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By Knut H. Hubert

The GRATE-KILN System plant at Svappavaara, Sweden, was constructed for LKAB by Allis-Chalmers under a turnkey contract and commissioned in 1969. The plant was designed to produce iron ore pellets from magnetite concentrate at 6100 mtpd using imported fuel oil. It represented the state of the art for plants of its type at the time. Fuel rated capacity was attained within one week of start-up. Product quality, power usage, fuel consumption and machine wear were within warranty limits during sustained production thereafter. As operator skills improved and gas handling system reserve capability was utilized, the plant frequently produced acceptable product at up to 115% of design capacity. During the period 1969 to 1976, market demands increased for high-quality pellets while energy costs rose steadily. At the same time, important advances in the design of GRATE-KILN Systems were being made in other plants constructed by Allis-Chalmers.

Jan 1, 1980

By Ian M. Thomson, Robert W. Greene

To move 7 million tons annually from their new inland coal mines at Camp Breckenridge, Ky., TVA selected a transportation package proposed by American Commercial Barge Line. The land portion includes two cable-driven conveyors covering 12.7 miles; a 260,000-ton storage area on a man-made island with a stacking-reclaiming bucket wheel; and a barge-loading system of 5500-tph capacity. The 183mile river portion will utilize three unit-tows with towboats and barges specially designed to carry the maximum tonnage allowed by locks and channel depth. The system has two noteworthy features. The first is a single-flight cable belt conveyor over nine miles long. The other is a high capacity twin belt conveyor using the principal of two separate belts supported in 60° troughing idlers. This conveyor exhibits a high carrying capacity combined with accurate tracking and lack of spillage. A description is given of the mechanical problems and solutions to the design, construction, and operation of the conveyor system which provides the link between the coal mine and the barge loading dock.

Jan 1, 1974

By PHILIP N. MOORE

THE development of the power of the Tennessee River at Muscle Shoals has become a matter of political interest as well as engineering possibility. The controversy over it has been so active that the facts have been obscured, the possibilities exaggerated. Although the members of the American Institute of Mining & Metallurgical Engineers are not generally specialists in hydroelectric development, those who visited Muscle Shoals in October, following the Birmingham meeting of the Institute, were interested, and many of them surprised to learn the actual conditions. These have long been familiar to those who have studied the matter through the reports of the U. S. Engineers on the subject. The approved plan contemplates three dams-No. 1, a low dam close to the City of Florence, planned in the interests of navigation, since the construction of the other dams has rendered impossible the use of the river without it. No. 2-named the Wilson Dam is now under construction. Concerning it political argumentation has waged. No. 3 Dam-much smaller, is planned to be erected several miles above No. 2.

Jan 1, 1925

By Bradford F. Townsend, Matthew E. Fowler, Michael F. Smithson, Lawrence R. Eckert

All Rights Reserved. Printed in the United States of America. Information contained in this work has been obtained by SME, Inc. from sources believed to be reliable. However, neither SME nor its authors guarantee the accuracy or completeness of any information published herein, and neither SME nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that SME and its authors are supplying information but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. Any statement or views presented here are those of the authors and are not necessarily those of SME. The mention of trade names for commercial products does not imply the approval or endorsement of SME.

Dec 1, 2010

By Dalton. J. L., H. P. Dibbs

An account is given of investigations into the application of two neutron methods to the on-line analysis of slurries. One deals with the application of the neutron moisture gauge principle to the determination of the water content of iron oxide slurries, and the other with the application of gamma radiation from thermal-neutron-capture to the determination of the composition of aqueous slurries of iron oxide, copper oxide, zinc oxide and sulphur. Linear relationships were found between the composition of the slurry and the neutron count-rate in the first study, and between the slurry composition and the prompt-gamma-ray count-rate in the second study. A mathematical relationship has also been developed which relates changes in the prompt-gamma-ray counts from hydrogen to changes in slurry composition.

Jan 1, 1973

By E. h. Erwin Gaertner

Before dealing with the technical equipment of this paper a short survey of the Rhenish Brown Coal Area is given in order to illustrate the special geologic and environmental conditions in this region, which led to the development of the mining technics, used today.

Jan 1, 1975

By Torben Edens

Norddeutsche Affinerie?s (NA?s) primary smelter continually increased production in the past decade. The smelter?s concentrate capacity was expanded from 500,000 in 1993 to 1,000,000 t/a dry concentrate in 2000 and the goal of the present upgrade is 1,150,000 t/a. These goals were reached without erecting new equipment in the anode area, but instead by refitting the existing plant. The life-span extension of the casting moulds was absolutely necessary to increase the casting performance from 260,000 to 450,000 t anodes per year on a single casting wheel. Different mould manufacturing processes and alloys were tested in order to find the optimal mould. In the past the moulds were cast directly, now the anode mould is milled into NA copper cakes. Accompanying measures taken were the shortening of maintenance and repair times as well as improvements in the refining furnace equipment.

