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By N. N. Malila, N. R. Shoko

The ever-increasing pressure on the profit margins of ferro-chrome producers and the gradual depletion of deposits of rich hard lumpy chrome ores calls for the ferrochrome industry to maximise the use of fine fractions of concentrates and friable chromite ores. Zimbabwe is endowed with huge deposits of refractory and friable ores that occur on and off the Great Dyke complex. The conventional metallurgical process of smelting of chromite ores in submerged arc furnaces is favoured by the use of refractory hard lumpy ores. The requirement to use all lumpy ore has been circumvented to a large extent at Zimbabwe Alloys. The use of briquetted chrome ore fines in the production of Ferrosilicon Chrome and High Carbon Ferrochrome has yielded positive results over a period in excess of twenty-five years. Of the three industrially used methods of agglomeration of chromite ores; sintering, pelletisation and briquetting, briquetting is preferred because the other two are associated with higher capital and operational cost. Zimbabwe Alloys has developed operational and technical expertise on the briquetting and utilisation of chromite ore fines and concentrates. Variations in the quality of available chromite ore fines imply that their amenability to briquetting is a dynamic problem. Appropriate briquetting parameters to guarantee quality briquettes are essential to the successful use of briquetted chromite ore fines. In developing a technology for briquetting of chromite ores, it is important not only to study the mineralogical and grain-size characteristics of the chromite ore fines but also to make an informed choice of the type and quantity of the binder and the conditions for producing a physically and chemically competent green and cured briquette. This paper discusses Zimbabwe Alloys' experience on the briquetting process and the advantages derived in the smelting of the briquetted chromite ore fines in comparison to the use of conventional lumpy chromite ore with respect to improvements in chromium recovery and as a consequence related efficiencies and unit cost of production.

Jan 1, 2004

By S E. Munro, P D. Munro

The commonly traded base metals concentrates of copper, lead, tin and zinc are sold by miners to custom smelters using contracts whose terms were generally established at the beginning of the 20th century or even earlier. Technical clauses in these concentrates for items such as payable metals and penalty elements do not reflect current realities of extractive metallurgical technologies and hygiene/environmental issues.It is an axiom that the miners and smelters have a symbiotic relationship. While the existing antique and arcane commercial arrangements serve the purpose of transferring money from the buyer to the seller, they are not likely to result in the industry achieving better overall technical and economic outcomes. By examining the cases for copper concentrates and zinc concentrates in particular, it will be shown that the practical application of these antiquated technical clauses does not drive the miners to produce the better quality concentrates that should be desired by the smelters. This is despite development of mineral beneficiation and hydrometallurgical technologies that would allow the miners to make better products.The adage that any extractive metallurgical problem in the smelter is cheaper to solve in the concentrator still generally holds.While nickel concentrates are only touched on lightly in this discussion because sales terms are more opaque than those for the other base metals, it is expected that the same conclusions will apply.CITATION:Munro, P D and Munro, S E, 2015. Base metals concentrate sales contracts – change Pavlov and the dog, in Proceedings MetPlant 2015, pp 46–60 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 7, 2015

By Peter Amelunxen, Craig Lockhart

Significant effort was made in 2003 and 2004 to upgrade the existing instrumentation and process control infrastructure at the Phelps Dodge Bagdad copper concentrator. Specifically, • cameras were installed on the feed belt for online image analysis data, • ultrasonic level sensors were installed for froth height and sump level control, • a trial froth image system was installed on one of the rougher rows, and • a new expert system to tie everything together was integrated and tuned in-house. Control philosophy, observations, opinions, and general tips and tricks are discussed with the hope of assisting other plant personnel and expert system integrators.

Jan 1, 2005

By Samuel J. Kosa

The Monotube is a uniformly tapered high-strength steel shell pile manufactured for friction pile applications. The Monotube pile was developed in the early 1920's in Canton, Ohio. Its first commercial installation was an Ohio railroad trestle in 1926. The Monotube has been manufactured in the same Canton plant since its inception. The Monotube is produced in four diameters, 12, 14, 16 and 18 inches, with U. S. Standard Gage wall thicknesses of 9, 7, 5 and 3. The uniformly tapered Monotube section can be manufactured in one of three rates of taper.

