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By Altemar Dettogne do Nascimento

O colamento de aço no molde (sticker) é uma anomalia de processo de lingotamento, que quando não detectado pelos modelos de prevenção de sticker, pode gerar breakout, o que significa perdas de produção significativas e aumentos de custos de manutenção para recuperação de componentes de segmentos e moldes, além dos riscos de segurança durante a limpeza do aço dentro da máquina e reprocessamento das placas para eliminação de defeitos superficiais. Outro aspecto a ser considerado é a ocorrência de falso alarme de sticker que também gera custos adicionais de produção, aumento de defeitos superficiais nas placas e powder slivers em laminado a quente devido a redução brusca da velocidade de lingotamento. Visando reduzir as ocorrências citadas acima e otimizar o processo de lingotamento, um novo sistema de detecção de sticker foi implantando, em AM Tubarão, nas 03 máquinas de lingotamento contínuo de placas, com uma configuração diferente da que que habitualmente é encontrada no mercado. O sistema é baseado em dois eixos: uma imagem termográfica do molde e um sistema de cálculo bastante avançado. Este trabalho apresenta os resultados deste processo e os ganhos obtidos quanto à redução de alarme falso de sticker.

Oct 30, 2017

By Carlos Magno Palacios Arbizu

La calidad total es la estrategia que busca la mejorar la productividad y eficiencia de los productos que ofrece -en tanto sean reconocidos por este valor-, de forma que genera competitividad en las organizaciones peruanas y se presenta como respuesta a nuevos enfoques de gestión surgidos ante el proceso de globalización. En este sentido, el presente trabajo analiza la forma del avance en el nuevo enfoque de gestión de las empresas mineras, para así proponer alternativas de tratamiento e implementación de un modelo basado en la Calidad Total, de manera que esté alineado dentro de un sector que tenga características propias y diferenciadas de organizaciones de otros sectores productivos.

Sep 12, 2005

By W. J. Whiten

Current developments in one type of crushing and screening model is reviewed and general design techniques and policies are proposed for the control of crushing plants.

Jan 1, 1984

By A. Drumond, J. F. C. L. Costa, M. G. Lemos, A. L. Rodrigues, F. G. Niquini

The past decade has seen a renewed possibility of using machine learning algorithms to solve a large collection of problems in several fields. Data acquisition for mining operations has increased with the growth in sensor-based technologies, and therefore the amount of information available for mining applications has dramatically increased. Ore sorting equipment is available for separating ore from waste based on differences in physical properties detected by a real-time analyser. The separation efficiency depends on the contrast in these properties. In this study we investigate the application of machine learning models trained using data from the output of a dual-energy X-ray ore sorting apparatus at a gold mine. The particles were first hand-sorted into ore and gangue classes based on their mineralogical composition. Classification models were then used to help decide the balance between the number of true and false positives for ore in the concentrate, with a view to economic parameters, using their receiver operator characteristic (ROC) curves. The results showed AUC (area under the ROC curve) scores of up to 0.85 for the classification models and a maximum reward condition Fpr/Tpr around 0.5/0.9 for a simplified economic model.

Aug 8, 2024

By M. E. Gershon

Software for coal blending has gained a lot of recent attention as micro-computer programs have come on the market. Some of this software is appropriate and some is not. This paper looks at the types of models being used and points out the strengths and weaknesses of each. Recommendations are then made concerning the level of detail required for these programs, relating this concern to the various ways in which coal companies are using these programs. A checklist of company requirements for these programs and available pro-gram-features provides an aid in matching the program to the company.

Jan 1, 1988

This paper considers two particular empi- rical models for the processes of the generati- on of hydrochemical zoning and epithermal near- surface mineralization of mercury-antimony-arse- nic formation in the discharge area of the Uzon Caldera ore generating hydrothermal system in Kamchatka. Vertical and horizontal hydrochemical zo- ning is caused by mixture of infiltration waters of the surface formation with fluid of chloride- sodium composition which are supplied up the-zo- ne of deep fault. Ore formation is caused by simultaneous existence of two geochemical barriers, namely oxidizing and reductive. The first barrier is determined by the-level of ground waters. The second one forms under the clay-opal screen un- der the influence of two factors, namely the inflow of deep reduction sulphur compounds (which are transported together with arsenic, antimony and mercury) and the generation of hyd- rogen sulphide as a result of sulphur- and sul- phate reduction. X-ray-amorphous phase of orpi- ment composition and realgar phase are formed, respectively, on the oxidizing and reductive Barriers.

