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By J. M. Lovejoy

Tests are described that show that back pressure on flowing wells is a waste rather than a conservation of natural forces. Stop-cocking, however, gives encouraging results. VARIOUS estimates have been made as to the percentage of oil left in a field after the wells have become so small that it is no longer practical to produce them. Engineers have given the matter much study and can substantiate their figures by data taken from fields from the Appalachians to California. The average oil sand has a porosity of about 20 per cent., which gives a capacity per acre-foot of approximately 1500 bbl. The sand thickness in Oklahoma pools averages 20 ft. With 20 per cent. porosity and a 20-ft. sand thickness, the capacity per acre is 30,000 bbl., yet these pools will seldom yield more than 5000 bbl. to the acre. These figures support the theory that at least 50 per cent. of the oil remains in a sand after all known methods to recover it have been used. Certainly we can never recover all the oil, unless in years to come oil becomes so rare and yet so necessary that the price will justify sinking shafts into the abandoned fields and regular mining methods of drifting and stoping. However, with improved methods of production and conservation of the natural agencies of expulsion, we should be able to increase recovery. It is with this in mind that this paper, relating to the effect of back pressure on wells, is presented. Except in the fields where production is caused by hydrostatic pressure, the chief agency for getting, oil out of the sand into the hole is the gas that occurs with the oil. After the pressure has declined, probably gravity also is a factor, but not an important one. With a given amount of oil in a sand and a given amount of gas occurring with the oil, the ratio of gas volume per barrel of oil is the key to the ultimate recovery from that sand. Our efforts should be along lines that will, lower this ratio and make the gas, the agency given us by nature, do its work better and yield more of the oil, of which it is a part.

Jan 1, 1924

By Muhammad Zaka Emad

Cemented rockfill (CRF) is a mixture of rock aggregate and binder slurry. It is a stiff backfill, it is fast curing, its operation is simple, placement rate is reasonably high and no drainage is required. The main demerit of CRF is failure of exposed faces causing ore dilution, which can be associated with the fill placement method. This paper discusses the effects of two placement methods being practiced by mines and numerical modelling is used as a tool to evaluate stability of the backfill column. In the first method, practiced in longitudinal retreat mining of a narrow vein deposit, the rockfill is hauled and dumped into the stope with a LHD scooptram. Once dumped, cement slurry is sprayed into the stope. In the second method, a raise situated centrally above the mined stope is used to convey already mixed CRF into the stope. Stopes are mined out transversely in primary and secondary blocks in a sublevel stoping system. Problems of poor mixing in combination with both placement methods are discussed. The two backfill placement methods are analyzed for blast induced vibration damage using the dynamic Flac3D modelling technique accounting for rock mass and fill damping characteristics, and a pressure wave is used to simulate the blast vibrations. Fill heterogeneity has also been considered for the two cases and results are compared.

Jun 1, 2012

By G Huggins

Excavation in underground jointed rock masses creates cavities into which the surrounding rock mass deforms. Deformations, besides intact rock deformation, include mechanistic deformations such as slip and rotation. In this paper deformational moduli were measured for prototype and blocky (jointed) models using elastic analogue methods for stopes from MIM LimitedÆs Lead Mine. The blocks for the models were defined in terms of the prototypeÆs joint sets, their spatial separations, orientations and average friction characteristics. From dimensional analyses, a relationship between prototype and model deformations was used to predict stope mid-span deformations. The results of this physical modelling work, conducted in the 1970s, motivated an investigation into the electro-treatment of tailings backfill to achieve improved strength and stiffness characteristics. Tailings backfill containing fines and having a high clay content can be electrically dewatered, and at times grouted, cemented, ion exchanged or agglutinated, to achieve relatively high magnitudes of strength and stiffness. These treated tailings stiffnesses can reduce the deformation magnitudes within a rock mass and, in doing so, reduce problems encountered in mine pillar extraction. The application of these tailings modification techniques is examined in relation to the elastic analogue methods.

