paper is also useful as a starting point for more in-depth examination of specific elements of the design process, and lends itself to the creation of student exercises.

Jan 1, 2014

By K. Ramji

"The development curve in the extractive sector has become longer, steeper, and riskier due to increased social, legal, and political risks from various stakeholders. Indigenous peoples are a unique stakeholder because their growing legal rights to lands and resources can often determine a project’s outcome. A project will only be successful if it is able to obtain the legal permits, withstand any judicial reviews, and gain and maintain the social license to operate. Stakeholder identification, management, and engagement are key risk-mitigation tools required to successfully convert risks into opportunities.RÉSUMÉ La courbe de développement du secteur de l’extraction s’est allongée, elle est devenue plus abrupte et plus hasardeuse en raison de l’accroissement des risques sociaux, légaux et politiques venant des divers intervenants. Les peuples autochtones sont des intervenants uniques puisque leurs droits légaux croissants sur les terres et les ressources déterminent souvent ce qu’il adviendra d’un projet. Un projet ne pourra réussir que s’il est capable d’obtenir les permis légaux, passer à travers les analyses judiciaires, puis obtenir et maintenir le permis social d’exploitation. L’identification des intervenants, la direction et l’engagement constituent les outils clés de l’atténuation des risques nécessaires pour bien convertir les risques en possibilités."

Jan 1, 2016

By A. A. Sadegh

A laboratory investigation was carried out on the characterization and beneficiation of sillimanite ore. Petrographic analysis indicated that the ore consisted of massive elongated sillimanite grains in a matrix of hematite, garnet, feldspar and silica. A procedure for estimating the percentage of sillimanite was developed using float-sink and magnetic-separation techniques. A liberation study was carried out to determine the level of size reduction required to achieve sufficient liberation while ensuring that gravity concentration techniques would be applicable. Laboratory testing was performed on the liberated ore to investigate the applicability of using wide-angle dense-medium cycloning to upgrade this ore. Initially, medium-only tests were carried out using various size distributions of magnetite and ferrosilicon as the dense-medium solids to evaluate the effects of operating conditions on medium segregation. Depending on the medium solids and operating conditions, either positive of negative differentials (difference between the relative densities of the underflow and overflow streams) were obtained. Based on these results, separation tests were performed to process nominal -1.2-mm sillimanite ore. The results indicated that sillimanite concentration could be obtained using a medium relative density that was much lower than would typically be used in a dense-medium cyclone separation.

Jan 1, 2007

For its Hellyer project, Aberfoyle sought to establish a high degree of confidence in all aspects of the feasibility study. Accurate capital and operating cost estimates were an integral and essential part of the study. They were crucial to the evaluation of investment returns and competitive cost position. Both the capital and operating cost estimates were based on the comprehensive data available from exploratory mine development, pilot plant operation, detailed engineering design, and Aberfoyle's experience in the area. One of the principal project objectives was to maximise operating productivity and efficiencies and this created capital cost alternatives which needed thorough cost-benefit assessment. The estimated capital cost for construction and development was $90 million, and the project was completed virtually on time for $80 million. The first year's experience indicated that operating costs would settle to well within 10% of the estimates.

Jan 1, 1990

By R. J. Hickson

From 1993 through 1999 Cyprus Amax Minerals Company successfully completed eight major construction projects around the world. Six greenfield mines were brought into production, an ongoing operation was completely modernized, and an environmental issue was appropriately remediated. The projects stretched over three continents, from arctic Russia to the Atacama Desert, from 16,000feet to sea level, from city suburbs to remote wilderness, from a low of $130 million to over $1 billion. Open pit and underground; mill and leach; gold, copper, molybdenum, and coal were all encompassed. The breadth of diversity experience from these projects inspired Cyprus Amax to create a “best practices” project management protocol, to steer corporate expansion into the next millenium. This paper summarizes those best practices, while high-lighting project management pitfalls to avoid.

