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By R L. Langak, R A. Heins

The use of differences in specific gravity between minerals to separate them has long been utilized in the extractive industries. The environmental and cost benefits of the commercialized forms of these processes are well understood and widely used. Gravity concentration is used inter alia in the primary beneficiation of gold, diamonds, coal, tin, ferrous metal ores and andalusite. The potential for economic loss due to poor performance of these gravity processes is significant, but diverse in manifestation and regular process monitoring can prevent or at least reduce these losses. The measurement of performance of gravity processes has always presented a challenge, due primarily to the masses of material involved and the physical nature of the processes, generally typified by long reporting time, and hazardous materials (such as Tetrabromoethane) for float and sink type tests. The development of density tracers has improved this situation, however recovery of these tracers from the process streams created the next set of challenges, requiring significant manpower to physically remove tracers from product dewatering screens. Additions to these tracers (magnetic or x-ray fluorescent) eased the recovery mechanism issues but made them much more expensive to produce, hence operators became concerned about losses during process testing. In addition, magnetic recovery of smaller size tracers by a magnet suspended above a loaded screen panel is still problematic. The development of new low cost magnetic tracers has improved statistical significance of tracer tests, as the tracers themselves can be bought and used in much larger quantities, whilst still remaining economically viable. Coupled with the development of effective magnetic recovery technology, such as the Gekko MagScreen, for even fine sized tracers, on-line, continuous tracer testing is now becoming a reality. Whilst the development of high technology radio frequency detection tracer systems continues, enabling the real time measurement of the process and interpretation of results, miniaturization and recovery of these tracers, which is critical given their costs at present, remains an issue. Keywords: Gravity, process measurement, tracers, magnetic recovery

Jan 1, 2006

By J. Werfling, J. R. Kiehl

SUMMARY: The effects of blasting on structures are assessed on the basis of the maximum amplitudes of the occuring vibration velocities. If the standard values in the German Standard DIN 4150 are not exceeded, damages to structures are not to be expected. The estimation of the maximum vibration amplitudes is usually based on experience or on emperical formulae. However, a comparison of expected with measured values shows that these estimations are not conservative, particulary in case of small distances between blasting locations and structures. More reliable predictions are possible on the basis of numerical analyses, which simulate the three-dimensional propagation of waves with consideration of the geomechanical and geometrical conditions. In addition to the expected velocities, these analyses also allow the determination of stresses resulting from dynamic loading. If the dynamic stresses are known, the effects of blasting on structures can be predicted. ZUSAMMENFASSUNG: Die Auswirkungen sprengbedingter Erschütterungen auf bauliche Anlagen werden in der Praxis auf der Grundlage der Maximalamplituden der auftretenden Schwinggeschwindigkeiten beurteilt. In der DIN 4150 werden Anhaltswerte angegeben, bei deren Einhaltung Schäden von Gebäuden nicht zu erwarten sind. Die Abschätzung dieser Schwing-geschwindigkeiten erfolgt meist auf der Grundlage von Erfahrungswerten oder empirischer Formeln. Der Vergleich der prognostizierten Werte mit Meßergebnissen zeigt jedoch, daß diese Ansätze insbesondere dann, wenn die Abstände zwischen den Sprengorten und den Gebäuden gering sind, nicht konservativ sind. Zuverlässigere Prognosen sind auf der Grundlage von numerischen Berechnungen möglich, in denen die räumliche Ausbreitung von Erschütterungen unter Berücksichtigung der geomechanischen und geometrischen Verhältnisse simuliert wird. Mit derartigen Berechnungen können die zu erwartenden Schwinggeschwindigkeiten und die aus der dynamischen Beanspruchung resultierenden Spannungen ermittelt werden. Dies ermöglicht Aussagen über die Auswirkungen sprengbedingter Erschütterungen auf Bauwerke. RÉSUMÉ: Les conséquences de vibrations résultantes d'explosions pour des bâtiments sont estimés dans la pratique à partir des amplitudes maximales des vitesses d'oscillation. Dans la norme allemande DIN 4150 des valeurs d'orientation sont données, avec l'observation desquelles de dommage à des bâtiments n'est pas à présumer. Ces vitesses d'oscillation sont estimés généralement à partir de valeurs d'expérience ou de formules empiriques. La comparaison des valeurs prédits avec des résultats de mesures montre cependant que ces hypothèses ne sont pas conservateurs, en particulier si les distances entre les lieux de sautage et les bâtiments sont petites. Des prédictions plus fiables sont possibles à partir de calculs numériques, dans lesquelles la dissipation spatiale de vibrations est simulée en considération de la situation géoméchanique et géométrique. Avec tels calculs les vitesses de vibration à présumer et les contraintes résultantes de l'effort dynamique peuvent être établies. Cela permet de constater sur les conséquences de vibrations résultantes d'explosions pour des bâtiments.