Jan 1, 1998

By Y. A. Attia, M. Elzeky

The effects of bacterial adaptation and partial replacement of leaching solution on the rate and extent of bioleaching reactions of a complex sulfidic gold ore were investigated. The ore was first concentrated by bulk sulfide, flotation, and the sulfide concentrate was treated by bioleaching using Thiobacillus ferrooxidans. The residues from bioleaching were treated by cyanidation to extract the gold and silver. Bacterial adaptation before bioleaching significantly increased the rate and extent of bioleaching reactions. Similarly, the daily partial replacement of leaching liquor enhanced to a great extent the leaching rate, and in some cases, increases of up to ten fold were observed. Both bacterial adaptation and solution replacement increased the gold recovery by about 2-fold and that of silver by about 1.3-fold. In this work, more than 95% of the gold and more than 98% of the silver could be recovered from the sulfidic gold ore when bioleaching was used ahead of cyanidation, compared with 18.3% and 52.3% by direct cyanidation.

Jan 1, 1992

By M. Elzeky, A. Attia

The effects of bacterial adaptation and partial replacement of leaching solution on the rate and extent of bioleaching reactions of a complex sulfidic gold ore were investigated. The ore was first concentrated by bulk sulfide flotation and the sulfide concentrate was treated by bioleaching using T. Ferrooxidans bacteria. The residues from bioleaching were treated by cyanidation to extract the gold and silver. Bacterial adaptation before bioleaching significantly increased the rate and extent of bioleaching reactions. Similarly, the daily partial replacement of leaching liquor enhanced to a great extent the leaching rate and in some cases up to ten fold increase was observed. Both bacterial adaptation and solution replacement increased the gold recovery by about 2-fold and that of silver by about 1.3-fold. In this work more than 95% of the gold and more than 98% of the silver could be recovered from the sulfidic gold ore, when bioleaching was used ahead of cyanidation compared with 18.3% and 52.3% by direct cyanidation.

Jan 1, 1989

By M. K. Yelloji Roa

Effect of conditioning with Thiobacillus ferrooxidans on the floatability of sphaierite and galena has been determined in this work. The flotation behavior of the conditioned minerals clearly shows that such bacterial conditioning does produce marked modification of their surfaces. The variables affecting the surface modification and thereby the flotation response of the minerals were found to be cell concentration used for bacterial conditioning, the period of biotreatment and the pulp density. Importantly, while the enhancement in flotation obtained due to sulphuric acid treatment was retarded by biotreatment in the case of galena at all cell concentrations due to electrochemical effects, such decrease occurred in the case of sphalerite only at cell concentration sufficiently high for their attachment to the mineral surface. The effect of bacterial conditioning has significant implications to the differential flotation of sphalerite and galena. Mechanisms responsible for the modification of the surface properties of these sulphides due, to bacterial conditioning are discussed.

Jan 1, 1991

By Julia R. Budden, Peter A. Spencer

Bacterial oxidation processes have often been repo1ted as releasing large amounts of energy so that a large scale operation would require cooling to maintain the required operating temperature for the bacterial culture. These reports are based on the chemical heat release which in some eases has been adjusted for the energy required to fonn the mass of bacterial cell matter per unit volume of solution. There are two flaws in this approach for calculating energy release in the fonn of heat. The first flaw is that it only considers the bacteria in solution. The second assumption is that the only bacterial reaction is the fonnation of cell material and others such as energy for respiration and locomotion are not considered.

Jan 1, 1992

By J. J. Moore, I. Iwasaki, L. A. Lindeke

Correlation of scale-up from small-scale batch laboratory mills to large-diameter industrial mills was established by performing two series of laboratory and pilot plant grinding tests using a magnetic taconite ore and a siliceous sulfide ore. In one series, controlled batch grinding tests in 203-, 508-, and 914-mm (8-, 20-, and 36-in.) diameter mills were carried out followed by a second series involving continuous grinding tests using 305-mm (12-in.) and then 1067-mm (42-in.) diameter pilot plant ball mills in open circuits. The effects of ball diameter on wear and of mill diameter on grinding power and ball wear are illustrated.

