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By D. D. Banerjee, S. K. Kawatra, T. C. Eisele

A high calcium fluid-bed combustor ash has been shown to be an effective binder at dosages of 1 to 2% of the magnetite concentrate weight. Magnetite pellets 1.3 cm (1/2 inch) in diameter were produced with dry crushing strengths greater than 22.3 Newtons/pellet (5.0 pounds force/pellet), which is comparable to the results produced using conventional bentonite binder. The effectiveness of fly-ash-based binders was considerably improved when calcium chloride was added as an accelerator. Addition of calcium chloride at a rate of 0.1 to 0.2% of the total powder weight increased the strength of dried pellets by as much as 22% compared to the strength of pellets made using fly-ash without accelerators.

Feb 24, 1997

By J. A. Lamonica

The Bureau of Mines conducted an environmental noise survey to determine the noise levels to which underground coal mine employees are exposed, to evaluate noise survey techniques and equipment, and to compare noise exposures using two criteria, Walsh-Healey and CHABA, for determining allowable exposures that were under consideration for the Federal Coal Mine Health and Safety Act of 1969- Time study techniques and Bureau-approved standard sound level meters were employed. The shift exposures of 20 percent of the miners studied were in excess of the safe standards established by both criteria. The shift exposures calculated using the Walsh-Healey criteria were greater than those calculated using the CHABA criteria owing to the intermittent nature of the exposure. Ultimately the CHABA criteria were rejected, and the Walsh-Healey criteria were adopted.

Jan 1, 1971

By Arthur Notman

THE raw material men in all industries, and copper is no exception, are accustomed to think of them- selves as the whole show, and not without justice, for if there were no copper mines the world would have no copper. Nevertheless, many different things costing money and resulting in profits must be done to their product before it is ready for the world's use. In other words, they are making the frequent mistake of Chinking in terms of partial costs. Nobody really uses electrolytic copper. Possibly that is why nobody seems willing to pay anything for it. The manufacturers, being canny, do not buy any more electrolytic than they feel that they can work up and sell profitably, although they like to make the raw material men Chink that they will take all that can be produced. This is a state of affairs that has aroused my sympathy and curiosity, and has induced me to study the financial history of the copper wire and brass industry of the country or such portion of it as publishes any records readily available to the curious minded. About 60 per cent of the electrolytic copper used in this country is drawn into wire and consumed by the electrical industries. The remaining 40 per cent is

Jan 1, 1926

By J Samosir, L Snyman

Northparkes was the first mine in Australia to use block cave mining method which relies on gravity and natural rock stresses to fragment and recover the ore. It was also the first hard rock mine to use hydraulic fracturing, in conjunction with CSIRO, to promote caving of E26 Lift 1. The technique was later used on E26 Lift 2 wedge and E48 prior to undercutting.Northparkes production is currently sourced from the E48 Lift 1 block cave mine and E26SLC. The E48 block cave contains economic ore to the north and south of the current cave footprint. To recover this ore the footprint has been extended on the north and south with two extraction drives and one extraction drive, respectively. Modelling of cavability above the additional drives indicated that the cave would not readily propagate to a sufficient height of draw to mobilise the ore and tended to arch over into the existing cave. To address the modelling results and to reduce the risk of the project, rock mass preconditioning was adopted.This fracturing campaign was performed from surface drill holes adjacent the subsidence zone angled to intersect the higher grade and higher elevation ore zones.Optical televiewer surveys, run prior to fracturing, picked intervals and fault zones to be avoided. Holes were resurveyed post-fracturing to detect newly created fractures and as a measure of success of the program.During fracturing operations water and gel fractures were run at varying depths and pumping pressure was logged for each fracture. The mine seismic system monitored significant events and dye in the fluids utilised for tracking water inflow locations during underground inspections.Towards the end of the project, guar fibres from gel were detected within the mill circuit and required treatment to resume optimum processing.CITATION:Webster, S, Snyman, L and Samosir, J, 2016. Preconditioning E48 cave extension adjacent to an active cave, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 471–478 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By H. Warren Newcomen