Jan 1, 2003

By Gary Cavanough, Stuart Addinell, Hector Parra

Drilling deep, straight, accurate holes in hard rock to achieve efficient blasting is a challenge for the mining/quarrying industries with short holes normally drilled using “top hole hammer” (THH) and deep holes using “down the hole Hammer” (DTH).

Jan 1, 2013

By C. R. Copeland

Combustion processes, comminution and materials handling can generate airborne particulates. Regulation of these particulates by the U.S. Environmental Protection Agency (U.S. EPA) is becoming progressively more stringent, and regulations will soon include ?nanoparticulates,? which are particles finer than 100 nanometers (0.1 mm). Nanoparticulates are believed to have significant negative health effects due to their high surface area and reactivity. Although it was argued that nanoparticulate concerns were only important for combustion, studies at Michigan Technological University have shown that materials handling and comminution release significant quantities of nanoparticles into the air. Laboratory studies have shown that the use of sodium metasilicate reduced airborne particles finer than 10 mm (PM10) by 86% and particles finer than 2.5 mm (PM2.5) by 80% for iron ore. Additional studies were conducted that revealed that nanoparticulate emissions were present in the types of operations conducted at pyrometallurgical facilities.

Jan 1, 2008

By D David

The majority of SAG and ball mill design methodologies are applied using a single design value for mill selection, such as the 80th percentile ball mill work index or SMC value. Inherent in the selection of this design value is a desire for the mill to accommodate unfavourable, but not absolute worst case, feed conditions. It has been observed in numerous “post-mortems” of unsuccessful designs and also in many optimisation studies, that the selection of the design value has been poor. Statistical analysis of testwork data sets shows that inherent variability in the data can, by itself, lead to design errors. Metallurgical testing is an attempt to measure the characteristics of millions of tonnes of ore using only a few kilograms of sample. In this paper some realistic but synthetic test work data sets are used to explore old and new methods of defining the design envelope and subsequently selecting a reliable point. The aim of the paper is to provide practitioners with tools that reveal the adequacy (or otherwise) of metallurgical test programs intended to support various levels of project design. It also provide guidance as to how it is possible to statistically justify a comparatively high design point in the absence of adequate test data.CITATION:David, D, 2015. Measuring and taking notice of orebody variability – an essential ingredient for reliable plant design, in Proceedings MetPlant 2015, pp 10–26 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 7, 2015

By M. J. Farrell

The threat of global warming and its prominent position in public discussion and political debate requires all industry to take stock of its contribution to rising atmospheric concentration of greenhouse gases. For the primary metals industry, the first step must be to identify the pattern and range of emissions at each step in the production chain. Only then can the industry assess the economic consequences of the penalties on emissions that will be imposed by governments and regulators and devise cost-effective plans to avoid or mitigate such penalties. While some work has been done to estimate carbon dioxide (CO2) emissions using Life Cycle Inventory analysis, this approach is less useful than site-by-site emissions estimates. It is the level of specific emissions at each site that will ultimately deter-mine carbon taxation liabilities and participation in emissions trading schemes. Most mining companies have moved with the times to issue sustainability reports for their operations. But in the absence of any standardized reporting format, it is difficult to make useful comparisons between even the best-reported producers on a like-with-like basis. For this reason, Minecost.com modeled the use of fuels and energy used in mining, milling, shipping and metallurgical treatment to cover ?cradle-to-gate? emissions of greenhouse gases resulting from the production of the major base metals copper, zinc, lead and nickel. Greenhouse gas emissions ? overwhelmingly carbon dioxide ? are associated with the consumption of energy at every step in the production chain, from exploration through mining to the production of refined metal. Producers of primary metal employ diverse technologies to mine, mill, smelt and refine several different types of ore. Every orebody has its own special characteristics. In addition, most base metals are produced in concentrate that must be transported to smelters, with con-sequent emissions consequences.