Jan 1, 1988

By S. Banisi, M. Poorkani, M. Farzaneh, M. Askari

"At the Sarcheshmeh copper mine 40,000 t of ore per day with an average grade of 0.9 % Cu is ground to 70% passing 75 microns. Grinding is effected in 8 parallel lines of 8 x 5 m ball mills in a closed circuit with cyclones. The make-up balls are 80-mm forged alloy steel balls and the average ball consumption is 750 gh of ore ground. In order to optimize ball size distribution inside the mill, based on the previous investigation instead of using only 80 mm make-up balls a combination of 80 and 60 mm (75% to 25% by weight) ball charge was used in one of the mills. To evaluate the performance of three ball types namely forged alloy steel balls (A), ductile cast iron (C), high chromium cast iron (D) and also a combined (80 and 60 mm) charge of forged alloy steel balls (B), four identical parallel mills were charged accordingly. These four mills were sampled during a period of six months. The amount of material finer than 75 microns of cyclone overflows was selected as a criterion for the performance evaluation. It was observed that in a mill with the combined make-up balls the amount of fine produced was 4% higher than the other mills. The consumption of ball types A, C and D were 730, 710 and 534 g/t, respectively. The results of laboratory flotation tests showed that due to an improvement in the production of fines an increase of 1.4% in the overall copper recovery is obtainable. Due to the promising results, the new make-up ball regime was implemented in all mills in the plant.INTRODUCTIONThe Sarcheshmeh copper ore body which may rank as third or fourth largest in the world contains 1 billion tonnes averaging 0.90 % copper and 0.03 % molybdenum. It is located southeast of Iran and has been processing 40,000 t/d of ore since 1982. The mine produces 100,000 tonnes of copper and 2,200 tonnes of molybednite concentrate per year. After three stages of crushing, the ore with a F80 of 12.7 mm is fed to 8 parallel ball mills in closed circuit with cyclones to produce a product 70% finer than 75 microns. The concentrate of the first stage of flotation is reground and the tailing constitutes the main component of the plant final tailings. A concentrate with an average grade of 31% Cu is obtained after cleaning and re-cleaning stages. Total recovery of the plant varies between 83 and 87 % depending on the operating conditions and ore type."

Jan 1, 2002

By Ö. Genç

In this paper, full-scale mill data collected from three different circuit configurations in cement plants demonstrated the size reduction performance of dry ball mills in relation with the ball size classification achieved by the classifying liners used in the grinding compartments. Findings indicated that, breakage rates at the last 2 ~ 4 meters of the mill are not sufficient to give reasonable size reduction ratios for the production of fines. Application of only damming rings without classifying liners resulted in inverse ball size classification which lead to reduction in size reduction performance thus specific breakage rates.

Jan 1, 2014

By Saurabh Rastogi, Vikram Shishodia, B. Pitchumani

Comminution is a unit operation which consumes major part of energy in mineral processing industries such as fertilizer production. Ball mills are widely used for size reduction of a given ore to the liberation size that is required in further beneficiation processes. In grinding of materials much effort is concentrated on control of top size of the product and this results in production of fines, also creates secondary problems of pollution due to the difficulty in the collection of fine particles. The present work has been carried out to control product size distribution for rock phosphate grinding in an Industrial Ball Mill of 600 TPD. The plant data are taken for a given feed distribution and mill operating conditions. The information at various Ball Size distributions are collected. The comminution functions such as specific rate of breakage and breakage distribution functions are estimated by back calculation technique to solve the mass balance equation. A simulation program is written to study the product size distribution obtained for various ball size distribution.

Jan 1, 1993

By F. B. Eiseman

IT is desired -to determine the effect of the extent of bank repairs on the final slag volume in acid electric steel-melting practice. It is understood that the repairs stud- TABLE I-Summary of Effect of Bank Repairs on Slag Volume [ ] ied here are necessary and the amount of sand added is that needed to maintain hearth and banks in a satisfactory condition. In this way the effect of repair materials on the amount of slag tapped would be found with a reasonable degree of accuracy. Ten heats were made for this study with careful attention to a uniform charge. The steel was the usual grade B and melting was carried out in a 3 1/2-ton top-charge Lectromelt furnace. Melting practice in all cases was the same-complete oxidation, with recarbonization by means of low-silicon pig iron.

