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By Leonard Sugin

Recent changes in the field of ore and bulk commodity handling has forced a reevaluation of previously conceived notions. When vessels were small, and sources of raw material were reasonably close to areas of need, the role of the shipping terminal was of secondary importance. Now terminals must be built to take advantage of the economic benefits of the supercarriers. The shipping rates of the 80's will not be determined by the 60,000 DWT or even 150,000 ton capacity bulk carrier, but rather by the supercarriers in the 250,000 DWT class or larger. When the Suez Canal was closed, the shipping industry took a hard look at the economics of the large bulk carrier. Naval architects overcame the problems and successfully designed large supertankers, which today are plying the seas in excess of 350,000 DWT. Orders have been placed for tankers of 480,000 DWT. The shippers of dry bulk materials are now coming to similar conclusions about the economics of supercarriers. As of today, over 40 orders have been placed for vessels in the 250,000 DWT class, representing an investment of over 11/2 billion dollars, and many more are being considered. These vessels are being designed as combination ore/oil (0/0) or ore/bulk/oil (OBO's) carriers. The oil industry has seen the need for terminals which can accommodate these supertankers. The dry bulk shippers, and particularly ore shippers, must now act.

Jan 1, 1972

By Errol D. Sehnke

This U.S. Bureau of Mines report provides detailed information on worldwide alumina production capacity by plant and country. The information was compiled from a variety of domestic and international sources and was based on information available to the Bureau through December 31, 1993. Capacity data represent announced installed and planned capacities and do not necessarily reflect a Bureau of Mines judgment of actual plant operating levels or timing of planned expansions, The year-end capacity is the ?nameplate" capacity or estimated production capacity, whichever is larger.

Jan 1, 1993

By T. Kumaresan

The Bayer process used for refining bauxite to smelting grade Alumina serves as the linchpin of the Aluminum production industry worldwide. Even though the process is well established, the presence of impurities in the liquor affects the quality of product and imposes a major economic cost on the industry. This review article focuses on the issues pertaining to Gibbsitic (Al2O3.3H2O) precipitation circuit. The comprehensive review provides a basic understanding of the aluminum trihydrate precipitation and agglomeration phenomena. Crystal growth rate and agglomeration play a significant role in determining the output PSD of agglomerates. Hence, the effect of certain thermodynamic and hydrodynamic parameters along with the impact of impurities (oxalates, aldols, acids etc.) and additives on hydrate growth has been reviewed.

Sep 1, 2012

By I. Lackey

In 2004, Zinifex Budel Zink commenced testing with the objective to increase the precipitation of aluminium in the iron purification stage of its hydrometallurgical zinc circuit, without the use of expensive reagents. Findings from the literature applied to the leach circuit at Zinifex Budel Zink demonstrated that aluminium removal from the leach circuit could be increased by lowering the ferric concentration and acidity in the vessels where jarosite precipitation occurs. An associated increase in copper precipitation was mitigated by limiting the extent to which the ferric concentration was lowered in the vessels where jarosite forms and lowering the ratio of copper to aluminium in the solutions entering these vessels.

Jan 1, 2006

By B. M. Currell, M. J. Neate, P. W. Bowden

Historically the hydrogen fluoride laden fume emitted from the electrolytic cells in the aluminium reduction process is further treated in pulse jet dust collectors. These dust collectors act as dry scrubbers performing two duties: adsorbing the gaseous fluoride emitted from the cells onto alumina dust; and collecting the alumina dust minimising particulate and fluoride emissions to the environment.Patented StarBag (TM) technology has been used in aluminium smelters in Australia as a means of increasing the dust collection and fluoride scrubbing capacity of existing collectors. This technology provides an alternative to major capital equipment upgrade where increased capacity is required, and potentially lowers the production cost per tonne of aluminium where capacity limitations are being realised and production expansion is required. This paper presents the findings of on-site pilot scale, and full production scale comparative tests, highlighting the operational and variable differences observed utilising the Star-Bag(TM) technology at Boyne Smelters Ltd in Australia. The results illustrate how this technology can be utilised to increase the hydrogen fluoride scrubbing efficiency and dust collection capacity of existing capital equipment.