Jan 1, 2000

By J. Mackintosh Bell

External trade strongly influences the well being of all nations. In the modern economic mechanism, no country is so well endowed that it has not to import commodities from others and to export its products in turn to make good its deficiencies, to rectify or improve its financial structure. From the standpoint of international commerce, Canada is strategically well placed. On the south she is bounded by the richest country in the world. On the east she faces the Atlantic, on the west the Pacific. On both coasts there are fine harbours to which lead great lines of railway that span the continent. Canada is now fifth among the exporting nations of the world. For disposal abroad, she has enormous quantities of primary commodities and substantial amounts of manufactured goods as well. But she is far from being self-sustaining. She is unusually dependent on foreign trade, not only because of the commodities she has to sell but because of the lack of many essential articles she does not or cannot produce. To Canada, external commerce is vastly more important than internal trade. The wealth of nations is decided by their ability to produce more than they need, to sell more than they buy, and to build up favourable balances resulting from trade or services. With few countries, however, are returns perennially satisfactory. Fruitful periods are followed by leaner years. In times of prosperity foreign credits are increased, monetary systems strengthened, reserves accumulated to withstand recurring days of strain. Today, the foundations of financial systems are being re-examined, "dogmas hitherto accepted as canonical are being questioned" . It is not only in Europe and America that men search for illumination in problems arising from monetary restrictions.

Jan 1, 1933

By R. R. Sayers

The hazards connected with work under abnormal air conditions are becoming of increasing importance from a financial as well as a physiological stand- point, due to the extension of compensation laws to include diseases caused by dusts, toxic gases, and abnormal temperatures and humidities. The United States, with the excention of California, North Dakota, Wiscon- sin, Massachusetts, and Connecticut, is the only English-speaking country to-day where silicosis is not compensated.3 Cases of permenent total disability or death due to silicosis mar aprear in common-law courts, particularly in the States that have not recognized silicosis as an occupational disease for which compensation should be provided. Such cases have recently been tried in one State, according to a magazine editorial, not providing scheduled commensation for employees affected by silicosis, with results favorable to the claimant. Clearly established cases definitely linked with occupation as the cause may be expected to be recognized as deserving by juries and courts, and awards will be made. In one Atlantic Coast State, according to this editorial, 108 claims for silicosis, including 21 deaths therefrom, are said to have been filed against two small plants engaged in finely pulverizing quartz sand.

Sep 1, 1932

By A. P. I. Popoola, D. O. Okanigbe, A. A. Adeleke

In view of the steady depletion of primary sources of copper and the increased global demand for refined copper, it becomes necessary to explore some secondary sources for possible extraction of copper. The waste copper smelter dust (CSD) is a rich secondary resource for copper as shown by the chemical composition of the South African Palabora coppers smelter plant CSD that assayed 18.02, 13.36, and 3.4 wt% copper, iron and sulphur, respectively. Studies on CSD have focused majorly on either dust characterization or treatment, while hydrometallurgical extraction without pretreatment and with pretreatment using techniques such as oxidative roasting are also considered quite attractive. The challenge of iron dissolution during the leaching stage in these processes necessitates adequate purification of the leach liquor before the extraction of the metal as nano-particles. Hence, this review examined the theories relating to the characterization and treatment of CSD for copper recovery as nanoparticles; with factors having a bearing on the treatment process such as kinetics considered with the aim of providing scientific basis for the research.

Mar 1, 2017

By Zhang Chuanfu

Keywords: solid solution, Ni-Co alloy powders, thermal decomposition, fibres. Synthesis of fibrous Ni-Co alloy powders was achieved by thermal decomposition of precursor of complex Ni-Co oxalates solid solutions obtained via modified coprecipitation method among intimate mixing solution of NiCl2?6H2O , CoCl2?6H2O and H2C2O4?2H2O in the presence of surfactant polyvinylpyrrolidone (PVP) and organic solvent ethanol. Scan electron microscopy (SEM), X-ray diffraction (XRD), X-Ray photoelectron spectroscopy (XPS), disperse energy X-ray analyses (EDX) were used to characterize the structure features and chemical compositions of the as-prepared fibres. The influences of decomposition conditions, including temperature, time, the flow rate of N2+H2, and the heating rate, on the morphology, average size and specific surface area of the Ni-Co alloy powders were investigated. It is found that a trend of the mutual alloying of nickel and cobalt: the formation of perfect solid solution for any compositions NixCo100-x was indicated and corresponding NixCo100-x alloys with fcc phase can be obtained under the optimal conditions.

Jan 1, 2005

By C. L. Lin

The image-based On-line Particle Size Analyzer (OPSA) system has been developed at the University of Utah to measure particle size distributions under plant conditions where overlapped and segregated particles are being transported on a moving belt conveyor. Evaluation of the OPSA system at several plant sites has been completed. The results show a consistent agreement between the particle size distributions obtained from the OPSA system and those obtained from laboratory screen analysis of belt samples. These results and the stable performance of the OPSA system during the field tests suggest that continuous quality control of crushed products is possible using the OPSA system.

