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By M. G. Vieira

This investigation addressed the possibility of producing pellet feed at a silica content of = 1.0% using a representative sample of Samarco´s mechanical flotation tailings. This sample contained 11.0% Fe and presented an F80 = 116 µm and a d50 = 63 µm. The higher silica content was verified in the coarser fractions and the higher iron content in the fraction -37 µm. Specular hematite is the most abundant mineralogical phase in the fraction -37 µm. The technological tests used one of four methods: magnetic concentration using a wet high-intensity magnetic separator, magnetic concentration using a SLon high-gradient magnetic separator, reverse flotation or direct flotation. The methods using the magnetic concentrator SLon, reverse flotation and direct flotation did not present results meeting the target of the study: iron content in the concentrate (rougher stage) greater than 34% or iron recovery greater than 80%. Cleaner stages were not achievable with the resulting concentrates. In contrast, the most successful method consisted of using wet high-intensity magnetic separators (WHIMS) as a rougher stage and reverse flotation as a cleaner stage. Using this route, it was possible to produce a pellet feed with a silica grade of 1.0% and high specular hematite content.

Jan 1, 2010

By R. C. Moe

Pelletizing studies were conducted to find ways of improving the metallurgical properties of acid and fluxed pellets. In acid pellets, melting temperature was controlled by the formation of low melting temperature fayalite during reduction. Formation of a permeable metallic shell during reduction allows diffusion of reducing gas to the pellet core, decreasing fayalite formation. With fluxed pellets, slag chemistry had the main influence on metallurgical properties. Mineralogical, chemical and structural transformations that occur during reduction were studied at various intervals for a number of Mesabi Range pellet types. Six pellet types were selected for further investigation based on significant differences in softening/melting characteristics. Retention of porosity in the metallic shell was found to be the overriding factor in determining softening/melting behavior.

Jan 1, 1990

By Hou Xilun

Three production methods of rapid cold bonding and low temperature bonding pellets using sponge iron powder as a binder have been successfully developed. These methods differ from ordinary bonding method by no addition of salt and other catalyzers, no corrosion of equipment and no pollution of environment. Mechanism of pellet bonding is studied. Experiment shows that these pellets have good metallurgical properties. A semi-industrial test has proven the laboratory results, with the production of metallic pellets continuous and stable. These methods are substituted for traditional high temperature firing of oxidized pellets in direct reduction. As a result, the plant for oxidized pellets can be saved and substituted for grate in the grate-kiln system. Thus, 20% of the investment could be saved. Production cost may also be decreased. The production of cold bonding pellets does not need additional area.

Jan 1, 1980

By B. K. Parekh, R. H. Mehta

Handling of fine coal is an importance issue for coal as well as the utility industry. Reconstitution in form of pellet or briquet would be desirable if it could be done economically. This paper evaluates the effectiveness of three binders e.g., asphalt- emulsion, corn starch and Brewex, in forming pellets of ultra-fine clean coal. It was found that asphalt emulsion and corn starch were not effective binders for ultra-fine clean coal, however, Brewex provided excellent quality of pellets, which exceeded all the minimum quasi requirements of coal pellets. INTRODUCTION Advanced coal preparation techniques (physical or chemical) are designed to process ultra-fine (minus 200 mesh or 74 pm) coal. The average particle size of the clean coal product is about 25 pm. Currently available dewatering techniques are effective in providing a 25 to 30 percent moisture product of this size coal slurry (Parekh et al. 1989). Handling and utilization of this dewatered ultra-fine size coal is difficult. Reconstitution, which includes pelletization, briquetting, extrusion, etc., of the dewatered coal product provides an ideal answer to handling and transportation problems. However, reconstitution of fines in the coal industry has not been successful due to various reasons. The most important criterion for its unsuccessful application in the coal industry is the cost of the binder (Capes et al. 1965). Various methods of reconstitution, such as briquetting, disk pelletization, extrusion pelletization and roller and die-pelletization, have been tested for fine coal agglomeration (Conkle et al., 1991) (Richards, 1990). Conkle et al., (1992) have provided a detail analysis of each technique in terms of moisture and operating cost requirements. According to Conkle, briquetting requires a product containing very low moisture, whereas pelletization can be done with coal containing up to 30 percent moisture. Currently available dewatering technique provides about 25 percent moisture product, thus, pelletization appears to be an ideal route for reconstitution. In this paper, results are presented on the comparison of three different binders i.e., asphalt-emulsion, corn starch and Brewers condensed solids (BCS or Brewex), for fine coal pelletization.