Jan 1, 2006

By Dale A. Zuck

Recovery of aluminum metal from drosses? is a major factor in the recyclability success story enjoyed by the United States aluminum industry. Today's modern dross processor uses the latest technology to maximize metal recovery at the lowest cost while complying with all environmental laws and regulations. Most dross processors, however, pay little attention to the resulting saltcake, the end residual of dross recyCling, and rely on landfills for .disposition of this material.. The alternative is to recycle the saltcake, but the success of this technology is dependent on the development of reliable outlets for each of the saltcake constituents. This paper discusses the evolution of an aluminum dross oxide processing technology that ,produces an economically attractive source of alumina for the production of portland cement.

Jan 1, 1995

By G. M. Scamans

In the past ten years there has been considerable penetration of aluminum automotive body sheet (ABS) into automotive structures. The exponential increase in demand is resulting in major investments in heat treatment and finishing capacity across the globe. Line speed and tonnage throughput is limited by the continuous heat treatment (CHT) floater furnace rather than the cleaning and pretreatment section where electrolytic treatments that offer higher line speeds should come into favour and roll coating of pretreatment should predominate. The capacity limiting surface texturing pass will either be eliminated or moved to the finishing line or a dedicated mill. The key to making aluminum both embedded carbon and cost competitive with steel for more and more affordable classes of vehicles lies in recycling of both prompt scrap and, in the longer term, end of life vehicle scrap. For the first time scrap separation technology is available that can compete effectively with hand sorting and can sort aluminum shredded vehicle scrap into wrought and cast alloys and then into individual alloy groups. The challenge is to use more end of life scrap in alloy formulation whilst at the same time extending the property range in terms of both strength and formability.

Jan 1, 2015

By G. M. Scamans

In the past ten years there has been considerable penetration of aluminum automotive body sheet (ABS) into automotive structures. The exponential increase in demand is resulting in major investments in heat treatment and finishing capacity across the globe. Line speed and tonnage throughput is limited by the continuous heat treatment (CHT) floater furnace rather than the cleaning and pretreatment section where electrolytic treatments that offer higher line speeds should come into favour and roll coating of pretreatment should predominate. The capacity limiting surface texturing pass will either be eliminated or moved to the finishing line or a dedicated mill. The key to making aluminum both embedded carbon and cost competitive with steel for more and more affordable classes of vehicles lies in recycling of both prompt scrap and, in the longer term, end of life vehicle scrap. For the first time scrap separation technology is available that can compete effectively with hand sorting and can sort aluminum shredded vehicle scrap into wrought and cast alloys and then into individual alloy groups. The challenge is to use more end of life scrap in alloy formulation whilst at the same time extending the property range in terms of both strength and formability.

Jan 1, 2015

By F. Kassabji

This publication presents the main experimental and theoretical results on the recovery of aluminum scrap (dross and Used Beverage Can) without use of any addition of fluxing salts. Dross and UBC's processing experiments have been conducted in a rotary plasma furnace operating in the transferred and non-transferred mode, using different plasma gases. The investigation involved the treatment of more than 100 kg of dross and other aluminum residues using plasma torches with less than 100 kW power. The experimental work showed that this process is .far more economical and kind to the environment than the conventional route using a salt flux. An equilibrium thermodynamic calculation at elevated temperature makes possible the prediction of by-products at various temperatures for different plasma gases.

Jan 1, 1994

This paper states how alloy and welding advances have made possible the rapid development of the use of aluminum in the construction of equipment for earth moving and off -highway rock hauling. The main details are given regarding the construction and field testing carried out on an aluminum prototype body. The test results of strain gauge readings are analysed, and a description is given of how these have been applied in subsequent designs. The increase in the number of aluminum units put into the various types of service in Canada, as well as the problems encountered, is described, and the experience gained from five years of field service is discussed in some detail. An assessment is also made of the durability of the e units. The economics of using aluminum, together with the current development position, are reviewed, and predictions are made for considerable future increases in the use of aluminum units in open-pit and off-highway operations.