Jan 1, 1993

By Jean Cayouette

"In 1995, Louvicourt Mine started one of the first paste backfill operations in Canada. From 500,000 tonnes in 1995, the annual paste backfill tonnage produced reached 800,000 tonnes in 1999. The maximum throughput of the surface plant (including binders) is 3,50Ot/d with a final density of 75 to 76% solids which gives a slump of 15 to 17cm. Following the start-up of the paste backfill plant, the backfill strength performance levels were well below the pilot plant’s predictions. The introduction of ferrous slag, laboratory tests on various binder ratios with or without additives, and the desliming of the tailings enabled us to optimize the mix and operation costs. Primary and secondary stopes are filled respectively with a paste containing 4.5% and 2% binders consisting of a mixture of 20% cement and 80% ferrous slag. In certain stopes, the binder ratio may vary from 2 to 7%, but always in a ratio of 80/20. Six years after start-up, or 4.5mt of paste backfill later, this paper discusses the present operation and the major changes that have occurred over the years to optimize both the operation and the paste fill quality.INTRODUCTIONLouvicourt Mine is operated by Aur Resources Inc. which owns 30% of the shares. Its partners are Novicourt Inc. (45%, subsidiary of Noranda Inc.) and Teck Corporation (25%). The mine is located in the north-west part of Quebec, about 600 km north of Montreal and about 25 km east of Val d’Or. The mine commenced commercial production in July 1994."

Jan 1, 2002

By F Rashidinejad

Iran has had an active mining sector for some 7000 years. Exceptional in terms of its mineral diversity, Iran produces 62 minerals, and is ranked among the world’s 15 most mineral-rich countries. Many people around the world know Iran as one of the major petroleum exporters. Oil and natural gas dominate Iran’s economy, and oil exports provide the principal source of income, contributing more than 80 per cent of foreign exchange earnings. Transformation of Iran from an oil exporter to an independent country to oil has been on the table for many years, even before the Islamic Revolution of 1979. Development of the Iran’s mineral industry is one of the major replacements for petroleum exports. In the last decade, Iran invested billion dollars in the mining and mineral industry sectors and to increase the added value, tried to export processed minerals instead of the raw materials. In accordance with the ‘20-year Perspective 2025’ that targeted by the Supreme Leader, Iran will be a country with the first rank in economy, science and technology in its region. The objectives over this perspective include briefly increasing annual production to 55 Mt of crude steel, 800 000 tonne of copper cathode, 1.5 Mt of aluminium, 200 Mt mineral products, 300 000 tonne of zinc and 5 000 kg of gold. These goals are achievable in normal circumstances, but concurrency of the 20-year Perspective 2025 with commencement of the UN Security Council sanctions against Iran, frustrated objectives of the perspective, at least the ones related to the mining and mineral industry sectors. This paper tries to elaborate the development programs and following challenges for the mining activities of Iran by 2025.

Nov 22, 2011

By T. M. Barczak, S. C. Tadolini

Reduction in the recovery time required and improvements in safety during a longwall face move have compelled coal mine operators to examine and use pre-driven longwall recovery rooms. The recovery entry is developed at the longwall stop position and supported ahead of time so that the required combinations of standing and internal supports can be installed before the longwall face approaches. A calibrated three-dimensional finite element model, developed in conjunction with an underground test area, provided the critical components and design principals for a comprehensive parametric study. The study indicates that vertical, horizontal, and shear stresses concentrated on the outby abutment pillar corner of the recovery room resulting in deformations in the immediate roof above the primary roof support anchorage level. The results of the numerical model and field site observations indicated that the combination of the internal bolting system and the standing concrete supports are critical for the successful and safe extraction of the longwall equipment. Cable supports installed at and angle over the pillars can help stabilize the disturbed zone above the adjacent fender and outby pillars, however; standing supports are required in most sedimentary roof conditions to increase stability and assure a safe longwall extraction.

Shaft sinking through an amphibolite-granite rock mass experienced rock bursts on the shaft walls and benches. However, rock burst phenomena was exhibited only in granite, which is e1asto-brittle with ability to store strain energy caused by orogenic and man made stresses. To improve ground conditions, blasting of destressing holes at shaft corners was carried out. By this technique rock burst during shaft sinking was minimized, but not eliminated.

Jan 1, 1982

By A. Lyndon

Combined loading tests are described to three 1.2m diameter cast-in-place bored piles, 12m long, formed through cohesionless material into stiff sandy clay. The maximum loading conditions imposed at the pile head were 2400 kN vertical, 160 kN lateral and 3120 kNm in bending, corresponding to twice the working load. Settlements, deflections and rotations of the piles were measured during the tests. An interesting finding which the test results suggest is that, in the short term, vertical movement had apparently no marked effect on lateral performance for piles working at design loadings.

