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By D. C. Torre

Since the early 1960s, there have been efforts to develop and produce reliable continuous haulage systems capable of taking the full output of a continuous miner and transporting it, in one continuous flow, from the face to the tipple. The majority of the successful continuous haulage systems were placed in operation in the early 1970s. These were all of the bridge conveyor type. They usually consisted of bridges and mobile bridge carriers (MBC) attached at the inby end to the continuous miner and at the outby end to the panel conveyor itself. These successful bridge conveyor continuous haulage systems are either of the belted or chain type. The most successful belt type continuous haulage systems are those manufactured and marketed by the Long-Airdox Co. Until early 1977, Jeffrey Mining Machinery Division manufactured and marketed the most successful chain conveyor type haulage sys¬tems. In 1977, Long-Airdox reentered the market with a chain-type system to complement its belted system. The original bridge-type continuous haulage system was introduced to the coal mining industry in the early 1960s by the old Long Co., a predecessor to the current Long-Airdox Co. These original units were of the chain conveyor type. In the early 1970s, there were also developments in continuous haulage, employing different material handling media. These in¬cluded the Serpentix, a flexible type belt, introduced by the Joy Manufacturing Co. There was also a serious attempt to introduce hydraulic-type continuous haulage by Consolidation Coal Co. and Conoco Research. Despite some startling successes, particularly with the bridge-type haulage systems, the general and widespread application of continuous haulage has eluded the mining industry. Some of the problems are related to underground conditions; others to people, both management and labor. One of the greatest obstacles to universal success continues to be the difficulty of accepting the philosophy as well as the machinery of continuous haulage. Nevertheless, efforts continue to spread the success of commercial and viable systems in the industry. There is also effort to improve on these systems, and on methods for their successful use. In addition, efforts continue, with private and public support, to develop new types of continuous haulage equipment and systems. Bridge Type System Developments Because they have already been successful in some US and overseas mines, new developments in bridge-type systems will first be touched on. The Long-Airdox Co. has continued to improve both its belted and chain continuous haulage system. In the belted system, the company recently introduced a new design that will be mainly applicable in higher coals and in noncoal mining applications, as shown in the accompanying figure. This new system is equipped with 305-mm-diam (12-in.-diam) pulleys in the bridges and mobile bridge carriers, in place of the 150-mm-diam (6 in.-diam) pulleys in the standard system. The modification is designed primarily to improve belt life and keep belt problems to a minimum. An operator, the Clinchfield Coal Co., a Division of Pittston Coal, developed the detaching of the bridge-type continuous haulage system from the miner by placing a mobile bridge carrier at the head of the string. However, Long-Airdox and Jeffrey have now made this an option to their at¬tached-type system. In the US, there are many chain type haulage systems detached from the miner with an extra MBC at the head. There are two such belted systems

Jan 7, 1982

By V. I. Lakshmanan, Dan A. Mackie

Traditional vat leaching methods have had limited success, primarily due to the high cost of loading and unloading the vats. In general, such batch methods are labor-intensive and costly. Heap leaching has emerged as a viable, low- cost alternative, but low recoveries, normally in the 70% range, offer opportunities for improvement. Also increased regulatory guidlelines for effluent and spent heap leach pads disposal offer potential for alternative methods. The Mackie Vat Leaching Jig (MVLJ) has had its incubation at Ortech International, where bench scale through pilot scale testing continues. Design developments and testwork over the past two years indicate that the time may be right for field trials.

Jan 1, 1990

By P. Altounyan

Techniques used to safely control the roof in UK coal mines for some 10 years have been applied to a South African coal mine. This new approach known in the UK as advanced rockbolting technology, is based on applying four fundamental principles: ?Understanding the roof failure mechanisms ?Using an effective roof support system ?Designing this support using measurement ?Monitoring the performance of the system. The paper summarizes the approach in detail and describes how it is being applied by Anglo Coal, giving results obtained to date. Investigations at a number of South African coal mines, including stress measurements at two Anglo Coal mines, have confirmed that the mode of roof failure (lateral shearing due to horizontal stress) is the same as in other coalfields worldwide, and aspects of current world best practice, including the use of advanced technology rockbolting, are therefore relevant in South Africa. The stress measurements indicated a high level of stress field anisotropy and further investigation of stress conditions in South African coal mines is recommended. The most effective bolting system to resist shear failure is one with high bond strength and stiffness. Short encapsulation pull testing of existing South African systems confirmed that they have low bond strength and stiffness. An improved rockbolt system with the required performance, and features allowing rapid installation and installation quality and performance audit, has been developed and is currently under full-scale trial. Design by measurement and routine monitoring procedures including the use of a rotary telltale device are also under trial. It is anticipated that South African coal mines will be able to obtain significant safety and productivity benefits from the application of this technology.