Jan 1, 1987

By T. Kalliomäki, B. P. Wilson, M. Lundström, J. Aromaa

"The diffusion rate of cupric ions and limiting current density are important factors that determine the rate of copper mass transport in electrolytes proximal to the electrodes used in electrorefining. As a result, diffusion can critically affect both the rate and morphology of cathodic copper deposition thus it is crucial that it be optimized to improve production. The diffusion coefficient of cupric ion (DCu(II)) in copper electrolytes has been previously researched but the values detailed in the literature show significant variations and moreover arsenic - a common impurity - is generally excluded. Furthermore, in previous studies the models have only been validated with model solutions rather than real industrial electrolytes. In this study, the limiting current density and diffusion coefficient of cupric ion were defined for synthetic electrolytes containing copper (40–60 g/dm3), nickel (0–20 g/dm3), sulfuric acid (130–220 g/dm3) and arsenic (0–45 g/dm3). The cathodic limiting current densities were measured at three temperatures (50, 60, 70 °C) with linear sweep voltammetry using the rotating disc electrode (RDE) as the cathode. By utilizing the limiting current density, models for the DCu(II) were constructed using Levich equation. The validity of the DCu(II) model for technical use was confirmed through their application to industrial electrorefining electrolytes with known element concentrations. Consequently, this study provides improved models for limiting current density and diffusion coefficient of cupric ion that can be utilized for industrial process optimization.INTRODUCTION For an efficient copper electrolysis process, the mass transport of copper ions has to be effective. The main mass transport types of copper ions in copper electrorefining are diffusion and convection while the effect of migration is negligible. In order to maintain good mass transport, it is beneficial to keep both diffusion and convection high to maximize the limiting current density (jlim) (Bard and Faulkner, 2001). jlim is the highest current density that can flow in the cell, thus by maximizing jlim the deposition time can be minimized and the good quality of cathodic copper can be ensured. Thus, it is important to research possibilities that increase and optimize diffusion since slow diffusion in the electrolyte limits the rate of the process (Levich, 1947; Moats et al., 2000; Subbaiah and Das, 1989)."

Jan 1, 2018

By John A. Herbst, K. Rajamani

Process improvement is probably the most widespread objective of mineral process plant operators in the late 1980's. An important part of such improvements is dynamic optimization which involves reacting to inevitable plant disturbances in such a way that productivity is maximized at every instant of time. This paper describes the way in which mathematical models can be and have been used in dynamic optimization. Both off-line and on-line model applications are described.

Jan 1, 1989

By Daniel Saramak, Agnieszka Saramak

A big issue in crushing and grinding operations in raw materials handling is high energy consumption and low breakage effectiveness. According to the Legendre [7], only 10% of energy input is directly consumed on the feed material breakage, while the remaining portion is dissipated in the form of heat and noise [8]. In the industry of limestone powder production, the grinding operations constitute integral part of technological circuits, and the energy consumption in operations of industrial comminution consume as high as 2% of world energy [14]. High-pressure grinding is the technology with proved energy benefits both in ore processing circuits and in limestone grinding. The promising results concerned mostly the achieved energy savings and good results of material breakage were achieved and demonstrated in numerous investigations [1,3,12]. However, it appears that a proper selection of operational parameters of the press devise, determination the feed material characteristics and adjustment of process course san be of a key-significance in improving an effectiveness the HPGR operation. Operational parameters of devices and process course should be verified towards the characteristics of the feed material, which mainly applies to the particle size and shape of the feed material and its moisture, and also mineralization in case of ores [2,4,9]. There are various investigations concerning an impact of the operational pressing force on comminution results which mostly refer to the determination of energy consumption and crushing ratio [5,6,10,13]. Investigations on the moisture content are less common, however their results suggest that, in general, the HPGR feed with higher moisture shows the tendency to higher comminution intensity, while the energy consumption increases together with increasing of feed material moisture. Investigations on olivine sand feed [11] showed that crushing ratio decreases for higher moisture, especially when the material is crushed at higher pressing force. HPGR devices, however, shouldn’t be regarded as a unique and perfect solution for comminution of each type of material. But they indeed may bring technological and economic benefits, comparing to conventional crushing and grinding machines, resulting in more favourable breakage of material particles and lower consumption of energy per unit mass of processed feed material.