Jan 1, 1989

By T. Hudaverdi

Control of the particle size distribution of a muckpile after blasting is always an important subject for mining industry. Blasting has a significant impact on downstream processes such as loading, crushing and grinding. Improvement of blasting results provides increase in loader and excavator productivity due to increased diggability capacity, and increased bucket and truck fill factors. Suitable and uniform particle size distribution results increase in crusher and mill throughput and decrease in energy consumption in size reduction process. Digital image analysis technique has been used for many years in mining industry in order to determine blast fragmentation. The images of muckpile surface can be used to determine the mean fragment size (x50). The source of digital images can also be haul truck, leach pile, waste dump, stockpile, and conveyor belt. The screening that is conventional method to measure blast fragmentation is time consuming and expensive. Digital image analysis is a cost effective and faster method (1).

Jan 1, 2012

By Arun .. J. Basu

The paper introduces Intelligent Air Management (IAM) as the core activity of M&I Group of Companies (M&I) for providing a total solution to any air management problems for mining and mineral processing operations implementing a comprehensive systems approach through a world-wide network of strategic alliance partners and in-house engineering team and manufacturing facilities in Mississauga, Ontario, Canada. Recommendations for energy-efficient ventilation in a vibration and noise free environment are made with the patented and innovative solutions supported by extensive computational fluid dynamics (CFD) studies. The solution scope extends from an intelligent and integrated exhaust silencer to a complete ventilation sys-tem solution including inlet and outlet control design and ducting for diffusers and silencers.

Apr 1, 2005

Some design and feasibility studies have been made into possible methods of economic recovery of sulphur from smelter gases emitted at Western Mining Corporation's Nickel smelter at KalgoorIie in Western Australia. The smelter discharges some 330 000 tonne/yr of sulphur dioxide in a stream of approximately 6 per cent by volume of S02.Three possible recovery methods have been considered:1. The manufacture of sulphuric acid using the contact process.2. The concentration of sulphur dioxide to a pure form using dimethyl aniline as an absorbing medium.3. The reduction to elemental sulphur using natural gas as the reducing agent.Design studies were carried out by final year chemical engineering undergraduate students at Royal Melbourne Institute of Technology (RMIT) in 1981 under the supervision of the author and other teaching staff of the chemical engineering department. These studies indicate that sulphuric acid manufacture is the economically preferred recovery route.Markets for sulphuric acid include several potential mineral processing applications and the established fertiliser industry.Sulphuric acid is currently manufactured in a number of plants located at coastal regions of Western Australia using imported sulphur. The sulphuric acid is then used for superphosphate or titanium dioxide pigment manufacture at adjacent plants.The possibility is considered of manufacturing superphosphate at Kalgoorlie from locally produced acid obtained from the smelter gases and from phosphate rock railed to the site from the coast. The advantages of such a scheme include improved scale and technology of operation compared with some existing coastal operations, use of a waste material to replace imported sulphur, and avoidance of costs and hazards associated with railing large quantities of sulphuric acid.

Jan 1, 1983

By K. Bounou, K. Komnitsas

"Risk quantification may be used as a sustainable development index in the mining industry, since it encompasses both economic and social factors. In addition, it may assist in the development of a framework, which is also indirectly related to sustainable development, to prevent accidents and improve health and safety standards. However, risk quantification in the mineral sector involves diverse activities and is considered a very difficult task. Although statistical data report accident severity rates, incident rates and accident frequency rates, none of these allow for accurate risk calculations. In this paper, two risk calculation formulas, which may be used to quantify risk, as well as to identify hazardous activities in a workplace, are proposed. Numerical examples are given based on statistical data available through the MSHA database. Also a combination of a decision/fault/event tree that allows risk quantification is presented."

