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By A. C. Legg, M. T. Malema

Keywords: Pyrometallurgy, flash, smelting, furnace, nickel, copper, Botswana BCL Limited operates the only Flash Smelting Furnace on the African continent, at Selebi-Phikwe, situated in north-eastern Botswana. The furnace was commissioned in 1973 and produces a high-grade sulphide matte containing nickel, copper and cobalt, which is shipped to refineries in Zimbabwe and Norway for further processing. This paper outlines the recent process improvements and plant expansions that have resulted in a capacity increase from 40 000 to 60 000 tons per annum of metal production.

Jan 1, 2006

With the proving of a mineable orebody at Orlando in May 1961, Peko Mines N.L. was faced with the decision of whether to mill the ore on site or to haul it 25 miles to central facilities at Peko. Orlando was a relatively small orebody, so that it was decided to haul, although no reliable assessment of possible ore haulage costs was available.The necessity for a good haul road was recognised from the beginning and a 17 mile, 12 ft wide, single seal bitumen road was constructed, to link the mine to the Stuart Highway and Peko. The initial selection of 20 ton capacity diesel-powered end-tipping ore carts was made, with the best information available at the time.Since then some 130,000 tons of ore have been carted over a period of 3 years, and this paper presents the experiences of this haulage operation and the lessons learned.A second mine has just been brought into operation at Ivanhoe, 19 miles from Peko. For this haul it was decided to use an ore haulage vehicle of the side tipping road train type, which would cart some 70 tons, or more than three times the load of the vehicles initially selected.Only about 5,000 tons had been hauled at the date of this paper, but preliminary figures indicate a cost 01 1· 65d./ton-mile as against 2·47d. for the smaller vehicles.It would appear that the road haulage of ore from small outlying mines to a central plant can be highly economical, if certain basic rules concerning haul roads and vehicle selection are followed. This paper does not try to determine the maximum tonnages and haul distances which would finally make road hauling uneconomical...

Jan 1, 1966

By C B. McCampbell, R W. Jr Bickes

Sandia National Laboratories has developed a semiconductor bridge (SCB) igniter for the ignition of a variety of explosive materials. When subjected to a low-energy current pulse, the bridge bursts into a plasma causing rapid ignition of the explosive material pressed against the bridge. Despite the low energies required for ignition, SCB components have proven to be explosively safe, meeting both no-fire and electrostatic discharge (ESD) safety requirements.

Jan 1, 1991

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 Forrest T. Moyer

The overall injury experience, excluding officeworkers, at metal mines and mills during the period 1961-63, reported by operators, was 174 fatal and 11,357 nonfatal disabling work injuries during an aggregate worktime of 451 million man-hours. These injuries occurred at a frequency rate of 25.55 per million man-hours, comprising 0.39 for the fatal and 25.17 for the nonfatal injuries. The combined severity rate of the disabilities was 3,779 days lost or charged per million man- hours, consisting of 2,314 for the fatal and 1,465 for the nonfatal injuries. The average severity of all disabilities during 1961-63, was 148 days per injury. The number of days lost and/or charged, ex- cluding officeworkers, at metal mines and mills during the period 1961-63, was 1,440,000 days charged to fatal injuries and 661,290 days lost from nonfatal injuries. An average of 70,966 men were at work daily. The outstanding cause for fatal injuries was the fall of rock or ore from the back, while most of the nonfatal injuries were caused by handling materials, slips or falls of persons, machinery, falls of rock or ore from back and side, and haulage. Injury experience at primary nonferrous smelters, refineries, and reduction plants during 1961-63, excluding officeworkers, was 23 fatal and 3,214 nonfatal disabling injuries during a total work- time of 277 million man-hours. The injuries occurred at frequency rates of 0.08 per million man-hours for the fatalities and 11.61 for the nonfatal disabilities. The severity rate for all injuries of 1,085 days lost or charged per million man-hours comprised 498 for fatal and 587 for nonfatal injuries. The number of days lost, excluding officeworkers, at primary nonferrous smelters, refineries, and reduction plants during 1961-63 was 138,000 from fatal injuries and 162,385 from nonfatal injuries, An average of 34,938 men were at work daily an active plant days during the three year period. The injury experience for officeworkers at metal mines and mills during the period 1961-63 was 20 nonfatal disabling work injuries, (there were no fatal injuries reported), during an aggregate work-time of 28,694,244 man-hours. These injuries occurred at a frequency rate of 0.70 per million man-hours. There were no fatal injuries reported for officeworkers at non-ferrous smelters, refineries, and reduction plants during 1961-63, but seven nonfatal injuries were reported during an aggregate work-time of 30,814,772 man-hours. The frequency rate for these injuries was 0.23 per million man-hours for this period.