Jan 1, 1964

By D. Eugene Rannels, Yu-Chen Lee

"Lee, Yu-Chen, and D. Eugene Rannels. Alveolar macrophages modulate the epithelial cell response to coal dust in vitro. Am. J. Physicl. 270 (Lung Cell. Mol. Physiol. 14): L123-L132, 1996.-The response of the alveolar epithelium to coal dust exposure is poorly understood. Coal or other dusts may act on the epithelium directly or indirectly through nearby alveolar macrophages (AM) that produce cytokines and other soluble products. AM and type II pneumocytes (T2P) were thus exposed to dust in coculture to evaluate their possible interactions. Anthracite coal dust PSOC 867 increased synthesis of extracellular matrix (ECM) components by T2P. AM alone did not produce ECM. Similarly, coculture ofT2P with AM (3.75:1) had little effect on epithelial ECM synthesis. In contrast, coculture ofT2P with AM significantly increased PSOC 867 effects on T2P rates of ECM synthesis, ECM fibronectin content, and T2P levels of fibronectin mRNA. AM-conditioned medium did not change the PSOC 867 effect on T2P. Neither control nor PSOC 867-treated AM on Falcon culture inserts (0.45-µm pore size) over T2P stimulated ECM synthesis by either untreated or dust-exposed epithelium. Thus AM-mediated changes in ECM synthesis by PSOC 867-treated T2P require close cell-cell interactions, suggesting a role for cell-cell contact or for short-lived soluble mediators of the AM effects. DEVELOPMENT OF PNEUMOCONIOSIS, a chronic disease of coal workers that results in pulmonary fibrosis and low lung compliance, is associated with inhalation of mineral or coal dust in the work place (14). Although the pathology of pneumoconiosis has been studied extensively, cellular mechanisms that cause changes in lung structure and function are not fully understood. Particulate matter that enters the respiratory system distributes according to size, with larger particles being removed in proximal airways. Dust components of small size may enter distal alveolar region, which is populated by two types of epithelial cells, type I and - type II cells, and by alveolar macrophages (16). Each of these cell types may interact with inhaled particles, but only the effects of coal dust on alveolar macrophages have been studied extensively. Less is known regarding the response of the alveolar epithelium, or of effects on epithelial cell-alveolar macrophage interactions, in the dust-exposed lung.Function of the alveolar epithelium is well known to be influenced by the underlying basement membrane, or extracellular matrix (28). Alveolar epithelial cell extracellular matrix interactions, which may involve modulation of cell migration, attachment, or differentiation (17), are reflected in type II cell morphology, metabolism, secretory activity, hormone responsiveness, lamellar body content, and gene expression (21). The extent to which basement membrane modulates differentiation of the overlying epithelium is determined by both molecular composition and three-dimensional structure of the matrix. Type II epithelial cells in vitro synthesize, secrete, assemble, and degrade a variety of basement membrane components, including laminin, fibronectin, type IV collagen, and thrombospondin (22, 27). How expression of these components is regulated, directly or indirectly, upon exposure of the alveolar epithelium to injury by coal dust or by other particulates remains to be resolved."

Jan 1, 1998

By F. F. Lins

There is a large use of mercury in Brazil by the gold miners in the so called "garimpos" (non registered mining operations), where it is usual to recover the gold contained in the gravity concentrates by amalgamation, which is highly deleterious to environment if not conducted properly. Unfortunately, this is a common practice there. After presenting in brief the modus operandi generally practiced in the garimpos and the environmental problems, this work reviews some of the research conducted in CETEM according to two approaches: (i) replace amalgamation by other processes and (ii) develop technology to treat mercury-contaminated soils and effluents. Conventional processes like froth flotation, to recover gold from gravity concentrates, and centrifuges were considered. Also as alternatives to amalgamation, innovative process like the recovery of gold by coal-oil agglomerates and a technology that is currently under development in our laboratory, called gold-paraffin process, are described in brief, some results presented and their potential use assessed. To reclaim sites already polluted a technology was developed to float mercury selectively from contaminated soils. The potential use of centrifuges to pre-concentrate the mercury is also discussed. The scope for applying the last techniques is to concentrate the pollutants in a small volume of mass which would be suitable for recycling or isolation from the environment. A prospective technology to treat contaminated soils, or mercury concentrates, is the immobilization of mercury by adding inorganics. Concerning the ionic mercury which may be present in effluents, precipitation of the ions and flotation of the precipitates are being studied.

