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By B. Huffman

This paper examines several new trends in the design and application of linings for copper melting shaft furnaces including the use of large shapes, monolithic back-up linings and improved refractory engineering to significantly reduce refractory installation time, diamond saw blade costs, fuel and down-time. The net results are shown to be dramatically increased refractory service life, reusable safety linings, elimination of hot spots and lower refractory disposal costs.

Jan 1, 2007

As we are all well aware, the demand for coal is increasing very rapidly. This makes the coal industry one of great opportunity for both the miner and the-supplier. Up until the middle 1960's, the price of coal had been one of the most stable of all commodities for the proceeding fifty years. In somewhat oversimplified terms this was because the inflationary tendencies had been offset by improved mine techniques and more efficient, more productive, and more reliable equipment; but, in the last seven years the price of coal has doubled. It is not the intent of this paper to discuss the many reasons for this price increase, but to show how the cost of hauling coal can be sharply decreased with a new truck concept. Not long ago a mining executive stated that all haulage trucks now available are basically the same. They look the same; they cost about the same; they have the same engine, power train, and tires; and, they have about the same operating cost. Truck size has increased which has reduced the number of drivers, but the purchase price and maintenance and repair costs have increased proportionally. Pits must be widened and loading shovels enlarged, out, all this has not reduced the cost of moving coal. Another executive said that he saw no advantage in buying new trucks because his people now know how to maintain and operate the ones they presently have. They have all the right spare parts along with a good maintenance program. Most replaceable parts of the trucks now in operation have been replaced and improved at least once and the trucks are now running better than when they were new. Besides, the trucks are no pretty well written off.

Jan 1, 1972

By Jerry Motz, Gary Beerkircher

Through a joint development program between Bougainville Copper Ltd. and Nordberg, the MP1000 cone crusher was developed and tested during the period between 1982 and 1987. Following the successful prototype work, Bougainville Copper purchased an additional three units. A second prototype was installed at Codelco's El Teniente three-stage crushing installation in 1987. This unit has also completed its test period successfully. Three additional units have been sold, making a total of eight, to date. Two will be installed as secondary crushers in two separate large aggregate plants. The first unit installed in the United States was placed in operation at Vulcan Materials Company's plant in Manassas, Virginia in early May 1990. Another unit is being installed in Asarco's Ray Mines expansion. The Asarco installation will be a SAG MILL pebble crusher producing approximately 600 STPH of nominal 1/2" product. Application Objective The objective was to design a crusher that would fit on an existing 7' foundation with minimum modification and yet be capable of twice the production of a 7' cone crusher. In meeting this objective, the power rating was increased to 1000 HP, the maximum design crushing force was increased and the crusher was designed to operate at higher speeds than an equivalent size Symons cone crusher. The MP1000 was also designed to operate with a head throw that can be greater than the equivalent Symons design. Design The crusher design criteria involved the recognition of the crushing force increase required for the finer crushed products than

Jan 1, 1992

By Zoltan F. Oszter

The frictional resistance to motion of a belt conveyor has always been a subject of intensive studies and research by engineers throughout the years. Numerous informations have been developed by analysing series of field tests on belt conveyors of different characteristics and carrying different materials at various capacities. Within certain limits of weight per unit length and tension, the theoretical considerations and the analysis of the field tests, both in the US and abroad, resulted in the development of similar formulas. In general these formulas are safe to use up to the following limits:

Jan 1, 1977

In the past decade several significant intrusion-related gold deposits have been discovered in terranes historically exploited for tin-tungsten mineralization (eg Tintina Gold Province, Yukon and Alaska, Tasman Fold Belt, Australia and the Altaid orogenic collage in central Eurasia). This paper presents new data on the geological and geochemical characteristics of these deposits that links them to magmatic-hydrothermal processes and highlights their implications for exploration. New data from several intrusion-related gold provinces suggest that these deposits are found in areas that contain granodiorite to granite, but with a locally significant mafic component, have Rb/Sr ratios ranging between 0.1 and 1.0, and are moderately reduced (Fe2O3/FeO ~ 0.1 to 0.6) ilmenite series, metaluminous, I-types. The intrusions are distinct from porphyry copper intrusions and tin granites, but are more akin to tungsten granites. Hydrothermal fluid types vary with depth of emplacement in intrusion-related gold deposits and new proton induced X-ray emission (PIXE) data from syn-ore fluid inclusions in shallow and deep deposits provide fascinating insight into the variation in metal content between the different settings consistent with observed deposit metal associations. Exploration for intrusion-related gold deposits in tintungsten terranes should focus on regions that contain both mafic and felsic intrusion that are moderately reduced, metaluminous, I-type granites rather than terranes with dominantly highly fractionated, strongly reduced, peraluminous S-types. Intrusion-related gold systems occur in variety of deposit styles (in part controlled by host rock, proximity to granite, and depth of emplacement) and exploration geologists need to be aware of the variety of target types in and around the intrusive environment, and be able to recognise whether they are exploring a shallow or deep intrusion-related gold setting.

