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By Wolfgang Pietsch

DR iron') is a generic term for metallized product that results from the direct or solid state reduction of iron ore. In direct reduction, iron oxides are reduced to metallic iron in the solid state without an intermediate melting step. MIDREX ® Iron is the DR iron material produced in the MIDREX ® Direct Reduction Process. Except for some thermal and mechanical degradation, the external physical form of as-reduced DR iron is the same as the feed material. Chemically, oxygen associated with iron is removed leaving a very porous structure. Figure 1 is the scanning electron micrograph (SEM) of the internal surface of a MIDREX Iron pellet obtained from a Swedish oxide pellet during reduction at 760 °C. Figure 2 is the SEM of a polished and etched cross-section through the same pellet showing the amount of intraparticle porosity. As a result of this high porosity, apparent density of DR iron is relatively low, typically a¬round 2 g/cm3, and specific surface is extremely high, typically around 1.0 m2/g or more. Both density and specific surface depend on the raw materi¬al and the operating conditions of the direct reduction plant. Normally, more than 97% of the available iron is reduced into metallic iron with the rest mainly in the form of wustite (FeO). During direct reduction, the gangue in the iron remains essentially unchanged. Removal of oxygen and the corre¬sponding reduction in weight result in a slightly higher percentage gangue in the product than in the raw material.

Jan 1, 1976

By W. J. D. Stone

In 1960, Magnetics International Ltd. undertook the development of the Jones High Intensity Wet Magnetic Separator in the Americas. Magnetics International had a number of possible applications in its own projects plus the intention of developing the equipment for sale to others. It was soon recognized that no matter how innovative a piece of mineral separation equipment may be, it takes many years and much finance before it is finally accepted for large scale use. For this reason, many good ideas die in their infancy. One of the chief reasons for such a time lag between conception and large scale implementation is the usual lack of finance to construct and put into operation a large demonstration unit. Even with a large unit for demonstration, the first major user usually requires a guarantee that is not normal in accepted separation equipment. Such problems are also normally accompanied by major design changes from the first conception.

Jan 1, 1971

By J. Gauntt

Calcium carbonate is one of the most widely used industrial minerals in applications like cement, lime, agriculture, power plant fluegas desulfurization (FGD) and construction aggregates. Most applications are generally high-volume and low value ($9/t or $10/st) or less free-on-board (f.o.b.) mine site) uses of this material. Specialty uses of ground calcium carbonate (GCC) are typically referred to as ?performance mineral? or ?extender and ?ller? applications. Primary specialty markets for GCC include paper and plastics as well as a number of construction applications including joint compounds, carpet backing, paint, and adhesives, caulks and sealants (ACS). Other important specialty applications for GCC include rubber, food and personal care products. A new and growing application for GCC is in nonwoven fabrics, where this mineral replaces a small percentage of the polymer. Typical specialty applications for GCC are color sensitive and require extremely white/bright materials. Although deposits of limestone are located in most states, high brightness resources are relatively rare and controlled by a limited group of suppliers.

By Raúl Castro, René Gómez

In underground mining, rock fragment size is a key variable for productivity because it impacts equipment selection and mining structure design. This study characterizes granular material fragmentation during its flow to understand its characteristics and mechanisms. Tests were conducted using a laboratory setup to emulate various heights where material is drawn. The fragment-size distribution was measured before and after tests for clay, concrete fragments, and gravel. Results showed that fragmentation mainly occurs in minor sizes, with significant increases in fine material as travel distance increases.

Jan 10, 2022

By J. Platt

Debate over acid rain legislation has presented a moving target for coal and utility company planners attempting to figure out how legislation will affect their business environment. In spite of disagreement among experts, the prospect for continued change, and persistent --perhaps even growing --uncertainty, a great deal has been learned about coal market dynamics. This paper reviews progress and describes some of the major problems and controversies.

