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By S. Duvah Pentiah

The transformation of an open pit coal mine to a horizontal-punch underground mine is subject to a number of challenges. These include scheduling the operation of various sizes of trucks over a long period, as well as updating delivery routes and dump site locations as the mine transformation progresses. In this process, rock is excavated from a quarry through earthworks. The bulk earthwork and quarry material delivery were initially drawn from traditional planning and experienced issues in their early phases. As a result, a traffic simulator was developed in order to validate schedules and predict achievable throughput, likely delays or blockages in the long term. The dynamic traffic simulator was also used to provide traffic density and vehicle arrival data at selected intersections in order to identify possible safety and efficiency issues.

Aug 1, 2013

By Timothy W. Ellis, Abbas H. Mirza, R. David Prengaman

Recycled lead, i.e. material produced by the recycling of lead-acid batteries, has become the primary source of lead in much of the world. This has been important to the recycled lead industry as other uses have dwindled, e.g. lead based pigments, chemicals, fuel additives, solders and CRT glasses. Presently, battery manufacturing accounts for greater than 85% of lead consumption worldwide while recycled lead accounts for approximately the same market share of lead supply. Battery manufacturing and production of recycled lead are intimately coupled. In 2007, of all the industrial base metals, lead from lead-acid batteries had the highest recycling rate in North America at greater than 95%. In this paper we will review some of the processes and technologies used in a modern lead acid battery recycling facility, and how recycled lead has become the material of choice for battery construction through the development of a recovery and refining process that exceeds the industry requirements. We will also briefly review an advanced air emissions treatment system in a modern lead recycling plant that demonstrates the feasibility of a new maximum available control technology (MACT) for secondary lead smelters.

Jan 1, 2011

By I. Cifuentes

Chemical and physical characterization of copper electrodeposits obtained on mesh and plate cathodes in conventional and reactive electrodialysis lab-scale cells have been carried out. The effect of Fe, Mn, Cl and guar on electrodeposit composition and morphology were determined by means of metallographies, scanning electron microscopy (SEM), atomic force microscopy (AFM), inductively coupled plasma mass spectrometry (ICP-MS) and Auger electron spectroscopy (AES). Each impurity influenced the deposit morphology in a different way (e. g. grain size, surface roughness). AFM proved to be a very effective tool for quantifiying and classifiying surface quality.

Jan 1, 2007

By Agbo Chima

Low-lying sections of open-pit mines accumulate water, especially during the rainy seasons, preventing access to resource-bearing areas. To sustain mining operations, the water must be lifted out of the flooded pits at a high flow rate using pumps. These pumps need to be mobile so that they can be removed during drill-and-blast operations. Most mobile pumps rely on diesel engines with high maintenance requirements. A special pump design was developed to address the unique needs of open-pit mining while making the dewatering process more sustainable. Using the target flow rate and head data, an efficient pump was designed, encased, and deployed in the open pit. A variable speed drive (VSD) was installed in a protective skid so that the pump could be tuned to match the preferred flow rate at any point during its operation. This system was tied to the national electrical grid instead of being powered by diesel pumps, which reduced the carbon intensity per kilowatt-hour. The high availability, low maintenance requirement, and greater reliability reduced the use of spare parts, the fuel consumption, and the logistics associated with operating the pump. This further reduced the carbon footprint of the dewatering process. This paper provides some of the two-year performance metrics for a deployment in West Africa. With a focus on availability, maintenance costs, average cost per volume lifted, and carbon footprint, this encased pump system is compared to the diesel-driven pumps that it aims to replace.

Jan 1, 2023

By N. R. Thote, J. L. Porathur, C. P. Verma

Highwall mining is a highly mechanized coal mining method associated with several advantages, such as a very high production rate (approximately 3,000 t/d) and low production costs. There is no requirement for underground support, ventilation, or blasting. Production leads to added recovery, which is otherwise lost in the ultimate pit. The use of highwall mining can bridge the gap that exists between supply and demand in the energy sector. This paper presents a brief review of highwall mining technology, including current status, analysis tools, and design techniques. In addition, it identifies important parameters from the analysis of failure case studies.