Jan 1, 1999

By R. E. Vivas, J. A. Villa

"Located in the state of Colima, Peña Colorada is one of the largest iron ore operations in Mexico. The project is owned in equal parts by ArcelorMittal and Ternium. Though boasting a production capacity of 4.1 Mt/a (4.5 million stpy) of concentrate per year, Peña Colorada is faced with declining ore grades. In order to respond to this situation, Peña Colorada had to expand production even further. This expansion created various challenges that were overcome by the adoption and application of new technology. Examples of these technological innovations are discussed in detail in this article and include improvements in geo-modeling, mine planning, and mine operations. The successful implementation of these technologies paid for itself many times over, and has led to significant improvements in production and performance, while lowering the operating costs and reducing the variance between planning and execution.Project overviewPeña Colorada is a mining company that produces about 30 percent of the iron ore in Mexico. This project generates about 1,200 direct jobs and 3,000 indirect jobs, making a significant contribution to the local economy. Similarly, Peña Colorada invests in its local communities through numerous educational programs, scholarships, university agreements, social development, environmental agreements, etc. Peña Colorada’s operations consist of an open pit mine located in Minatitlán and a pellet plant located in the port city of Manzanillo, as shown in Fig. 1. Technological innovationsMost mining projects around the world typically follow the logic of “mining the next best ore.” Consequently, head grades tend to decline over the life of the mine. In the case of Peña Colorada, a decline in head grade combined with a decline in iron ore prices forced the operation to adapt to a new business environment and adopt new technologies to face these challenges. However, the first step along this process was to increase the confidence and reliability of the resource model. This task involved additional drillhole campaigns coupled with more detailed modeling techniques. Once the block model was completed, new optimization studies and production schedules were evaluated with new optimization tools that improved many aspects of the mine plan. The Peña Colorada block model has undergone 3 expansions to reflect additional information not available in the past. The model has expanded to the East and Southwest. The latest model expansion increased the total number of benches to 98 as a result of positive exploration results. Similarly, new geotechnical studies were prepared, which provided new guidelines for pit slope design, and new technology was implemented to monitor ground movement and slope stability. Two sectional block model views in Hexagon Mining’s MineSight 3D, along with the pit designs and geologic solids are shown in Fig. 2."

Feb 1, 2017

By Mandius C. Lundal

This report describes the work done to develop a coal mining machine to increase productivity and recovery from thin seams beyond the highwall, in addition to decreasing the miner's susceptibility to to highwall hazards First, radar transducers were adapted to measure coal thinkness and detect rock and coal interfaces; Then, the radar was incorporated into a cutterhead with steering controls. Next, visual displays were designed to show cutter position in the coal seam, and anticipated change in coal seam inclination, Finally, development of a telemetry system made remote control of the cutterhead possible. Simultaneously, a high-performance extended depth (HPxD) auger machine was designed with an automatic system to handle 600 ft of 36-in, diameter dual spiral flight conveyor sections. A two man crew controls all operations from a weather conditioned cab outside the VDZ, either at night or day time. As a primary mining tool, working 4000 hr/yr (2 shifts/day) recovering 60% of the coal 600 ft beyond the highwall, productlon to 500,000 ton/yr can be achieved. Volume I provides an overview of machine, systems and productivity.

Jan 1, 1977

By U. Schoepf

Economic and at the same time environmentally acceptable mining of small vertical ore bodies and veins to great depths has always been a challenge for miners. The Bauer cutter system, widely used in civil engineering, has been further developed for applications in exploration and mining, to a sustainable system for selective mining with a focus on small vertical ore bodies and veins, as well as residual ore in open pit operations. Current situation of conventional mining of small ore bodies and vertical veins Small ore bodies and vertical or near-vertical ore veins often pose a challenge to the mining industry. The relatively small size of the ore deposit over great depths or lengths, with only limited exposure to the surface makes economical mining difficult. Open pit mining of such ore bodies must either be terminated early because of the high stripping ratio and the enormous environmental impact or is unprofitable from the very beginning. The required massive stripping of waste rock leads to high material hauling times and costs, intensive roadway and bench construction and maintenance, possible safety hazards due to heavy vehicle movement, pit wall stability risks, intensive surface water management and massive waste dump requirements. In addition, it can be assumed that increasingly extensive rehabilitation measures will be required in the future after mine closure. Particularly in vertically oriented magmatic and hydrothermal deposits the technical, economic and environmental limits for further pushbacks, to extend the open pit depth, can lead to an early end of mine life even if a significant quantity of residual ore is left behind. Going underground is only a viable option in a limited number of mines with very high ore values and volumes. The high development cost of an underground mine, as well as the higher underground mining costs, often prevent further mining to greater depths.

