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By T. S. Govindan

The first step in energy conservation in any industrial plant involves implementing many of the day-to-day "housekeeping" items, such as fixing leaks, turning out lights, etc. When this step has been accomplished, additional opportunities require a detailed analysis of the energy systems, evaluation of risks and costs, and assignment of priorities. Examples of conservation schemes drawn from the experience of Du Pont's Energy Management Consulting Services will be discussed. The utility of heat balances for kilns and dryers in minerals processing will be outlined. The input needed from management for the success of conservation efforts will be discussed.

Jan 1, 1981

By Jonathan S. Jackson, Bruce P. Ream

Leach water management is one of the few areas in dump leaching subject to operator control. As such, it is of considerable importance. Theoretical considerations indicate that high leach solution application rates are inefficient in washing solubilized copper from dumps. The high rates cause unnecessary dilution of copper values, raising unit recovery costs. Use of excessive amounts of leach solution also cools dumps, resulting in reduced leaching rates. This paper reviews leach solution application methods and details the results of field tests run to determine the benefits and feasibility of low versus high application rate techniques of applying water to dump surfaces.

Jan 1, 1980

By M. Cross

INTRODUCTION The development of refining processes involving gas injection into liquid metals has seen the evolution of a variety of designs [I]. During the last few years or so the top, bottom and side blown processes have, essentially, been combined to produce a series of mixed gas blowing schemes (eg. the LBE [2,3] and LD-OB processes [4,5]). Although, a variety of mixed gas blowing processes have been carefully engineered and recorded operational experience now attests to their effectiveness, optimising their design and operational performance is another matter. Detailed process analysis of such operations is impeded by the complex nature of the physical and chemical processes involved: . fluid flow behaviour of the liquid metal and injected gases, . chemical reactions in the vessel, . mass and heat transfer within the fluid phases in the vessel, . influence of the geometry (eg. location of the tuyeres, etc.), . monitoring the operational performance. By and large, design and operating parameters evolve from a combination of laboratory scale experiments, pilot plant work and, of course, practical engineering experience. Conventionally, the gas-liquid system used to model the industrial process is air-water, for a number of valid reasons including – . visual demonstration plus geometric and (to some extent) dynamic similarity, . the fact that the system demonstrates, at least, qualitatively many of the complex features of gas injection - interaction between the gas and the liquid - the nature of the gas flow behaviour - qualitative indications of mass transfer rates Important experimental contributions to the understanding of gas liquid systems include the work of Brimacombe [6], Wraith [7], T.Robertson [8], D.Robertson [9], Guthrie [10] and Szekely [11] (these references provide starting points to identify the major published work in this area). Although air-water systems have been instrumental in providing a great deal of qualitative insight into the fluid flow behaviour of the processes, reliable quantitative predictions are more problematic. A number of workers (notably Brimacombe and colleagues [6, 12])have demonstrated that different gas-liquid systems can lead to wide variations in behaviour. Other limitations of physical modelling include the assumptions of isothermal flow, scale- up of turbulent flow behaviour and the inability to directly include the effects of chemical reactions. The above limitations in physical modelling, therefore, yield a natural role for mathematical modelling provided that it can be made comprehensive enough whilst remaining cost-effective. The major physical processes involved in gas injection systems may be summarised as . behaviour of the gas envelope structure in moving through the liquid metal . the global movement of the liquid metal . momentum interaction between the liquid metal and the injected gas . heat transfer and mass exchange via the chemical react ions. The behaviour of gas envelopes forming at a tuyere and then moving through the liquid has been investigated thoroughly by a large number of workers. Such models are generally based upon simple physic- al concepts derived from visual observation. An early model by Davidson and Schuler (DS), based upon a force balance between the liquid inertia and a combination of the bouyancy and momentum forces on the envelope, has proved to be a useful tool in predicting bubble volumes at detachment [13]. The DS model has been successfully modified in a number of ways [14-17] to cope with heat transfer and reactive transfer rates, etc. Furthermore, the basic ideas summarised above have also been confirmed on industrial converters by both Guthrie [I8] and Brimacombe [19]. Models have also been developed to predict the behaviour of the "chemical" component of some gas-liquid systems. However, one thing is clear; all gas-liquid reactive systems are governed by the degree to which effective mixing occurs. As such, the processes are dominated by the behaviour of the heat and mass exchange of the two phase fluid flow system. It is the pattern of movement of the turbulent liquid metal plus its interaction with the injected gas which must be predicted reliably, if sufficiently comprehensive comp-