The southwest wall of the Lornex Pit at the Highland Valley Copper mine has been experiencing slope displacements since 1978. Measures to manage the displacements on previous pushbacks have included stepping out, scheduling pushbacks to unload the crest of unstable areas, slope dewatering and mining with intensive slope monitoring. The final pushback on this wall is currently being mined and substantial modifications to the slope geometry could prove to be uneconomic. As a result, a campaign of surface water collection and diversion, horizontal drainhole drilling and deep well drilling is currently underway to maintain an acceptable degree of stability to the end of mine life. The various factors contributing to instability, including engineering geologic controls, rock mass strength, and surface and groundwater hydrology are presented. Movement trends, displacement magnitudes and stability analyses results are also discussed.

May 1, 2002

By D. S. Burgess

About 100 tests of flammability were carried out with H2, CH4, and CO in mixtures with air using the Federal Bureau of Mines 12-ft-diameter spherical pressure vessel as an explosion test chamber. The LeChatelier approximation gave slightly conservative estimates of the limits of downward flame propagation (onset of significant pressure rise) using the following measured values for the individual gases, in percent: H2, 8.5; CH4, 5.25; CO, 13.0. No justification could be offered for using the LeChatelier law for upward flame propagation limits and indeed reported data suggest that calculated values would not be conservative. The observed upward limit for methane-air mixtures (4.85 pct) was less than the widely accepted lean limit for this fuel; those for lean hydrogen-air mixtures and carbon monoxide-air mixtures did not differ from the lowest accepted values. Diffusional effects on the propagation of single, binary, and ternary fuel mixtures are discussed.

Jan 1, 1982

By G. R. Hopkins

The average heat requirement per barrel of crude processed in the United states rose from 555,000 B. t. u. in 1939 to 579,000 B. t. u. in 1940, although crude runs increased from 1,237,840,000 barrels to 1,294,162,000 barrels in that period. Thus the almost invariable rule that the average amount of heat needed to refine a barrel of crude oil declines when total crude runs to stills increases was broken. (See fig. 1.) The reasons underlying the apparent loss in fuel efficiency in 1940 are quite obscure. There is little question but that the principle of heat exchange, the most important fuel saver, was used as extensively in 1940, as in 1939. A few companies replaced purchased power with electricity made at their plants, but for the country as a whole purchased electricity increased 7 percent, as compared with a 5-percent gain in crude run to stills. Furthermore, the premise the more complex the products the more fuel required -does not hold, as the yield of ?complex" products, including gasoline, declined in 1940.

Jan 1, 1942

[RALPH ADAIR Ore Dressing Consultant Bull Mtn. Rd., Asheville, N. C. Phone 4-1693 JAMES A. BARR Consulting Engineer Mt. Pleasant, Tennessee Washington, D.C. BEHRE DOLBEAR & COMPANY Consulting Mining Engineers and Geologists 11 Broadway New York 4. N. Y. I. R. BERENT Engineering Consultants and Contractors Mineral Exploration, Mine Evaluation, Mine Designs and Mine Management 156, Ataturk Bulvarl-Ankara, Turkey BLANDFORD C. BURGESS Registered Professional Engineer Mining Consultant Monticello, Georgia GLENVILLE A. COLLINS Mining Engineer Uranium examinations Cable "Coins" 210 La Arcade Bids. Santa Barbara, Calif.]

Jan 1, 1952

By Wils L. Cooley

This report analyzes electrical accident data in the metal/non-metal mining industry. Accidents are categorized to determine their root causes. Special attention is given to accidents associated with inadequate or defective grounding of mine power systems. Recommendations are made concerning proper grounding practice, especially for dredges and for quarries in hard rock or sand. The costs of instituting the recommended practices are estimated for model mine power systems which are based on field data obtained from 37 mines and several electrical contractors. The expected benefits of various suggested safety practices are also estimated.