Feb 1, 2025

By A. Broussaud

An original methodology has been developed for steady state simulation of selective grinding and mineral liberation in rod and ball mills. Three fundamental aspects of the methodology are presented successively : modeling ore texture, modeling grinding and its selectivity, and modeling mineral liberation. The methodology for modeling ore texture includes the conversion of 2D data into 3D reconstructed information and the use of the BILCO coherent material balance software. The models for grinding Simulation are classified into three levels, corresponding to three levels of available experimental data. All models account for grinding selectivity and for variations of engineering para-meters and operating conditions. An algorithm has been introduced to forecast mineral liberation, compatible with accurate simulation of selective grinding, which generates reasonable results.

Jan 1, 1987

By M. M. Hajdasinski

"Any study in the field of theoretical investment analysis, or practical project evaluation, must be based on the assumption of one of the commonly applied models of time and value representation, and the corresponding interest convention. The lack of clear assumptions in this regard may easily confuse both the author of the study and the reader, and sometimes even lead to inaccurate results.In the first part of this paper formal definitions of the continuous and discrete models of time and value representation are introduced; in the second part, the importance of transparent assumptions is shown using a concrete example of inflation calculation in project evaluation.IntroductionIn his recent paper, L.D. Smith(10) discusses an important aspect of mine investment analysis: inflation in project evaluation. His interesting presentation of current practices of handling inflation by Canadian and international mining companies in their feasibility studies ends, in the conclusions, with a call for clear assumptions made when evaluating mining projects.With this call, an important issue has been addressed. The lack of clearly stated assumptions, or their incompleteness, are relatively frequent with regard to the interest convention or the model of time and value representation assumed when evaluating mining projects. It is, for example, fairly common that the quantitative evaluation of a project is performed according to the discrete model of time and value representation and the discrete interest convention, and the graphical presentation, supporting this evaluation, reflects the continuous model.Sometimes such an ambivalency means nothing more than just a formal inconsistency; there are cases , however, that may well lead to a serious confusion and /or to inaccurate results . Before this can be demonstrated on a specific example, a concise description of the models of time and value representation used in the evaluation of industrial projects seems to be in order. Although these models (especially the discrete one) have been in common use in the research and practice of financial analysis for considerable period of time, they have been applied rather intuitively, and their forma] definitions are difficult to find even in the standard textbooks on Engineering Economy."

Jan 1, 1990

By Andreas Siegmund

During the decade of the nineties the conventional method of primary lead smelting (sinter machine/blast furnace) was successfully challenged by the introduction of novel direct and continuous smelting processes. In combination with a significant shift in market structure, as well as more stringent government regulations these modem technological innovations like the QSL, Kivcet, and Isa/Ausmelt processes became more than major competitors. They have proven to be economically and environmentally viable. The intensification of the metallurgical reaction by applying oxygen enriched or pure oxygen bath or flash smelting principles resulted in cost savings and a higher flexibility with respect to raw materials and additives usage. By synchronizing individual auxiliary plant sections with the smelting process a virtually waste-free production and low-emission mode of operation with nearly optimum energy exploitation is achieved. The primary lead industry will gradually substitute the sinter -blast furnace operation with novel high-energy efficient technologies in the new millennium.

