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By J. V. Bymark

It is the intent of this paper to discuss the autogenous grinding circuit at Hibbing Taconite. The scope of the presentation includes; a brief history, the process flowsheet and the steps taken to improve mill productivity, availability and metallurgical performance. Hibbing Taconite is located near the center of the Mesabi Range in Northern Minnesota 100 miles from the Canadian border and 80 miles north of the Lake Superior Port Cities of Duluth and Superior. A 105 mile railroad connects us with the port of Superior, Wisconsin, where our pellets are loaded into lake carriers for lower lake destinations. It is worthy to mention the Mesabi Range's most famous landmark which is immediately to the south of our mine area. This is the Hull Rust Mahoning Mine which operated until the mid-1970's producing more than 700 million tons of red ore between 1893 and 1973.

Jan 1, 1985

By Olav K1omstad1ien

The lean, but extensive iron ore deposits of the Dunderland Valley north of Mo i Rana, Norway, is the raw material for the Rana Mines which is a division of the state owned steel mill A/S Norsk Jernverk. Activities for the exploitation of the orebodies were commenced in 1902 by the English Dunderland Iron Ore Company. During its operating period the company constructed a total of two large scale concentrating plants. The activities were strongly marked by technical problems and labor disputes. Thus actual production was limited to the years 1904-1908, 1928-1931 and 1937-1939. During these periods a total of 1.9 million tons of crude ore was mined and 0.6 million tons of concentrates produced for export. The present plant commenced operations in late fall of 1964. Up to and including 1976 about 26.6 million tons of crude have been put through the concentrating plant and about 10.7 million tons of concentrate produced.

Jan 1, 1978

By Henry E. Swanson

In the early 1960's the Company, then named the United States Smelting Refining and Mining Company, was drilling the Continental ore body located near Fierro, New Mexico. Reserves of underground ore of sufficient quantity were indicated to build a mill. At the same time some ore from the Continental No. 1 mine was being milled at the Company's Bullfrog Mill, formerly a lead-zinc mill. The copper ore in comparison to the lead-zinc ores was very hard, abrasive, and heavy. These factors pointed out the possibility and attractiveness of autogenous grinding. While prior to this some study had been given to autogenous grinding, no large scale tests had been made. Such a program was carried out and from the pilot plant data the following was established: 1. Grinding of the ore by autogenous means could be accomplished. 2. This could be done in one stage; however, not at a satisfactory tonnage throughput rate. Thus, the use of a secondary unit has been employed. 3. Grinding in the secondary unit could be done by pebbles generated in the primary unit. This resulted in the scheme whereby the ore would be ground 100% autogenously. 4. Liberation of the copper minerals was excellent so that good recovery at a satisfactory concentrate grade would be obtainable.

Jan 1, 1976

By Gary F. Rajala, Bruce R. Greenwood

INTRODUCTION The Empire Mine is an iron ore mining, concentrating and pelletizing facility operated by The Cleveland-Cliffs Iron Company in the Upper Peninsula of Michigan. Owners of the mine are Inland Steel, LTV Steel, Wheeling-Pittsburgh Steel and Cleveland-Cliff s. The orebody is a fine-grained, low grade iron formation with magnetite as the primary constituent. Also present are iron carbonates, iron silicates, chert, hematite, goethite and quartz. The original six concentrating lines were started in late 1963. Successive expansions of ten lines in 1967, five lines in 1974 and 3 lines in 1979 have resulted in Empire reaching a present annual capacity of 8.0 million long tons of pellets. The Empire flowsheet was developed over several years of laboratory bench testing, pilot plant testing and testing of a full-scale primary autogenous grinding circuit. Since the original flowsheet was established, modifications have been made based on pilot plant and full-scale plant tests. The present flowsheet for three sections of the concentrator consists of one stage of crushing, two stages of closed circuit autogenous grinding, two stages of magnetic separation, one stage of hydraulic concentration and two stages of flotation (rougher and scavenger). The flowsheet for the fourth section of the concentrator (Empire 4) is the same as the first three sections, except a crusher has been added to crush excess pebbles. The Empire 4 flowsheet appears in the at- tached figure. PRIMARY GRINDING CIRCUIT FLOWSHEET Empire has a total of 24 individual grinding lines. However, at the present time, Line 1 is not being used for processing crude ore. The primary mill on Line 1 is now grinding flux stone for fluxed pellet production and the secondary mill is being used as a ball mill to grind rougher flotation tailings prior to a scavenger flotation circuit.