Jan 1, 1981

By Roy A. Bell

A 200-foot diameter, 72-foot high petroleum storage tank was built in a hillside ravine where a portion of the site contained soft clay fill. Soil-cement piles, 40 inches in diameter and up to 38 feet long, were installed to support the tank shell and ringwall, and a portion of the tank floor by drilling into the stiff to hard underlying soils and weathered bedrock. The goal was to provide a strong enough foundation to resist the seismic tank shell loading and to minimize differential settlement of the tank shell to avoid out-of-round clearance problems between the shell and floating-roof. A cantilevered retaining wall up to 8 feet high was constructed around a portion of the tank perimeter by inserting steel H-beams into soil-cement piles. The cantilever soldier piles for the retaining wall were installed from a temporary earth embankment on the hillside directly over the top of the wall. The temporary embankment was then removed and the tank pad was cut to grade in front of the soldier piles. Some of the soil-cement piles for both the tank foundation and retaining wall could not be advanced to design depth because the drill/mixing tools could not penetrate to the required depth in the hard soils/bedrock. Smaller diameter borings (22 inches in diameter) were drilled through the centers of the short-of-design soil-cement piles to the design depth and then backfilled with concrete.

Jan 1, 1997

By G. R. Hopkins

The average heat requirement per barrel of crude processed in the United states rose from 555,000 B. t. u. in 1939 to 579,000 B. t. u. in 1940, although crude runs increased from 1,237,840,000 barrels to 1,294,162,000 barrels in that period. Thus the almost invariable rule that the average amount of heat needed to refine a barrel of crude oil declines when total crude runs to stills increases was broken. (See fig. 1.) The reasons underlying the apparent loss in fuel efficiency in 1940 are quite obscure. There is little question but that the principle of heat exchange, the most important fuel saver, was used as extensively in 1940, as in 1939. A few companies replaced purchased power with electricity made at their plants, but for the country as a whole purchased electricity increased 7 percent, as compared with a 5-percent gain in crude runs to stills. Furthermore, the premise -the more complex the products the more fuel required -does not hold, as the yield of ?complex" products, including gasoline, declined in 1940.

Jan 1, 1942

By Gilles Landry, Mohamed Ourriban, Pierre Pelletier, Ahmed Bouajila, Claude Gagnon

"This paper summarizes the work carried out to develop and implement the gold cyanidation by size class (CSC) process, a novel concept aiming to reduce cyanide consumption.First, the authors will present the methodology and results of laboratory tests conducted to evaluate the response and the expected gains for the selected ore when submitted to the CSC processing. In the second part, focus will be on the methodology behind the CSC scheme development prior to its implementation at Sleeping Giant Mine concentrator. Finally, the evaluation of the modified circuit performance (operating since July 2007) will be addressed as a reduction of cyanide consumption by more than 30% and of free NaCN in the tailings by more than 50% is confirmed.INTRODUCTIONCyanidation is the most widely used technique to extract gold from hard rock ore. Its use of oxygen as an oxidant still makes it the cheapest process available after more than a hundred years. Unfortunately, gold cyanidation is known to be a slow process that requires high consumption of cyanide. In fact, cyanidation plants are designed with very long residence times (Habashi, F., 1967). Drawbacks of long cyanidation times are, among others, loss of gold in tailings, high reagent consumption and high capital investment and maintenance costs.Responding to their members expectations for the improvement of cyanidation process, COREM undertook a challenging R&D program covering the development of alternative concepts (processes) and the understanding and solving of mass transfer, gold passivation and process water chemistry problems. One of the interesting findings of the R&D program is a patent pending process technology based on the cyanidation by size class (CSC) concept (Côté and Ourriban, 2004; Gagnon and Ourriban, 2007; Gagnon and Ourriban, 2004).The new technology was tested at the Sleeping Giant concentrator, a plant member of COREM. The existing flowsheet was modified in order to implement the CSC process in the full-scale plant. The plant has been operated using the modified CSC based process since August 2007. Laboratory testwork was conducted prior to the industrial application in order to properly design the new process scheme. The modifications included:1) Reclassification of the grinding circuit product through an hydrocyclone2) Leaching of the coarse size fraction3) Addition of the fine fraction to the coarse leaching circuit tails."