Feb 1, 2023

LARGE-SCALE production of zirconium by the Northwest Electrodevelopment Laboratory of the Bureau of Mines at Albany, Oreg., is an anomaly that justifies some explanation. The reduction of titanium tetrachloride with magnesium in an inert atmosphere, as perfected by Dr. W. J. Kroll before 1940, aroused renewed interest in zirconium, and in 1945 development work on this metal was initiated at Albany under Dr. Kroll's technical direction. Preliminary results were promising, and in February 1947 a pilot plant with a weekly capacity of 60 pounds of zirconium-metal sponge was put in operation. Shortly thereafter the Oak Ridge National Laboratory of the Atomic Energy Commission requested production of 1 ton of zirconium-metal sheet, with the provision that it have a low hafnium content. The Bureau of Mines was furnished with a. supply of Brazilian baddeleyite ore, containing less than 1 percent hafnium with respect to zirconium, from which was made about. 2,700 pounds of relatively low hafnium zirconium sheet of 0.080-inch thickness for test purposes. This was accomplished by melting zirconium sponge in a graphite crucible, hot-rolling the ingot in an iron sheath, and finishing by cold rolling. Concomitantly the Oak Ridge Laboratory developed a method for separating hafnium from zirconium; and, in cooperation with the Atomic Energy Commission and the Bureau of Ships of the Department of the Navy, a, larger pilot plant was erected to produce zirconium from very low hafnium zirconium tetrachloride furnished by the Commission. Pilot-plant work on producing zirconium tetrachloride from zircon sand and baddeleyite was discontinued. Production of zirconium sponge in the larger pilot plant of 500 pounds per week capacity was begun in June 1949.

Jan 1, 1956

By Jose R. Hernandez-Aguilar

"This paper revisits data from previous studies (Hernandez-Aguilar, 2010, 2011) to better understand the link between metallurgical performance and pulp-zone bubble size (Db) in full-scale flotation systems. To obtain conclusive evidence exclusively related to the pulp (collection) zone, the experiments were designed in those studies to control both the bubble generation method and the influence of the froth zone on the overall metallurgical performance in industrial and pilot-scale flotation columns. The results showed that Db had a significantly larger effect on the recovery of coarse (> 75 µm) particles compared to the effect on fine (< 16 µm) particles. It was observed that, under certain practical conditions, the recovery of coarse particles was close to zero, but dramatically increased by reducing Db. The evidence revealed an inconsistency of the so-called “k–PSb” model: at constant froth recovery, increasing Sb (i.e., the rate of production of bubble surface area) did not always result in higher recovery, as the model predicts. Furthermore, the evidence showed that it was not the Sb but the bubble size that proved to be a more reliable link to metallurgical performance. Only in the presence of suboptimal-sized bubbles (Db > 2 mm) did the froth zone seem to play a role, possibly reflecting an effect of pulp-zone bubble size on froth stability. However, the role of the froth was negligible for Db < 1 mm.High-resolution mineralogical measurements performed on process samples revealed that, regardless of the degree of liberation, Db had a profound effect on the shape of the recovery-by-size curve, particularly the coarse particle size fraction. This observation is key as it implies that the loss in efficiency associated with floating the coarse particles was not the result of neither particle hydrophobicity nor particle detachment issues: even in the absence of mechanical agitation, liberated and highly hydrophobic coarse particles did not seem to attach to the bubbles in the first place, an inefficiency that was corrected by reducing bubble size. The data analysis suggests that poor attachment efficiency can practically affect both fine and coarse particles but via different mechanisms which are discussed here."