Jan 1, 2005

By James P. Ulery

In This Chapter [Geologic features associated with anomalous methane emissions Gas outbursts and blowers Methane drainage strategies for mitigating anomalous methane emissions and General considerations for a methane drainage program] This chapter summarizes how certain geologic features may be associated with unexpected increases in gas emissions during coal mining. These unexpected emissions have the potential to create explosive conditions in the underground workplace. Also discussed are the generally used practices to alleviate potential hazards caused by gas emissions associated with these geologic features. INTRODUCTION Unforeseen mine gas emissions in quantities sufficient to create hazardous conditions have been attributed to sources outside the mined coalbed since the first documentation of methane explosions in coal mines [Payman and Statham 1930]. Geologic features such as faults have long been recognized as conduits for gas flow from strata adjacent to mined coalbeds [Moss 1927; Payman and Statham 1930]. Other features such as sandstone paleochannels, clay veins, and localized folding have also been recognized for their impact on gas emissions into mine work-ings [Darton 1915; Price and Headlee 1943; McCulloch et al. 1975; Ulery and Molinda 1984]. The fact that strata adjacent to mined coalbeds can emit large quantities of methane gas into mine workings is not surprising from a theoretical perspective. Many researchers have recognized that during the burial and diagenesis of the organic matter forming today’s minable coalbeds, similar dispersed organic matter in adjacent strata has produced methane in quantities far exceeding the storage capacity of the coal and surrounding rock [Juntgen and Klein 1975]. It is not surprising then that large quantities of methane can remain trapped in these strata. A potential hazard occurs when mining of a nearby coalbed causes pressure differentials and mining-induced fractures conducive to gas flow into the mine workings from these strata. This gas flow may be facilitated or temporarily impeded by the presence of geologic structures or anomalies.

Jan 6, 2006

By H Sofatzis, J Kinal, J Siliezar, B Kirkwood

Ernest Henry Mining (EHM) is a copper, gold and magnetite mining and processing operation located 38 kilometres north east of Cloncurry in the Mount Isa - Cloncurry mineral district of north west Queensland, Australia. The EHM ore body is an iron oxide copper gold deposit with an average grade of 1.1 percent copper, 0.5 g/tonne gold and 22 percent magnetite.At the end of 2009, after a series of promising laboratory test work, EHM converted the ball mill media charge from forged steel to high chrome media. Laboratory test work also indicated that with the use of high chrome media, the pH was able to be reduced with no negative impact on plant performance. At high pH values (above 10.5), the forged media is passivated, so as the pH of the system drops the media corrosion rate increases and floods the system with corrosion products, affecting flotation. As the high chrome media is much more inert, pH has less of an effect on copper flotation response.This paper provides an overview of the effects of reducing the pH in the EHM copper rougher flotation circuit. The pH in the roughers was dropped from 10.6 to 9.6 to determine the impact on the rougher performance and the subsequent performance of the whole copper flotation circuit. It was found that there was a slightly increased improvement in copper recovery and no statistical change in either the rougher or final copper concentrate grades for copper and gold.With the reduction in pH, there was a noticeable reduction in lime usage from 0.85 kg of lime per tonne of ore processed to 0.55 kg/t. This reduction in lime is equivalent to approximately $700,000 per annum at current production rates.CITATION:Kirkwood, B, Kinal, J, Siliezar, J and Sofatzis, H, 2013. Low pH trial in the Ernest Henry Mining copper rougher flotation circuit, in Proceedings MetPlant 2013 , pp 371-377 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

By Gerard de Vries

pipeline industry and are still growing in size. Liquid epoxy and polyurethanes are an excellent choice for whatever the aggressiveness of the substance transported and whatever the harmful outside influences, maximum protection is required. They can be used as coatings on all kind of pipelines varying from the mainline coating to the field joint coating. Compared with traditional systems like dual layer FBE and 3-layer polyolefin there are some benefits to be considered like easiness of repairs, amount of coats, application temperature and film thickness. The interior coating renders the pipe surface so much smoother that considerable savings can be realized in pump stations. Apart from the interior of the pipeline, the industry is faced with new challenges like higher operating temperatures of lines and an emphasis on product benefits in order to save money. Key words: liquid epoxy, liquid polyurethane, phenolic epoxy, pipeline, field joint coating, internal coating, corrosion control

Jan 1, 2006

By Walter Ensinger

Special foundation works is one of the most innovative sectors in civil engineering and construction. Both engineering techniques and construction machinery are undergoing continu­ous further development. These developments are providing ways to meeting the world-wide requirement for special geotechnical works even faster, even better and more efficiently. Unfortunately, accident prevention organisations have had to realise that the figures on in­dustrial accidents in special foundation works are still above average in number. The Safety & Environmental Working Group of the EFFC thereupon started to carry out a survey on acci­dents occurring in this sector and used this information as a basis for the preparation of acci­dent statistics and an accident analysis. The objective of this undertaking is to determine key accident occurrences and their causes and to consequently determine measures for improved health and industrial safety.