Jan 1, 1990

By S. Potgieter-Vermaak, T. T. Chiweshe, W. Purcell

The advantage of using ammonium phosphate salt as flux is the selective precipitation of chromium(III) compounds, which are considered nontoxic and environmentally friendly. The technique in this paper is determined to have potential to be applied in the metallurgical industry, where it can be used in the beneficiation of chromite mineral ores. The higher chromium contents of chromite ores often require furnaces to run at higher temperatures of above 1,300 °C, which can cause shutdown of the ore processing plant and accumulation of the sticky chrome compounds — including toxic chromium(VI) waste — which are generated as byproducts. The other advantage of this technique is its low to moderate energy consumption compared to existing techniques.

By Angelina Anani, Nilufer K. B. Akbulut, Sefiu O. Adewuyi

Crucial information about safety, design, and operation can be utilized in underground mines from ground movement data. Communicating the information and exploring new findings can be a challenge in a decade where there is an ever-increasing volume and velocity of data due to advancements in mining technologies. This challenge escalates for geotechnical data as it is multidimensional, depending on the space and the rate it takes place. To tackle this challenge, geotechnical engineers should focus on utilizing simple yet compelling visualization of rock mass data in 3D. Competent visualizations of ground conditions as a Trigger Action and Response Plan (TARP) could ease the communication of safety concerns and the exploration of rock mass displacement and strain surrounding an opening at an underground mine. Therefore, this study focuses on using scientific visualization methods by rendering geotechnical data over the surface of a 3D mesh model to display TARP levels. The study is conducted at the San Xavier (SX) Underground Mine Laboratory’s East decline. The project aims to produce visualizations that optimize the use of geotechnical data in near-real-time.

Feb 1, 2025

The Colorado portion of the Rio Grande rift is clearly defined physiographically from the south in the San Luis valley northward to the latitude of Leadville where sediments of the Dry Union Formation (Tweto, 1961) accumulated within the subsiding rift zone. To the north of Leadville is a system of faults active in the late Tertiary, including the Mosquito fault that offset a portion of the Climax mineralization (Wallace et al., 1968). Tweto (197B) describes remnants of Dry Union Formation against the Mosquito fault north of Dillon in the Blue River valley, so it is apparent that the rift and associated sediments extended well to the north of Leadville. Kelley (1952, 1954, 1956) and Chapin (1971) have noted in New Mexico that the Rio Grande rift is a series of en echelon basins, offset to the east, with constrictions connecting them (Fig. 1). In Colorado the structural basins are offset to the west. The net effect of all the rift zone basins in New Mexico and Colorado is an arcuate pattern (Fig. 1) abutting the Colorado Plateau and Sari Juan Volcanic Province on the west. The width of the rift system gradually decreases northward to about Leadville where rift definition is not apparent.

Jan 1, 1987

By S. A. Lang

Mine management in general, and mine maintenance in particular, has lagged in using computers as an effective management tool. SF Coal Corporation, in conjunction with the development of the new Lee Ranch Mine, is developing a computer-based maintenance system as an integral part of a total mine management information system. The system includes the ability to schedule and plan preventative maintenance on all rolling stock and mine facilities, project and track component life, and evaluate and schedule manpower requirements. The system hardware, shared by accounting, warehousing, engineering, production and management, consists of a multi-user, multi-processor micro-computer.

Jan 1, 1985

By Jan M. Mutmansky

Since 1973 when the first edition of the SME Mining Engineering Handbook was published, many significant changes have occurred in the US mining industry. The industry went through a fairly prosperous period immediately after 1973, but then many economic pressures came to bear on mining companies, particularly in the metal and coal branches of the industry. These pressures changed both the mining methods used and the general economics of the mining methods. As a result, the industry today is different in many ways titan it was in 1973. A general summary of some of the more important changes that have come about will be provided here as well as some assessment of the effects of these changes on the choices of mining methods. In the metal mining industry, the most significant trends were increased surface mining, the use of larger and more efficient equipment, and increased technology and automation. The primary impetus for these changes was unprecedented competition from foreign producers. In many cases, this competition came about because of the nationalization of foreign mines and the tendency for these mines to become a source of foreign exchange. Under these circumstances, the mines could be operated even though they were not profitable. As a result, domestic

