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By Tack K

During its 28-year life the MHD ISP smelter has gone through two phases, each of about a dozen years. The first phase was a learning one; in the second phase the lessons were applied and throughput and production rose strongly. Early experience revealed the robustness and the flexibility of the Imperial Smelting Process. The experience was demonstrated by strong increases in the throughput of mixed lead-zinc concentrates and of secondary (oxide) zinc materials. Purchased material quantities rose from 175 000 tonnes/year to 200 000. The required capacity increase of the IS furnace to smelt the higher throughput was achieved by relatively minor modifications; for instance a change to the internal furnace profile gained an extra two square metres in cross sectional area. The furnace hearth area has remained practically unchanged over its entire history. The paper concludes that there is still more potential to be drawn from the process and MHD intends to sustain raw material input at a new level of 240 000 tonnes/year. However, this rate will have to be achieved under the imposition of more stringent environmental and product quality standards than ever before.

Jan 1, 1993

By Harrison R. Cooper

Composition data is needed as input for executing process control and management of particulate separation for flotation control. While requirements for composition data can be satisfied in many cases by manual sampling and analysis, automatic sampling and assay systems are now viewed as justified for all but the simplest or smallest processes. On-stream X-ray fluorescence analysis (XRFA) has satisfied requirements for the main portion of metalliferous sulfide ore flotation processes as XRFA technology evolved in reliability and sophistication from its beginnings in the late 1950's. In recent years, advanced on-stream analysis technologies have reached levels of development suitable for use in process control to increase efficiencies of important processes in mining and minerals industries such as coal fines flotation and industrial minerals beneficiation (particularly phosphate beneficiation) where XRFA methods have been inapplicable. Recent technical developments pertinent to use of advanced technologies as well as improvements to established on-stream composition analysis methods are discussed.

Jan 1, 1989

By W. Wallace

The aerospace industry celebrated 100 years of powered flight in 2003, and the remarkable achievements that have occurred during the past 100 years are in no small way due to major developments in materials. Modern alloys for airframes, engines and other major sub-systems have evolved through the intelligent application of new processing concepts involving melting, casting, hot and cold working, heat treatment and more recently vapour phase processing. Alloy design has evolved in parallel to allow maximum benefits to be achieved from these processing advances. However, the pace of development seems to be slowing and future gains are likely to be made by learning how to extract major value from aerospace assets. Understanding the modes of deterioration and establishing cost effective lifetimes by holistic life cycle management seem to be the way of the future. Extending component lifetimes by repair, rejuvenation and refurbishment are all viable possibilities and they offer great opportunities for Canada, which, traditionally, has been a major user of modern aerospace materials rather than a supplier. The challenges for metallurgist, physicists and engineers will be no less than in the past and should create new business opportunities for Canada. The scenario described above will be developed by calling upon examples drawn from the author's experience.

Jan 1, 2004

By Paul E. Lamoureux

Introduction The Author As the pail of smoke and wartime destruction gradually rises from the surface of the earth, from all countries, statesmen assemble to discuss and prepare pacts and treaties which are designed to, once more, bring people of all nations to understand each other and live in harmony. Scientists and engineers throughout the world are also undergoing a drastic reconversion in their ideas and objectives. No longer do they think only in terms of destruction and twist their brains to develop more devastating weapons or to surpass production records of war machinery. They have turned their eyes and ambitions to more pleasant tasks and are taking stock of wartime developments in materials, fabricating procedures, and equipment, many of which had been carefully shrouded with a veil of secrecy, and are applying their new knowledge to the fabrication or improvement of the tools of peace. The next few years will see the gradual elimination of scores of substitutes and makeshifts, expedients which the constantly changing law of supply and demand' under wartime stress necessitated. The universal search for satisfactory substitutes, however, has resulted in a general awakening of plant engineers to the possibilities of materials with which they were relatively inexperienced, with the result that, in many instances, what was considered a substitution at the outset turned out to be more satisfactory than the original material, and, in reality, can be considered a worthwhile development. Not only have materials been explored, but existing fabricating processes have been reviewed, and others, built around the properties and characteristics of new materials, created.

Jan 1, 1947

By C P. Kramers

The need to provide a sufficient quality and quantity of backfill continues to increase in South Africa, particularly as related to the increasing depth of mining. More and more applications require well designed fill systems either as classified or cemented backfill, and in some applications even tailings/aggregate based backfills. The paper discusses developments in backfill technology in South Africa with special emphasis on reliable system designs and operations, particularly as related to the preparation and hydraulic transportation aspects. Approaches for the alleviation of previous problems associated with premature pipe failures in vertical shaft columns for the distribution of tailings based backfills are discussed. Resulting from CSIRÆs developmental work, reliable full-flow systems, which can operate at low system pressures, have become a common practice, provided that backfill flowrates and internal pipe sizes are well matched. This aspect is reviewed. With regard to the tailings/aggregate based backfills the paper reviews some of the results of comprehensive in situ monitoring and the development of such systems. It is shown that a thorough understanding of the effects of aggregate top size, fines content and slurry relative density is required in order to ensure the restartability of temporarily shut-down pipelines. Some innovative technologies for the comminution of development waste underground to yield aggregate products potentially suitable or hydraulic transportation and backfilling, are briefly discussed.