Jan 1, 1995

By B. K. Parekh, R. H. Mehta

The handling of fine coal is an important issue for both the coal and utility industries. Reconstitution of fine coal in the form of pellets or briquettes would be desirable if it could be done economically. This paper evaluates the effectiveness of three binders, asphalt-emulsion, corn starch and Brewex, informing pellets of ultrafine clean coal. It was found that asphalt-emulsion and corn starch were not effective binders. However, the use of Brewex resulted in pellets that exceeded all of the minimum quality requirements for coal pellets.

Jan 1, 1997

By Howard N. Egan

EASTERN COAL CORPORATION is located in the heart of the Appalachian Mountain area of extreme Eastern Kentucky, The mountains are of sedimentary origin, and have been deeply eroded by streams as the area has been thrust up during geologic time. There are many seams of coal interspersed between beds of shale and sandstone. While some of the seams are thin, there are a number that can be economically mined. We are mining the Pond Creek, or No. 2 Gas Seam, at a rate in excess of 6,000 tons per day. Our central preparation plant utilizes tromp baths for the plus 3/8" size and Rheolaveur for the minus 3/8" portion. No provision was made to recover the fine coal, which was included with the plant effluent pumped to a 12 acre refuse pond. The pond is impounded behind the coarse refuse dump. This pond rose 15 feet last year. Obviously, no pond could stand many years at this rate. Limited pond space in this rugged area of steep hills and narrow valleys dictated a revised disposal method. Our first thought was that it would be necessary to dry the fine refuse sufficiently to permit inclusion with the coarse refuse, which is hauled uphill by monitor and then trucked to final disposal.

Jan 1, 1967

By L. J. Vincze

The program of study of pellet binder materials was begun by the ORF in 1963 to examine various Canadian materials as substitutes for bentonite which is imported in large tonnages (199,270 tons in 1969) from the U.S.A. for Canadian pellet plant operations. Most of the raw bentonite used in Canada originates in Wyoming, North Dakota and more recently Greece, resulting in relatively high transportation costs to pellet producers. Some Canadian bentonites available in Western Canada (Alberta) can be beneficiated for uses as pellet binders but could not compete in cost with U.S. sources due to the cost of beneficiation and the higher rail transport charges to Eastern Canada. It is difficult to find a substitute for bentonite, and many materials have been investigated by research groups but, so far, no economic substitute is in use. However, some success is apparent in studies of low cost materials such as clays, sea weed, peat moss and low grade coal, The work done by the ORF over several years has covered systematic test¬ing of Ontario clays, lignite, some types of tree bark, waste sulphite liquors of various kinds, and peat moss as binders for iron ore pellets. The major effort has been concentrated on peat moss and has included a study of the influence of different additives. Since analysis of peat moss for humic acid is difficult and time consuming, a certain amount of time was devoted to development of improved methods, the most useful of which was a spectrophotometric method based on extraction of peat by sodium pyrophosphate for determination of humic substances. In the present paper, only the most recent work concerning the use of peat moss with suitable additives is discussed in detail, since it is the most conclusive and best documented portion of the program.

Jan 1, 1971

By Roy A. Koski

This paper describes variations in feed characteristics, preparation techniques, response to induration and product quality in pelletizing magnetite concentrates, earthy hematite ore fines, and specular hematite concentrates in grate kiln systems. The Cleveland-Cliffs Iron Company manages plants processing these various materials on the Marquette Iron Range in northern Michigan. The operations include the Humboldt Mining Company, Marquette Iron Mining Company, Empire Iron Mining Company and the Pioneer Pellet Plant. The combined output of the operations is approximately 9,000,000 long tons per year. The Humboldt Mining Company, owned by Ford Motor Company and Cliffs, produces pellets from a specular hematite concentrate. The Empire operation, which processes magnetite ore, is owned by Inland Steel Company, McLouth Steel Corporation, International Harvester and Cliffs. The Pioneer operation, which processes earthy hematite ores, is a joint venture of Republic Steel Corporation, McLouth Steel Corporation, Bethlehem Steel Corporation and Cliffs. The Marquette Iron Mining Company, owned by hones and Laughlin Steel Corporation, International Harvester, Wheeling-Pittsburgh Steel Corporation and Cliffs, produces pellets from specular hematite concentrate at the Republic Mine and Eagle Mills Pellet Plant. With the exception of the Eagle Mills plant, the operations employ the grate-kiln pelletizing system. Descriptions of the Empire, Pioneer and Republic operations, which have a combined capacity of 7,200,000 tons per year, are given in the paper.