Jan 1, 2008

By Bernd Friedrich, Elif Emil‑Kaya, Merve Papakci

In the production of SmCo permanent magnets with excellent temperature stability, corrosion resistance, and oxidation resistance, samarium (Sm), one of the rare earth elements (REEs), and cobalt (Co) are employed. Cobalt (Co) is a crucial component in tool materials, nickel-based alloys, tablet and smartphone batteries, and electric car batteries. REEs and Co have been listed as critical raw materials by the European Union Commission for many years. Due to the ever-growing demand for Co and REEs in technological applications, the recovery of these elements from secondary sources has garnered significant interest. There are two types of SmCo magnets, one of which contains a high amount of iron, approximately 15.2%. This paper focuses on the recycling of Fe-bearing SmCo. In this study, an oxidative leaching process with nitric acid was developed to eliminate iron through in situ hydrolysis and to dissolve REEs and Co. The influence of experimental conditions on the formation of an amorphous iron compound through the hydrolysis of Fe3+ in a nitric acid environment was thoroughly examined based on a Taguchi orthogonal array. The optimal parameters for oxidative leaching were determined to be an acid concentration of 3 mol/L, a solid-to-liquid ratio of 1/10, and a process temperature of 60 °C.

Feb 15, 2024

By Ryan Marsters, Adam Pring

The Rawah Ditch is a mountainous water supply diversion which supplies Larimer County, Colorado with water since 1903. The ditch includes two historic tunnels excavated by drill and blast through a gneissic rock buttress. Both rock tunnels were failing with annual convergence. After a snowshoe-accessed eld investigation, nite element modeling, and an alternatives analysis, a diameter DE pipe was inserted within each tunnel and the annulus lled. The proect was implemented in an Alternative Delivery contract lasting ve months from eld investigation through procurement and construction.

Jun 23, 2024

By Roger Malmström, H. Heden, Kjell Lidin

INTRODUCTION LKAB was formed at the turn of the century when the railways between the ore fields and harbors were built. The mines are situated north of the Arctic Circle in Sweden. Kiirunavaara is the largest mine, with a pro¬duction capacity of approximately 30 Mt/a. Malm¬berget has a capacity of about 12 Mt/ a. Both are under¬ground mines. Svappavaara, the only opencast mine currently in operation, has a capacity of about 4.5 Mt/a. The ore harbors are at Narvik for the Kiruna and Svappavaara mines and at Lulea for the Malmberget mine (see Fig. 1). Production in the form of finished products is shown in Fig. 2a, b, c, and d. Due to poor ore markets in re¬cent years, production and shipments have been cut back, but there was a positive swing in 1978. LKAB has been 96% state-owned since 1957. In addition to the iron mines in northern Sweden, LKAB has subsidiaries in central Sweden which produce sulfide ores, quartz sand, and uranium (Fig. 3). The mining methods employed are opencast bench stoping at Svappavaara and sublevel caving at Kiirunavaara and Malmberget. GEOLOGY The Kiirunavaara ore body is 4000 m long and av¬erages about 90 m wide, with variations in width from a few meters to around 150 m. The ore has been ex¬plored by deep drilling down to about 1000 m, but mag¬netic measurements indicate a depth of at least 1500 m. The Kiirunavaara ore is oriented in a north-northeasterly direction with a number of ores in the boundaries be¬tween the wall rock types. The ore in Kiirunavaara is mainly a fine-grained magnetite with a varying content of fine-grained apatite. The apatite content of the ore decreases with increasing depth. The other ores are all apatite-bearing and a couple are hematite ores (Fig. 4a, b). The ores are sedimentary, tilted, and tectonically de¬formed. They have a lateral dip of 0.87 to 1.2 rad (50 to 70°). The contacts between ore and wall rock are distinct and sharp, but both the hanging wall and the footwall are brecciated and impregnated with magnetite. The footwall of the Kiirunavaara ore consists of syenite porphyry with a low quartz content and rela¬tively good strength; the hanging wall consists of quartz porphyry. Both types are known as Kiruna porphyries. The ore at the boundary with the hanging wall is often rich in kaolin. There are a few veins of syenite porphyry running through the ore, which has a few major faults (Fig. 4c, d). There are two sharply delineated ore grades in Kiirunavaara: low phosphorus ore with less than 0.1 % phosphorus (about one-third of the ore) and high phos¬phorus ore with greater than 0.5% phosphorus. The iron content is 67% in the low phosphorus ore and 60% in the high phosphorus ore. These ore types are sold as different grades and so are kept separate during mining. MINING AT KIIRUNAVAARA The Kiirunavaara and Luossavaara ores were first mined using opencast bench stoping in 1902. When mining costs rose owing to higher waste removal, under¬ground methods were adopted. In the mid-1950s, the ores were still being mined on the surface at the same