Jan 1, 2005

By Unknown

We are indebted to the Consolidated Mining and Smelting Company of Canada Limited for the several pictures in this issue showing the progress made in new construction at Tadanac and at Bonnington Falls, B.C. Plate No. 1 shows the down-stream side of the No. 1 hydro-electric station of the West Kootenay Power and Light Co. Limited at Bonnington Falls, on the Kootenay river, at which 17,500 k.v.a. will be developed to meet the requirements of the enlarged zinc and lead refineries at Tadanac. The generators, exciters and switch apparatus were supplied by the Canadian General Electric Company and the step-up transformers by the Canadian Westinghouse Company Limited. The plant throughout was designed, manufactured and erected by Canadians. Plate No. 2 shows the casting room of the new lead-plant and plate No. 3 the new tank-room of the electrolytic lead refinery at Tadanac. These additions will increase the capacity of the lead refinery by some 150 tons daily. The extensions also include practically doubling the zinc plant, and the gold and silver refineries. With the exception of the new stack, all designing construction and installation of the various plants is being done by the Company's own employees at Tadanac. Plate No. 4 shows the progress made in the construction of the new reinforced concrete stack at Tadanac. This stack, of 21 feet inside diameter at the top, will be brick lined and when completed will rise 400 feet above its foundations: the tallest of its kind in the world. The construction is in charge of the Rust Engineering Company of Pittsburgh, Pa. Plate No. 5 is a panorama of the Tadanac smelters and refineries. The photograph was taken from the roof of the lead smelter and gives an excellent idea of the size of the plant and its surroundings. Tadanac produces electrolytic lead, zinc and copper and fine gold and silver. During 1924 the company treated 1,333,523 tons of ore and produced: 161,400,- 769 pounds of lead; 92,197,824 pounds of zinc; l,382,750pounds of copper; 4,074,044 ounces of silver, and 26,976 ounces of gold.

Jan 1, 1925

By Guillermo Rios, Arbizum Cristina, Joa Viflals, Alba Sunyer

"Atlantic Copper is one of the largest copper producers in Europe. Its production facilities are located in Huelva (Spain) and account for the smelting of over one million tpy of concentrates to produce up to 260 ktpy cathodes and 900 ktpy of sulphuric acid. During copper concentrate smelting, the slag coming from the flash furnace and PS converters are treated in an electrical slag cleaning furnace. As a result of the treatment of the off gases from this furnace, approximately 2,000 tpy of a Zn-rich filter cake are produced and are sent to authorized waste managers. This paper describes the characterization of this material and the preliminary results of a new process to recover zinc as a pure zinc hydroxycarbonate while lead is collected as an indium-rich anglesite product. The behavior of impurities (Cd, As, Tl, Sn, Sb, Bi, Cu, Se, Te) in the leaching, solution purification and precipitation steps is also reported.IntroductionThe Atlantic Copper Metallurgical Complex in Huelva (Spain) was commissioned in 1970 with a capacity of 40,000 tpy of copper from concentrate. In 1975, the old blast furnaces were replaced by Outokumpu flash smelting furnace (FSF) technology, and the copper refinery capacity was increased to 108,000 tpy. Between 1994 and 1996, an expansion project was carried out to increase the copper from concentrate and cathodes to 250,000 tpy and 215,000 tpy, respectively. This expansion basically consisted of a new sulphuric acid plant, replacement of the anode furnaces by two 400 t units, redesign of the slag cleaning furnace (SCF), an increase in the electrolytic cells to 1,120 and implementation of ISA permanent cathode technology. Furthermore, a debottlenecking project has led to a capacity of 1,000,000 tpy of fresh concentrate since 1997. Meanwhile between 1995 and 1998, a cathode production rate of 260,000 tpy was reached as a result of a progressive increase in the current density in the refinery."

