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By Wayne Burmeister, Danie Benade, Louis Meyer, Hugo Joubert

What is not measured cannot be managed. This is true of most things, including a furnace lining. This paper describes a Lining Management System used for this purpose. It provides the operations staff with a management tool to predict long term lining life and acts as a process optimisation tool. It alarms and records upset furnace conditions. Outputs from the system are described as presented through a specially developed software package and interface. It includes vertical and horizontal furnace sections showing estimated isotherms through the lining as well as the furnace bath. It also shows calculated heat flux values, estimated lining wear and the freeze layer profile. A novel three-dimensional display is described which provides the operator with a big picture view of the furnace crucible profile under real time operating conditions. The powerful trending facility for analysing both measured and calculated values is discussed. The required instrumentation hardware as well as the installation thereof is described, with special reference to an electrically insulating thermocouple socket design. Finally feedback is provided on the first year?s performance of the system installed on an open ferrochrome furnace at Assmang Chrome, Machadodorp, South Africa.

Jan 1, 2007

By F. Hassani, K. Moozar, J. Ouellet, P. Gauthier

"This paper describes a sudden spill of waste rock used for backfilling from a waste pass at an underground mine in Canada, thus causing a major failure/accident. The mine operator immediately launched a detailed investigation to understand the causes of this accident and develop procedures to prevent any recurrence of such events in the future. The authors from McGill University were invited to collaborate with the engineers at the mine to examine this accident. The events leading to the accident were studied, appropriate measurements were taken and samples of the waste material were collected for further testing and analysis.The field visit and the interview of the witnesses allowed the detailed documentation of the events. The sequence of events related to the incident, along with the experimental results obtained in the course of the investigation, are presented. The waste material was characterized in the laboratory with regard to its behaviour in the presence of water. This information is discussed and the failure mechanism involved in the accident is identified. Finally, the full recommendations as well as the immediate operational measures implemented by the mine to prevent the future occurrence of such events are presented and discussed."

Jan 1, 2004

By F. Hassani

This Paper describes a sudden spill of rock waste used for backfilling from a waste pass at one of the underground mine in Canada thus causing a major failure/accident. The mine operator immediately launched a detailed investigation to understand the causes of this accident and develop procedures to prevent any recurrence of such events in future. The investigators from McGill University were invited to collaborate with the engineers at the mine to examine this accident. The events leading to the accident were studied and appropriate measurements were taken and samples of the waste material was collected for further test and analysis. The field visit and the interview of the witnesses allowed a detail documentation of the events. The sequences of events related to the incident together with the experimental results obtained in the course of the investigation is detailed. The waste material was characterised in the laboratory with regard to its behaviour in the presence of water. This information is then discussed and the failure mechanism involved in this accident is identified. The full recommendation as well as the immediate operational measures implemented by the mine to prevent future occurrence of such events are discussed and presented.

May 1, 2003

By Andy L. Shaffer

A novel liquid settlement system (LSS) was installed in advance of mining at a western United States (U.S.) longwall mine to measure total roof sag from the time of cutting to days after mining during gate road development. The system was used to compare differences in roof sag between conventional place-change mining using a Joy continuous miner and a Fletcher roof bolter and mining using a miner-bolter. The LSS was installed with an intrinsically safe, miniature data acquisition system (MIDAS) to record roof response at four locations in the same gate road. The system utilized pressure transducers to measure roof sag by the principle of falling head (fluid pressure) in fluid-filletubes installed in the immediate roof. Details of the LSS design, installation, data collection, post-processing, and future applications are discussed.