Jan 1, 2009

By Jay L. Hodkinson

Replacement of an aging twin span river crossing in Vermont required a temporary bridge to accommodate traffic during construction. Soils beneath the temporary approach embankment consisted of very soft organic clayey silt underlain by interbedded, loose alluvial fine sand and silt/clayey silt. Reinforcement was required for the southern temporary approach embankment to limit settlement and to increase global stability factors of safety. A ground improvement design was developed using Rammed Aggregate Pier® reinforcement and was included in the contract documents as an FHWA Category II Experimental Feature. Instrumentation intended to document the performance of the supported embankment was installed. Piers were then constructed and monitoring commenced as embankment and bridge construction occurred. Weekly instrumentation data reports indicated continuing excess pore water pressure, settlement, and lateral deformation of the subgrade soils as the embankment and temporary bridge abutment was constructed. In response to the unanticipated monitoring results, further investigation indicated that significant deviations from the conditions and basis upon which the ground support design was developed were made during construction. This paper discusses these deviations and their specific impacts to embankment support performance, how these deviations occurred, the role that the ground support system played in maintaining global stability, measures taken to limit further detrimental impacts to the embankment, and provides recommendations for contract document preparation and construction oversight to prevent similar situations from occurring on future projects.

Jan 1, 2011

By Charles Hart

In this paper it is the author's intention to show the extent and character of foreign ores now known to be available; these deposits may be in active production or held in reserve until economic conditions may make them active. He hopes to show the relation existing between these ores and the American supply, and which of the former are now producing or will in turn come into production when our better ores have been exhausted. This phase of this discussion must of necessity include some data as to the present rate of consumption and a study of the changes we may expect here and abroad in the general steel trade and its sources of supply in raw materials. It is obvious that the occurrence of coal, ore and limestone in relation to one another and the proximity of a market are the elements in control of this feature of the problem. If the foregoing situation is favorable, all the other questions may be solved, for it is clear that with proper basic conditions finance, labor and operations will fall in line. We present a short outline of the present methods of carrying on the foreign iron ore trade, believing that it is of general interest in comparison with our own highly specialized methods, and that with the exhaustion of our better ores we will be compelled to seek a part of our supply abroad. A partial list of iron ores, with incomplete analyses (Table I), is added, to give a better understanding of the general situation and explain to some extent the reason for things being as they are in the iron and steel trade of the world and to help in bringing this paper to an informing conclusion. The question of the world supply of iron ores has been a subject for study on the part of geologists and engineers for many years, and found its best results in the Eleventh International Geological Congress, appropriately held at Stockholm, Sweden, in 1910. The proceedings are published in two volumes and are undoubtedly the best records available on this subject at the date of publication. It should be borne in mind, however, that much has happened in the 20 years since these figures were assembled. There is just as much known ore at present as at that time, minus the quantity consumed, plus newly discovered reserves. The World War had great effect upon this situation; during that time explorations were greatly reduced and the settlements after the