Jan 1, 2012

By E. W. Engle

For several years the Fansteel Products Co. has been engaged in e production and development of various of the rarer metals. It is at present engaged in the commercial production of tantalum, tungsten, and molybdenum in a very high state of purity. The information contained in this paper is partly a general compilation from various sources and partly information obtained as a result of recent years of work in the laboratory of this company. Tantalum, tungsten, and molybdenum form a group peculiar to themselves among the commercially available metals. Their very high melting points (tantalum 2770' C., tungsten 3350' C., and molybdenum 2550" C.) set them apart so far as the metallurgical processes for their production are concerned. Further, when properly prepared and treated they will stand a somewhat unusual degree of cold work, that is work below the temperature at which marked crystal growth takes place. Such cold-worked metal may show a high tensile strength; tantalum to 130,000 lb. per sq. in., tungsten to 490,000 lb., and molybdenum to 260,000 lb., in the form of fine wire. In physical appearance, these metals are not unlike some steels; they may be better described by saying that polished tantalum somewhat resembles lead; polished tungsten, iron; and polished molybdenum, nickel. The polished surfaces of all three remain untarnished in ordinary air. Air containing corrosion-producing impurities will, in general, show molybdenum the least resistant to corrosion and tantalum the most resistant. Molybdenum has, however, a high degree of resistance to corrosion by hydrochloric acid, a property that should render it of commercial interest. On the other hand, it is markedly attacked by some of the weaker organic acids. The three metals oxidize rapidly when heated at or above a dull red in air. This feature limits their use in many applications where their high melting point and strength make them appear usable. Tungsten and molybdenum, at red heat, are quite inert to hydrogen and nitrogen; while tantalum has a rather remarkable affinity for all the ordinary gases, which results in its becoming embrittled in their presence. This

Jan 1, 1925

By George K. Clement

Manual estimating method through use of equations, factors and curves for preparation of feasibility type estimates for capital and operating cost of mining and primary beneficiation in the United States and Canada of various types of minerals occurrences, except fossil fuels, using state-of-the-art technology. User should have basic estimating experience in the mining industry and/or related fields. Primary usage of this handbook will be for the preparation of preliminary estimate within a reasonable degree of accuracy with relative small amounts of hard input data. Output may be used to determine if a more finite type of estimate should be produced.

Jan 1, 1978

By E. K. Stanek

This report contains the results of several related research efforts, all of which were aimed at enhancement of mine power system safety and reliability. The largest single effort was on optimum spares and maintenance scheduling for various components of a mine power system. Two closely related tasks involved calculation of the minimum arcing faults that could occur on dc trailing cables and the use of trippable load break switches to clear ground faults. Both of these tasks are concerned with reliable fault clearing to prevent shock and fire hazards. Three other closely related tasks were concerned with aspects of mine power system design: (1) alternate network topologies, (2) optimum voltage selection for mine power systems, and (3) selection of system components. The other research task consisted of laboratory tests to ascertain the effects of repetitive, low-level transients on insulation systems.

Jan 1, 1979

By K. B. Bengtson

This task report provides the process technology, preliminary design, capital and operating costs for a 25 TPD pilot plant to produce cell-grade alumina using a clay/hydrochloric acid extraction - HCI gas induced crystallization process. The report consists of six volumes: I - Process Technology and Costs; II and III - Equipment Lists, Specifications and Quotations; IV and V - General Specifications; VI - Drawings. The process was selected by the Bureau of Mines as the more promising method to produce cell-grade alumina from clay based on the results of the two previous task reports under this contract: Task I - Comparison of Six Processes (alunite, anorthosite-lime sinter, clay/sulfurous acid, clay/nitric acid, clay/hydrochloric acid evaporative and gas-induced crystallization) and Task 2 - Comparison of Two Processes (clay/nitric acid and clay/hydrochloric acid - gas induced (crystallization). The pilot plant process utilizes a unique dual crystallization process to produce aluminum-chloride-hexahydrate crystals having sufficient purity when decomposed to meet stringent alumina product specifications. The size of the 25 TPD pilot plant has been selected to permit scale-up to commercial size plants of equipment, technical and economic parameters. The capital cost estimate for the pilot plant, exclusive of fee and escalation, for a southeastern U.S. location is $52,311,000 expressed in 1979 dollars. The total time required to construct the pilot plant including engineering and procurement is 32 months. The operating cost to produce the estimated 9,000 tons of alumina required for testing in Hall cells is $40,91[0],190 expressed in 1979 dollars.

Jan 1, 1979

By G. F. Kuncir

This volume was prepared in support of an evaluation of the Advancing Oil Shale Mining Technology Program performed by The Aerospace Corporation under a Bureau of Mines contract. The evaluation is described in part within a companion volume entitled Benefit-Cost Analysis. The economic mine models outlined herein provide a quantitative basis for the assessment of program benefits. Reference is made to estimated oil shale mine costs to delineate the beneficial impacts that can be expected to accrue for the future implementation of program developed technology. Estimated mine cost data are provided for surface, underground, and modified in situ oil shale mining operations.