Jan 1, 1998

By R. K. Singhal

Canada is a world class producer and exporter of minerals and mineral products. It is also a major exporter of minerals. Canadian open pits are highly mechanized and use state of the art equipment and support technology. During the past few years significant productivity improvements have been achieved by taking advantage of larger equipment; in pit crushing and conveying; truck dispatch systems and electronic management tools. The most recent developments in Canadian Open-pit Mining are related to hydraulic transportation and the application of Global Positioning Systems. Mine planning is computerized; environmental issues are dealt with in all phases of planning; equipment modifications are pursued with vigor to keep them functioning in the hostile Canadian North.

Jan 1, 1999

"The outlook for Eastern Canada is decreasing coal production over the next few years; however, a reappraisal of the long-term requirements and increased prices of coal could lead to a revitalizing of the industry. The market for Western coal is expanding and is expected to exceed 50 million tons per year in the metallurgical and thermal power fields. Western coal reserves are currently estimated at 119 billion tons. Technical developments in Eastern Canada include a shearer and gate-end support system to mechanically cut the stall and brushing at the tail-end of a longwall. In Western Canada, the most modern equipment is used in mining, beneficiating and shipping coal. Results to date on the underground hydraulic experiments exceed expectations. The importance of reclamation is recognized and plans have been made to restore and re-vegetate disturbed areas and mine dumps. In Eastern Canada, experiments were started to determine the feasibility of coal reclamation from mine dumps, including one dump that is on fire. The Mining Research Centre, Mines Branch, continued to conduct research work oriented toward solving Canadian mining problems The Western office of the Centre, opened in 1970, was set up primarily to study problems associated with a resurgent coal industry."

Jan 1, 1971

"The outlook for Eastern Canada is decreased coal production and for Western Canada increased production. The market for Western coal is expected to reach 40 million tons per year in metallurgical and thermal-power markets.Technical developments in Eastern Canada include successful methane drainage experiments, modifications to the shearer-loader to improve cutting rates, mechanized mining of a tail-gate stable and mechanical stowage of level brushing. In Western Canada, the most modern equipment is used in mining, beneficiating and shipping coal. Underground hydraulic experiments were started in 1969. The importance of reclamation was recognized and plans have been made to re-vegetate disturbed areas and mine dumps.The Mining Research Centre closed the field office in Nova Scotia and is preparing to open a new field office in Calgary, Alberta."

Jan 1, 1970

By S. Deming

Coal is China's main source of energy. In 1988, 76.1% of commercial energy consumption was supplied by coal. To provide a rational utilization of its coal resources, China has paid considerable attention to coal preparation over the last 10 years. In 1980, there were only 105 washeries treating about 100 million tonnes of coal, but by 1988 there were 151 washeries treating 171 million tonnes per year. This paper describes the development of China's coal preparation industry; its growth, the equipment, and the technology. Statistics and information on the current status of the industry are also be presented.

Jan 1, 1991

By G. L. Oldright

THE metallurgist is familiar with the rapid development of concentration -by flotation and smelting in the reverberatory in recent years, brought 'about chiefly by the exhaustion of' bodies of .rich, coarse, direct smelting ore. Geologically speaking, in many porphyry-copper districts, the richer contact or replace let deposits surrounding 'the main ore-forming igneous intrusion have been exhausted, and it is necessary to beneficiate the copper minerals disseminated throughout the mass of the intrusion itself. The organization of great companies to treat such low- grade ores on a large scale and the practices resulting from the necessity for an economic method of treatment 'are among the most prominent metallurgical developments of the past decade. It is interesting to note the effect of the present trend of practice on the inter-relationship of the concentrator and smelter, on the constituents of the smelter charge, and on smelting in general.