Jan 1, 2014

By Robert Dickson

Princess colliery is operated by Old Sydney Collieries, Limited, a direct descendant of the General Mining Association of London, England, which, in the first quarter of the nineteenth century, pioneered in coal mining in Nova Scotia. The coal worked is a 5 ft. 6 in. seam known generally through the Sydney coalfield as the Harbour seam but referred to locally as the Sydney Main. Entry is made by shafts, 680 feet deep, sunk in 1871 on a headland forming the northern entrance to Sydney harbour. From them extend the main roadways of the colliery, a distance of 700 feet to the shore line and a further distance of 14,700 feet in submarine areas to a total length of 15,400 feet. It was the first colliery in Nova Scotia designed to work submarine areas. Lateral development extends across a frontage of 16,000 feet and the submarine area from which the coal has been extracted is slightly over 6 square miles. There yet remains sufficient territory ahead of the workings to assure a future life to this colliery estimated at over 80 years at the current rate of production. In this area the seam dips at 6 to 7 per cent and face workings have reached a depth of 1,690 feet below the sea level. Until 1923 extraction of the coal was by room-and-pillar, followed by the drawing of the pillars. At that date the superincumbent strata had reached a thickness of 1,400 feet, resulting in heavy weighting on the roof and severe side pressure on the coal ribs. In combination with a soft, heaving pavement this created a set of conditions involving great difficulties and expense in keeping open places driven in the solid sufficiently long to permit recovery of the coal in the pillars by methods and equipment then available. The operator was forced to resort to extraction by longwall as the only economical method of winning the coal.

Jan 1, 1948

By K. Poorhaydari, B. M. Patchett, D. G. Ivey

In this paper, some applications of carbon extraction replicas, as samples for transmission electron microscopy (TEM), are discussed. Modern high strength microalloyed (HSMA) steels, used as structural or pipeline materials, have very small grains with substructures. Replicas used in TEM can resolve the grain boundaries and can be used for grain size measurements in cases where the small size of the grains pushes the resolution of conventional optical microscopes. The grain size variations obtained from replicas correlated very well with mechanical property variations, indicated by hardness, in the fine-grained heat-affected zone and base metal of some welded HSMA steels. Replicas are also very suitable samples for precipitate examination with analytical TEM. Advantages and limitations of the application of replicas, as well as some corrections for the estimation of the volume fraction of fine precipitates, are discussed.

Jan 1, 2005

By R. Maxwell

"At Opemiska Copper Mines we have, over the past four years, operated 300 cu. ft. and 700 cu. ft. flotation cells as roughers, scavengers and cleaners and found them competitive with conventional flotation cells on a cu. ft. basis on all phases of flotation.The economics are very much in favour of the large cells for the following reasons:Power consumption is 35 to 40%, of conventional machinesMaintenance cost is about 20 to 25% of conventional machinesSpace required is about 30 to 35% of conventional machinesInstallect cost is about 40%, of conventional machinesTo put the above in more concrete terms below is what we are doing at Opemiska:1. Increasing mill capacity from 2000 to 3000 T.P.D. and will use only 5Cff, of the flotation space for 3000 tons that we used for 2000 T.P.D. with conventional flotation machines.2. Will require only 10 flotation cells for 3000 tons against 85 conventional cells for 2000 tons.3. Cells will be, one 2000 cu. ft. rougher, six 700 cu. ft. scavengers (2 banks of 3 each) and one cleaning circuit using three 300 cu. ft. cells.You will note that in this 3000 ton per day plant, we are going to have only ten cells. Had we put in conventional cells for this tonnage, we would have needed 120 cells."

Jan 1, 1970

By J. W. Craig

THERE are, broadly speaking, three classes of refractories: acid, basic, and neutral. Fireclay, diaspore, silica, and the sillimanite group of minerals are included in the acid class, which for the most part are not very resistant to basic slags. The neutra! class includes chrome, graphite, and silicon carbide, while most important in the basic class are magnesite and dolomite. Although chrome is a neutral refractory, it has no sharp distinction from magnesitic refractoriness. The two are mineralogically (1) and chemically related, and there is available on the market a complete range of brick from straight chrome to straight magnesite. In many indus trial applications, one. type may be replaced by another. The present paper is confined entirely to such refractories. The following types of basic and neutra! brick, each sold under sorne special trade name, are available for use in Canada: (1) Burned chrome from crude ores (2) Burned chrome from treated ores (3) Chemically bonded (unburned) chrome-magnesite ( 4) Burned chrome-magnesite (5) Chemically bonded ( unburned) magnesite-chrome (6) Chemically bonded (unburned) high-iron magnesite (7) Burned high-iron magnesite (Regular) (8) Burned low-iron magnesite (9) Burned olivine-magnesite (10) Burned magnesitic dolomite-chrome (Magnecon) (11) Chemically bonded magnesitic dolomite-chrome (Magmecom) (12) Dolomitic brick