Jan 1, 1992

By Robert R. Turner, Arthur R. MacPherson

This chapter reviews the steps which should be taken from the time it is decided to consider autogenous grinding in the development of a new ore deposit or the expansion of an existing plant up until the purchase of the new autogenous mills. In this case the term autogenous includes semi -autogenous, secondary pebble mills, and lump milling as well as fully autogenous grinding systems. Also, both wet and dry grinding alternatives have been included. Before the test program it must be decided how many bulk samples are required to properly assess the autogenous grinding possibilities of the deposit. Also, a decision must be made on where and how the samples are to be ground i.e. pilot mill at site or in established location, wet and or dry grinding, etc. In the test program itself, certain fundamental data must be obtained. The testing should include enough work to determine whether fully autogenous or semi-autogenous grinding should be used and what type produces best power efficiency. Also, all the other pertinent data should be collected such as power; tonnages; feed, charge, and product sizing; circulating loads, etc. If a secondary mill is required to produce a final grind the decision on whether a pebble or ball mill should be used may require additional test work. Finally, the concentration of the mineral may play an important part in selection of the circuit and should become a part of the final testing once the grinding has been established.

Jan 1, 1978

By Timo Heikkinen

We have read, with great interest, Mr. Crocker's article on "Recent Trends in Autogenous Grinding," published in the October issue of The Canadian Mining and Metallurgical Bulletin. Referring to our paper, "Two-Stage Autogenous Grinding Investigations at Outokumpu," we can now report that last August we changed to this method at the Keretti concentrator. Prior to the conversion, the Keretti plant (see flow-sheet, Figure 1) had two primary rod mills, 6 ft. in diameter and 12ft. in length, in open circuit, followed by four secondary 9-by 12-ft. pebble grate mills in closed circuit with rake classifiers. Last summer, wl1en the Since August, grinding has been successfully carried out autogenously in two stages, with two mills being employed in the primary stage and four in the secondary. The size of the pebbles in the secondary mills is about the same as earlier -l V: i to 3 inches (Figures 4 and 5). Also, we generally prefer two-stage grinding to single-stage grinding because, in the former,

Jan 1, 1964

By Johann F. Kerl

Autogenous batch grinding tests were performed in laboratory-scale tumbling mills with magnetite, limestone, and sandstone pebbles. The influence of pebble size, feed size, mill speed and loading, and grinding time on the fineness of grinding was investigated. Comparisons were made with the results from ball mill grinding experiments.

Jan 1, 1972

By J. E. Danoczi

ABSTRACT A diamond processing plant is being designed for the Star–Orion South diamond project in central Saskatchewan. Key to the plant is diamond liberation, which occurs in the comminution section and is the process of breaking up kimberlite rock as gently as possible to minimize diamond damage, particularly in larger, high-value diamonds. Kimberlite from the crater area of a volcanic pipe is generally softer than kimberlite from the diatreme zone. Softer kimberlite, comprising the majority of Star– Orion South deposits, can be readily broken up using abrasion and attrition by autogenous grinding mills, the preferred comminution method for minimizing diamond damage.

Jan 1, 2013

By W. D. Bachman

A study has been made of wet, autogenous grinding of disseminated copper ores, including testing of a large number of samples from Kennecott Copper Corporation's Chino mine. The efficiency with which the various samples could be ground was found to vary over an extremely wide range, even among samples taken from different locations within the same ore body. These variations in grindability can be qualitatively correlated with the composition of the rock and the fracturing and alteration that had occurred. Because of the large-scale non-homogeneity of disseminated copper ore bodies, extensive and careful testing of autogenous grinding is needed. An accurate correlation of the grinding data from various samples with the geology of the ore body and with mining plans will indicate if variations in grinding mill throughput can be avoided in practice by mixing or blending of mill feed and if, therefore, autogenous grinding can be applied successfully.