Jan 1, 1984

By Edward Jeffrey

THE use of coke in metallurgy, to any important degree, dates from the middle of the 18th century. Its utilization came most opportunely for European civilization. The forests of Europe, except in the most remote and inaccessible regions, had been largely fed, in the form of charcoal, into the smelting furnaces. For a hundred years-the middle of the 17th to the middle of the 18th century-there was a stationary condition of population corresponding to the exhaustion of European forests. This situation, which was particularly evident in Great Britain, was due to the fact that the forests had been depleted and the practical utilization of coke had not begun. The coking industry is essential for our metallurgical industries, which in turn are basal to healthy economic progress. But coke is of great importance, not only on its own account, but for its byproducts, which enter fundamentally into all the arts of peace and war. The dyestuff industry and the manufacture of explosives are intimately connected with one another, as was shown by the recent war. The subject of coking coal, therefore, is well worthy the serious attention both of practical industry and the scientific investigator. The most valuable coking coals, from the metallurgical standpoint, are derived from the coals of highest ranks. Coals, for example, that have a carbon ratio of from 70 to 80 per cent. yield the most valuable coke for the blast furnace. The difficulty of investigating these coals, however, is great, for they are rather friable and delicate and possess a high carbon content, which makes them difficult to manipulate. They present, on account of their high carbon content, a considerable degree of opacity when examined, in thin sections, under the microscope. The tenderness of structure and blackness of such high-grade coking coals as those of Connellsville and the Pocahontas region make them extremely difficult to investigate.

Jan 1, 1925

By Charles H. Thurman

THE data given herein were first included in a paper read before San Francisco Section, A.I.M.E., in October 1940, and are applicable to conditions existing until the gold-dredging industry was temporarily suspended by Order L-208 of the War Production Board in the fall of 1942. There is no doubt that gold dredging will be resumed at some future time, and on a scale equivalent to that of the recent past, but the cost data given herein will be affected to some extent by conditions existing at that time, and by labor rates and prices for materials then prevailing. DRAGLINE VS. BUCKET-LINE Dragline dredges should not be considered for mining large areas of low-grade placer gravel. In such deposits a dragline operator with a 5-cu. yd. dragline would be doing well to maintain an operating cost of 6¢ per cu. yd., while a bucket-line dredge with buckets no smaller than 7 cu. ft. each could be operated for less than 4¢ per cu. yd. By operating costs, I mean only field charges such as direct operating and overhead, which includes pay roll, power or fuel, repairs and maintenance, insurance, land clearing and general expenses, but not including such items as prospecting, depletion, depreciation of equipment, State Franchise Tax, or Federal Income Tax. It is not to be inferred that a dragline dredge cannot make a profit in small low-grade deposits, where the extent of a given property is too small to justify the use of the more costly bucket-line dredge. Consider small deposits of 10¢ gravel. It is obvious that a deposit of 5,000,000 cu. yd. of such gravel could not be mined profitably with a new, 7-cu. ft. bucket-line dredge, costing upward of $250,000, and with operation costs at 4¢ per cu. yd., paying for land or royalties out of earnings; nor could a new combination 5-cu. yd. dragline and washing plant, worth upward of $125,000 and working at 6¢ per cu. yd., make a profit. These comparisons are made because the hourly capacity of both types of dredges is nearly the same. The bucket-line dredge averages 93 per cent operating time in 24 hr., as against about 80 per cent or less for the dragline dredge. These percentages of operating time are important factors in making a comparison of this kind. The bucket-line dredge has greater efficiency in cleaning soft bedrock, usually characteristic of dredging deposits, and a 7-cu. ft. bucket-line dredge can be efficient to a total digging depth of 80 ft. (65 ft. below water, 15 ft. above). A 5-cu. yd. dragline dredge is limited to about 30 ft. of efficient digging depth, 5 ft. of which could be above water. In small areas of gravel not over 30 ft. deep, a 5-cu. yd. dragline dredge could make a profit where a bucket-line dredge could not do so. As an example: compare the dredging of 3,000,000 cu. yd. of 10¢ gravel 28 ft. deep with bucket line, costing 4¢ per cu. yd., and with a 5-cu. yd. dragline dredge operating at 6¢ per cu. yd. Because of small yardage, new equipment is not warranted, therefore we can assume that the dredges of both types are used equipment, fully depreciated. Dismantling, mov-