Jan 1, 1969

By J. M. Van Langen

In 1965 Hoogovens was looking for additional capacity for burden preparation in the order of 2,5 to 3 million metric tons per annum of some kind of optimal blast furnace ore feed. In principle four solutions offered them-selves for further investigation: 1. purchase of screened ore and/or run of mine ores with the provision of a corresponding ore screening capacity on the blast furnace site; 2. manufacture of sinter; 3. purchase of pellets; 4. manufacture of pellets. After studying the technological, technical, economical and commercial factors Hoogovens decided for the last mentioned possibility. Before taking this decision not only a great number of different mixtures of iron ore were tested, but during a long period in one of the big blast furnaces a number of tests were also executed with purchased pellets from South and North America. It was found, that using 50% acid pellets with 40% basic sinter a coke rate saving of 25 kg per ton hot metal (50 lbs/net THM) and a production gain of 15% could be obtained as compared with a full sinter practice. With some pellets it became clear, that due to properties, commonly referred to as swelling, we got very poor furnace performances; so in studying the production of pellets, pellet quality should be regarded as the most important aspect of the problem.

Jan 1, 1972

By Barry J. Hansen

In the past six years, the Hanna Mining Company has increased its pellet producing capabilities greatly by the construction and expansion of six pelletizing plants in North America. At the present time Hanna managed pelletizers have a nominal capacity of 18 million long tons per year. This capability makes Hanna one of the world's largest pellet producers. To create and maintain such an operation has required the skill and dedication of many people in all aspects of the company's activities, in the various fields of exploration, operations and research. The Research and Development Group consists of the staffs of two laboratories situated on the Mesabi Range in northern Minnesota. These laboratories are well equipped to carry out work in the fields of beneficiation and extractive metallurgy especially iron ore treatment. Facilities exist for the batch and semi- continuous investigation of the unit operations common to iron ore beneficiation and pelletizing. The R and D Division is divided into groups according to specialized areas of interest. Presented in this paper today are some aspects of the activities of the Pelletizing Group of the Research & Development Organization.

Jan 1, 1969

By Gunnar Thaning

The iron ores mined by LKAB in the north of Sweden have excellent beneficiation properties. This gives LKAB a favourable position as regards the production of low silica pellets for direct reduction. LKAB have concentrated on developing and marketing grades of pellets for the Midrex-Purofer-HyL process group, i.e. such D.R. processes which are carried out in a shaft furnace or a static bed using reformed natural gas as a reducing agent. The paper deals with properties and quality demands of iron ore pellets for such processes. Matters such as the effect of the residual magnetite in the fired pellets on the degree of metallization, the amount and composition of the slag phase in the pellets, the mechanism of the disintegration during reduction, the state of swelling of the pellets during the conditions prevailing in these processes, the importance of the porosity, the improvement of the reducibility and lowering of the sticking tendency of the pellets by small additions of suitable additives and the influence of the pellet size are discussed. A special test procedure for D.R. pellets has been elaborated by LKAB. Thus, three metallurgical properties are routinely determined separately, namely reducibility, reduction strength and sticking. The test methods are described. Finally the present and future LKAB pellets for direct reduction are presented with respect to chemical analyses and metallurgical properties.