Jan 1, 1982

By C. J. Toberman

Improvements in fine (28x0) and ultrafine (200x0) coal cleaning is an acknowledged goal with potential benefits in both steam and metallurgical coal markets. This work focuses on adaptation to fine coal flotation of FLOTE, a computer simulation model of the froth flotation process originally developed in the hard minerals field. FLOTE describes the flotation of solids based on particle surface activity, composition, and size. The quasi steady state model was applied to predict flotation performance at an Eastern Kentucky, full scale metallurgical coal preparation plant. Parameter estimation and model testing used detailed flotation test data from a five stage rougher flotation bank. Overall grade/recovery predictions compared well with known plant performance under variation of principally feed grade, plant throughput and reagent addition; however, grade/ recovery predictions for each cell weaken under overloading conditions. Analysis of grade/recovery over a range of sizes is presented. Suggested model improvements and extensions are discussed.

Jan 1, 1984

By S. Lu

The particle-bubble attachment and the rupture of formed aggregates in flotation cell were investigated in terms of turbulent regime. It was found that the particle-bubble collision rate is closely correlated to the energy barrier between particles and bubbles, and no adhesion takes place for the hydrophilic particle-bubble system due to the introduced ?capture efficiency? f(a) being zero. The values of an especially defined Weber number, i.e. the ratios of turbulent stress to aggregate strength in the inertial subrange of turbulence were estimated, the results showed that the detachment of a particle from a bubble involved in an aggregate is mainly caused by the turbulent stress only in the impeller zone, no bubble splitting occurs both in the impeller zone and in the bulk zone.

Jan 1, 1993

By W Medina, G Angulo, A Anani

A current challenge faced by the mining industry is solving the integrated transition mine problem (TMP) that maximizes the net present value (NPV). This study aims to develop an optimization framework capable of solving the TMP. The problem is NP-hard and therefore computationally intractable. Three ad hoc approaches – Exact solution, Benders’ decomposition, and Benders’ decomposition with Bienstock-Zuckerberg (BZ) algorithm – are compared for different scheduling periods. The TMP is formulated as a mixed integer linear programming model, implemented in Python, and solved with the Gurobi optimizer. The results showed that Bender's decomposition with the BZ algorithm outperforms the other approaches in execution time, computational cost, and feasibility to address large problems in exchange for a marginal cost in the quality of the NPV obtained. In addition, the probability of finding the optimal point of transition is higher regardless of the number of feasible crown pillar locations evaluated. This is achieved through the optimality cuts proposed in the algorithm.

Jun 25, 2023

A viable mineral economy requires availability of economic deposits, the ability to exploit then, and protection of the public interests. The natural tendency for each party to consider only its legitimate self interests can lead to delays or deadlocks. The paper presents several viewpoints aimed at opening each party's mind to the ideas of others in the hope that negotiations might be more reasonable and rapid for the benefit of all concerned.