Jan 1, 1994

By W. David Tyler

Any mining or engineering-construction excavation that extends below the water table must be dewatered. In many situations, the ground is of low permeability or the workings extend only a short distance below the water table. So water removal can be handled easily and economically by using mobile centrifugal pumps. However, there is an increasing number of mines that have a continuous high flow of water into the workings. Controlling this flow can significantly increase the cost of ore production. Successful implementation of any major dewatering scheme will ultimately rely on a clear understanding of the local geology. This understanding is necessary before an interpretation of ground water conditions can be made. It will dictate which dewatering methods are feasible. Once the geology and the ground water system are known, the scope and timing of the dewatering measures can be varied with the mine plan. Ground water modeling can assist in optimizing the dewatering system, though the precise objective of each model should be clearly defined. Production wells must be sited and drilled so that individual well efficiencies are high. Any lost efficiencies will translate into higher operating costs. Each well must be designed for maximum long-term control of the water table, and pumps sized to operate under continually changing heads. Finally, the investment in each production well must be protected during the mining process.

Jan 1, 1991

By Warren D. Stanford Stanford

Introduction The Sleeper mine is a near-surface gold mine located in a remote area 56 km (35 air miles) northwest of Winnemucca, NV (Fig. 1). The deposit was discovered in 1984 by an Amax exploration geologist. Favorable drilling results led to feasibility studies and metallurgical testwork. Final evaluation of the mine potential proceeded very quickly. The project received Amax board approval in July 1985. Eight months later, the process plant was fully operational. The first gold ($1 million) was shipped one month later, in March 1986. Total plant capital was $27 million. Payback was achieved in six months. The Sleeper mine was expected to produce 1.6 t (53,000 oz) of gold and 1.3 t (41,000 oz) of silver annually. However, the ore body exceeded all expectations. Production for the first 10 months of operation amounted to 4 t (128,000 oz) of gold and 2.9 t (94,000 oz) of silver. Direct cash operating costs are in the $1.77/g ($55 per oz) range. Amax is actively conducting exploration nearby for additional reserves to extend the mine's life. (See update on page 242.) Geology The Sleeper gold deposit is located on the northwestern flank of the Slumbering Hills and in the Awakening Mining District. Rocks exposed in the vicinity of the deposit are interbedded siltstones, sandstones, and limestones of Triassic age. They are overlain by latite lava flows and tuffs of Tertiary age. Dikes and sills of latite and andesite intrude the sedimentary rocks. Quaternary deposits of mostly sand with minor gravel and clay cover a pediment containing the gold deposit. The sedimentary and volcanic rock units have been transsected and offset by extensive north- northeast trending faults and less abundant northwest trending faults. Both fault systems fractured and prepared the ground for subsequent invasions of mineral-bearing hot spring geothermal waters. The hot spring systems produced widespread hydrothermal alteration and gold mineralization at silicified centers near feeder fault structures. The deposit is hosted by siltstone and latite that have been hydrothermally brecciated. The main breccia is elongated north-northeasterly. The hydrothermal breccia zones appear to dip steeply to the west. Gold mineralization consists of native gold and electrum deposited in two or more high-grade quartz-breccia veins. Lower grade gold mineralization occurs

Jan 4, 1987

By D. J. Droppert

This paper describes the precipitation-production of crystalline scorodite (FeAs04.2H20) from arsenic-rich sulphate-based metallurgical solutions at ambient pressure (95°C). Arsenic is precipitated by means of a controlled precipitation technique in which the supersaturation of the solution is carefully controlled. By controlling the supersaturation in the presence of seed material. the formation of amorphous ferric arsenate is prevented. Scorodite is known to be the most stable As(V) compound and is therefore preferred as host mineral for arsenic immobilization. The effect of the following parameters on the preCipitation behaviour and kinetics of scorodite are discussed: Type of base seed concentration initial [As]. sulphate concentration. neutralization rate. seed recycling and method of Fe(ll!) addition to Fe-deficient arsenic solutions.