Jan 1, 2005

By Unknown

We are indebted to the Consolidated Mining and Smelting Company of Canada Limited for the several pictures in this issue showing the progress made in new construction at Tadanac and at Bonnington Falls, B.C. Plate No. 1 shows the down-stream side of the No. 1 hydro-electric station of the West Kootenay Power and Light Co. Limited at Bonnington Falls, on the Kootenay river, at which 17,500 k.v.a. will be developed to meet the requirements of the enlarged zinc and lead refineries at Tadanac. The generators, exciters and switch apparatus were supplied by the Canadian General Electric Company and the step-up transformers by the Canadian Westinghouse Company Limited. The plant throughout was designed, manufactured and erected by Canadians. Plate No. 2 shows the casting room of the new lead-plant and plate No. 3 the new tank-room of the electrolytic lead refinery at Tadanac. These additions will increase the capacity of the lead refinery by some 150 tons daily. The extensions also include practically doubling the zinc plant, and the gold and silver refineries. With the exception of the new stack, all designing construction and installation of the various plants is being done by the Company's own employees at Tadanac. Plate No. 4 shows the progress made in the construction of the new reinforced concrete stack at Tadanac. This stack, of 21 feet inside diameter at the top, will be brick lined and when completed will rise 400 feet above its foundations: the tallest of its kind in the world. The construction is in charge of the Rust Engineering Company of Pittsburgh, Pa. Plate No. 5 is a panorama of the Tadanac smelters and refineries. The photograph was taken from the roof of the lead smelter and gives an excellent idea of the size of the plant and its surroundings. Tadanac produces electrolytic lead, zinc and copper and fine gold and silver. During 1924 the company treated 1,333,523 tons of ore and produced: 161,400,- 769 pounds of lead; 92,197,824 pounds of zinc; l,382,750pounds of copper; 4,074,044 ounces of silver, and 26,976 ounces of gold.

Jan 1, 1925

By M Frenzel

At the last MassMin Conference in Sudbury, Caterpillar’s vision of a continuous mining concept for block caving operations was presented on the background of global raw material demand and its continuous increase. By analysing today’s structure of mining processes in block caving, the paper (Krings, Steinberg and Frenzel, 2012) highlighted the main bottlenecks in the process chain and identified conceptual solutions by help of a case study. The main focus was the paradigm shift from discontinuous batch type operation to a continuous mining process of the blocks.In 2016, the strategic vision has taken major strides forwards and remote continuous operation has become a reality. Caterpillar’s continuous operation system – the Rock Flow system – was successfully installed in Codelco’s Andina mine and start of operation is scheduled in the first half of 2016.Based on continuous product developments, this paper sets the focus on two main aspects of continuous mining. First, field experiences of the Rock Flow system will be shared, highlighting the Andina project course from system installation, to commissioning and successful system start. The second aspect concentrates on the system and mine layout as discussed in the case study scenario in MassMin 2012 (Krings, Steinberg and Frenzel, 2012).Based on Caterpillar`s continuous product development, the Rock Flow system set-up and panel design were modified for a general roadway design and drawpoint layout. The new design allows an optimised use in block preparation phase (spreading) and full production phase (reaping), operating a fleet of load-haul-dumps (LHDs) and Rock Flow systems. The combined use of the two technologies optimises the mining process in every stage of block life and significantly increases the performance of the continuous block caving operation in the production panel to pave the road for the next generation of super caves.CITATION:Frenzel, M, 2016. New continuous production system in block cave mining – the rock flow system, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 543–548 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By George J. Dvorznak, Robert W. Waytulonis