Jan 1, 2014

By Liang Yu, Yuhua Li, Yuanchi Dong

"High alumina slag, with alumina normally more than 15 pct, is encountered with blast furnaces in China because of high alumina/silica ratio in iron ore as well as sinter and high ash content in coke for cost reason. High alumina slag with high viscosity and high liquidus temperature would lead to higher slag volume and thereby, furnace productivity. In the present work, liquidus temperature of high alumina slag, based on Meishan factory, Baosteel China, were investigated. A liquidus temperature model was introduced in the present work based on basic physical chemistry theory and focused on the chemical composition area used in Meishan factory(pct): Al2O3 from 14 to 17.5 and MgO from 8 to 12, so that the blast furnace slag could be designed for optimum blast furnace performance.IntroductionBlast furnace slag composition[1] has very important bearing on its physicochemical characteristics which affects smoothness of operation, slag handling, coke consumption, the degree of desulphurization, hot metal productivity and its quality etc. The slag properties which affect most are liquidus temperature, viscosity, sulphide capacity and alkali capacity. Variation of these slag characteristics with composition and temperature has been a field of active researches as these its great influence on the blast furnace operation. In the early years, most of these studies were carried out over low alumina blast furnace slags with alumina normally less than 15 pct. High alumina slag was first introduced in India because of its high alumina/silica ratio iron ore as well as sinter and high ash content in coke[2]. And then this problem becomes common as higher alumina/silica ratio iron ore imported and used [2-5]. The most important problem caused by high alumina content is liquidus temperature and then viscosity of the slag.Generally speaking those reported works [2-5] investigated a pretty wide range of chemical compositions and then obtained complex model, respectively. In fact, every factory has its own interest because of different resources. For example, the Al2O3 content from 20% to 30% pct was studied in Tata Steel India [2], but it is too high for Baosteel Meishan. A very lower percentage of alumina content, 14-18 % pct, was mainly used."

Jan 1, 2008

By J. E. Nesset, J. A. Finch

A model of the fully-loaded condition of particle accumulation on the matrix of a high gradient magnetic separator is developed. The model accurately predicts the build-up profiles reported recently by Friedlaender et al. A powerful development from the model is that loading (volume of accumulated material per unit volume of matrix) is uniquely defined by a dimensionless group, called the loading number, NL. From direct measurements, NL proved superior to the dimensionless group proposed by Watson as a measure of loading. The fine size limit of hematite recovery is examined using NL.

Jan 1, 1980

By Z. Y. Liu

A local additional potential model (LAPM) was developed to illustrate the role of strain rate in stress corrosion cracking (SCC) of pipelines. According to LAPM, both density and mobility of the local active spots on the steel surface, i.e., dislocation emergence points, increase linearly with strain rate. Generation of such active spots introduces an additional negative potential locally, affecting the electrochemical reaction and, consequently, the susceptibility of the steel to SCC. Electrochemical corrosion measurements, slow strain rate tests and electrochemical hydrogen permeation test were combined to demonstrate the validity of LAPM to illustrate pipeline SCC in an acidic soil solution. It is found that a maximum of the SCC susceptibility occurs at strain rate of 10-6 s1, which is associated with an enhanced hydrogen evolution due to the local additional potential (LAP) effect.

Jan 1, 2010

Mining is still a significant economic activity within the Hauraki District. The Martha project is particularly significant. Estimates are that in the order of 850 direct and indirect jobs are derived as a consequence of the Martha project within the Waikato Region. The Resource Management Act 1991 (RMA) is New Zealand's primary piece of environmental legislation. It sets out to provide the framework for the control of the use, development and protection of almost all physical and natural resources. Minerals are excluded from the sustainability requirements of the legislation but as mining invariably involves the use of land, all the other elements of RMA apply. The Council's role in dealing with mining changed with the introduction of RMA. It became responsible for administration of those matters that fell within the functions set out in section 31 of the RMA in respect to existing authorisations. Mineral development needed to be considered in the development of the District Plan that the Council is required to prepare. Implementation of the Act has been a challenge for not only local government but for many industries and resource users since it came into force in 1991. There have been, and are, differing views on both the way it is administered and its intent. The Hauraki District Council has been at the forefront of some of the challenges that are a consequence of the Act. Its reactions to these challenges have been consistent. It treats mining in the same why it treats any other industry. At times this approach has not been understood and without challenge from sections of the community.

Jan 1, 2000

The importance of the accurate determination and interpretation of the bulk density and porosity of a given iron ore deposit is very often disregarded or neglected. Large amounts of time and money are spent on delineating and testing orebodies, and yet one of the most important factors in resource evaluation is sometimes estimated or, at best, determined from existing data from similar deposits. The Thabazimbi and Sishen South iron ore deposits are two well-known economical occurrences of high-grade iron ore in South Africa. Both these deposits formed as secondary enrichment of banded iron formation lithologies. Ongoing density studies on both these deposits are underway and results thus far proved very effective and necessary. Small-scale methods are used to determine average values for different ore types on both deposits. These values are used in resource estimation and geophysical interpretation.