Jan 1, 1996

By Oscar Perales Perez, Atsuo Kasuya, Kazuyuki Tohji, Yoshiaki Umetsu

"The removal of iron and various heavy-metal ions by their incorporation into stable ferrite-type precipitates at 25°C is a promising alternative to clean up large volumes of polluted aqueous effluents. Our research work investigated the conditions to produce magnetite and various M-bearing ferrites (where M: Zn, Cu, Co, Ni, Cd, etc.) directly from aqueous solutions at 25°C by simultaneous control of the oxidizing conditions and pH. The formation of the solids was followed by monit9ring the oxidation-reduction potential (ORP) and rate of proton release during the aerial oxidation of the suspensions at constant pH (contact stage). Only mildly oxidizing conditions, represented by ORP values between -110 mV and -150 mV and a moderate oxidation rate of Fe(II) species were conducive to well-crystallized ferrites at ambient temperature.' It was also found that increasing the Fe/M mole ratio in starting· solutions enhanced the stability ·of the M-bearing ferrites at ambient temperature. When the formation of the ferrite was incomplete, aging of the sludges in their mother liquors at 25°C promoted the crystallinity of the precipitates. The mentioned conditions ·favored the suitable progress of the ferrite-forming reaction involving the oxidation of Fe(II) entities, subsequent hydrolysis of produced Fe(III) species and dehydration of the intermediate:· Furthermore,· the ferrite formation at· low temperature permits the elimination of iron and co-existing heavy metal ions to sufficiently low concentration.In tum, the characterization of the precipitates evidenced their magnetic nature (room-temperature saturation magnetization above 60 emu/g) as well as the effective incorporation of target metal ions into the ferrite structure."

Jan 1, 2000

By Roger M. Zimmerman

The G-Tunnel heated block experiment is being conducted on the Nevada Test Site (NTS) as part of the Nevada Nuclear Waste Storage Investigations project (NNWSI). The purpose of the ambient temperature testing ph se is to evaluate rock-mass mechanical properties of a block (- 8 m3) under biaxial stress changes up to 7.5 MPa above an initialization in situ value of 3.1 MPa. Results indicate that the modulus of deformation ranges from 9.7 to 17.0 GPa and Poisson's ratio ranges from 0.21 to 0.33. In general, the higher values of the modulus and Poisson' s ratio were influenced by fracture propagations parallel to the compressive stress field. Other measurements indicated that cross-hole compression (p) wave velocities and single fracture permeability values were relatively insensitive to stress changes above the in situ value.

Jan 1, 1984

By B Hayes

The Ambuklao and Binga Rehabilitation Project is a 175 MW hydro power project currently under construction across dual sites in the north region of Luzon Island, Philippines. When it was built in 1956, the Ambuklao Dam harnessed the second largest hydro-electric reservoir in Asia. However, due to landslide erosion and prolonged silt infiltration caused by an earthquake in 1990, the power plant has been rendered inoperable since 1999.To bring the power generating facility back to life, the project scope entails the rehabilitation and construction of civil structures, shafts and tunnels. A major component of these works is the decommissioning of a section of the seven metre diameter headrace tunnel by installing a concrete plug. The headrace tunnel is part of a closed waterway system that connects the dam via a shaft, exhibiting a hydrostatic pressure of 13 bar (1300 kPa) at the location of the new tunnel plug. In addition, the power station ball valves have seized ajar and the damaged intake riser is unsafe toaccess thereby requiring the plugging operation to be carried out under live flowing conditions.Working under hydrostatic pressure and live conditions, the headrace plug will be an underwater tremie pour operation that includes drilling and concrete injection through blow out preventer caissons installed in the floor of an underground chamber above the tunnel. The purpose of this paper is to describe the key engineering and planning components involved in this operation including pre- and post-grouting, chamber crane, sonar, local water compensation, jet flushing, drilling, caisson installation, and concrete design, production, delivery and placement. The success of this task rests on the strategic preparation and operational management of risk and safety in a challenging rural environment.