The Bureau of Mines is conducting a research project in cooperation with the Mine Safety and Health Administration (MSHA). Mining companies, and equipment manufacturers are also participating through the Colorado Mining Association (CMA). The objectives of this cooperative research project are to determine the practicality of coupling a dry exhaust conditioning system (dry system) and diesel particulate filter (DPF) to make an integrated control system, and to determine the effectiveness and durability of the integrated system in an underground coal mine. Diesel-powered mining machines must be equipped with control devices to reduce surface and exhaust temperatures to safe levels and prevent flames and sparks from being emitted to the mine atmosphere. Diesel exhaust-gas water scrubbers have been successfully used for many years but they have several disadvantages; they are large, consume large quantities of water, and require frequent maintenance to remain functional. Additionally, diesel exhaust is a source of noxious gases and particulate matter. Particulate emissions are composed primarily of small carbon particles with absorbed hydrocarbons and they are almost entirely respirable in size. Even an engine in good mechanical condition can emit up to 400 mg/cu m of respirable particulate matter. A dry system for control of diesel fire and explosion hazards, coupled to a DPF, promises to be a complete control system for diesel engines. The dry system cools the exhaust and suppresses sparks and flame with a heat exchanger and flame and spark traps. The conditioner is smaller, consumes no water, and requires less maintenance than a comparable water scrubber. The DPF uses a ceramic substrate as a wall-flow filter and is very efficient at collecting exhaust particles. Average particulate mass collection efficiency is 90%. This report describes a cooperative research project to combine the dry system with the DPF, conduct performance tests on the integrated system at Bureau and MSHA 1aboratory facilities, and conduct field tests of the system on a production machine in an underground coal mine.

Jan 1, 1987

By Samir Garcia, Alain Mestanza

This technical work was carried out in an open pit copper mining unit, located in central Peru, which has a daily production of 440 thousand tons per day. Currently the pit consists of three mining phases, however, in phase 05 north, there is the construction of a shaft with a height of 375 meters, the function of this structure is to collect and drain the water coming from the pit, there is the importance of preserving its stability and keeping it operational, guaranteeing the sustainability of the operation. For this, a controlled blasting plan was developed that goes from level 4530 to level 4455 to place the central well on a bench, reactivating the pools.

Jan 21, 2025

YEARS ago, when metal mining was more an adventure than a well-organized business, it was often said (with some color of truth) that unless a mine could stand bad management or mismanagement, it was not much good. Today, the natural excellencies of an ore deposit are merely a challenge to the engineers to exploit it as skillfully, as efficiently, and as profit- ably as possible. A vast amount of competent and imaginative engineering management (which includes economic analysis no less than the technologic arts of mining ore and treating it) has been required to make New Cornelia the smooth-running and successful operation that can be seen at Ajo today. New Cornelia was acquired by the Phelps Dodge Corporation when it absorbed the Calumet and Arizona Mining Company in 1931. Next to Morenci, it doubtless is the corporation's biggest asset. It in no way detracts from the achievement of Phelps Dodge engineers to say that they had an admirable ore deposit to work on. New Cornelia ore, as mined, is relatively low in grade and the deposit is by no means the largest of the Porphyries; but it has these attractive features : (1) It is peculiarly suitable for opencut mining because: (a) The overburden of waste rock lying above the ore deposit was (it has long since disappeared) almost negligible. (b) The deposit is roughly circular in horizontal section, with the horizontal dimensions four to five times as great as the maximum thickness. (Nevertheless, eventually some underground mining may be desirable.)

Jan 1, 1957

RESEMBLING in some respects the enterprise at R Chuquicamata is that of the New Cornelia Copper Co. at Ajo, Arizona. Controlled from its inception by the Calumet & Arizona Mining Co., New Cornelia became a unit of the Phelps Dodge Corporation when the latter absorbed the Calumet & Arizona company in 1931. Both Ajo and Chuquicamata are situated in low mountains in extremely arid desert country. Both ore deposits consisted-the past tense is used advisedly because the oxidized ore has nearly all been mined at Ajo-of a horizon of leachable oxidized ores overlying sulphide or concentrating ore. The principal technical problem in each case was the development of a method for treating the oxidized ore. In both instances the capping of waste rock was comparatively thin and power-shovel mining in open cuts was the obvious method of exploitation. Nature had smiled on neither place in the matter of climate. Though Ajo does not have the persistent winds for which Chuquicamata is notorious, the comforts of living are largely artificial. And it is only fair to emphasize that at each place the mining companies have achieved remarkable success in providing these comforts. Of course, in point of size New Cornelia must be content with the inferior role. From May, 1917, when production was started, to the middle of June, 1930, the company leached 16,368,000 tons of oxidized ore, thereby virtually exhausting the ores of this class. Up to the same date, about 15,000,000 tons of sulphide ore had been mined, and a rough estimate gives 170,000,000 tons remaining in reserve. The total tonnage does not loom very large in comparison with Chuquicamata's billion tons; but it is exceeded by similar figures for only four of the Porphyry group.