Jan 1, 1936

By R. J. Smyth

A Steel Compression Reinforcement Repair Technique (PetroSleevel) system has been developed that has the ability to repair pipeline defects such as stress corrosion cracking (SCC) without requiring welding to the operating pipeline. The Technology has been used to repair active cracking in ERW seam and cracking in the pipe body. All repairs were performed while the pipeline was in operation. This paper will discuss the engineering theory, testing performed to verify the engineering theory, and examples of actual sleeve installations.

Jan 1, 2005

By N. Bahrani

Knowledge of the state of stress in the Earth?s crust is very important to the safe and efficient development of underground excavations in mining and civil engineering projects. A number of methods have been developed over the past 40 years to assess the stress field in the rock mass. These range from local estimates derived from compilation of regional stress databases to back-analysis of field observations to dedicated in situ measurements. The Geomechanics Research Centre (GRC) at MIRARCO has a long history of undertaking in situ stress characterization and measurement. In this paper, the stress measurement techniques used by the GRC, including overcoring and undercoring in addition to borehole breakout back-analysis, are briefly reviewed. The limitations and application of each technique for different ground conditions and the challenges involved during the field work and in interpretation of the results are discussed. A successful stress measurement campaign is not limited to acquiring valid local measurement, but must include a careful interpretation and integration of the measurement with other geological and geotechnical context information. Based on our experience, it is suggested that all available stress indicators and data are combined and integrated with the local geological and geomechanical conditions to derive a consistent stress characterization for a given site.

Aug 1, 2013

By Donald Carlisle

"IntroductionTHE OPINION is held by many persons outside the mining industry, and by some within it, that mine •operators customarily find it advantageous to mine •only the richer parts of orebodies and to leave behind, perhaps permanently, leaner material which could be mined only at a lesser profit. This opinion and the inference which might be drawn from it that 'gutting' of mineral resources is a common feruture• of the mining industry are prejudicial to the intertsts of the industry and deserve careful scrutiny. Oddly enough, a theory of mine economics which gives much support for the opinion was advanced first by members of the mining profession itself, has been repeated •several times in mining literature, and to my knowledge has never been adequately refoted.According to the theory, selective mining of the rich ore first on a large scale will yield substantial gains and these gains do not merely reflect the desire of 'money minded investors' for a quick return but derive from the logical application of compound interest rates and the concept of ;present value. W. O. Hotchkiss and R. D. Parks (1) illustrate the reasoning with a hypothetical example in which an orebody of 4,000,000 tons may be mined either in its entirety in forty years at $1.00 per ton profit or selectively with the recovery of only the richest half in twenty years at $1.50 per ton profit. They show that, with Hoskold rates of 4 and 8 per cent, the present value of profits from mining only the richer 2,000,000 tons exceeds the present value of profits :from mining the whole orebody by about 20 per cent."

Jan 1, 1953

By W. B. Paton

Introduction For several reasons the accident history of Flin Flon has been quite unlike that of any other mine in northern Canada, and very much unlike that of the average American metal mine. Towards the end of 1928, the mining project that is now Flin Flon, and that is now in the very: forefront of Canada's big producers was launched; but, metaphorically, it was launched in a tempest of mining troubles. Each branch of the mammoth enterprise was beset with extraordinary difficulties, and the Safety Department had its relative share. Difficulties in Accident Prevention The unusually rugged contour of the plant site made roads, and even moderately safe pathways, out of the immediate question. The project established an industrial outlet for depression-stricken areas which hitherto had been essentially agricultural; but through that outlet poured labour whose working atmosphere had been the bald prairie, labour that knew nothing of safety consciousness, labour that had to be moulded to industrialism, labour in the raw. A considerable length of the ore-body lay under the eastern section of Flin Flon lake. Open-pit methods were adopted to work the upper limits of the ore-body, and consequently the eastern section of the lake had to be dammed and pumped dry. The subsequent difficulties and hazards created by silt deposit cannot be fully visualized. And, finally, there was a geographical hindrance: the ore-body was partly in the Province of Manitoba and partly in the Province of Saskatchewan. The workmen's compensation problem became intricate. Insofar as accident prevention is concerned, Flin Flon's young industrial life may be conveniently divided into three distinct periods, namely: (a) Construction (Nov. 1928-June 1930) (b) Tuning up, and production till the strike (June 1930-June 1934) (c) Production from the strike till the present time At the peak of construction, due to the usual labour fluctuations of big jobs, there was a weekly turnover of about a hundred men. A very large percentage were Central Europeans, most of whom could neither read nor write English. Consequently, an organized safety programme was out of the question.