Jan 1, 1977

By D. Randolph Berry

This report describes a study to develop a detailed set of guidelines and equipment recommendations to be used as a guide for mine operators, mine inspectors, and equipment manufacturers in implementing the emergency escapeway standards for metal and nonmetal underground mines. It was sponsored by the United States Bureau of Mines. The first part of this report reviews the historical background of metal and nonmetal mine fires and the development of present and proposed mandatory standards. This is followed by a discussion of the survey of representative mines and how the proposed standard effects these mines. The remainder of the report covers technical discussions of each escapeway component including a comprehensive computer simulation of mine evacuation. Following the technical discussion of each group of escapeway components is a list of the pertinent guidelines. The major escapeway components discussed are the following: Escaperoutes Refuge Chambers Hoisting System. Escapeway Signs Ventilation Fuel Storage Fire Retardants Warning Systems Auxiliary Transportation

Jan 1, 1976

By Fred Leonard

This report is principally concerned with the engineering and economic feasibility of area surface coal mining systems other than draglines. This analysis evaluates shovel/ trucks, shovel/crusher/conveyors, and shovel/rail excavation and haulage systems for an assortment of geologic environments and production rates in the Powder River Basin (PRB) Shovel/trucks, front-end loaders/ trucks, and shovel/crusher/conveyors were studied in a multi-seam, dipping geologic area of the Four Corners Region. The Texas lignite engineering and economic research involved bucket-wheel excavators (BWE), BWE/backhoes, and scraper/backhoe combinations for overburden and coal excavation. The PRE truck/shovel study utilized the most recent computer simulation available in both the design and cost analyses. Detailed engineering analysis, followed by in-depth operating costs (operating and depreciation) result in a complete evaluation of each mining system. Cost comparisons of the different mining systems under similar geologic and production constraints are presented in the report to illustrate the estimated capital investment and production costs per ton of coal and bank cubic yard of overburden.

Jan 1, 1980

By R. C. Adams

This report describes the feasibility of mining the oil shale deposits of the Piceance Creek basin in Colorado by an integrated open pit system. The study is based upon a comprehensive analysis of pertinent environmental, economic, and engineering factors. Ten mining cases are investigated, and the mine design and cost estimates for each case are presented in this report. Nine of the cases represent three cutoff grades, defining oil shale ore as equal to and above 15 gallons per ton (gpt), 20 gpt, and 25 gpt at three ore production levels of 500,000 tons per day (TPD), 1,250,000 TPD, and 2,500,000 TPD. The tenth case is an alternate design of the 500,000 TPD production rate at the above 15 gpt cutoff grade. The report consists of Volume I, a technical and cost comparison of the ten cases; Volume II-Part I, a detailed explanation of the estimating methods used; and Volume II-Part 2, a more detailed discussion of the technical and cost features of the ten cases than is presented in Volume I.

Jan 1, 1976

By Steve C. Albrecht

The objective of this study is "to assess the impact of surface mining on soil compaction in the Midwest". The study revolves around a unique field sampling program targeted at four mine sites utilizing four distinct types of soil movement of midwestern prime land. Through the preparation of a final report for use as a guidebook, an assessment is made of the degree to which surface mining operations contribute to the soil compaction problem. The final report is formulated through the use of field study data as well as information gathered in an intense literature review. The final report centers on applying collected data to practical field applications. Soil sampling on the four mine sites centers on a comparison of natural and replaced soils for moist bulk density. This characterization evaluates changes in density and texture throughout the soil profile to a depth of 48 inches. Fertility of the topsoil is also assessed for natural and replaced soils. During field sampling and observations, a base of information has been gathered to compile a case study on each mine site. The report accesses the regulations in the prime farmland areas through the use of a matrix. The regulatory matrix allows easy access of mining personnel to State and Federal regulations.

Jan 1, 1982

By A. Brown

This report details work performed and results obtained in a study of the water management aspects of oil shale mining and retorting in the Piceance Creek Basin. Three specific sites were investigated, and optimal water management systems for both conventional and in-situ extraction processes were generated. Water-related legal and environmental constraints on development were identified and the water management schemes were developed in compliance with these regulations. Limitations on shale oil production implied by limited water supplies were evaluated. Potential Basin-wide effects of development were evaluated using a computer model, and mitigation strategies were developed. Recommendations for additional investigation and analyses were presented.

Jan 1, 1977

By R. E. Gray

[The purpose of the study is to investigate cases of subsidence over abandoned mined-out areas of the Pittsburgh Coal identified from published and unpublished sources and to determine through a consideration of the geology, topography, climate, mining activity, and evidence at ground surface, what mechanisms control subsidence .and under what circumstances it takes place. The study wan performed it two phases, the first to identify all documented incidents of subsidence in mined-out areas of the Pittsburgh coal Region; and the second, to study a particular portion of the region in detail, collecting pertinent data relative to the sites within, characterizing roil the nature of the subsidence and its economic consequences, and determining the applicability of the findings to other areas whore similar problems with the collapse of abandoned miner have been encountered.]

Jan 1, 1977