Jan 1, 2001

By J. B. Kitchin

"The design of conveyor belting for use in mines poses problems to the manufacturer that are unique. The challenge to be met is that of the production of a conveyor belt which can withstand use and misuse in an environment that may differ vastly from one country to another, and even between one mine and its neighbour.The development of a product to meet such varying requirements necessitates a protracted program of trials, both in the laboratory and in the field; a new successful development, the only criterion, can be said to have been achieved only after very long-term usage under actual, deliberately chosen, arduous mining conditions.New developments in conveyor belt construction can never stop, no more than can developments in new and advanced mining techniques. A new problem is set-an answer must be found. Some of the problems are noted here, and answered where possible, in what must after all be little more than an excursion into a very comprehensive and detailed subject."

Jan 1, 1967

By David Mitchell, Daan Delport, Frik Marx, Mike Shapiro

The use of copper cooling elements to enhance refractory lining life in pyrometallurgical vessels is common in modern furnace design. Copper elements typically incorporate a base panel with cast in cooling passages and an integral extended surface (formed of pins, fins or similar) onto which suitable refractory material is cast. The metallic, conducting parts are located towards the cold face of the lining, with the refractory material interposing between the coolers and the process. The coolers are designed to arrest wear of the refractory material by freezing a layer of slag or partially reacted material onto the hot face, thereby rendering the lining inert to further attack [1]. These coolers have achieved success in new furnaces and relining of existing vessels. The freeze layer is prone to mechanical damage during operational and process instability. The coolers must be capable of extracting the additional heat flux under upset conditions to facilitate rapid self-repair of the freeze layer and prevent further refractory wear in the intermittently exposed areas. However, operational experience has shown that the high heat flux capabilities of the copper coolers have some disadvantages, especially in processes producing vapours which form corrosive compounds when condensing onto the cold surfaces of the coolers. When corrosive conditions develop, the entire composite will fail due to loss of structural integrity, and as a result of leaks from the cooling water passages. This paper describes recent developments in the approach to the design and manufacture of copper cooler panels customized to achieve specified heat fluxes and temperature profiles, thereby reducing the formation of corrosion mechanisms in applications with corrosive gaseous environments and enhancing refractory lining life. Condensation formation prevention is achieved by adjusting the geometry of the cooler and selection of suitable materials of construction.

Jan 1, 2007

By Phillip J. Mackey, Gerardo R. F. Alvear F.

It is now 38 years since the publication of the first edition of "Extractive Metallurgy of Copper" by Professor W.G. Davenport and the late Professor A.K. Biswas. The text book would be issued in a total of five editions, soon became the standard for students and those in industry. Interestingly it was published at the onset of great change in the industry. This was a time when sulphur dioxide controls in the USA were introduced, and almost simultaneously, world oil shocks caused significant increases in the cost of fuel - all leading to efforts to adopt new technology and move away from the reverberatory furnace, which had no potential for sulfur capture and required large amounts of fuel. At the time of publication of the book, new processes such as the Noranda Process and the Mitsubishi Process were in their infancy, while flash smelting (which was first commercialized in 1949 at Harjavalta, Finland) had made significant in-roads in boosting copper output, with some 22 new flash smelters licensed by 1976. Computer technology and associated process control techniques were rudimentary compared to systems today, available physico-chemical data remained largely in tabulated format and needed to be manually entered into the main frame computers of the era, while modeling techniques common today had not yet been developed. The copper industry has therefore seen immense changes since the time of this textbook: world tonnage of smelted copper has risen from 7.34 million tonnes/year in 1976 to 16.7 million tonnes/year in 2012, over a two times increase. Technologies such as the El Teniente Process, or Top Submerged Lance technologies, typified by the ISASMELTTM, not commercialized at the time, now treat large tonnages of copper concentrate in a single furnace. Advanced heat and mass balance software and thermochemical modeling are now used extensively to examine chemical and physical characteristics for process design and to support process optimization. These changes in the industry have been chronicled in subsequent editions of the book. This paper looks at the issues and problems seen in 1976 and over the intervening years, and compares this with the challenges facing the industry with the available tools and technologies today. Some ideas looking into the future are also discussed in the paper.