Jan 1, 1970

By S. A. Elmquist

Research activities performed by Cleveland-Cliffs Research and Hibbing Taconite plant personnel during the last decade have resulted in the development of an improved autogenous mill grinding circuit. Minus one (1) inch autogenous mill trommel oversize material, con-sidered to be a critical size, is magnetically cobbed and then crushed to 100% minus 3/8" prior to reentry into the feed end of the mill. Autogenous mill capacity increases, up to 25%, have been measured in pilot plant tests using this approach and are also anticipated for the Hibbing Taconite concentrator which presently has reached a 15.5% improvement.

Jan 1, 1994

By James E. Wennen

The through-put and energy efficiency of an autogenous (AG) grinding mill are adversely affected by variability in rock size and rock competency. This applies to both fully autogenous and semi-autogenous (SAG) grinding circuits. In this paper we focus on an approach to overcome the problem of inconsistent mill through-put related to variability in mill feed size and rock competency. The focus is on ores containing hard, competent rock. This approach consists of preparing feed to an autogenous mill that contains 20% coarse media rock and 80% of material crushed to pass 37 mm. Results of pilot-scale testing for two iron-ores will be presented to show that a 10% to 12% reduction in unit energy consumption is possible with prepared feed, compared with feeding the mill with conventional primary crusher discharge.

Jan 1, 2012

By N. C. Clarke, T. Wu, M. le Page, K. J. Henley

In 1994, Gold Mines of Australia acquired the rights to the historic Mt. Lyell copper mine, and commenced a feasibility study into expanding production. The ore was shown in laboratory tests to be amenable to single-stage, fully autogenous grinding (FAG) of underground primary crushed ore, and this route offered the maximum cost savings. Flotation performance was expected to be enhanced. However, batch flotation tests done on pilot-scale autogenously ground ore showed an unexplainable recovery loss of between 1% and 3% Cu. A second pilot plant trial was set up, with the ground product feeding banks of continuous flotation cells. Single-stage FAG, FAG/pebble and FAG/ball circuits were tested. Results confirmed a loss of about 3% recovery with single-stage FAG milling. The FAG/ball circuit eliminated the loss. Analyses showed that autogenous milling probably produced more chalcopyrite/pyrite composites and that recovery of these composites was lower than with ball milling. In size fractions below about 53 microns, where chalcopyrite is well liberated, copper recovery was less affected by milling method and flotation selectivity. It was concluded that for the Mt. Lyell situation, a FAG/ball circuit was preferable to single-stage FAG.

Jan 1, 2002

By J. Donnelly, A. V. Deev

Substitution of coal and coke by renewable carbon (charcoal) is a low-risk and low-capital path to 50% or more reduction in net CO2 emissions by the steel industry. However, the high cost of charcoal and its low availability in most countries are barriers for the implementation of this approach. Development of an efficient wood carbonisation technology (slow pyrolysis) capable of producing large-volumes of charcoal from low-cost wood feed (e.g. wood wastes or forest residues) is an essential step towards the use of renewable carbon by the iron and steel industry. This paper provides a summary of the progress made over several years of R&D covering: (1) development and piloting of a new energy efficient slow pyrolysis process for production of charcoal from woody biomass at a competitive cost to the PCI coal, (2) techno-economic evaluation of the process. The main feature of the process is that the material undergoing pyrolysis is heated spontaneously without the supply of heat or air to the reactor. This makes it possible to carbonize large volumes of small-sized wood (e.g. wastes and residues) in a single reactor unit and capture high calorific value pyrolysis by-products

Jan 1, 2015

Autogenous-Carrier Effect and Gangue Influence in Fine Particle Flotation of Ilmenite/Titanaugite System

Sep 13, 2010

By Fabien Miller

Automation technologies are increasingly envisaged to improve underground mining productivity. However, the technologies need to be used and adopted gradually in order to get the best benefits. This paper presents the technical and operational aspects of autoguided production vehicles at Brunswick Mine. During 2001 Noranda?s Brunswick Mine has successfully commissioned an automated haulage zone where two optically guided trucks transport ore from a remotely operated chute to two orepasses. Operational advantages include increased system capacity and enhanced safety and comfort for the operator. The data obtained up to now indicate that the system can operate reliably in mine production

May 1, 2002

By Fabrício Tibúrcio Silva Araújo

O AutoLog é uma solução em tecnologia de automação e informação para controle absoluto do carregamento e descarregamento de caminhões em um grande cliente no ramo de fertilizantes. Seu objetivo é garantir uma operação autônoma que otimize os lucros e reduza os custos em logística. Este trabalho visa demonstrar o problema que originou a solução, a metodologia utilizada no seu desenvolvimento e o seu objetivo final.