Jan 1, 1929

By O. F. Oxtoby, J. E. Olsen, M. W. Erwee, Q. G. Reynolds

"The extraction of molten products and wastes through smelting furnace tap-holes during the tapping process is a complex procedure involving many coupled thermophysical effects. Insight into the fluid flow behaviour in such systems can be gained by using computational mechanics tools to build highfidelity models of the fluid flow and other relevant physics. Previous work using such models indicates that the nature of the flow in the tap-hole, as well as operational parameters such as the tapping flow rate, depends strongly on the properties of the material being tapped and the geometry of the tap-hole channel. Additional complications arise when multiple fluid phases (for example, slag and metal) are present simultaneously, when porous coke beds hinder flow to the tap-hole entrance, and when the geometry of the tap-hole changes over time due to cycles of wear and repair. In the present work, challenges with the coupling of phenomena such as multiphase flow and porosity into computational fluid dynamics methods for tap-hole modelling are discussed in the context of electric furnaces used for ferromanganese production. Qualitative and quantitative results of computational models of flow through tap-holes are presented and compared as a function of material parameters to determine sensitivity effects, and in response to operational parameters to determine typical process behaviour over the duration of a tap. IntroductionPyrometallurgical production using electric furnaces accounts for substantial portion of the world supply of ferroalloys and other strategic materials (Degel et al., 2015). A range of different furnace designs may be used depending on the metallurgical process, with circular three-electrode submerged arc furnaces (SAFs) powered by alternating current being the most common for commodities such as ferromanganese and silicomanganese (Olsen, Tangstad, and Lindstad, 2007).As shown in Figure 1, manganese furnaces typically operate with a deep charge consisting of an upper layer of loose burden (onto the upper surface of which is fed solid raw material), a molten slag layer partially or completely filled with unreacted carbonaceous reductant (generally metallurgical coke), and a molten metal layer which settles to the bottom of the furnace due to its high density. The solid particles present in the slag and burden layers form porous beds which hinder the fluid flow of molten process material and gases inside the furnace (Olsen, Tangstad, and Lindstad, 2007).In order to remove material from the furnace during normal operations, a single tap-hole is built into the sidewall of the vessel near to the level of the hearth. Tapping involves removing both slag and metal phases through the same tap-hole channel, which makes tap-hole design, operation, and maintenance particularly complex. In the case of processes such as ferromanganese, which operate with no external gas injection or open arcs present at the furnace electrodes, flow of material out of the tap-hole is driven primarily by the hydrostatic pressure generated by the weight of the solid and liquid phases above the tap-hole."

Jun 1, 2019

By Patricio Santis, Jacopo Seccatore

Artisanal and Small-scale Mining (ASM) is a prominent activity in the extractive industry: considering only gold, it produces about 20% of world market supply. Despite this fact, ASM is generally associated with negative aspects of its environmental impact, and operational research is generally neglected. This paper emphasizes the peculiarity of the drilling and blasting systems of small underground mines in selected South American Countries. Such Countries, while having large mineral deposits and well recognized large-scale mining activities, at the same time still present on their territory ASM activities that are archaic, highly inefficient and dangerous for the safety of its operators. This paper documents drilling and blasting activities from gold mining in Ecuador and Chile. First, are described the outdated and often non-rational techniques employed by miners, to provide a general framework of the current methods. Then, it is shown what can be improved and how the current methods can be modified. Finally, are shown some field applications and the comparisons of the results obtained. One case shows how blast pull efficiency can be increased of from 82% to 98% by changing non-rational applications of explosive products. Another case shows how, by rationalizing blast designs, drilling and blasting costs can be reduced by 9% per month, the advance by blasting increased by 29% and the blasting efficiency increased from 70% to 90%. Finally, it is concluded that examples of application show how operational improvements are easily applicable on the field, relying only on tools and resources of artisanal mining, but combining solid engineering bases with confidence-gain and respect for the experience of the miners.

By Tiago Nunes Lima

As ligas titânio beta têm sido desenvolvidas devido as suas excelentes combinações de boas propriedades mecânicas e alta resistência a ambientes corrosivos. Novas ligas de titânio ao nióbio estão em desenvolvimento e apresentam grande potencial de aplicação em diversas áreas da engenharia. O presente estudo tem como objetivo verificar propriedades mecânicas da liga Ti42Nb2Sn na condição deformada e também envelhecida. Um lote de amostras foi laminado a frio com 80% de encruamento e outro lote foi laminado e envelhecido na temperatura de 400 °C durante 48 horas. Foram realizados ensaios de tração, medidas de dureza, metalografia e microscopia das superfícies de fratura. Foi possível observar baixo valor de módulo de elasticidade e alta ductilidade para a amostra deformada e alta dureza e módulo de elasticidade para a amostra envelhecida.