Jan 1, 2014

By Vernon Read, John K. Hayes

Generally speaking, drilling equipment and techniques presently in use are not capable of meeting the complex technical-and economic-requirements of deep core drilling. Drilling to great depths involves increasing risk, time, and money. And it is especially true that costs increase with depth when conventional core drilling methods are used. Introduction of wire-line drilling techniques has been a great boon to deep core drilling, and is rapidly gaining general acceptance. But, in spite of recent progress, there remains a great need to improve productive drilling time and penetration rates, and still maintain high core recoveries.

Jan 1, 1959

By E S. Bernard

Steel fibre reinforced shotcrete (SFRS) is increasingly being used as ground support in both civil and mining applications. In recent years, methods of assessing the performance of SFRS have been developed. These include the beam test such as that prescribed by ASTM C-1018 and the panel test prescribed in the EFNARC European Shotcreting Standard. The panel test has gained popularity in recent times due to the two-way action modelled in the test. However, some difficulties have been noticed. Shear failures sometimes occur and there appears to be a rather high degree of variability in the panel test results. A new method of testing panels has been proposed. A circular panel supported on three symmetrically arranged points has been assessed at the University of Western Sydney. This paper describes the new test which may be the basis of a new specification for the testing of toughness of SFRS and summarises research work which has been carried out to-date.

Jan 1, 1999

By Jones S. C

A specific arc can be cut in hard rock formations using a specially designed multistep piloI bit, variable sized drift joint and long heavy control rod as a stabilizer rather than the Vaughan Thompson "Lifting" arc cuttingequipment. The rate of deflection can be controlled after an initial determination of behaviour in any particular rock type.

Jan 1, 1966

By Arthur G. Hunt

Smelting using the direct-to-blister process commenced at Olympic Dam on 31 July 1988. The unique nature of the Olympic Dam ore body led to the selection of the direct to blister smelting process. Significant improvement in the design of the furnace and the understanding of the fundamentals of the process and its operation has occurred in the 10 years of operation. The paper will discuss the operation of the #1 Smelter and the design, preparation for start up and early operating experience of the #2 Smelter.

Jan 1, 1999

By J. Bacho

The modern drilling fluids industry is a dynamic, evolutionary environment. It is continuously striving to satisfy and anticipate the ever-changing needs of the oil and gas industry. The predominant driving forces in the industry over the past decade have changed dramatically. Health and environmental issues, coupled with economic and performance requirements, demand innovation and change from the drilling fluids industry. Emerging drilling fluid technologies will demand environmental considerations from mined components with additional emphasis on cost and performance criteria. Drilling fluids providers continue to search for and identify environmentally sensitive components which meet or exceed the performance of their more toxic predecessors. These changes have and will impact the components of drilling fluids that are mined.

Jan 1, 1994

Operation of the tankhouse at the Electro lytic Refining and Smelting Company's works has been improved, but further automation is re- quired to cut the labour intensive nature of the routine tasks. Anode quality, both chemical and physical, plays an important role in efficient refinery practice, and impurities such as lead, antimony and nickel have required careful monitoring for smooth operation. The gradual replacement of copper blanks by titanium has markedly improved the quality of starting sheets, but problems have been ex- perienced with surface preconditioning of the titanium blanks. Polishing with emery paper proved to be a successful technique.