Jan 1, 2003

By Andreas Siegmund

During the decade of the nineties the conventional method of primary lead smelting (sinter machine/blast furnace) was successfully challenged by the introduction of novel direct and continuous smelting processes. In combination with a significant shift in market structure, as well as more stringent government regulations these modem technological innovations like the QSL, Kivcet, and Isa/Ausmelt processes became more than major competitors. They have proven to be economically and environmentally viable. The intensification of the metallurgical reaction by applying oxygen enriched or pure oxygen bath or flash smelting principles resulted in cost savings and a higher flexibility with respect to raw materials and additives usage. By synchronizing individual auxiliary plant sections with the smelting process a virtually waste- free production and low-emission mode of operation with nearly optimum energy exploitation is achieved. The primary lead industry will gradually substitute the sinter -blast furnace operation with novel high-energy efficient technologies in the new millennium.

Jan 1, 2003

By Ihsan Berk Tulu, Mark Alexander Van Dyke, Deniz Tuncay, Ted M. Klemetti

Bleeder entries are critically important to longwall mining for the moving of supplies, personnel, and the dilution of mine air contaminants. By design, these entries must stay open for many years for ventilation. Standing supports in moderate cover bleeder entries were observed, numerically modeled, and instrumented by researchers at the National Institute for Occupational Safety and Health (NIOSH). The measurements of the installed borehole pressure cells (BPCs), standing support load cells and convergence meters, and roof extensometers are presented in this paper in addition to the numerical modeling results and visual observations made by the NIOSH researchers in the bleeder entries. The results include the effects of multiple panels being extracted in close proximity to the instrumented site as well as over one and a half years of aging. As expected, standing supports closer to the longwall gob showed the greatest load and convergence. The roof sag appeared generally independent of the proximity to the longwall gob. The BPC readings were driven by both the proximity to the gob and the depth into the pillar. The results of this study demonstrated that the entry roof can respond independently of the pillar and standing support loading. In addition, the rear abutment stress experienced by this bleeder entry design was minimal. The closer the mine development, pillar, or supports are to the gob, the greater the applied load due to rear abutment stress.

Jan 7, 2021

By Ihsan Berk Tulu, Deniz Tuncay, DYKE MARK ALEXANDER VAN, Ted M. Klemetti

Bleeder entries are critically important to longwall mining for the moving of supplies and miners as well as the dilution of mine air contaminants and must stay open for many years. In this study, standing supports in moderate cover bleeder entries were observed, numerically modeled and instrumented by researchers at the U.S. National Institute for Occupational Safety and Health (NIOSH). The measurements of the installed borehole pressure cells (BPCs), standing support load cells and convergence meters, and roof extensometers are presented in addition to the numerical modeling results and visual observations made by the NIOSH researchers in the bleeder entries. The results include the effects of multiple panels being extracted in close proximity to the instrumented site as well as over one and a half years of aging. As expected, standing supports closer to the longwall gob showed the greatest load and convergence. The roof sag appeared generally independent of the proximity to the longwall gob. The BPC readings were driven by both the proximity to the gob and the depth into the pillar. The results of this study demonstrated that the entry roof can respond independently of the pillar and standing support loading. In addition, the rear abutment stress experienced by this bleeder entry design was minimal. The closer the mine development, pillar or supports are to the gob, the greater the applied load due to rear abutment stress.