Jan 1, 1945

By AIME

Rapid exhaustion of iron ore in Minnesota's Mesabi range has led the Jones & Laughlin Steel Corp. to develop the world's largest open quarry mine for magnetite iron ore, at Star Lake, N. Y. Already contributing more than one eighth of the total iron ore used by the Corporation, the expanding Benson mines are destined to become Jones & Laughlin's important source of ore within the next ten years. In 1947 over 650,000 long tons of high-grade ore was produced. Output this year is expected to reach 800,000 long tons and studies are under way to increase production further. The future of the Benson mines is assured as present indications show large reserves of ore. The property, briefly described in M & M for November 1943, then under

Jan 1, 1948

Australian research scientists at the University of Melbourne's Institute of Materials Research have discovered two methods of extracting metals from raw ore, using brown coal. The discoveries could lead to extensive new markets for the brown coal producers of Australia (boasting the world's largest brown coal deposits in the Latrobe Valley region of Victoria), the United States and West Germany. Research on the extraction processes began at the University's Department of Metallurgy in mid-1969 under the direction of Geoffrey Cullen, manager of the Materials Research Institute. In June of this year. Cullen announced that both metal extraction processes, using brown coal, had proven successful.

Jan 1, 1971

By D. F. Kelsall

During the past twenty years, and especially in the last decade, hydraulic cyclones have found increasing application in metallurgical processing as classifiers and, under special circumstances, as thickeners. To a more limited extent cyclones have been used to extend heavy, or dense, medium separation into the finer size ranges, and several attempts have been made to separate dispersions of immiscible liquids with a view to use in the field of liquid- liquid extraction. Before considering several aspects of conventional application, less conventional applications and some potential uses of modified cyclones, the mechanism of separation within a cyclone and the effect of the, major variables will he summarized.

Jan 10, 1963

By J. P. Dovel

HAVING been requested to prepare a paper referring especially to my patents as applied to blast furnaces, I shall confine my discussion to those improvements and inventions pertaining directly to the blast furnace itself, omitting a number of patents pertaining to blast furnace operations. I spent the early part of my life in the construction of blast furnaces, from rivet-heating to drafting and designing, much of the work relating to repairs and rebuilding. Later, as I became more interested in maintenance and operation of a group of blast furnaces, one fact especially made a lasting impression on me, namely that a very expensive piece of equipment was very short lived, and the expense of replacement, relining, etc., in many instances consumed most of the profits made while in actual operation. As far back as 1910, I began to lay plans to build with a view to permanency and not merely for a blast, the common expression at that time, which really meant only one or two years in southern practice. Since we did not then blow so hard most failures occurred in the bosh and hearth. The failure of either generally meant a complete new lining, as the inwall did not look good enough to last another blast. At that time we were using two types of hearth, one of heavy steel plate protected by well and sprays on the outside, and .one of heavy. cast iron, made in sections and bound together with wrought-iron bands. The former type proved dangerous, for if the iron should come through, as it frequently did, it would cut away the steel plate, quickly turning large quantities of molten iron into the water, causing a severe explosion and costly repairs. The cast-iron type gave trouble also by the iron finding its way through the joints between the sections, which was' not so serious; since the iron would not cut away the heavy cast-iron sections very quickly, and generally caused only small damage, and repairs-were easily made. Both types have been improved; the former by the introduction of cast-iron -water-cooled plates, placed on the, inside of the steel, jacket. This has proved to be very good construction, but has no real claim to permanency: As the cast-iron plates cannot be replaced from the outside, therefore the operator must assume that some time, at no late date, he must replace them from the inside, which will mean a blowing out of the furnace. The heavy cast-iron hearth has been improved by making the