Jan 1, 1976

The brown coal deposits of the Latrobe Valley are ideal for open cut mining and this method has been used since the start of coal winning in 1894. Operations at the main Yall9urn open cut commenced in 1922, but after a few years the main excavators were replaced by German continuous excavators and subsequent developments of Yallourn and the newer Morwell open cut have been based on this type of plant. The reasons for preferring continuous to intermittent excavators in the Latrobe Valley are indicated in this paper.Under the pressure of post-war conditions, and from their long experience and ability, German engineers have recently made substantial improvements in their continuous excavators and these developments have been enhanced by some American innovations. These changes have extended the economic limits of open cut mining and also serve to emphasize the close inter-relation between the nature of coal and overburden deposits, excavator design and methods of operation.As an aid to descriRing recent excavator developments, this interdependence is demonstrated by means of diagrams which show typical methods of operations, together with examples of actual machines using these methods. The types of excavator dealt with are mainly those in use at, or destined for Yallourn or Morwell open cuts, together with additional types used in U.S.A. and Western Europe. For completeness, and also because they will continue in service at Yallourn and Morwell for some years, rail-mounted dredgers have been included in this paper even though in Europe they are now regarded as obsolescent.Explanations are given of how the intrinsic qualities of Latrobe Valley brown coal and overburden have sometimes prevented overseas plants from operating with the full efficiencies and/or in the methods visualized by the manufacturer, and references are made to the modifications and investigations being undertaken to overcome these problems.A compresensive bibliography is given. Dates shown on illustrations are not commissioning dates of the plant concerned, but the year when photographed.

Jan 1, 1960

On the 18th November, 19'58, the first coal was delivered to the Morwell Power Station from the adjacent Open Cut using conveyors for the transport of the coal from the working face to the boiler bunkers. As the cut develops the coal seam will be worked for its full depth of about 360 feet from four benches, each feeding a conveyor line along th.e face and up out of the cut to the power station and briquette factory. By 1970 the estimated maximum daily demand reaches 60,000 tons and the total annual output 18 million tons. The complete conveyor installation will then total some 9 miles with a capital cost of over £3~ million.The choice of conveyors in place of the more usual rail system was made possible by the development of movable belt conveyors which use mechanical conveyor shifting, high belt speeds and flexible high strength belts and the paper deals with these and some other aspects of the scheme.INTRODUCTIONThe development of brown coal deposits is usually based on open cut workings equipped with a few large dredgers giving an almost continuous output of coal or overburden which has to be hauled a comparatively short distance. These are ideal conditions for conveyor operation, and it is surprising that, until recently, rail transport has been used almost exclusively in brown coal open cuts. In some cases inclined conveyors have been introduced to take the coal from the coal levels up out of the cut to bunkers at groundlevel, but trains have been left to operate between the ditch bunker feeding the conveyor system and the dredger.

Jan 1, 1960

The original and most basic relationship between mining company and explosive supplier was a simple one of consumer and product supplier. The divide between the two was quite clear-cut with neither taking much interest in the activities of the other. The explosive supplier had little understanding or share in the outcome, efficient rock breakage and therefore impact on mining and milling. Likewise, the mining company did not encourage the improvement or development of products. The transactions were limited to product and funds. This environment does not encourage any form of knowledge sharing, trust or optimisation of the mining process.Conversely, there are now a variety of relationships to the point that the mining company may simply be an asset manager whereby all æoperationalÆ aspects are contracted out. For the drill and blast aspect this takes the form of a æRock-On-GroundÆ contract whereby the explosives company takes on design, drill, load and fire responsibilities and is paid a rate per volume of broken rock. This removes the majority of risk to the mining company derived from having to produce broken rock and guarantees the cost of a portion of the overall unit cost of mining. The onus is now on the explosives supplier to break rock to a specification as efficiently as possible.There exist a number of variations between the æbasic supplyÆ and æRock-On-GroundÆ. These contracts may also include value sharing to encourage the explosive supplier to optimise the mining operation to maximise profit.This paper looks at some of the drivers for the change in explosive supplierûconsumer relationships and examines the æprosÆ and æconsÆ of a few of the options.

Jan 1, 2004

By S. S. Sephton

Sintering as applied to agglomeration of ferrous fines has shown little growth in the United States in recent years. The general concensus was that most of the existing facilities would remain in production at a reduced tonnage to dispose of and recover solid waste from steel plants. Further growth for ferrous sintering technology was not in sight in the United States and in the early sixties expansion came to a virtual standstill, however, we witnessed a rapid emergence of a tremendous pelletizing industry. On other continents, due to different raw materials supply and capital structure, sintering technology continued to grow, with a more cautious development of pelletizing installations. In the U.S. the diminishing supply of good quality, high grade coarse ore resulted in eventual disappearance of high grade ore fines for sintering. The finely divided concentrates produced from lower grade ores were not amenable to this type of agglomeration, but were more suitable for pelletizing. Furthermore, pellets seemed to possess all the features of an ideal blast furnace feed; namely pellets are free flowing, uniform in size, strong, with extremely uniform chemical composition and good reducibility. Importance and demand for such well stabilized furnace feed further increased as size of newly installed blast furnaces continued to grow. The in- creasing demand for a uniform, stabilized burden coincided with the effort to produce a fully beneficiated burden for smelting, thus reverting the blast furnace to its primary function of smelting.