Jan 1, 1967

By Thomas A. Giordano

Portable communications equipment is becoming increasingly important in underground mining. Proper selection of microphones and hearing devices to be part of these communication systems is essential if the messages are to be transmitted intelligibly. In this program a thorough study of the requirements for these transducers was made with respect to intelligibility, mechanical configuration, human factors and safety. A computer analysis was made to predict how several combinations of transducers would perform at typical mining noise levels. A survey has been made of those microphones and hearing devices on the market today that might be applicable to the miner communication system. Several systems are proposed and evaluated.

Jan 1, 1976

By Bradford F. Townsend

A study was made on six collapses that occurred during large-diameter tunnelling through weak sedimentary rocks and soil using SES methods in three stages?top heading, bench and invert. The collapsed lengths are between 20 m and 277 m. The collapses were re-mined using essentially the same tunnel-ling method with larger excavation profiles to accommodate the designed remedial measures consisting of ground treatment, pre-support and stronger initial support/outer lining required to carry higher ground loads acting in the collapsed lengths. The paper presents information on the collapses and the design and execution of the remedial measures.

Jan 1, 2008

By W. J. Schlitt

The development of forced aeration as an approach to enhancing copper sulfide leaching is traced from its earliest development up to present day operations using this technology. Both large-scale field tests and commercial operations are covered. The historical portion is preceded by an introductory discussion of the role of air (oxygen) in sulfide leaching. Sufficient aeration may be achieved via naturally induced convective airflow. However, cases are identified where this is insufficient, leading to retardation of the sulfide leach rate. For these situations, forced aeration may be beneficial. The historical portion of the paper focuses on the major field tests that have been conducted in Montana, Nevada and Utah, along with commercial operations in the United States, Australia, Chile and Peru. The paper concludes with some general comments about the applicability of forced aeration, which are based on the information developed to-date.

Jan 1, 2006

Outsourcing of specialist and non-continuous services is common practice in international mining operations. There is an increasing trend towards this practice in South Africa as a result of the major organisational changes that have taken place in the industry, and as lower revenues and production cost pressures have reduced profit margins. Many specialist functions have been outsourced in the industry for a long time, an example being shaft sinking, which is undertaken by specialist shaft sinking contractors. In the professional services area, some activities have been outsourced, for example the design and construction supervision of tailings dams, but mining related activities such as geology, mine planning and scheduling, engineering, ventilation, and rock engineering, have traditionally been carried out by in-house staff. In this paper some of the industry problems which have led to an increase in outsourcing of professional services are considered. Then the pros and cons of outsourcing are dealt with before outlining the factors which should be taken into account in choosing an outsourcing partner.

Jan 1, 1999

By W. H. Schiffbauer

The protection of miners, equipment, and infrastructure is discussed. While the primary focus of the described technology is to prevent miners from being injured, struck-by, or crushed by heavy equipment; another major benefit realized is also the protection of equipment and infrastructure. An attempt is made to define and classify the systems used to provide proximity detection and warnings as well as collision detection and avoidance. Information about the speed of vehicles and human operator response time can be a factor in the choice of what type of system and what features are needed to properly address the needs. How the technology adjusts to compensate for various vehicle speeds, while maintaining the same level of protection is noted. The statistics which justify the need of miner protection are provided. The primary system components required, what attributes they feature, and how they respond in the environment, is briefly highlighted. The physics behind the danger zone marker technology and what makes it so robust and reliable is established. Examples of a few mining applications and specific operational modes are provided for both surface and underground.

Jan 1, 2011

By Andrew Chapman

The scope of the SA (Situational Awareness) working group is to analyze the effectiveness of information delivery systems in mining equipment and develop a unified display design, to mitigate against the proliferation of screens within equipment cabs. This working group comprises a variety of stakeholders representing a cross-section of relevant mining and mining-related organizations. This stakeholder network will help guide the direction of the working group towards a common, mutually beneficial end. For now, the focus is on shovel displays; however it should be noted that this work is expected to form the foundation for similar work with other equipment in the future.

Aug 1, 2013

By Robert M. Valentine, Randall L. Lentell

Interpretive geotechnical investigations were performed for the construction of approximately 15,250 m (50,000 ft) of wastewater interceptor tunnels in Austin, Texas. Subsurface materials consist of claystone (or clay shale), siltstone, altered volcanic tuffs, chalk and limestone. Special conditions include multiple crossings of Onion Creek with cover ranging from about 1/2 to 3 m (2 to 10 ft.), and the potential for mixed-face conditions consisting of water-bearing gravels overlying clay shale or siltstone. The methods and results of the geotechnical investigations are discussed and the inferred construction conditions are compared to those encountered during tunneling. A suggested format is presented for interpretive geotechnical reports for underground construction projects.