Jan 1, 2007

By W. D. Northrop

This paper gives an account of the development of a technique whereby the vertical limits of geological horizons may be identified by the use of vertical variograms on the mineral of economic interest. This information may supplement or guide the correct subdivision of the individual horizons into meaning full data sets by diligent geological observation. This process then improves the quality of the variance modelling of the gold distribution in the plane of the individual layers and therefore enables better estimates to be made into the grids or blocks of the mine model. The technique is explained by an account of the development work, which was performed, on duplicate superimposed reef horizons in the Kimberley formations. The paper then shows how the correct approach was developed to evaluate the mineralized layers in a multiple stacked conglomerate layer sequence in the Elsburg reefs of the Witwatersrand Rand System at the Target deposit. The method of categorization of resources according to confidence in the estimate is also explained. The feasibility processes carried out on the three-dimensional model, in accordance with the SAMREC code are also described. An example of the development of a reconciliation process utilizing chip sampling is also explained.

Jan 1, 2003

By D. J. Crawford

The Lucerne Valley Operations of the Minerals, Pigments and Metals Division of Chas. Pfizer & Co., Inca, are located about 5 miles south of the town of Lucerne Valley, California. These operations consist of several limestone quarries, a whiting plant which produces finely pulverized limestone products, a-kiln which produces granular quicklime and lime products, and maintenance shops, warehousing, shipping, and office facilities. Construction of the Lucerne Valley plant began in 1961 as the result of a decision to utilize large undeveloped reserves of limestone in that area. Quarry development was started in the following year; and by 1965, Lucerne Valley had become the principle limestone and lime facility of the Western Operations of the Minerals, Pigments and Metals Division.

Jan 1, 1967

By P. Valicek, M. Farren, R. G. B. Pickering, G. Harrison, P. van Dorssen, W. Joubert, H. J. van Rensburg

Introduction In South African metalliferous mines, stoping operations are largely confined to narrow, tabular orebodies making mechanization extremely difficult. Limited flexibility in terms of stope width has necessitated drilling by means of hand held, pneumatic rock drills at most of our operations. As the largest producer of platinum in the world, we drill in excess of forty million stope blast holes per annum. Cleaning of the broken ore is also done by conventional means—utilizing scrapers and scraper winches. Conventional methods such as these carry high costs in terms of risk exposure as well as labour intensity. The purpose of this paper is to describe the development of a long hole stoping system suitable for the narrow platinum reefs. The new system had to be substantially safer and more cost effective than conventional mining. We selected a site that was conducive to mechanized mining and set out the parameters that we considered would meet our requirements. We then conducted a feasibility study to evaluate the conceptualized long hole stoping system in terms of specific goals. An analysis of the proposed system identified the Key Performance Indicators (KPIs). One of the most critical goals was to be able to create a man-freestope. This would mitigate the safety risk associated with normal stoping operations, as well as the inefficiency cost previously referred to. Other challenges included setting targets for long hole accuracy, stoping width reduction and specific blasting system performance for long hole stoping. We also modelled a critical span that we considered to be inherently safe and to ensure hangingwall stability, throw-blastcleaning and overall system productivity. Anglo Platinum Research and Development and Sandvik Tamrock entered into an agreement for the supply of a specialized long hole-drilling machine. The system was implemented and tested by the mine with the support of the other participants. The results achieved met our expectations. It was demonstrated that with this method of mining it is possible to have a man-free/support-free stope face and to achieve a reduction in shaft head cost per ton whilst reducing dilution. Key performance indicators assessed during the trial •Safety targets •Mining layout •Drill rig •Production targets •Support requirement •Explosives requirement •Services requirement •Ore removal and cleaning requirement •Training requirement Safety targets All persons involved with the project had to adhere to the mine’s safety programme including the zero-tolerance campaign, and were required to report all hazards observed immediately. Mine personnel and Tamrock carried out a full risk assessment on the drill rig before transporting underground. A further risk assessment was carried out when the machine was in position underground. Mining layout See Figure 1 and Figure 2 for a detailed description. Drill rig The drill rig was a combination of a Secoma P-Low LC 10long hole feed and an Axera low profile carrier. The choice of this equipment was made through consultation with Tamrock Sandvik. All relevant design perimeters of the area to be mined were taken into consideration. Production targets