Jan 1, 2009

By Patrick J. Coleman, John C. Kerkering

Problem: Mining in the United States remains one of the most hazardous industries, despite significant reductions in fatal injury rates over the last century. Coal mine fatality rates, for example, have dropped almost a thousand fold since their peak in 1908. While incidence rates are very important indicators, lost worktime measures offer an alternative metric for evaluating job safety and health performance. The first objective of this study examined the distributions and summary statistics of all injuries reported to the Mine Safety and Health Administration from 1983 through 2004. Over the period studied (1983 2004), there were 31,515,368 lost workdays associated with mining injuries, for an equivalent of 5,700 person years lost annually. The second objective addressed the problem of comparing safety program performance in mines for situations where denominator data were lacking. By examining the consequences of injuries, comparisons can be made between disparate operations without the need for denominators. Total risk in the form of lost workday sums can help to distinguish between lower and higher risk operations or time periods. Method: Our method was to use a beta distribution to model the losses and to compare underground coal mining to underground metal/nonmetal mining from 2000 to 2004. Results: Our results showed the probability of an injury having 10 or more lost workdays was 0.52 for coal mine cases versus 0.35 for metal/nonmetal mine cases. In addition, a comparison of injuries involving continuous mining machines over 2001 2002 versus 2003 2004 showed that the ratio of average losses in the later period to those in the earlier period was approximately 1.08, suggesting increasing risks for such operations. Discussion: This denominator free safety measure will help the mining industry more effectively identify higher risk operations and more realistically evaluate their safety improvement programs. Impact on Industry: Attention to a variety of metrics concerning the performance of a job safety and health program will enhance industry's ability to manage these programs and reduce risk.

Previous methods for measuring the flow of solids in Jnrdraulic conveying have not considered the important effects of slip velocity and particle concentration. In this paper an extension of the method proposed byShirato et al. (J. Chem. Engng. 'Japan, 1: 164-167) for determining mass flow in a vertical conduit is outlined.The present method consists of measuring' the volumetric flow of the slurry (by a magnetic flow meter for instance) and the density of the slurry in two pipe sections of different diameters. Effects of variation of slip withparticle concentration, not previously considered, are allowed.Problems involved in estimating the density of a slurry from differential pressure measurement are discussed.The major problem is the uncertainties in estimating frictional losses due to the wall in two-phase flows. The greater reliability of a more "direct" technique, such as by 'Y-ray absorption, for measuring solid concentration is emphasized.

Jan 1, 1971

By H. Hurkchand

Background: A cross-sectional study was conducted in November2001 to establish the prevalence rates of Human Immunodeficiency Virus (HIV) and sexually transmitted infections (STIs) (Chlamydia trachomatis and Neisseria gonorrhoea) in a coalmining town in Mpumalanga. Methods: 155 adults were recruited (79 males and 76 females), by holding community meetings, and by door-to-door recruitment. Saliva and urine specimens were collected for the analysis of HIV and STI prevalence, respectively. Results: The mean age for males was 31.35 years (min = 19 yrs and max = 50 yrs) and the mean age of the female participants was31.90 years (min = 17 yrs, max = 49 yrs). The prevalence of HIV was found to be 22.78% [95% CI (14.09?33.59)] in the males vs. 47.37%[95% CI (35.79?55.16)] in the females, [p = 0.001, OR = 3.05, 95%CI(1.49?6.26)]. The prevalence of C. trachomatis was 7.90% [95% CI(2.95?16.39)] in the males vs. 12.86% [95% CI (6.05?23.00)] in the females, p = 0.324. The prevalence of N. gonorrhoea was 3.79%[95% CI (0.79?1.08)] in the males vs. 9.86% [95% CI (4.06?19.26)]in the females, p = 0.137. HIV was significantly associated with C. trachomatis, [p = 0.032, OR = 3.18, 95% CI (1.04?9.72)], but was not significant when stratified by gender. HIV was not significantly associated with N. gonorrhoea (p = 0.072) but it was significantly associated when stratified by gender, p = 0.001 for females. There were no significant associations between HIV and age (p = 0.408), even upon stratification by gender. Conclusions: HIV prevalence in this community is high, and corresponds to national figures. However, the prevalence of STIs is surprisingly low as it would be expected to be high in a migrant population. Although communities are exposed to expanding peer-education activities that encourage behaviour change, the prevalence of HIV in this group. There is an urgent need for interventions designed to treat or prevent HIV infection in women generally and in women at high risk. Keywords: HIV prevalence, STI prevalence, antenatal, mining