By T. J. Crebs

The latest estimates compiled by the Society of Exploration Geophysicists again indicate a moderate increase in mining geophysical activity in 1980 over the 1979 level. While North American activity remained at above the 1979 level, a considerable increase in mining geophysics was reported in South America, Australia, and the Far East. The total worldwide expenditures for mining geophysics were reported to be $53.7 million in 1980, compared to $44.4 million in 1979, and $31.6 million in 1978. During 1980, approximately 2% of all dollars spent on geophysics were attributed to mining geophysical activities; this percentage has remained relatively constant in recent years. Airborne surveys accounted for 51% of the total worldwide mining geophysical expenditure, 43% was spent for land surveys, and 6% for borehole surveys. Within the US, the breakdown of expenditures for land surveys was 60% for elec¬trical methods, 23% for gravity and magnetic methods, and 17% for seismic techniques. Electrical techniques remain the primary exploration tool for US mining geophysicists. Electrical Methods With inductive or electromagnetic (EM) techniques, significant developments were achieved in both frequency-domain and time-domain systems. Work continued on increasing the signal level on most time-domain (TEM) methods, to increase the exploration depth. The Crone group increased the power of its Pulse ElectroMagnetic system (PEM) to a 20-amp transmitter-loop capability. The GEOEX group is modifying the SIROTEM II system to obtain larger transmitter amperage from a portable motor generator. Geonics developed a new digital recording system (data logger) for its EM-37 system. This development should increase the productivity of EM-37 crews. A new ground, frequency-domain EM system was developed by the Scintrex group. This novel Genie system does not require a wire link between the receiver and transmitter. Because an amplitude-ratio is measured, the Genie data are reported to be relatively insensitive to coil orientation and distance errors. This new technique does not need extensive line-cutting or accurate station-chaining and would appear to be a good reconnaissance instrument. Scintrex also began marketing the new IPR-11 induced polarization spectral receiver. This receiver is microprocessor controlled, and can output to a cassette tape and record 10 windows of secondary voltage decay simultaneously from up to six receiver dipoles. The Phoenix group's new 100 kW induced polarization/resistivity (IP/R) transmitter began tests using their IPV-3 multifrequency, multichannel receiver. While this unit was primarily developed for "oilfield" IP exploration research, it has obvious application to "deep" mineral exploration. The Phoenix group also developed a new remote-reference, real-time magneto-telluric (MT) device in 1981. This five-component MT sys¬tem has a frequency range from 0.0005-384 Hz. Helicopter-borne electromagnetic (HEM) developments also continued in 1981. The mining in¬dustry increased its use of the new Geonics EM-33-3 multifrequency, multicoil instrument. In 1981, the Dighem group developed software for estimating magnetite as a mapping parameter from its HEM system. Dighem's work is said to complement airborne magnetic intensity surveys, since the HEM estimate is independent of remanent magnetism and magnetic latitude effects. Gravity and Magnetic Methods Probably one of the most innovative techniques in geophysics in 1981 was the use of airborne gravity surveys for both mining and petroleum exploration. The Carson group is using a modified, shipborne LaCoste-Romberg platform in helicopters. Data accuracies to 0.5 milligal have been achieved by flying gridded surveys. Although this airborne method is expensive-up to $186/ km ($300/line-mile)-the geophysical community has been excited by initial results. On the ground, the portable proton-precession magnetometers are becoming sophisticated. Both GeoMetrics and EDA recently introduced field magnetometers having data storage and processing capabilities. This development should greatly increase the productivity of ground-magnetic surveys. Seismic Methods Development of high-resolution seismic techniques continued in 1981. These techniques have primarily been directed toward coal studies for fault detection. OYO Instruments introduced their McSEIS-1500 seismic data acquisition system in 1981. This device contains a 24-channel recording capability, with digital output to 256-kbyte floppy disks. The high-speed data transfer using the disk media is considered a desirable feature. Borehole Methods The general decrease in uranium exploration, where borehole logging is extensively used, probbly led to the overall decline of geophysical logging activity in the minerals industry. However, a number of new sondes and logging systems were introduced in 1981: • Mount Sopris recently introduced their Series III logging system. This microprocessor-controlled unit records up to four channels of data on nine-track or cassette magnetic tape. The logging package is relatively light-weight, so helicopter transport to mountainous or roadless exploration sites is possible. (Both the Edcon and Woodware-Clyde consulting groups offer "slinging" capabilities for their Mount Sopris units.) Mount Sopris is continuing work on their 500-mm-diam (2¬in-diam) spectral gamma-ray sonde. This tool is expected to be available soon. • Owl Technical "slim-downed" its successful digital deviation probe to 380-mm (1.5-in) outside diameter. This new sonde will also measure inclinations up to 80° from the vertical, as compared with its older instrument that could measure inclinations to 30°. • A magnetic susceptibility sonde was introduced in the US by the OYO Instruments group. This Kappalog sonde contains two aircored coils for measurements slightly affected by thermal changes within the borehole. The increased activity in massive-sulfide exploration and the need to "look" deeper no