Jan 1, 2002

By José Arango

La Planta Hidrometalúrgica de Cerro Verde tiene como objetivo alcanzar la máxima calidad en cada uno de sus procesos operativos. Para ello, desarrolla un diseño que permita la transformación del control remoto a una operación automática, generando decisiones lógicas. En ese sentido, el presente texto señala la importancia de los Sistemas de información de operaciones en el sistema de automatización de Cerro Verde - en tanto es soporte de la implementación de un completo sistema de instrumentación y de la instalación de una red de PLC’s que colectan la información y en base a esta, desarrollan una lógica de operación manteniendo interconectados todos los circuitos operativos. Posteriormente, con el uso de software se crea una interfase de conexión entre la red industrial y la red Administrativa, permitiendo adjuntar la información en una base de datos que junto a la otra base administrativa, constituyen un ERP que da vitalidad a nuestra operación. De forma que los sistemas de informacion instalados en Cerro Verde consideran a los sistemas de instrumentación como los ojos del operador de planta.

Jul 17, 2000

By Kristian E. Waters, Hao Ma, Haibei Wang

Over the past few decades, ELM based separation processes have become an attractive and efficient way to remove toxic metal ions from the various aqueous waste effluent streams. This paper provides a comprehensive review of the generation, characterization, and applications of emulsion liquid membrane (ELM) from the more than 280 papers and books published so far. First, the ELM formation and the transport mechanism are introduced. Then the ELM stability and emulsion splitting methods are discussed in detail, followed by the latest research and findings of the extraction of copper and nickel using the ELM technique during the past few decades, including a thorough discussion of ELM operating parameters that impact ELM stability and extraction. In addition, the kinetics study and industrial application of this technique for the removal of coppers/nickel solutes are also presented and discussed.

Jan 6, 2023

By Wayne N. Marchant

Introduction The issue of coal mining safety plays an important role in the United States' growing dependence on coal to supply its future needs. This article will address the federal government's role, principally the US Bureau of Mines, in meeting this challenging growth and demand while reducing the social and economic costs attributed to injuries and fatalities in underground mining. Some interesting facts and projections with respect to the nation's energy picture will be discussed. This includes the distribution of its reserves and the projected role of coal in the energy and economics of the nation's future. Underground mining will continue to be an important means of providing this coal. The author will discuss how the Bureau of Mines' research program addresses the problems of health and safety that grow out of the demand for more coal. Future projections First, a synopsis of salient facts and projections concerning the US's situation with respect to energy and the economy. Figure 1 depicts the relative quantities of recoverable energy reserves in the United States by their type. Most people are aware of the nation's use of oil. We hear a lot about natural gas. And we are aware of the controversy over the use of nuclear energy. But, while looking at Fig. 1, the question becomes, "Where will our fuel to meet the demand for energy in the future most certainly have to come from?" With 82% of the nation's recoverable fuel reserves being coal, the answer is irrefutable. Coal will be that source. Figure 2 is the present market for coal. It shows that 77% of the coal mined goes to supply electric utilities. Therefore, the coal industry as a whole is most sensitive to the trends and demands for electricity. It is less affected by what happens in other markets, such as export and direct industrial use. In fact, the coal industry is three times more sensitive to the electric utility market than to all other markets combined. Therefore, the trend in the demand for electricity must be examined. Electricity demand is expected to increase steadily over the next 15 years. It is projected to grow from its present 2.3 trillion kWh per year to 3.5 trillion kWh per year by the year 2000. The fuel to supply this increase in demand must come from somewhere. The question is "How much of this extra fuel will be coal?" Although the demand for electricity is predicted to increase, the demand for coal does not necessarily follow. Coal must maintain its fraction of the energy sources used for electricity generation if its demand is to increase at the same or greater rate as electricity. Except for a near-term dip in demand due to a slight increase in nuclear capacity, the domestic electric generation accruing to coal will go from 56% in 1985 to more than 60% in 2005. Thus, the predicted trend is for coal to become a larger part of the fuel mix for electric power generation. Similarly, looking at the most recent forecast for total coal consumption trends, it can be seen that for electric power generation alone, the coal industry must be able to supply an additional 316 Mt/a (348.5 million stpy) by the year 2000 (Fig. 3). It must be stressed here, though, that without significant improvements in mining safety, it can also be easily predicted that injuries and fatalities will increase in proportion to the increase in coal production. Will society consider that acceptable? This author does not believe so. Figure 4 examines the effect of coal prices on the price of electricity. The projections show that the already high proportion of fuel cost will become a greater fraction of the consumer price for electricity. Specifically in 1985, 36% of the price of electricity was the cost of the fuel. In 1995, 46% of the price of electricity will be the fuel cost. That implies that the price of coal will have an increasing influence on the consumer price for electricity. Thus, as coal is used more to generate electricity and as fuel becomes a greater

Jan 4, 1987