Jan 1, 1947

By Mahmut Altiner

This study aimed to produce magnesium oxide (MgO) particles with different properties from dolomite ore using an experimental procedure comprising four stages: sample preparation (S1), HCl leaching (S2), precipitation (S3), and calcination (S4). Three different base sources (NaOH, KOH, and NH4OH) were used as precipitant in the third stage to obtain magnesium hydroxide [Mg(OH)2] from a leachate solution, which was obtained in the second stage. Next, Mg(OH)2 particles generated by different alkali sources were calcined at various temperatures from 600–1000 °C for different durations (1–5 h). The effect of these base types on the properties of each product was investigated by X-ray diffraction (XRD), scanning electron microscopy (SEM), Brunauer–Emmett–Teller (BET), atomic force microscopy (AFM), and wet chemical analyses. The experimental results indicated that each product was identified as periclase (MgO) mineral, which was produced with a specific surface area (SSA) of 4.49–44.54 m2 /g depending on the production conditions. The surface roughness of the MgO particles increased with increasing calcination temperature. SEM analyses showed that MgO particles produced at a temperature of 600 or 800 °C were amorphous, indicating that the process was not influenced by the base type, but MgO crystals were smooth when the calcination temperature was 1000 °C. Finally, it was determined from all experimental findings that MgO particles produced via the addition of NaOH have superior properties (such as higher SSA and lower surface roughness) compared with MgO particles produced with KOH or NH4OH as the alkali source. These properties led to great improvement of its usability in industry.

By Mahmut Altiner

This study aimed to produce magnesium oxide (MgO) particles with different properties from dolomite ore using an experimental procedure comprising four stages: sample preparation (S1), HCl leaching (S2), precipitation (S3), and calcination (S4). Three different base sources (NaOH, KOH, and NH4OH) were used as precipitant in the third stage to obtain magnesium hydroxide [Mg(OH)2] from a leachate solution, which was obtained in the second stage. Next, Mg(OH)2 particles generated by different alkali sources were calcined at various temperatures from 600–1000 °C for different durations (1–5 h). The effect of these base types on the properties of each product was investigated by X-ray diffraction (XRD), scanning electron microscopy (SEM), Brunauer–Emmett–Teller (BET), atomic force microscopy (AFM), and wet chemical analyses. The experimental results indicated that each product was identified as periclase (MgO) mineral, which was produced with a specific surface area (SSA) of 4.49–44.54 m2 /g depending on the production conditions. The surface roughness of the MgO particles increased with increasing calcination temperature. SEM analyses showed that MgO particles produced at a temperature of 600 or 800 °C were amorphous, indicating that the process was not influenced by the base type, but MgO crystals were smooth when the calcination temperature was 1000 °C. Finally, it was determined from all experimental findings that MgO particles produced via the addition of NaOH have superior properties (such as higher SSA and lower surface roughness) compared with MgO particles produced with KOH or NH4OH as the alkali source. These properties led to great improvement of its usability in industry.

By Mahmut Altiner

Magnesium is listed as a key critical raw material in a report by the European Commission that evaluated raw materials based on supply risk versus economic importance [1]. It has extraordinary properties, such as nontoxicity, inertness, high melting point, stability, low weight, chemical resistance, electrical insulation, optical transparency, corrosion-resistant behavior and refractory nature. It is widely used in the areas of agriculture; the environment, for antibacterial and water-purification purposes; electronics; automotive; drug delivery; ceramics; construction, as filler in brick; and concrete production, in the forms of magnesium oxychloride and magnesium oxysulfate. Magnesium oxide (MgO) particles can be produced through the calcination of magnesite ore at different calcination conditions depending on the desired quality of the product, classified as fused (2,800 °C), dead-burned (>1,400 °C), hard-burned (1,000–1,400 °C), or light-burned MgO (700–1,000 °C) [2]. However, the global availability of magnesite ore is limited.