Jan 1, 1978

By W. A. Mathews

We report on the progress of an automated mineralogical deportment of fluorine (F) in two portions of the Grasberg District for the development of metallurgical amelioration protocols for Cu sulfide concentrates. Fluorine detection limits in automated SEM technologies range from 1% (TIMA) to about 9% (QEMSCAN), however substitution in hydrophobic minerals or those reporting to concentrate is typically much lower (

Mar 2, 2022

By Sheldon P. Wimpfen

Back in 1970 Congress passed the National Mining and Minerals policy Act, which had as one of its basic tenets to rely on a strong and stable private minerals industry for the development and production of our mineral resources. Since then, a substantial amount of legislation has been introduced that impacts on the minerals industry. Although most of the bills proposed are not passed into law, each bill affecting minerals and mining is given careful review by the Bureau of Mines. Comment is forwarded with the object of being helpful to legislators by providing our assessment of the probable impact of each bill proposed along with suggestions to improve them. Actually few bills introduced become law. For example, in the 93rd Congress 4,260 bills were introduced in the Senate and 17,690 in the House. In the final accounting there were passed 123 private laws and 649 public, 3 percent of the bills introduced. There would be little merit here in attempting to analyze each mineral-related bill that was proposed. Many are similar and aim at making a certain aspect of our minerals activity fit needs. So, to simplify the task the many bills have been grouped by subjects. Slide 1 shows the principal topics and the number of related bills introduced. Putting it altogether, there are 26 principal subjects and almost 200 bills. And these numbers are probably off somewhat, as this accounting was made early in December.

Jan 1, 1976

By David D. Rabb

Leaching or solution mining, a relatively simple and economical process for beneficiating metallic ores, is likely to find increasing application in the treatment of low-grade ores that are impractical to mine by any other means. This process may be carried out in two different ways: 1. Dump leaching, where the ore is moved from its original location to be leached at another site. 2. In situ leaching, where the ore is leached in place by introducing the leach solution at the top, letting it flow down through the ore under gravity, and then recovering it plus the dissolved metals it contains.

Jan 1, 1969

By Emre Karakaya, Niyazi Bilim

Boreholes are used for many purposes in mining operations, petroleum engineering, and construction works. Numerous factors affect the performance of drilling equipment. Researchers continue to work on the variable drilling parameters that can be adjusted in order to reach more efficient drilling operations. Penetration rate is an essential indicator in drillability analysis and estimating. This parameter is of great importance in mining projects. There are almost no models that can estimate the penetration rate for core drilling operations. Under the abovementioned circumstances, this paper focuses on developing models that allow estimating the penetration rate based on rock material properties. During the conduct of this study, drilling experiments under 11 different pressure forces were performed on 8 different rock units, and the equations which estimated the penetration rate depending on the physico-mechanical properties of the rock samples were derived. Experiments were carried out under different pressure forces to investigate the effect of the pressure force on the derived estimation models. The obtained results allowed deriving equations that ensured estimating the penetration rate based on the physico-mechanical properties of the rocks and the applied pressure force. Using these equations, the penetration rate in core drilling operations can be estimated.

Sep 30, 2020

By C. J. Bise

In August, 1977, the Federal Surface Mining Control and Reclamation Act was signed into law [I]. It stated that: "The Congress finds and declares that because of the diversity in terrain ... and other physical conditions in areas subject to min ing operations, the primary governmental res- ponsibility for developing, authorizing, issuing, and enforcing regulations for-surface mining and reclamation operations subject to the Act should rest with the States." Section 516 of Title V (Control of the Environ mental Impacts of Surface Coal Mining) of the Act deals with the surface effects of underground coal mining operations. "Each permit issued under any approved State or Federal program pursuant to this Act and relating to underground coal mining shall re quire tfieoperator to adopt izeasures consist ent with known technology in order to prevent subsidence, causing material damage, to the extent technologically and economically feasible, maximize mine stability, and main tain the value and reasonable foreseeable use of such surface lands, except in those instances vhere the mining technology used requires planned subsidence in a predictable and controlled manner: Provided, that nothing in this subsection shall be construed to prohibit the standard method of room and pillar mining. "