Jan 1, 2005

By P N. Holtham

As part of a long-term study of titanium minerals processing being undertaken by the Julius Kruttschnitt Mineral Research Centre (JKMRC), techniques have been developed to measure the electrical properties of the various minerals. The measured values will be used to model the behaviour of the various minerals in high-tension roll and electrostatic plate separators. The resistivities of ilmenite, rutile and zircon from a number of Australian producers have been measured by applying a DC voltage across a test sample and measuring the resulting very small current flow. By appropriate design of the measurement cell and attention to the experimental procedure, reproducible resistivity values have been obtained, ranging from 106Ωm for ilmenite to 1013Ωm for zircon. However, the conditions of measurement are radically different from those under which electrical separation takes place. It is not certain that the measured values reflect the resistivities seen under high-tension separation, during which the particles are subject to a high intensity corona field. Consequently, an alternative technique for measurement of resistivity under conditions of corona bombardment has been developed. It is based on the experimental procedure of Castle and Yelle (1979) used to measure the resistivity of fly ash under the conditions occurring in electrostatic precipitators. This paper describes the development of the segmented ground plane measurement surface and a high-voltage switched resistor network which comprises the in situ resistivity apparatus. Results are presented comparing the measurements made under corona bombardment with those made using the DC measurement cell. The equipment has also been used to study the current distribution from a corona wire, as a function of high-tension voltage and wire-to-plane spacing.

Jan 1, 2001

By Sergio N. Monteiro

Natural lignocellulosic fibers are successfully replacing synthetic fibers in many engineering applications. In addition to well-known conventional lignocellulosic fibers, others with promising properties are now being considered. The present work investigated the mechanical and structural characteristics of a relatively high strength fiber, curaua (Ananas erectifolius) from the Amazon region of Brazil. The results obtained from tensile tests confirmed the superior strength while scanning electron microscopy (SEM) analysis displayed features that justify the possibility of using the curaua fiber as an effective reinforcement for polymeric composites.

Jan 1, 2006

By Ch. Schroeder, F. Collin, R. Charlier, Y. J. Cui

The paper proposes two numerical models ot the mechanical behaviour of chalk. First, an elasto-plastic constitutive law reproduces the different plastic mechanisms of the chalk and the influence of pore fluids by introducing the concept of suction. Secondly, a model able to reproduce time dependence behaviour. Eventually, the paper gives a simulation of an academic reservoir during depletion and waterflooding phase. Der Artikel stellt zwei numerische Modelle des mechanischen Verhaltens der Kreide vor. Das erste ist ein elasto-plastisches Modell, das verschiedene plastische Mechanismen der Kreide und den Einfluss von Porenflüssigkeit, unter dem Begriff der Suktion, reproduziert. Das zweite Modell berücksichtigt darüberhinaus das zeitabhängige Verhalten. Schliesslich zeigt die Veröffentlichung eine Simulation einer theoretischen Lagerstätte während der Entleerung und der Wasserinjektion. L'article propose deux modèles numériques du comportement mécanique de la craie. Le premier est une loi élasto-plastique qui reproduit les différents mécanismes plastiques de la craie et l'influence du fluide interstitiel par l'introduction de la notion de succion. Le second est un modèle prenant en compte les effets différés. Enfin, l'article présente une simulation d'un réservoir académique durant les phases de déplétion et d'injection d'eau.