Oct 30, 2017

By R. S. Adhikari

It is necessary to assess the physical and functional conditions of highway bridges at regular intervals to ensure they still meet their service requirements. Currently, this condition assessment is mainly performed through visual inspection, which has been identified with several limitations (e.g. the timeconsuming assessment process and heavy reliance on inspectors? personal experience). In order to overcome these limitations and enhance the current inspection practice, this paper presents a novel method for automated bridge condition assessment using a hybrid sensing system. Under the method, existing conditions of bridge components are first captured with a stream of point clouds and color images. Then, the bridge components and the defects inflicted on the components are detected utilizing their visual patterns. The detection results are mapped to the point cloud. This way, the 3D information of the components and defects can be retrieved. The bridge condition assessment can be made effectively through the 3D visualization of this information before carrying out any on-site detailed evaluations.

Aug 1, 2013

By N F. Glenn, S Thiruchittampalam, B P. Banerjee, S Raval

The determination of shear strength parameters for the spoil material plays a crucial role in the assessment of a dump’s stability; nevertheless, their evaluation necessitates laborious laboratory experiments. In order to address this issue, Simmons and McManus (2004) formulated a framework that serves as a foundation for categorising spoils according to their distinctive shear strength parameters based on observable and tactile characteristics. This framework, previously identified as the ‘BHP Mitsubishi Alliance Coal (BMAC) Spoil Shear Strength Framework’, is now recognised as the ‘CoalSpoil’ framework. The spoil characterisation provided by the CoalSpoil framework offers benefits but is not without limitations. The examination of these attributes in the field is a time-consuming task that demands expertise. Subjectivity arises in the spoil characterisation when attributes straddle the line between two categories, such as delineating matrix-supported and framework-supported fabric structures. To enhance consistency in the spoil characterisation process, minimising human intervention is crucial to mitigate bias, classification errors, and safety risks. This study seeks to achieve this aim by introducing image-assisted and automated methods for spoil characterisation.

Sep 1, 2024

By William G. Schultz

Sylvite of Canada, a wholly owned subsidiary of Hudson Bay Mining and Smelting Co., operates an 8000 TPD potash mine and refinery located nine miles North East of Rocanville, Saskatchewan. Prior to Hudson Bay's entry in 1968 into potash mining and refining, it was one of the more traditional and conservative Canadian Mining Companies whose principal business had been for many years a successful copper-zinc mining and smelting operation located at Flin Flon, Manitoba. The potash reserves being mined by Sylvite were acquired through the acquisition of Francana Oil and Gas. This acquisition was at the time when several major potash mines were being developed or had recently been brought into production in the Province. These mines are owned by either very substantial Canadian Mining Companies or Multi-National Mining Companies with considerable potash mining experience. At that time, it became very apparent because of the new mines coming into production, potash mining and refining would quickly become a very competitive industry. Because of long term considerations, Hudson Bay decided to proceed with the development of its potash reserves, recognizing the Mine and Refinery would have to be the most advanced available in order to successfully operate. This report deals with the mining operation at Sylvite and the degree of success Sylvite has achieved.

Jan 1, 1972

By W. G. Schultz

"Sylvite's potash mine, which produces 8,000 tons of ore per day, probably ranks as one of the most highly mechanized and automated mining operations in the world. Employing, on a normal 10-hour production shift, one supervisor and a crew of seven operators, Sylvite is able to mine at an average rate in excess of 600 tons per hour. The ore is produced by two Marietta miners weighing 258 tons, the largest and heaviest pieces of equipment ever taken underground. The ore produced by these two Marietta miners is conveyed to the shaft area, cycled through a 15,000-ton storage system and hoisted to surface completely automatically. The operation of all equipment in the mine can be monitored and controlled from a central control panel located underground. Because Sylvite's mine is a new operation with equipment of a new design, the full potential of the operation has not yet been realized. The ultimate capability is clearly evident from the success Sylvite has had over the past year as the average mining capability has risen from 100 tons per hour to 600 tons per hour."

Jan 1, 1973