Jan 1, 1979

By E. E. Caba

Copper smelter flue dusts containing arsenic are hazardous materials requiring environmentally accept-able disposal, preferably with re-source recovery under the RCRA and CRCLA regulations. However, the known resource recovery processes entail capital and operating costs greater than can be justified by the revenue of the recovered metal. Consequently, the smelting industry is tending to forego resource recovery in favor of encapsulation and storage in a certified class I hazardous waste site, or in a dedicated facility located at the source Superfund site. Order of magnitude costs for this option with portland cement encapsulation are estimated at $100 per ton, not including transportation. Industrial adoption of a new resource recovery process re-quires that its cost, including capital amortization, exceed the cost of encapsulation and storage only by the amount of the offsetting revenue from sale of metal. The lime-roast/ammoniacal leaching process is expected to meet this goal.

Jan 1, 1992

The National Mining Hall of Fame and Museum in Leadville, CO seized the opportunity to show off during its 10th anniversary induction banquet on Sept. 6. "We wanted to make people more aware of the mining hall of fame and museum," said Carl Miller, its executive director. The annual event honors inductees into the Mining Hall of Fame. This year, the inductees included Paul Wheeler Allen, Joseph Rosenblatt, Arthur Fay Taggart, Joseph Toy, Joseph Wharton and John Benjamin Zadra (ME, August, pp. 60-63). Allen, of Pasadena, CA and Rosenblatt, of Salt Lake City, are both living. Only Allen was able to attend. This year's induction banquet was the first held in Leadville, North America's highest incorporated city, at 3,094 m (10,152 ft) above sea level. The banquet gave attendees an opportunity to see the museum in its century-old 6,500-m2 (70,000-sq ft) Victorian schoolhouse. Many of the 350 guests came in 1890s dress to the black-tie affair. The evening included a cocktail reception and an open house along with a catered, prime rib dinner. During the open house, attendees had the opportunity to tour the museum's 12 rooms of exhibits and displays. Among items of interest, it was noted that a framed directory of inductees now enhances the entrance to the hall of fame. The directory is organized by the inductees' names and the location of their plaques, allowing visitors to quickly find hall of fame members. Noted mining historian and author Duane Smith delivered the keynote address at the banquet. After the induction of the six honorees, attendees danced to the big-band era music of the Leadville 17-piece band BandAge. Karl Elers was the master ceremonies for the evening's program. He is a member of the hall of fame's board of directors and is chairman of Battle Mountain Gold Co. Allen was honored by the presence of 26 former colleagues and associates. He told the audience that he originally thought the museum should have been located in Denver. "But I have been proven wrong," he said. For many years, Allen was the operational executive of Cyprus Mines Corp. and a key participant in the company's growth. Allen received a replica of his mining hall of fame plaque from Thomas Falkie, chairman of the hall of fame's board of governors and president of Berwind Natural Resources Co.

Jan 1, 1997

By Xiaozhen Song, Ashish Ranjan Kumar, Shimin Liu

To investigate the influence of boreholes, fans, and curtains for large opening underground mines (LOUM), we conducted a field survey for LOUM with the survey data serving as the numerical modeling inputs using computational fluid dynamics (CFD) models. Five different CFD modeling results were obtained with different borehole, box fan, and curtain setting conditions. The results indicate that most air quantity directly escapes through outlet 1 after coming into the inlet, causing a huge loss of airflow; volumetric air exchange index (VAEI) and minimum hours of fully exchanging the air (MHFEA) measure air exchange efficiency, with zone 2 of case 5 having the highest VAEI; The borehole minimally affects zones 2, 3, and 4, but drastically alters airflow direction in zone 1; The box fan enhances airflow to zone 2, improving ventilation efficiency and increasing VAEI; Curtains have little effect on distant working faces but influence airflow near inlets and outlets. This study provides a foundation for future research on the influence of boreholes, fans, and curtains, as well as optimizing their placement and effectiveness in face ventilation.

Feb 22, 2026