Jan 1, 2003

By Hugo Julien

According to OSHA 29 CFR Part 1910.119 (Process safety management of highly hazardous chemicals), Canadian Provincial Safety Standard Acts or Federal laws, the owner of stationary equipment (Boilers, stacks, piping, pressure vessel, etc.) should follow a complete inspection plan and follow an Integrity Operating Windows (IOW’s) adapted for each of them. Some important variables shall be included in the inspection plan such as specific damage mechanisms versus alloy used in the original design, process conditions, etc. Some North American’s standards exist, like the one listed in ASME PTB-2-2009, to help owner to create such inspection program. The new API RP 584, Integrity Operating Windows (IOW’s) can guide Mining & Metals owners to find out their specific IOW’s. Inspection frequencies are often described in the Jurisdiction Safety Acts such as the British Columbia B.C. Reg. 104/2004, etc. but often left in the owner representative responsibility (Bill C-21, federal Act to amend the Canadian Human Rights Act). Every deficiency should be repaired according to recognized Codes such as ASME PCC-2, etc.. If flaws not conforming to the original Code of construction are found, this article will introduce the Fitness-For- Service assessment principles to be able to accept it without any repairs.

Jan 1, 2014

By Charles Gottschalk

Some time after my arrival in Rock Springs to fill a short engagement with The Union Pacific Coal Company, Mr. Dickinson informed me that he had placed me on the program for a paper entitled "Mechanical Loading in Indiana." Since development of mechanical loading operations on a genuine coal producing basis for that section began near Oakland City, Indiana, and rapidly spread over Southern Indiana, Western Kentucky and Southern Illinois simultaneously, the results referred to are in many ways common to all three states. Prior to December, 1922, several attempts at mechanical loading had been registered, notably among which were installations of the Jeffry Entry Driver, and the Meyers-Whaley loader. The object of most of these earlier installations was quick development rather than lower production costs in face loading. In this measure it is claimed the machines were at least partially satisfactory. Three items which seemed to delay rapid progress in the adoption of either machine were, excessive first cost, height of coal seam necessary, and timidity of the operator relative to the labor situation which might develop. When the Joy machine was put on the market in the form of the 4-B.U., with a clearance overall which would perform in coal slightly under five feet in height, and at a cost price of less than one-half that of other machines being sold, many operators were at once ready to take a chance along with the manufacturer. This desire was accentuated by the difficulty to operate coal mines at all at prevailing production costs. This condition also made the coal miner more receptive to machinery which would give added employment to the field. At the convention held in Cincinnati during May, Mr. .Joy stated that about 200 of his machines were in operation at that time. Mr. Whaley said that about 40 of his were in use in coal mines. It is probable that of the above sum 75 machines were installed in Indiana, Illinois and Kentucky. Since that time, possibly 50 more machines of later design have been added. Like many of our troubles, those which seemed most difficult to overcome, proved in the end to have been least of all, and in this case the sup¬posed resistance which labor would advance has been more or less imaginary. In Illinois and Indiana a scale of wages is being accepted which is consistent with average earnings of machine men. The fact that a large number of coal operators want and are buying more loading machines has encouraged mining machinery manufcturers on every hand to devote renewed vigor to the cause and it is generally understood that new types and models are being developed both in factories and mines with the coal industry eager always to see the latest development. I understand that at present the Goodman, the Jeffry, and the Sullivan machinery companies are each offering new designs to meet Indiana and Illinois requirements. It is not strange that with so many installations many were made as a result of an impulse to ride the band wagon without any serious attempt to study the results or draw any conclusions from the experiences of others with loading machinery.

Jan 1, 1924

By R. J. Robbins

The mechanization of hard rock underground mines offers a large potential for reducing cost, improving efficiency, and increasing profitability. However, in spite of serious efforts by quite a number of equipment developers and mining company initiatives, the industry has achieved little real progress. The task is difficult and the blasting alternative to mechanical excavation is an effective and well-developed method, which continues to improve in spite of its inherent limitations. A large number of machines have been built and tried. Only a few developments have succeeded to make a major impact on underground hard rock mining. It is certain that hard rock mines would be laid out and designed quite differently if the mining engineers knew they had available continuous mechanical excavation machines. In the absence of the machines, mines will be designed for excavation by traditional methods. It is not easy to utilize mechanical excavation in a mine which is designed to operate with normal drill and blast excavation. This is certainly an impediment to machine development. But what if an ore body cannot be mined conventionally, simply because the mining company cannot get permits to satisfy the ever increasing strict EIS requirements of the general public and governmental agencies? This may provide the incentive necessary to develop the equipment that will be needed by a new mining method that will have almost no impact on the environment.