Jan 1, 1985

OVERVIEW OF PRESENTATION ? What is LMI ? Who uses LMI and how? ? Value of LMI to the Mining Industry ? Mining Industry Workforce Information Network (MIWIN) ? The Challenge: Forecasting the future in uncertain times ? Results: Hiring requirements in the next decade ? Results: Occupational information ? Next steps

May 1, 2009

By G. L. Smit

The Buffelsfontein Gold Mining Company is situated in the Klerks-dorp district of the Province of the Transvaal in the Republic of South Africa, approximately 100 miles west of Johannesburg. Gold production commenced in January 1957 and Uranium treatment of residue slimes as a by-product started in July 1957. The mining property is 5435 mining claims in extent, the equivalent of 7,988 acres or 12.5 square miles. The mine was initially exploited by the Pioneer Twin Shaft System, consisting of a 26 feet diameter down-cast shaft and a 22 feet diameter up-cast shaft, sunk in the north-west area of the mine to cater for the hoisting and ventilation requirements for a milling rate of 150,000 tons per month.

Jan 1, 1964

Efficiency, Economics, Energy and Emissions - Emerging Criteria for Comminution Circuit Decision Making

Sep 13, 2010

By Mark Sheppard

The technical literature on the general subject of crushing contains many references to the work of investigators on the laws governing, and the factors entering into, the economical production of fine materials. In fine grinding, whether for the purpose of producing fine material, or for the unlocking of minerals in an ore, close control of the screen sizes of primary-crusher products is of secondary consideration and accordingly has received very little attention. The growth and development of the nonmetallic industries, however, have drawn more attention to primary crushing. Many of these industries are interested in the production of relatively coarse products that meet certain definite size specifications, a condition entirely different from that existing in the field of ore dressing. Under such conditions, a knowledge of the factors governing the selection and operation of primary-crushing equipment is essential to the economical production of a satisfactory material.

Jan 1, 1939

By N. Q. Huy

This paper describes the application of finite element analysis to simulate the static and quasi-static pile load tests in different drainage conditions. The possible effect of excess pore water pressure will be studied from the simulations results. The results show that the drainage condition has effect on the bearing capacity of a pile derived from the quasi-static pile load test. The excess of pore pressure reduces the pile toe resistance while it increases the pile shaft resistance. The factors which influence the effect of excess pore pressure are also discussed.

Jan 1, 2006

By P. Venkatraman

Laboratory and pilot-scale test data have shown that the innovative feed presentation of the CrossFlow separator provides improved metallurgy when compared to traditional hindered-bed or teeter-bed classifiers. This design feature prevents excess water from entering the separation chamber and disrupting the overall fluidization flow rate within the teeter zone. Recent side-by-side industrial-scale evaluations have verified that this technology can improve overall efficiency, reduce the cut point of separation, and increase throughput capacity. This paper describes the important features that make this novel separator ideally suited for size classification and density concentration. Test data from heavy mineral, phosphate, and industrial mineral applications are also discussed.

Jan 1, 2005

By Zhonglin Ye, Guangping Dai, Ba Zhang, Yonggang Wei, Shiwei Zhou, Bo Li, Hua Wang

Decreasing copper content in slag is critical for improving copper recovery, where apparent viscosity is the main factor affecting the separation of matte/copper from the slag. The viscous behavior of copper converter slag was investigated during reduction process in this paper, and its non-Newtonian viscous behavior and shear thickening characteristics were clarified. The effects of silicate structure and solid particles in the melt on the slag apparent viscosity were investigated. As slag cleaning proceeded in an electric furnace, the magnetite gradually transformed into ferrous oxide, increasing the FeO/SiO2 ratio. With this ratio increased from 1.2 to 2.0, the slag structure was simplified, and its apparent viscosity decreased from 0.26 to 0.12 Pa·s at 1523 K. The iron phase was excessively reduced to metallic state; the slag contained metallic copper-iron alloy particles, increasing apparent viscosity. The apparent viscosity and phase structure of the slag corresponding to the iron phase reduction process were analyzed in detail; the results obtained in the present study are of great significance to the reasonable control of the converter copper slag cleaning process.

Nov 7, 2022

By P. D. I. Honeyman

DURING 1938 many copper companies again felt the economic pinch and smelter operations were often on a reduced basis which some- times resulted in intermittent operations and complete shutdowns. During the last half of the year production was stepped up and smelting operations resumed a more normal appearance. One of the present-day trends in reverberatory sme1ting is definitely toward high-tonnage operations. i\ t the Phelps Dodge Corporation's Douglas plant, the reconstructed 107 by 26- ft. reverberatory furnaces are operated at the rate of 1000 tons of solid charge per day. The arch, all of silica brick; is sufficiently high above the bath to give

Jan 1, 1939