Jan 1, 1935

By F. E. Lathe

RECENT events have emphasized with renewed force the well known fact that war greatly intensifies the demand for certain metals, particularly for iron, copper, and zinc. Any increase in the use of iron and steel, whether in war or peace, is also accompanied by increased consumption of those metals which find their chief application as ferro-alloys, such as nickel, chromium, manganese, molybdenum, tungsten, and vanadium. Further, since high temperatures are essential for the production of all these metals, activity in the metal industry is inevitably accompanied by an insistent demand for refractories. For example, in North American practice the consumption of magnesitic hearth refractories is frequently expressed in pounds per ton of steel. This quantity (not including straight dolomite) ranges on individual plants from about 7 to 12 pounds. When the industry is operating at approximately full capacity, the ratio of refractory to steel tends to increase, since the tonnage of steel produced is recognized as of paramount importance, and this leads to the harder driving of furnaces and less regard for the effect on refractories. It should also be observed that the cost of refractories per ton of metal produced is always so low, in comparison with other items, that it may even increase while the cost of metal per ton is being reduced through more continuous operation and the use of higher temperatures. As one prominent Canadian copper metallurgist has tersely expressed it, he is "not in business to save refractories but to smelt ore". The effect of war demands and of general industrial activity upon the production of basic and neutral refractories is clearly shown in Figure 1, which gives the value of chrome ore and magnesitic-dolomite produced in Canada during the period 1907 to 1937. Tonnages have not been shown, as these are not available for the full period; such figures as have been published from time to time are not strictly comparable, since both raw rock and finished products have on occasion been included. The preliminary figures for 1938, which are now available, have been prepared by the Dominion Bureau of Statistics on a different basis from those immediately preceding, and have therefore not been shown.

Jan 1, 1940

By Fred Delabbio

There are presently several issues that the mining industry is facing, such as underground air quality, deep mining and green house gas emissions, which could be addressed by the application of alternate energies. Several aspects must be considered by the industry in any drive to introduce new technologies within the context of a producing underground mine. This article presents several operational and support aspects that will evaluate the relevance of alternate energies, with emphasis on hydrogen power systems: operational drivers, commercial supply of technology, site supply system requirements, health and safety, capital and operating costs, mine production, corporate philosophy, and role of government. It is concluded that introduction of alternate energy technology requires a step-wise progression: Applicability to the industry, proof of concept testing, development of generic infrastructure, power systems and regulations, whole system studies and detailed studies of cost and risk versus benefits. The current initiative to apply fuel cells is at the proof of concept stage, entering the generic infrastructure stage.

May 1, 2007

By J. Paturaud, A. G. Villemiane, J. Y. Buffiere, D. Fabregue, M. Perrier

In this work, a detailed characterization of the cyclic damage mechanisms on duty in car heat exchangers has been carried out in order to improve their reliability. The material which consists in very thin (<0.3 mm thick) sheets formed of 3 co-rolled aluminum alloys (4045 /3916/ 4045) has been brazed in order to obtain metallurgical and surface conditions representative of those of the real components. Fatigue tests at constant stress amplitude have been performed at room temperature and 120°C in order i) to characterize the cyclic resistance of the studied materials and ii) to study the effect of temperature on the fatigue damage mechanism. The mechanisms leading to failure have been identified from post mortem fractographic analysis. The Wohler curves obtained show that, contrary to common structural Al alloys, this type of thin sheet brazed multi material can be cycled for several hundred thousand cycles at very high stress level (> ~ 80 % of the tensile strength). This behaviour is analysed with respect to the microstructure resulting from the brazing process and the low number of grains present in the sample thickness (around 5 grains).