Jan 1, 2001

By Richard E. Gertsch

Mechanical mining holds great promise for the mining industry. Realizing this promise depends on developing the tools needed to mechanize a mining operation with a reasonable expectation of success. Mechanical mining entered the 1990s with new machines, new operating methods and new ideas for the future. Mechanical mining can provide higher production, increase safety, reduce roof support requirements, create smoother openings for better ventilation, substitute continuous production for cyclical drill-and-blast procedures, and create opportunities for automatic and teleoperated control. The full promise of this important technology still lies ahead. Obstacles include: • Long-term production prediction: Mechanical systems have a high capital cost. Although recouped by lower operating costs, the tradeoffs are not always clear to mine operators. • Cutting tools for hard rock: Rock of more than 103.4 MPa (15,000 psi) cannot be cut by flexible mining machines. • Machine designs: Many machines cannot convert the required power into rock cutting capability. • Engineering: Better use of the machines in the mine is needed.

Jan 1, 1994

By L. Gertsch, R. Gertsch

Mechanical mining is steadily gaining usage in the mining industry. A variety of machines currently finds employment: tunnel boring machines, roadheaders, continuous miners, surface miners, and augers. These machines have advantages compared to drill and blast mining methods, including increased safety, lower cost, uniform muck size, and accurately sized openings. A century of experience with mechanical methods has already paid dividends to the coal industry. Current trends guarantee eventual development of true general-purpose hardrock mechanical mining machines. Mechanical miners will become integrated mining systems and will determine the design of mines, when several significant challenges have been met.

Jan 1, 2001

By J. P. Sancho, J. M. Duart, J. I. Verdeja, J. O. García

Following a short review of the history of rails used in the transport of passengers and goods, this paper describes the process for rail fabrication, rail structure, and properties, and summarizes the fatigue test curves carried out on rails used today. Also reported is the process for “continuous rail” production using aluminothermic welding via the introduction of weld metal in onsite casting, as a homogeneous melt. Weld characteristics of aluminothermic welding using different preheating procedures—fusion zone, heat-affected zone, microstructure, hardness, slow bend test, and fatigue test resistance (Wöhler curves)—are related to preheating and welding procedures of 700, 900, and 1,100 MPA rail grades. The Locati method is preferred over the staircase method for ascertaining the fatigue limit due to its simplicity. Macrographic and metallographic inspection of broken specimens reveals the reliability of welding techniques and the good metallurgical quality of welds.

Jan 1, 2007

By Meghan McGrath

Third generation advance high strength steels with microstructures of acicular ferrite and retained austenite were investigated and meet mechanical property goals. A good combination of strength and ductility were achieved with duplex ferrite and austenite microstructures where cementite formation was suppressed. Transformation induced plasticity (TRIP) behavior produced rapid work hardening. The mechanical properties of two hot-rolled steels with duplex microstructures were compared and had the following compositions: (1) Fe-0.14C-13.87Mn-1.42Si-3.51Al; and (2) Fe-0.06C-14.2Mn-1.85Si-2.38Al. These steels were cast, homogenized, and hot rolled at 900ºC to obtain a refined microstructure with ultimate tensile strengths and elongations to failure of 865 MPa and 39% and 1,217 MPa and 28%, respectively. The amount of metastable austenite in both compositions decreased after tensile testing from 58% and 28% to 6% and 0%, respectively. Microstructures were characterized using optical microscopy, scanning electron microscopy (SEM), and x-ray diffraction.

Jan 1, 2010

By M. V. Swain, N. Bristow, R. D. Dukino

During mining, crushing and handling the size of iron ore lumps decreases. Key factors in determining the amount and size of fines that are produced are the mechanical properties of the ore. In a continuation of earlier work on the same ores the mechanical properties of three Australian iron ores from Yandi, Koolan and Mt. Whaleback were determined. In particular, fracture toughness was investigated in greater detail by examining its relationship to crack length using the compact tension test. The elastic modulus and strength of the ores were also determined in flexure and compression. The results were interpreted using Weibull statistics, enabling the ores to be ranked according to strength and elastic modulus. These results, together with data on the mechanical response of the ores to stress and observations concerning the effect of mineralogy on cracking, provide a coherent understanding of the mechanisms involved when the ores fracture

Jun 18, 1905