Sep 1, 2001

By P. van Dorssen

In South African metalliferous mines, stoping operations are largely confined to narrow, tabular orebodies making mechanization extremely difficult. Limited flexibility in terms of stope width has necessitated drilling by means of handheld, pneumatic rock drills at most of our operations. As the largest producer of platinum in the world, we drill in excess of forty million stope blast holes per annum. Cleaning of the broken ore is also done by conventional means?utilizing scrapers and scraper winches. Conventional methods such as these carry high costs in terms of risk exposure as well as labour intensity. The purpose of this paper is to describe the development of a long hole stoping system suitable for the narrow platinum reefs. The new system had to be substantially safer and more cost effective than conventional mining. We selected a site that was conducive to mechanized mining and set out the parameters that we considered would meet our requirements. We then conducted a feasibility study to evaluate the conceptualized long hole stoping system in terms of specific goals. An analysis of the proposed system identified the Key Performance Indicators (KPIs). One of the most critical goals was to be able to create a man-free stope. This would mitigate the safety risk associated with normal stoping operations, as well as the inefficiency cost previously referred to.

Jan 1, 2002

By Thomas Barkley

Mining tradition holds that a parallel round underground can not be any deeper than it’s smallest face dimension. ln other words, a mine using a 12’ (3.7 m) high by 24’ (7.3 m) wide room and pillar mine, the deepest pull that can be achieved is plus or minus 12’ (3.7 m). After experience with decking of rounds in a 12’ (3.7 m) diameter shaft to achieve more than 12’ (3.7 m) advance per round, the concept of deepening the pull on horizontal parallel rounds seemed to be a feasible concept. Tests were conducted in a conventional room and pillar metal mine with a round size of 12’ (3.7 m) high by 24’(7.3 m) wide. Standard rounds were drilled with a 16’ (4.9 m) steel as parallel rounds to an average depth of 14.5’ (4.4 m). The average depth of pull on these rounds was about 13’ (4.0 m). Using the available drilling equipment, 20’ (6.1 m) drill steel was used to drill holes to an average depth of 18’ (5.5 m). Five rounds were drilled and shot with a resulting aven$e pull of 16.2’ (4.9 m) or 90 % of drilled depth. Rounds were designed with decked bum cuts to maximize depth of pull in the cut area An innovative method of de&mining drilling accuraq was used to estimate it’s effect on depth of pull in the rounds. This method used a standard automatic 35-mm camera and scaling to determine the average drill deviation for many of the holes in the rounds.

Jan 1, 2000

By Charles B. Manula

This paper describes the development of a mathematical model for simulating the behavior of a longwall coal production system. The longwall simulator is a design simulator incorporating both deterministic and stochastic methods to calculate: (a) the size and density of support; (b) the cutting force, power requirements and haulage speed for the loader-shearer; (c) the conveyor size, speed and power requirements; and (d) delay generation at head and tail-gates and the longwall face.

Jan 1, 1978

By Walter R. Hibbard

Whether we have occasion to think of it or not, an adequate and economic supply of energy fuels is vital to each of us. It is interesting to look ahead at the way in which fuels from supplementary sources will begin to enter into the energy mix to help meet the long-term national energy needs. From 1947 to 1965, the average annual rate of growth of energy consumption was 2.7%, with total energy demand in 1965 being equivalent to 54 quadrillion Btu's. During this short period of 18 years, the cumulative output of coal in the U.S. was 9.6 billion tons; natural gas, 193.5 trillion cu ft; and crude oil, 45.9 billion bbl. During the next decade and a half the nation's energy requirements are expected to grow at an average rate of 3.3% yearly, with consumption of energy expected to reach an annual rate of about 88 quadrillion Btu's by 1980, or 63% over the 1965 level.