Jan 5, 1982

Human creativity springs from the natural desire of mankind to know and its capability to learn. Explorers and discoverers possess these features in a high degree. They are driven by an unrelenting curiosity to go beyond the boundaries of the known, to explore into the nature of things, to reveal connections between ideas, facts, conceptions, to view things from new angles, to change perceptions. A well-known fact about the construction industry - and underground construction in particular - is that all projects are unique. The degree of complexity due to the intertwining of the variety of project-related parameters is higher than in many other industries, thus forcing contractors as well as suppliers to be truly adaptable and flexible. The enormous advantages of shotcrete as a construction and rock support process and the improvement of materials, equipment and application know-how have made it a very important and necessary tool for modern underground construction works. The development of modem wet shotcreting in particular has enlarged the field of underground construction work. Projects that were impossible to be realised, have now become practicable. Subsurface structures can be placed where they are needed, without regards as to rock and soil conditions.

Jan 1, 1995

In the last five years, new iron ore pellet plants have been built with significantly reduced air pollution levels compared to the older generation of plants. European and American pollution controls are more stringent that in China and Brazil. The recent American plants have successfully employed circulating fluidized beds for sulfur control, baghouses for particulate control, activated carbon injection for mercury and a new design of specialized low-NOx burners.

Jan 1, 2015

By Arthur L. Walker

DURING my trip around the world last year, covering a total of 45,000 miles, I saw many things of especial interest from an engineering viewpoint. Sailing from New York, I went through the Panama Canal, down along the west coast of South America, then over the Peruvian and Bolivian Uplands; thence to the celebrated copper mines of Chile; across the Andes, to Buenos Aires, then to Rio Janeiro; across the Atlantic to Lisbon, Portugal; through Spain to the Rio Tinto mines; across southern Europe to Italy; thence to Alexandria and Cairo; up the Nile to Assouan, to Palestine through the Suez Canal, Red Sea and across to Bombay; up to the country of the Moghul Emperors; then to Calcutta, from which point I shipped to Singapore, as having crossed the Equator twice, I wished to shake hands with it again; thence to Shanghai and Pekin; up to the Great Wall of China, back to Nanking and up the Yangtse to Hankow; then back and eastward across the Pacific Ocean. The climatic changes were sudden and severe; there was winter where, for me, it should have been summer and vice versa. The weather man was very kind, however, and until I was near the Aleutian Islands there were only three rainy days in a total of 220.

Jan 1, 1924

By S. U. Baltuch, E. G. Baltuch

"Ventilation in process buildings is key to proper mill function. Correctly engineered systems to evacuate surplus thermal energy from process areas allow optimized rates of air change, thus assuring the good functioning for the lifecycle of the process while demonstrating conformity with occupational hygiene standards. Computational fluid dynamic simulations, coupled with traditional calculations and physical modeling, can demonstrate to end users and assist engineers in the optimization of mill ventilation, reducing total installation costs while assuring that the proper solution is in place for the complete lifecycle of the process equipment. Results have been fully implemented on a number of steel mill and aluminium smelter applications and we continue to study, optimize, and innovate as new tools become available to provide the best possible engineered solutions for particular applications. INTRODUCTIONThe objective of this research project is the development and implementation of modern approaches and computational fluid dynamics (CFD) simulation in the engineering of green ventilation of hot process buildings. This will assure the predictive performance and improve the quality and ease of construction of industrial gravity ventilation equipment, along with the adjunct hot process buildings, while lowering the overall project costs and time to completion.In order for a hot process building, such as a steel mill, to properly function, heat must be extracted from within. This is accomplished by having air inlets at the bottom of the building and outlets at its apex. The reason for this is to maximize the potential chimney effect. When using stack (buoyancy) effect ventilation, the process heat becomes the driver. Therefore, increasing this distance (height) improves the ability of the heated airstream to utilize basic gravity for acceleration of the heat/air flow, allowing a regular number of air changes per hour while ensuring that the process environment remains weather resistant under normal operating conditions.This process has been understood since the time of King Charles I of England, who decreed in 1600 that buildings should have 10 foot ceilings and that windows should be made taller rather than wider to allow better smoke extraction.Figure 1 is a painting of the Bethlehem Steel Works in the 1860s, where the concept of air inlets and penthouses on the roofs for air outlet was already being put into practice. Figure 2 is an early photograph of the Pittsburgh Steel Works."

Jan 1, 2012