Jan 1, 1928

By Plato Malozemoff

Our young, technically oriented people today are entranced by the space program, by physics that unlocks the secrets of nature, by electronics, and by other new technologies. The mining industry seems to be their last choice. Enrollment in mining schools is dropping and so is the interest of our great universities in mining curricula. The image of the mining industry appears to be one of being conservative, nonprogressive, resistant to change, and lacking in excitement and challenge. I submit that this public image is wrong. While the initial development of mines is usually slow and seemingly plodding, the problem of solving the imponderables of nature-the ore emplacement, its structure and physical characteristics, its response to recovery processes, and its probable ultimate profitability-is stimulating to the most acute and searching of minds and requires careful application of a combination of many technologies. The paths to obtaining the desired results must be within the bounds of reasonable expenditures in the early stage of development when risks are still high, and this financial discipline is a further stimulus to the imaginative search for the right answers.

Jan 6, 1968

By E. K. C. Williams, Nathaniel Arbiter

INTRODUCTION The surface processes involved in preparing ores for flotation and for operations depending on their flocculation/dispersion characteristics * vary widely in agitation dependence. Most of the reagents used for these purposes are added to grinding circuits, pump sumps, launders, or directly to flotation cells with the turbulent flow conditions usually adequate both for mixing reagents and for surface reactions without special conditioners. However, some reagent systems do require specific control of agitation intensities and reaction times, the more important of these being the following: 1. Activation of ZnS with CuSO4. With the usual conditions pH about 10, with collector added with the CuSO4, Cu 2+ is almost completely precipitated as basic compounds and as collector salt. As a result the levels of reagent in solution are extremely low which probably accounts for the need for separate conditioning. The agitation intensities are at about the 0.01 HP/ton level.** 2. Flocculation with natural or synthetic polymers. In this case the agitation problem is two-fold; first, to insure adequate initial mixing of the viscous stock solution of the

Jan 1, 1980

By Robert L. Akre

When Marco Polo visited China in the 13th century, no one knew what black powder was except the Chinese: they knew enough to make dazzling fireworks with it. But the realization that black powder could also do useful work came much later and, like all important discoveries, it altered the course of history. It was in the 14th century that black powder was first used to break rock in a very crude way: there were no drills and the powder was simply poured into cracks and exploded by setting it afire. Because its energy value was pretty low, the need for something more powerful was felt when the industrial revolution arrived.

Jan 6, 1976

By Augustus Locke

THERE are three matters related to ore-hunting which I wish especially to discuss here: first, the paucity of the special writings applying to it; second, the failure of scientists to concern them-selves importantly with it; and, third, resting on these conditions, certain possible activities for economic geologists. First, as to the writings. Geological papers. are being produced in the United States alone at the rate of 10 to 12 shelf-feet per year.1 But papers specifically for the ore-hunter would go in a slim, annual pamphlet; all that have ever been written would go in a briefcase. The art of technical ore-hunting-geology conceived as a guide to ore-has only a scant literature.

Jan 4, 1922

By Richard P. Gerwels

Minas de Matahambre, a copper mine located 100 miles southwest of Havana, Cuba, has produced 10 million tons of copper ore since it was first opened up in 1913. During the mid-1950's the mine was producing approximately 1000 tpd and had attained a depth of 3600 ft. As shown in Fig. 1, the property contains three shafts: the No. 1 shaft, 2100 ft deep and located 2000 ft south of the No. 2 shaft, provided service to the 2100 level; the vertical 3600-ft No. 2 shaft handled all production to the 3400 level; the No. 3 shaft on the northeasterly fringe of the mining area was in a semi-active status.

Jan 12, 1960

By Ralph C. Holmer

IN the field of mineral exploration, 1956 can be looked upon as the International Geochemical Year. This is not because of unusual developments in geochemical prospecting but rather because of the world-wide effort in geochemistry and the realization that geochemistry is now an established exploration method. Use of mining geophysics has continued to increase. Those extensively employing exploration techniques indicate that developments of the past few years have permitted better programming of methods, from reconnaissance to location of drill- holes. There is greater diversification of methods- reliance is not placed on results of one. However, it is realized that often it is more economical to drill an anomaly than to conduct additional expensive geophysical surveys