Jan 1, 1973

By R. O. Burt, D. J. Ottley

"SYNOPSISRecent developments in the use of the Bartles-Mozley table and the Bartles CTS screen are described for the gravity preconcentration of fine heavy mineral and metal particles present in low grade pulps. The B-M table is a relatively new device used for the recovery of particles of up to 100 micron size down to 5 microns or in the case of gold and platinum, down to 1 micron. The CTS screen is a wet screening device used for feed preparation ahead of the Bartles-Mozley table and will size effectively down to about 300 mesh. Results and operating data for a number of different materials are given including outline flowsheets; the effects of the major variables on the performance of the table are briefly discussed. The potential of the B-M table to treat a variety of different ores, coal, tailings, and waste products are considered. The utilization of the B-M table in association with other unit processes to improve overall results as well as to improve the economics of design and performance of plants are also mentioned.INTRODUCTIONA number of new gravity concentration devices have been developed in recent years for the recovery of fine heavy mineral and metal particles but for reasons which include low capacity, high capital or operating costs, competition from other and better processes, the absence of simplicity or reliability in operation etc., only a few which include the Bartles-Mozley table, have been proved to be of commercial application.The name of the machine is derived from the inventors name, Richard Mozley, who developed the B-M table at the University of Bristol in England. The table was subsequently taken up and patented, world-wide, by the National Research Development Corporation a British government agency. An exclusive license to manufacture the table was granted by NRDC to Bartles (Carn Brea) Ltd. in Cornwall, England."

Jan 1, 1973

By B. J. Elliot

The Outokumpu Oy flash smelting furnace was designed for a capacity of 69,5 mtph of concentrate. The history of developments on the flash furnace, from the original operating capacity of 55 mtph to a proven capacity of 115 mtph of concentrate, is summarised. The new feature of operation at BCL Limited is ?the use of screened lump coal reduction in the settler region of the furnace. This paper considers the effects of settler bath reduction on the furnace smelting capacity, the condition of the furnace ?lining and bath, and ,the slag losses generated from the flash furnace and ultimately to discard. By using the settler bath reduction technique the capacity of the furnace for smelting new concentrate has been increased by 15% and hearth accretion has been eliminated by direct reduction with coal, which has also allowed the generation of a substantial protective lining on the furnace walls and roofs. As a result of improved slag losses from lump coal charging the metal recoveries on the flash furnace have increased from 70% to 87% for nickel, 68% to 82% for copper, and 28% to 45% for cobalt.

Jan 1, 1983

By John A. Herbst

Flotation control systems in use around the world today owe their effectiveness to the coordinated use of appropriate sensors, control hardware, and decision-making strategies. This paper traces the development of these three main elements of the "control triangle" over time. Based on an analysis of recent developments, it is concluded that improvements occurring in instrumentation have basically been evolutionary, while advances in hardware and strategies have, in contrast, been revolutionary. An attempt is made to extrapolate developments in each of the "control triangle" elements into the future in order to make a projection concerning flotation control systems for the next millenium.

Jan 1, 1999

By T. Gerritsen, A. Matyas, F. Stober, I. Candy

This paper describes developments in ferro-nickel furnace technology, specifically improvements to cooling methods, furnace controls, and high voltage furnace operating regime. The evolution of these technologies is briefly presented, as context for describing the current state of the art that has enabled ferro-nickel furnace operation at over 75 MW and specific energy consumption of less than 400 kWh/t dry ore. Examples from existing operations are used to illustrate present best practices, and potential future trends are discussed. The paper begins with an overview of the fundamental aspects of pyrometallurgical treatment of lateritic ores that drive ferro-nickel furnace design. Furnace wall cooling methods are related to the requirements resulting from specific furnace process conditions, including slag and metal compositions, as well as arc and bath power. The benefits of high productivity and low specific energy consumption resulting from high voltage (shielded-arc) operating practice are discussed, along with the furnace controls and electrical power train that enable such operation even with captive power generation.

Jan 1, 2004