By Jinliang Zhang, Jian Pan, Deqing Zhu

"Limestone and burnt magnesite were added to vary MgO content and basicity (CaO/SiO2 ratio) of pellets for investigating their influences on the properties of specularite pellets. At fixed MgO content, the addition of limestone does not affect on the properties of green balls significantly. The addition of burnt magnesite has obvious influence on the quality of green balls, especially on the thermal shock temperature. Without burnt magnesite, the thermal shock temperatures are about 400°C, and, the thermal shock temperature increases to 600~630°C by adding burnt magnesite. For preheated pellets, when the burnt magnesite is added, the compressive strength will be decreased. For roasted pellets without burnt magnesite, the calcium additives can form binding phase of calcium-ferrite, and suitable liquid phase will improve recrystallization of hematite, but excessive liquid will destroy the structure of pellets, so the compressive strength of pellet increases firstly and then decreases. When adding burnt magnesite, the compressive strength will increase as the basicity increases. When the basicity is more than 0.2, the compressive strength of the pellets various MgO content and basicity is above 2500N/pellet and then MgO-bearing fluxes can be added to prepare pellets with good high temperature properties.IntroductionWith the rapid development of the steel industry in China, oxidized pellets, possessing good mechanical and metallurgical properties, are becoming indispensable burdens for blast furnace ironmaking [1-3]. However, this has resulted in the shortage of domestic iron concentrates, so many Chinese steel plants begin to use imported hematite concentrate to prepare pellets. Compared with magnetite pellets, the hematite pellets require high roasting temperature and narrow roasting temperature range (1300–1350°C) and possess low compressive strength [4,5].1"

Jan 1, 2012

By S. Esfahani, M. Barati, K. Danaei

"Substituting Portland cement with slag cement is one of the most economically attractive uses of slags. For this application, high cooling rates are required to form an amorphous structure. However, this is counteracted by the need to use small coolant flowrate to allow recovery of slag thermal energy as high quality heat to the coolant fluid. Therefore, a relationship between cooling rate of slag and its structure is essential to recover the heat effectively while making an amorphous slag.A modified Single Hot Thermocouple Technique (SHTT) was employed to investigate the crystallization behavior of slags by plotting their TTT (Time-Temperature, Transformation) diagrams. Seven different slag compositions containing CaO, SiO2, Al2O3, MgO were prepared at varying basicity (CaO/SiO2 =0.5-1.4).The results indicate that with increasing basicity, the TTT curves of glassy to crystalline transformation shift to the left which means higher crystallization tendency. This agrees with the fact that with the increase of basicity, the Si-O bonds are weakened, which in turn facilitates the re-ordering and crystallization of the silicate structure."

Jan 1, 2014

By Mark Jolly, Nasim Soleimanian

"During the last 20 years CFD (Computational Fluid Dynamics) has been used as a tool to aid furnace designers and manufacturers to improve energy efficiency and effectiveness of glass furnaces. However as the models are maturing the effect of feeding equipment used to push the raw material into the furnace has not been included in the process models. This paper investigates the effects of batch pattern in the melt space caused by charging equipment on the energy efficiency of the furnace focusing on the melting zone. A simple batch patterns sensitivity study has been performed using purpose built software (Glass Furnace Model-GFM). It is concluded that in order to further reduce the energy consumption of the furnace it is necessary to model the batch charging process in more detail to find more opportunities for improvement.Introduction Glass manufacturing is a conservative industry which applies to all the four major segments (float glass, container glass, fiberglass, and specialty glasses). Risks due to the high capital investment, very long service life of the furnaces, and the demand for high performance and quality from the outset translates into evolutionary progress rather than revolutionary. The main problem facing glass manufacturers are the financial cost of manufacture, its impact on the environment, and mounting pressure imposed by the authorities for greener manufacturing and reduction in emissions.The main energy intensive activities involved in continuous glass manufacturing are: the need for high temperature to create and maintain the viscous flow, homogenisation of glass melt (melt residence time), and maintaining the two to achieve continuous output of glass at the right quality. The high temperature and long duration of homogenisation has resulted in the design oflarge furnaces, which have high energy consumption, low specific performance, and high C02 emissions. As an example in the container glass sector the most efficient furnace has a specific primary energy consumption of 3.8 GJ /tonne of glass at a level of 50% cullet in the batch. Even very small improvements in efficiency by optimising operation would have a high impact [1-14]. Given the conservative nature of the industry and the costs involved in experimental data gathering, CFD modeling of the process has been used extensively during last two decades to not only improve our understanding of the process but also as a tool in predicting possible optimisation windows, e.g. Glass Furnace Model ( GFM), a commercially available piece of software that has been developed to optimise furnace operation."