Mar 8, 2011

By Derek du Preez, Andrew Hall, Timothy M. Pelech

Net Present Value (NPV) derived from Discounted Cash Flow (DCF) analysis remains the dominant metric for evaluating mining projects despite its well-documented inability to capture managerial flexibility under uncertainty. DCF assumes that all risks are perfectly priced by financial markets. This is an unlikely assumption for volatile commodity prices, geological variability, or the array of mining technical and operational risks present on all mine sites. Real Options Analysis (ROA) was developed to remedy this limitation by explicitly valuing the ability of managers to defer, expand, scale, switch, or abandon investments as new information emerges, and to capture upside and mitigate downside risks. While ROA is philosophically correct and routinely shows an uplift in project value compared with DCF, its practical application at industrial scale is severely constrained, ROA faces the reality of a combinatorial explosion in complexity of decision trees, Monte Carlo simulations and other models required when multiple interdependent or sequential options exist across numerous mining zones and time periods. The AMC Hill of Value® (HoV) process adopts the same intellectual foundation as ROA, that flexibility has economic value, but operationalizes it through a far more robust and scalable architecture. It is built on parametric relationships, rapid scheduling, and multi-objective evolutionary optimisation. HoV can evaluate millions of compound, interdependent real options in a single optimisation run, delivering resilient, adaptive strategies that preserve managerial flexibility while simultaneously optimising NPV, mine life, risk exposure, and other corporate objectives. This paper demonstrates that HoV is the practical, industrial-scale embodiment of real options thinking in mining: it discovers, ranks, and translates the most valuable real options into strategic mine plans, overcoming the scalability barriers that have prevented widespread adoption of classical ROA.

Feb 22, 2026

By Mark G. Colwell, Russell Frith

"An Analytical Model for Coal Mine Roof Reinforcement (AMCMRR) has been developed. AMCMRR utilizes a Factor of Safety (FOS) approach, which is commonly used in all forms of engineering. The starting point in the development of AMCMRR was an existing analytical roof behavior and roof support design methodology/model, originally developed by Colwell. This technique was used successfully in the Australian underground coal industry for roof support evaluation and design prior to and during the course of the research project, and when used, it was essentially calibrated on a site by site basis.It has long been recognized that bolts and longer tendons can modify the behavior and load bearing capacity of the reinforced roof via the concept of beam building. The break-through in developing AMCMRR was combining the original analytical model with a comprehensive database (associated with Australian collieries) to effectively quantify this reinforcing effect, and this in turn provided the ""platform"" by which this analytical model can be calibrated for the entire Australian underground coal industry.This paper focuses on the application and use of AMCMRR and the analyses undertaken to quantify the reinforcement beam building offers to the immediate roof. Furthermore, this paper demonstrates that a combined empirical and analytical approach is currently the most practical way of developing credible geotechnical design tools for the Australian or any other underground coal industry.BACKGROUNDBy the start of 2006 the ALTS (Analysis of Longwall Tailgate Serviceability-Colwell et al., 2003) and ADRS (Analysis and Design of Rib Support-Colwell, 2006) design methodologies were being routinely and widely used within the Australian underground coal industry. As a result of their success, Colwell Geotechnical Services commenced a research project entitled, ""The Future Development and Integration of ALTS & ADRS for Improved Underground Roadway Design. "" The project (which became known as the ALTS 2006 Project) was funded directly by several of the major coal producers as well as individual Australian collieries."

Jan 1, 2010