Jan 1, 2015

By Wynne Potter

"On the west coast of Cape Breton Island four coal basins have been identified, varying in age and extending from Port Hood northeasterly to Chimney Corner. Those of Chimney Corner - St. Rose in the north and Port Hood in the south belong to the Pennsylvanian Riversdale Group while lying between them are the coal basins of Mabou and Inverness belonging to the younger Pictou Group. Almost all of the coal basins are submarine and coal mining was carried out on all basins at various times. The seams in all basins dip steeply seaward at angles from 10 to 20 degrees but were found to flatten seaward. The coal is ranked as a high volatile C bituminous coal. Ash and sulphur contents are high compared with Sydney coal and the coal has a tendency to spontaneous combustion when stored in large quantities.Of the four basins, the most significant is that of Mabou. At Mabou recent seismic and drilling investigations have indicated that although a sizable reserve of coal may be found offshore the structural problems, particularly faults, and the poor quality of the coal encountered will make it a resource of the future, if at all. Inferred resources have been calculated at 150 million tonnes in four seams over a 10 km2 area and extending 3 km from shore. The quality of the Mabou coals varies with ash, ranging from 5 to 25 per cent and sulphur up to 6 per cent. Calorific value ranges from 25.3 Mj I kg to 31. 7 Mj I kg. The Port Hood and St. Rose -Chimney Corner fields (Fig. 1) contain 16 million and 3 million tonnes respectively, but the Inverness basin is considered to have been depleted. The active mine in this area is the Evans Mine at St. Rose that is currently producing between 30 -50,000 tonnes a year from proven reserves of approximately 3 million tonnes."

Jan 1, 1985

By J. Gordon Parr, D. A. Whitaker, G. A. Yorko

High purity alloys of zinc with 25 per cent to 50 per cent aluminum, have been prepared. Mechanical properties of the as-cast and heat-treated alloys have been related to constitution, determined by x-ray diffraction and microscopic methods. Investigations include the effects of aging and of small nickel additions on the properties of the alloys.

Jan 1, 1960

By George H. Bodfish

This paper begins with a short history of air compressors, emphasizing their "roots" in the mining industry. It then describes the types of compressors available, including reciprocal, the various rotary positive-displacement compressors, and the centrifugal. The advantages and disadvantages of selecting a certain type of compressor over another are enumerated, considering customer requirements and operating costs, among other factors. Guidelines to operation and maintenance are discussed, including installation, monitoring and maintenance procedures. Finally, the paper addresses itself to future trends, with special attention being given to the system concept, the increasing use of rotary compressors, power consumption, reliability, packaging and noise attenuation.

Jan 1, 1978

Operating CIP/CIL gold recovery plants in the arid regions of Western Australia face unique challenges due to water and ore quality issues. The presence of cations of Mg, Fe and Cu metals in water supplies and leached sulphide ores can have considerable effect on plant consumption of lime and cyanide, due to pH buffering and complexation effects. Reagent costs are critical to many of these operations. In this paper, computational modelling is used to analyse a number of process options to mitigate such issues. This requires careful consideration of the chemistry of the process system, and the ability to predict accurately the response of speciation and precipitation reactions to changing process conditions. The Mg-Fe-Cu-CN-H20 system is specifically modelled in this application. The Gibbs Free Energy Minimisation thermodynamic framework has been selected to model equilibrium phenomena. Furthermore, this approach has been extended to the process flowsheet level, incorporating multiple unit operations and recycle streams in a steady-state mass balance model. The Gibbs equilibrium composition module of HSC Chemistry software has been successfully integrated into the commercial flowsheeting package SysCAD. Consideration of the Gibbs Energy Minimisation capabilities of other flowsheeting packages has also been given. This approach has been successful in simulating the aqueous process chemistry typical of such plants. It has resulted in a predictive capability where equilibrium states respond appropriately to process changes. Potential cost savings may be identified by examining alternative process conditions to minimise overall reagent consumption.This methodology may be extended to other hydrometallurgical plants where issues of solution ideality, temperature and other equilibrium processes are sufficiently understood.

Jan 1, 2005