Jan 1, 2013

By William Brinkman, Mark Jolly, Nasim Soleimanian, Karl Dearn, Oliver Brinkman

"Glass manufacturing is a heat intensive process. There is a direct correlation between the batch distribution techniques and the furnace energy consumption, productivity, and quality of the glass manufactured. All four major segments (float, container, fibre, and specialty glasses) would benefit from using an optimised batch distribution technique where possible. Oscillating batch chargers (OBC) have been in use since the early 70s, despite their superior batch shape, coverage, and in turn positive effects on the energy consumption and productivity of the furnace they are almost exclusively used in container glass manufacturing. The OBC’s main difference compared with other charging methods is its ability to directly influence the batch initial velocity. This paper reports on results achieved in CFD models (GFM) used to study effect of the machine on the overall energy consumption in the doghouse and the melt space.IntroductionGlass manufacturing can be divided to four major segments float glass, container glass, fiberglass, and specialty glasses. The financial cost of manufacture, its impact on the environment, lack of standardisation and mounting pressure imposed by the authorities for reduction in emissions means that the industry and its suppliers are utilising CFD modelling in order to tackle these challenges. The need for high temperature to create and maintain the viscous flow, homogenisation of the glass melt, and maintenance of the process to allow continuous output of glass of the right quality are the contributors to the energy intensive activities that are involved in continuous glass manufacturing. This in turn has resulted in design of large container glass furnaces which have high energy consumption, low specific performance, and high CO2 emissions where the most efficient furnaces in the container glass sector have a specific primary energy consumption of 3.8 GJ /tonne of glass at a level of 50% cullet in the batch making even very small improvements in efficiency by operation optimisation a value adding activity [1-14].The theoretical calculated energy required to melt glass is 2 to 3 times less than the energy actually used to melt glass as a result of glass melt passing a zone 5 to 8 times before leaving the tank.[8]. This causes contamination as the result of mixing between the completely molten glass free from bubbles returning to the batch area where there is freshly molten non-homogeneous glass, still containing very large numbers of bubbles and un-molten batch. At high temperature some components are dissolved rather than melted. Given that an un-molten batch is a good thermal insulator, it can be transported a long way into the furnace, increasing the need for homogenization which also increases the glass residence time of glass melt. This is why large unbroken strings of batch should be avoided, as should an overall blanket without gaps."

Jan 1, 2014

By S. Ostap

INTRODUCTION Paradoxically, it has been found that the people who are the most aware of the origin, mineralogy and composition of bauxite are also the people who are the least aware of how bauxite composition affects its treatment by the Bayer process. These people are the exploration and mining geologists normally associated with aluminum producing companies. The purpose of this paper is to give some idea of how the concentration and physical nature of the different minerals found in bauxites affect the operation of the Bayer process used to extract their alumina content. The bauxites we will consider here will be only the tropical bauxites such as occurring in Jamaica, various countries in South America i.e. Guyana, Surinam, Brazil, African bauxites, Malaysia and in Australia. When we speak of the Bayer process, it will be the North American version of the Bayer process using low caustic concentrations and bauxite digestion temperatures varying between 130° to 250°C. TABLE 1 shows the minerals and elements of interest occurring in tropical bauxites. The minerals and elements listed in the table do not by any means represent all of those identified in bauxites. Using mass spectrographic analysis on six bauxites from different geographic locations, we managed to identify between 50-60 different elements. Fortunately, only about 13-14 of these elements possess the necessary chemical properties to be able to accumulate in caustic Bayer solutions. The remainder are either not attacked, or form insoluble reaction products with some main liquor component, i.e., hydroxide, aluminate or carbonate, or reprecipitate with alumina trihydrate during the precipitation stage.

Jan 1, 1984