Jan 1, 1933

CRUSHING and concentration flow-sheets of western mills have become greatly simplified and more or less standardized of recent years with the introduction of modern grinding methods and flotation. Improvement has not stopped, however, and advancement is continually being made in crushing and milling practice. A case in point, where remarkable improvements in efficiency have resulted from comparatively minor changes in the flow-sheet, is in the New Cornelia mill of the Calumet and Arizona Mining Co. at Ajo, Ariz. This mill, completed in 1924 for the concentration ,of the sulfide ores of the New Cornelia mine, was originally designed for a 5000-ton capacity. Before recent changes and additions were made the five 1000-ton units were handling 6500 to 7000 tons per day, giving a flotation feed of approximately 14 per

Jan 1, 1930

Frank Michael Gowar Egerton was educated at Jeppe High School for Boys and the University of the Witwatersrand, both in Johannesburg. He holds a B.Sc. degree in mining engineering, and has attended numerous courses on management, finance, and industrial relations. In the Executive Development Programme run by the University's Business School in 1981, he was voted the student who had made the greatest contribution to the programme.

Jan 1, 1993

By Roy C. Fedotoff, Jon Hurt, Gregg Sherry, Gilbert Tang

The 1,380 m (4,200 ft) long New Crystal Springs Bypass (Polhemus)Tunnel (NCSBT) will replace the existing Crystal Springs Bypass Pipeline. This tunnel project is part of the SFPUC’s $4.3 billion capital improvement program to repair and seismically upgrade their aging pipelines, tunnels, reservoirs and dams that provide drinking water to more than 2.4 million customers in the San Francisco Bay Area. This paper describes the development of the tunnel alignment and design, and the complex ground conditions of the Franciscan Mélange. Of particular interest is the challenge of tunneling with a possible downhill grade of 3%, a rigorous environmental process and incorporating the lessons learned from 1960s construction of the adjoining Crystal Springs Bypass Tunnel.

Jan 1, 2007

By Matthew Wallin

A part of the East Bay Municipal Utility District?s Folsom South Canal Connection Project, 430 feet of raw water pipe was installed using micro tunneling beneath the Mokelumne River. The access shafts for this crossing were constructed 50 and 35 feet deep through very dense sands and soft sandstone and siltstone. High groundwater and the immediate source of recharge from the river required watertight shaft construction methods. The shaft contractor, Drill Tech of Antioch, CA, used a brand new Bauer cutter-soil mixing (CSM) rig to construct the large shafts. The structural concept is similar to secant piles, but instead of creating cylinders of soilcrete, the CSM rig creates interlocking rectangular panels. This technology has been used previously in Europe, Asia, and Canada, but this was the first project to use CSM technology in the United States. Cutter-soil mixing technology has other applications beyond shaft construction, including retaining wall construction and levee reinforcement.

By Bjorn Olsson

"Heavy impact. High frequency hammering. Extreme abrasion. Building on the experience of owning and operating its own mines, Ovako has developed a deep knowledge of how vital the right steel properties are in withstanding the extreme loads encountered in every part of the drill string. That is why Ovako’s product development process is focused on understanding the specific load cases and manufacturing operations associated with rock tools.The punishing conditions of percussive drilling can push the limits of most materials. And heavy mechanical loads are only the beginning. Highimpact energies at high frequency are a major source of fatigue. High temperatures result from impact energy losses. And abrasive, erosive and adhesive wear are constant risks. Handling any of these varying demands at a single point along the drill string is difficult enough — which makes optimizing for the entire drilling system an extremely complex challenge. Engineering for specific loadsOvako has specialized over many decades in analyzing the dominant loads for each of the parts and components used in rock tools, and testing for individual applications in its laboratories. The most critical fatigue properties are controlled through the steel metallurgy, and supported by performance measurements through extensive rotating bending fatigue (RBF) testing, along with special methods that combine impact load with various wear loads. The result is a fit-for-purpose steel with tightly controlled performance properties, making it possible for customers to precalculate the expected life time of their components for highly automated and repetitive processes Tailoring steels for the processing route.The same levels of control and predictability must be carried through to the customer’s own manufacturing processes. By ensuring minimal variations in chemical composition, everything from heat treatment and welding to automated machining can be carried out with high consistency. With precisely controlled material properties based on an existing processing route and exact load case, customers are able to minimize their total tool production costs while ensuring optimal performance for their end products. Development of Hybrid SteelBuilding on this experience in the mining industry, Ovako has developed a new steel family, known as Hybrid Steel, designed to meet the demands of high-stress, elevatedtemperature applications where mechanical and fatigue strength are critical. Traditionally, steels for these applications are produced by expensive small-batch processes. Hybrid Steel, however, enables high volume production at a competitive cost.The world of steel has traditionally been divided into clearly separated categories of tool steel, stainless steel and lower alloy engineering steel. Hybrid Steel is now challenging that division, offering attractive properties from all three categories."