Jan 2, 1957

By V. M. Lovell

The recovery of apatite from the phoscorite ores occurring in the Transvaal, Republic of South Africa, involves a flotation process that is particularly difficult to characterize from a fundamental point of view. However, the reagents used, (tall oil fatty acid, nonylphenyltetraglycol ether, sodium silicate, and sodium hydroxide) can successfully bring about a separation of apatite from dolomitic calcite, which is the most troublesome gangue component. Recently, it has been demonstrated with some flotation feeds that the addition of certain polysaccharides can improve the flotation significantly. It has been shown that the metallurgy obtained is closely linked to the nature of the froth, and this, in turn, is influenced, often dramatically, by the presence or absence of certain of the reagents. The character of the froth depends less on the inherent frothing ability of these reagents than on the presence or absence of fine mineral particles in the froth, and on their surface characteristics and state of aggregation. The polyglycol ether and the polysaccharides have been shown to affect these properties, and it is suggested that a major function of these reagents is to modulate the properties of the fine particles in the pulp, thereby changing the character of the froth and giving rise to improved results.

Jan 1, 1976

By A. T. Shurick

WHATEVER the outcome of the Industrial Recovery Act, it has currently injected the first hope and optimism into the coal industry for more than a decade. Compared with the recent drab years the results are impressive: Bituminous production for the first ten weeks, 78,000,000 tons, may be compared with 63,000,000 last year; anthracite, 14,600,000 tons and 9,600,000 tons for the same periods, respectively, bringing the heaviest payrolls in ten years with individual checks reminiscent of former boom times. Hurried calls for long deferred new equipment and replacements have stimulated foundry and machine works and the -invigorating effect on the railroads is indicated by the first actual car shortage in a decade. And even in the welter of confusion over code prices, this heavy tonnage has moved at the most profitable figure the coal man has realized for many years, though with the large volume on old contracts, profits were not as large as many think.\

Jan 1, 1934

By HERRBERT HOOVER

I AM glad to join with my fellow-members in this celebration of the fiftieth anniversary of the founding of the American Society of Mechanical Engineers. It would be a difficult task to measure the blessings brought by this association through the stimulation to invention, the improvement of methods, the adequate training of engineers and the advancement of knowledge in a large sense. During its span of life it has contributed a great part in the development of an art into a mighty profession upon whose capacity and fidelity rest so much of human progress. "I feel especially honored that the association should, through the beneficence of Mr. Lauer, have established a new distinction among engineers, and should have designated me as its first recipient. The purpose of this medal is to mark the public service of men who have gone outside their strictly professional work to interest themselves in civic and humanitarian affairs. And the engineers have something to contribute to public service. . "With the development of our great national tools -our engines, our railways, our automobiles, our airplanes, our steamships, our electric power and a score of other great implements, together with the supplies of material upon which they depend-the engineer has added vastly to the problems of government, for government must see that the control of these tools and these materials is not misused to limit liberty and freedom, that they advance and do not retard equality of opportunity among all our citizens.

Jan 1, 1930

By Roger L. Winter, Borje O. Saxberg

Some form of wage incentives has been used traditionally in the mining industry to determine miners' pay. However, very little is actually known about the administration of such wage incentive plans in mining. As far as the authors know this is the first time a general examination of wage incentive systems as applied to underground mining has been undertaken.* This article reports the results of an investigation pertaining to the administration of wage incentive programs for miners who drill, blast, and load- mainly in underground metallic mining operations. This investigation was conducted to obtain management's views and attitudes towards wage incentives; therefore, the results do not necessarily represent accurately the thoughts of the miners themselves nor those of any organized union of miners.

Jan 10, 1960

By Ronald E. Versaw

Environmental legislation, both existing and proposed, requires that mills, tailings dams, evaporation ponds, and related processing facilities be located, constructed, and operated within stringent guidelines. An early step in planning a new processing facility is performing a site selection study in which topographic, hydrologic, geotechnical, and environmental parameters are evaluated for several alternate sites. Once a site is selected, then an environmental report, including a description of the proposed action, alternatives, baseline surveys, and discussions of potential environmental impacts, mitigation measures and monitoring programs is required. The federal legislation, siting studies, and environmental studies (along with the implications of these as they affect design) are discussed. In addition, costs for performing these studies and implementing control of effluents are discussed.

Jan 1, 1978