Jan 1, 1980

By Alvin Kaufman

Malthus, an eighteenth century economist, predicted a rather dismal future for the world. It was his contention food supplies would not be sufficient for the population of the world because the economy of a nation grew arithmetically while population increased geometrically. As a consequence, within a relatively few years mass famine would spread throughout the world. This prophecy, based on an agrarian economic situation, did not come true at least insofar as the Western World was concerned. In largo measure, the salvation of our part of the earth resulted from the growth engendered by the Industrial Revolution. Throughout much of today's world, however, the Malthusian theory seems to be coming true. The advantages and benefits of the Industrial Revolution have net reached all nations. Further, the situation has been compounded by the benefits of modern medicine. This has reduced child mortality and extended life expectancy, but placed no limitations on births in the developed countries, child mortality has declined to 2 percent and adult life expectancy has doubled, but education and general prosperity have resulted in voluntary limitations on pregnancies thus partly offsetting the increased chance of survivals Even so, the present rate of population increase in Europe is approximately 6 percent per decade, and somewhat higher in the U.S., Japan, and other developed countries. The world as a whole, however, is expected to double its population by the year 2000, This would imply a rate of increase in the less developed countries approximately four times that in Europe.

Jan 1, 1966

By Brian Flintoff

SCOTT COULTER: Our second speaker today is Brian Flintoff. Brian graduated from the University of Alberta in 1973 with a master's of science degree and worked as a project metallurgist at Brenda Mines until 1977. He returned to the University of Alberta in late 1977 to work on his Ph.D. and later joined the faculty of engineering in 1980, leaving in 1988 to rejoin Brenda in the newly formed process technology division. In 1998 he left Svedala-Brenda to take a position with Simons International's newly formed enterprise development services group. His topic today is "People: Reduce, Reuse, and Recycle." INTRODUCTION BRIAN FLINTOFF: Historically, the mining industry has relied on the people within a corporation to get things done. The culture of most companies was one of a slow but sure development of people, processes, equipment, and technology. Many of the larger companies supported in-house engineering and research organizations. However, the metal market pressures of the 1980s and the emergence of the global economy in the late '80s and early '90s put enormous financial pressures on the industry. As the old adage says, "necessity is the mother of invention," and the mining industry, like many others, has undergone a transformation. A cornerstone element of the transformation was the downsizing (or right-sizing) that was calculated to "trim the fat" from the capital and operating budgets. The goal was and is to find the highest sustainable operating profit.' While I'm sure one can find examples of losers (e.g., those who can be classified as suffering from corporate anorexia or institutional Alzheimer's) in such business reengineering efforts, there is little doubt that, on the whole, the transformation has been successful. The reality that now faces mill management is "How to do more with less?" At the risk of oversimplifying, one can look at this on two levels:

Jan 1, 1998

By Swades Kumar Chaulya, Vikash Kumar, Sushma Kumari, Naresh Kumar, Girendra Mohan Prasad, Monika Choudhary

During harsh weather conditions, the presence of fog, dust in the environment degrades the image’s quality, which affects the visibility of drivers of heavy earth-moving machinery in opencast mines. Due to low visibility, mining operations cannot be carried out as drivers are easily prone to accidents. This paper proposes a technique that includes developing a vision enhancement system called perceptive driving assistant system for increasing visibility of real-time video of the road in front of the vehicle for operators of heavy earth-moving machinery at opencast mines during harsh weather conditions to overcome the problem. The system consists of high-quality Internet Protocol cameras and thermal cameras for real-time image processing and other well-defined devices, which is quite capable of enhancing the visibility of the image, outlining edges of the road, and detecting obstacles present on the path of operators for smooth driving and reducing threat of accidents. A high-speed graphical processing unit has been used for quality-performance parallel computing, which is well suited for real-time operations to empower fast real-time operations. The calculated frame per second (fps) of image enhancement, object detection, and edge detection is 17.91, 15.91, and 25.09 fps, respectively. The actual frame rate is 26.07 fps, and after applying the algorithm, the final frame rate is 19.65 fps. The calculated accuracy of the object detection model is 81.23%. Field trials indicate that the developed system has performed adequately during foggy weather.

Sep 21, 2022

By Swades Kumar Chaulya, Vikash Kumar, Sushma Kumari, Naresh Kumar, Girendra Mohan Prasad, Monika Choudhary

Opencast mines are vulnerable to inclement weather conditions as it disrupts the day-to-day activities at these mines. To address the problem, a perceptive driving assistant system (PDAS) has been developed to increase the visibility of real-time video of the road in front of the vehicle for operators of heavy earth-moving machinery (HEMM) at opencast mines in harsh weather conditions.

Apr 1, 2023