Jan 12, 2017

By Edo Engel

Blast furnace No. 3 at Zaporizhstal in Zaporozhye is rebuilt in 2016-2017. The Ukrainian company is targeting increased production and availability, mainly through the use of new technology. Zaporizhstal awarded a contract for a new Top Charging Unit to Danieli Corus, after comparing all available technologies. Reliability of the chosen charging device is pivotal, since long outages may be required for maintenance/replacement jobs, which strongly affects the availability of the blast furnace. This article describes the Top Charging Unit including DANCU (Danieli Charging Unit) - a robust hydraulic system. The main focus employed by Danieli and Danieli Corus during the development of this system has been availability and maintainability of equipment. This chute type charging unit has only few major moving parts, none of which is complex or vulnerable. The article also describes the main challenges of the project at Zaporizhstal, such as the use of hot sinter.

Oct 30, 2017

By Andrea Codutti, Gianni Tiussi, Andrea Tonnicchi, Morris Codarin

Essar Algoma Steel, Canada, awarded Danieli Transimissions a strategic order for the upgrade of the main drive spindles belonging to the most loaded stands of the Hot Strip Mill, F1-F2, F5 and F6. Featuring special heavy duty design and advanced torque monitoring system, these spindles replace existing competitors’ grease lubricated design with the efficient continuous oil lubricated solution to withstand the tough working conditions, increase life expectations and provide room for a product mix extension. The first couple of spindles have been installed in September 2017 by the expert Service team and are showing already good and reliable performance. Progressively all the others are being installed.

Oct 1, 2019

By Mills J. C

Concentration ranges are presented for 15 trace elements not previously reported in Australian bituminous coals. The results were obtained by instrumental neutron activation analysis, which has sufficiently high sensitivity to enable determination of many elements directly in coal at concentrations less than a few µg/g. The ranges found in Australian coal are similar to the ranges reported in North American bituminous coals.

Jan 1, 1983

By Randolph A. Koski

Recent investigations located at least six major massive sulfide deposits (dimensions measured in tens to hundreds of meters) within a 50-km-long segment of Escanaba Trough, the sediment-covered axial valley of southern Gorda Ridge. The sediment fill is intercalated silt and sand turbidites and hemipelagic mud with a maximum thickness of 500 m. Several volcanic edifices, spaced at approximately 15-km intervals along the ridge axis, penetrate and locally breach the sediment. The largest sulfide deposits form mounds and ridges on the steep flanks of structurally unstable sediment-capped blocks that have been uplifted above the volcanic edifices; both sediment and sulfide deposits are undergoing rapid erosion and redeposition. Although hydrothermal activity appears to be absent at most sulfide fields, 220°C fluids are discharging from the tops of sulfide mounds near 41°00'N lat, 127°31'W long. Recent pillow lavas and sheetflows erupted onto the sediment-covered sea floor less than 500 m away from the active vent field. The massive sulfide deposits have compositional characteristics that differ from deposits formed on sediment-free spreading axes. The Escanaba Trough deposits include Fe- and Cu-rich, Zn- and Pb-poor massive sulfide mounds, polymetal (Zn-Fe-Pb-Cu-As-Ag-Sb-Sn) sulfide vent structures, abundant barite-rich chimneys, crusts, and sinter cones, and thermogenic petroleum in the sulfide and sediment. Sulfate-rich crusts have high Au values ranging between 2 and 10 ppm. The unusual mineral assemblage at Escanaba Trough

Jan 1, 1989