Aug 16, 2017

By R. Sullivan, K. Joiner, B. Emery, M. de Vries, F. A. Stober, L. R. Nelson, J. M. A. Geldenhuis

Keywords: Pyrometallurgy, smelting, converting, furnace design, furnace retrofit, high-intensity smelting, copper coolers, plate coolers, waffle coolers, tap-blocks, lower sidewall air-cooling, wall hold-down system, platinum group metals, ferroalloys, ferrochrome, ferrocobalt, ilmenite smelting, ironmaking, operational readiness, operational support The paper describes the development of furnace designs by Hatch in conjunction with the smelting plants in Africa to meet the intense process requirements in certain applications; continued improvement in operating efficiency through increased throughput from existing crucibles; and improvement in campaign life and furnace integrity. The era of Hatch in Africa has seen the doubling of furnace power in retrofit projects using existing crucibles to developing the highest intensity immersed electrode operations in the world. This has resulted in minimized OPEX and CAPEX per unit of production. Through the continued development of its cooling, binding and furnace power supply technologies and working with the experienced and knowledgeable personnel at the smelting facilities in Africa, Hatch has managed to meet the challenges of ever increasing furnace process requirements associated with increased power density and superheats prevalent in the operations. In addition to developing furnace crucible designs, Hatch has also intensified its ?after sales service and support? with the construction, commissioning and start-up technical assistance and operational readiness and operational support for ramp-up to nameplate capacity and beyond. The key areas of furnace risk associated with high superheat molten material tapping has also seen the development of diagnostic systems to mitigate risks and produce early warning signals for the operators.

Jan 1, 2006

By R. T. Swinderman

"Virtually every article you read on safety has a statement to the effect: “It’s obvious that safety pays”. If it is so obvious, why is it so hard to answer these questions? • How does the Maintenance or Operations Manager convince the Plant Manager to spend money from the annual budget for safety improvements? • How does the Plant Manager influence Corporate to prioritize safety improvements? • How does an engineering firm persuade the owner to spend more on design and equipment up front to reduce risk? There are many cultural and structural reasons why it is so difficult to prove the obvious. In my opinion the main culprits are: the almost universally used ‘Low Bid’ process, variations in reporting incident statistics between industries and countries, and, the Generally Accepted Accounting procedures (GAAP) [or International Financial Reporting Standards (IFRS)]. Conventional wisdom is it’s smart not to spend more than you need to meet the minimum regulations and maximize production. But buying on price alone often harms people, degrades the environment, and reduces the company’s bottom line. How can this be? You met the minimum safety requirements and saved money by buying on price. Don’t those savings go right to the bottom line? When you buy on price you get minimum quality, minimum compliance and are often backed corner with no reasonable options to rectify the problems that arise from buying on price instead of buying on long term life cycle cost. Culturally few companies actually ‘walk the talk’. It is trendy to have giant billboards at plant entrances proclaiming world class compliance with quality and safety standards. Annual reports are embellished with safety slogans and sustainability statements. Behind the front gates and the glossy annual reports the message is clear: produce or be replaced. Only a few companies go beyond the window dressing and actually endorse, from the top down, continuously improving their safety culture. Those that do embrace safety, show significant performance advantages over their competition that are reflected in their safety, productivity and environmental records and, ultimately their financial statements and share price. Current accounting (and reward) systems make it unlikely financial managers will accept non-conventional approaches to justifying expenditures on safety because they are driven to report “hard” numbers that can be documented and are within the “GAAP or IFRS Rules.” But in reality, accountants quantify soft or intangible costs all the time in their financial statements. Justifying safety investments is greatly enhanced by quantifying what most financial managers would call intangible costs. Government agencies have no problem assigning intangible costs to justify regulations to improve safety. How many times have you heard that the regulation is justified because the cost to industry is X while the benefit to the society is 2 or 3X? How can they say that without including intangible costs? We find it hard to believe these government claims of benefits to society because we have been trained to think about saving hard direct costs to justify investments."

Jan 1, 2017

By Barry James

Energy, like labour and materials, is one of the basic production inputs in the industrial minerals industry. This paper discusses the significance of the changing energy situation in Canada as it affects the industry. It is apparent that the importance of energy as a management concern has increased considerably since 1973. The importance placed on energy management today will undoubtedly be an important factor in determining company and industry sector strength and profitability tomorrow.

Jan 1, 1978