Jan 1, 2017

By O. M. Arafat, J. A. Finch

"The Functional Performance Equation calculated from a plant grinding survey defines two distinct ball mill circuit efficiencies and how they relate to total production rate through the target grind size. The survey data are also used to calculate a complete ball mill size distribution model, represented by the energy specific grinding rates, not just through the target grind size, but through all the size classes. Cyclone separation performance is represented by individual size recoveries to underflow. When these two unit operation performances are entered into the circuit modelling program (Streamline™), along with the circuit feed rate and size distribution, all the circuit survey size distributions and mass flows are perfectly regenerated by the program. The many issues associated with the historical Epstein (breakage-selection) models are eliminated. Once the circuit program is populated, pump and cyclone performance changes can be evaluated using a step-by-step procedure in order to maximize Classification System Efficiency. Mill water use and media sizing opportunities are also diagnosed in order to maximize Mill Grinding Efficiency at the size of interest. An example is provided. This circuit analysis and modelling system, and related training, is provided through a web-based application.IntroductionSince its development (McIvor, 1988), the Functional Performance Equation for ball milling has facilitated new understanding of industrial circuit cause and effect relationships, leading to significant strides in operational performance. Success stories of this refreshing approach to plant circuit performance improvement are now too numerous to list. Finch and McIvor (circa 1986) also discovered that the Functional Performance “Mill Grinding Rate” at the size of interest was the same cumulative grinding rate that is calculated from mill feed and discharge size distributions using a first-order rate equation. By calculating these cumulative grinding rates for all screen sizes, a complete ball mill model is generated (as used by Finch and Ramirez, 1981). Others in industry, Hinde and Kalala (2009), for example, have noted the same. Lacking the complexity needed to maintain their interest, most researchers have ignored this model, broadly opting instead for Epstein’s (1948) characterization of grinding as a chemical reaction, combining “selection rate” and “breakage size distribution” functions. The much simpler ball mill model presented here has previously been incorporated into a proprietary circuit modeling program (McIvor, 2005) and used for plant improvement work (for example, see McIvor and Finch, 2007, and McIvor, 2014). Now, by combining this extremely business-friendly ball mill model with optimization criteria from Functional Performance Analysis, a circuit modeling system (including the needed supplementary steps to assure successful plant implementation of circuit design changes) is at the disposal of every plant metallurgist, grinding equipment/material provider, and circuit designer."

Jan 1, 2017

By J. E. Dutrizac, J. B. O'Reilly

"Zinc is a relatively abundant element which occurs as both high-grade sulphide ores {sphalerite ZnS) and oxide ores which the ancients collectively termed ""calamine"" (smithsonite ZnC03 and/ or hemimorphite Zn4Si201(0H)2 - H20 and/ or hydrozincite Zn5(C03) 2(0H)6). Although oxidic zinc is readily reduced by carbon, the process becomes thermodynamically viable only at - 1000°C, and at this temperature the zinc is released as a vapour (B.P. 907°C). Casual cooling of the vapour results in its re-oxidation by excess combustion air or even the carbon monoxide product of the reduction reaction. ZnO + C = C09,, + Zn vapom Only fairly rapid quenching of the zinc vapour and the isolation of the reduction products from the combustion gases will yield metallic zinc; these conditions were not produced deliberately until the advent of distillation technology. Until quite recently, the principal use of zinc was in brass manufacture; galvanized iron was not discovered until the 19th century and zinc casting alloys are a relatively recent invention. As will be seen, brass could be produced without recourse to a pure zinc intermediary, and the discovery of brass preceded that of zinc by many centuries. The purpose of this paper is to outline the discovery and early development of both zinc and brass with special reference to the European scene."

Jan 1, 1999

By Richard E. Thill

The Bureau of Mines&apos; Oil Shale Data Bank (OSDB) was created in 1976 to serve as a centralized source for the storage, retrieval, and dissemination of technical literature, patents, and information on research projects in oil shale. Thousands of bibliographic references, patents, and research projects relating to the mining of oil shale have been identified, abstracted, and indexed according to selected keyword topics. The resulting data bank listings are contained in three sections, each with a separate keyword breakdown for use in rapidly identifying references pertaining to a specific subject. All references cited in the OSDB were published prior to an established cut-off date of May 1, 1981, when a redirection of Bureau of Mines programs resulted in the loss of project funds and the subsequent phasing-out of data bank operations. ACKNOWLEDGMENTS The oil shale data bank listings are the result of a team effort of the project staff. The contributions of Jimaleen Jansma for keypunching, information acquisition, and data entry, and John Brandenburg and Sandra Brake for keywording and information acquisition are gratefully acknowledged. Appreciation is expressed to the staff members of the Smithsonian Science Information Exchange, Washington D.C. for their cooperation in supplying data on recent research projects in oil shale for inclusion in the OSDB listings. Appreciation is extended also to the staff of the Gallegos Research Group for assisting with computer services to obtain the final printouts and transfer of files onto magnetic tape.

Jan 1, 1982

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