Jan 12, 1967

By James A. Todd

Use of AN-FO in underground operations has greatly reduced the cost of primary explosives. AN-FO is also less sensitive than conventional dynamites, and when properly used, is safer. Maximum safety in the use of AN-FO, however, requires an understanding of potential hazards from toxic fumes as well as static electricity developed in pneumatic loading. Safe limits and guides have been established to permit most operations to pneumatically load holes that are bottom primed with electric blasting caps, but the toxic fume hazard is less widely understood. During 1959-1960 Du Pont cooperated with the U.S. Bureau of Mines to study the toxic fumes produced by prilled ammonium nitrate-NO. 2 fuel oil mixtures. The conclusions from this work were that oxygen balanced AN-FO, when thoroughly mixed, well primed and well confined in dry holes, produces no greater amounts of toxic fumes than conventional dynamites rated Class I by the Institute of Makers of Explosives. The study also showed, however, that any deviation from these guides tends to increase significantly the quantity of toxic fumes produced. This work was reported by the Bureau of International Symposium on Mining Research at Rolla, Mo., in February 1961.'

Jan 4, 1963

By M. J. Coolbaugh

There is a need for concepts and techniques developed specifically for blasting in areas where the rock is loose or highly fractured. Common practice has been to use techniques developed in hard homogeneous rock and reduce the amount and strength of explosive. However, this rule cannot cope with all of the special characteristics of highly fractured rock and has not adequately taken care of the problems of overbreak, gouging, and wall damage. The main problems encountered when blasting in highly fractured rock are controlling the amount of rock broken, minimizing the damage done to the remaining wall material, and adapting blasting methods to rapidly fluctuating ground conditions. In addition, because it frequently needs timber support right into the blasting area, there is also the problem of how not to shoot out the timber when heavy loading is needed in order to offset a loss of impact caused by deflection of the detonation wave off the numerous rock interfaces, and by the absorption of the wave by resilient clay particles. Another consideration is the fact that less attention needs to be directed toward producing satisfactory fragmentation of the broken rock. Those blasting methods designed for breaking hard rock into manageable segments are, as a rule, not needed in highly fractured rock which will usually break along its own numerous fracture lines.

Jan 8, 1965

By Charles M. Brinckerhoff

Everyone -- especially the engineer -- is aware of the great technological and social changes taking place in our world today, We realize that changes have been taking place since man's beginnings on earth, but the element we now face is the speed of change, rather than change itself. Developments in medicine, in transportation, in space exploration, in global communications, and in many other fields, are constantly being made known. These developments are affecting the lives of each of us, although some may appear remote and unrelated to us as individuals. New developments, almost on a daily basis, affect our work as well as our social, religious and educational lives. The effects are immediate and permanent.

Jan 1, 1967

By V. Dinesen

"Grinding is simply the function of reducing particles in size or creating new surface areas. This may be accomplished by many means but we will only concern ourselves with the continuous grinding process as performed in a revolving drum or mill, containing a grinding media. Such a mill consists essentially of a feed head, a cylindrical shell section and a discharge head. To prevent internal wear of these parts it is customary to attach replaceable linings over the wear areas. The specification and design of these mill liners is more important than generally conceded. As they reduce the effective internal volume of the mill, they will consequently affect the whole mill ·design and operation.A number of mill designs of various sizes are available for combined crushing and grinding of materials within a wide size range. For simplif1cahon purposes we will refer 1n particular to conditions relating to standard mill shapes having a length which is greater than the diameter. Such mills usually rotate at speeds between 60% to 85% of the critical speed and may, depending on the grinding media used, be classified as rod mills, ball mills and pebble mills.LINER MATERIALSA great variety of materials have been and are being used for mill linings. These include wood, ceramics and cements, rubber and plastic compounds, rolled and forged steels, cast steels and cast irons, both plain, alloyed and specially treated.The choice of a liner material depends on many factors. In both dry and \\.:et grinding, it may be necessary to consider product purity, colour, chemical reaction etc. but for our purpose we \viii refer to wet grinding operations as generally used within the mining industry."

Jan 1, 1972