Jan 1, 1925

By D. C. Torre

Since the early 1960s, there have been efforts to develop and produce reliable continuous haulage systems capable of taking the full output of a continuous miner and transporting it, in one continuous flow, from the face to the tipple. The majority of the successful continuous haulage systems were placed in operation in the early 1970s. These were all of the bridge conveyor type. They usually consisted of bridges and mobile bridge carriers (MBC) attached at the inby end to the continuous miner and at the outby end to the panel conveyor itself. These successful bridge conveyor continuous haulage systems are either of the belted or chain type. The most successful belt type continuous haulage systems are those manufactured and marketed by the Long-Airdox Co. Until early 1977, Jeffrey Mining Machinery Division manufactured and marketed the most successful chain conveyor type haulage sys¬tems. In 1977, Long-Airdox reentered the market with a chain-type system to complement its belted system. The original bridge-type continuous haulage system was introduced to the coal mining industry in the early 1960s by the old Long Co., a predecessor to the current Long-Airdox Co. These original units were of the chain conveyor type. In the early 1970s, there were also developments in continuous haulage, employing different material handling media. These in¬cluded the Serpentix, a flexible type belt, introduced by the Joy Manufacturing Co. There was also a serious attempt to introduce hydraulic-type continuous haulage by Consolidation Coal Co. and Conoco Research. Despite some startling successes, particularly with the bridge-type haulage systems, the general and widespread application of continuous haulage has eluded the mining industry. Some of the problems are related to underground conditions; others to people, both management and labor. One of the greatest obstacles to universal success continues to be the difficulty of accepting the philosophy as well as the machinery of continuous haulage. Nevertheless, efforts continue to spread the success of commercial and viable systems in the industry. There is also effort to improve on these systems, and on methods for their successful use. In addition, efforts continue, with private and public support, to develop new types of continuous haulage equipment and systems. Bridge Type System Developments Because they have already been successful in some US and overseas mines, new developments in bridge-type systems will first be touched on. The Long-Airdox Co. has continued to improve both its belted and chain continuous haulage system. In the belted system, the company recently introduced a new design that will be mainly applicable in higher coals and in noncoal mining applications, as shown in the accompanying figure. This new system is equipped with 305-mm-diam (12-in.-diam) pulleys in the bridges and mobile bridge carriers, in place of the 150-mm-diam (6 in.-diam) pulleys in the standard system. The modification is designed primarily to improve belt life and keep belt problems to a minimum. An operator, the Clinchfield Coal Co., a Division of Pittston Coal, developed the detaching of the bridge-type continuous haulage system from the miner by placing a mobile bridge carrier at the head of the string. However, Long-Airdox and Jeffrey have now made this an option to their at¬tached-type system. In the US, there are many chain type haulage systems detached from the miner with an extra MBC at the head. There are two such belted systems

Jan 7, 1982

By J. B. Kitchin

"The design of conveyor belting for use in mines poses problems to the manufacturer that are unique. The challenge to be met is that of the production of a conveyor belt which can withstand use and misuse in an environment that may differ vastly from one country to another, and even between one mine and its neighbour.The development of a product to meet such varying requirements necessitates a protracted program of trials, both in the laboratory and in the field; a new successful development, the only criterion, can be said to have been achieved only after very long-term usage under actual, deliberately chosen, arduous mining conditions.New developments in conveyor belt construction can never stop, no more than can developments in new and advanced mining techniques. A new problem is set-an answer must be found. Some of the problems are noted here, and answered where possible, in what must after all be little more than an excursion into a very comprehensive and detailed subject."

Jan 1, 1967

By David Mitchell, Daan Delport, Frik Marx, Mike Shapiro

The use of copper cooling elements to enhance refractory lining life in pyrometallurgical vessels is common in modern furnace design. Copper elements typically incorporate a base panel with cast in cooling passages and an integral extended surface (formed of pins, fins or similar) onto which suitable refractory material is cast. The metallic, conducting parts are located towards the cold face of the lining, with the refractory material interposing between the coolers and the process. The coolers are designed to arrest wear of the refractory material by freezing a layer of slag or partially reacted material onto the hot face, thereby rendering the lining inert to further attack [1]. These coolers have achieved success in new furnaces and relining of existing vessels. The freeze layer is prone to mechanical damage during operational and process instability. The coolers must be capable of extracting the additional heat flux under upset conditions to facilitate rapid self-repair of the freeze layer and prevent further refractory wear in the intermittently exposed areas. However, operational experience has shown that the high heat flux capabilities of the copper coolers have some disadvantages, especially in processes producing vapours which form corrosive compounds when condensing onto the cold surfaces of the coolers. When corrosive conditions develop, the entire composite will fail due to loss of structural integrity, and as a result of leaks from the cooling water passages. This paper describes recent developments in the approach to the design and manufacture of copper cooler panels customized to achieve specified heat fluxes and temperature profiles, thereby reducing the formation of corrosion mechanisms in applications with corrosive gaseous environments and enhancing refractory lining life. Condensation formation prevention is achieved by adjusting the geometry of the cooler and selection of suitable materials of construction.

Jan 1, 2007

By Phillip J. Mackey, Gerardo R. F. Alvear F.

It is now 38 years since the publication of the first edition of "Extractive Metallurgy of Copper" by Professor W.G. Davenport and the late Professor A.K. Biswas. The text book would be issued in a total of five editions, soon became the standard for students and those in industry. Interestingly it was published at the onset of great change in the industry. This was a time when sulphur dioxide controls in the USA were introduced, and almost simultaneously, world oil shocks caused significant increases in the cost of fuel - all leading to efforts to adopt new technology and move away from the reverberatory furnace, which had no potential for sulfur capture and required large amounts of fuel. At the time of publication of the book, new processes such as the Noranda Process and the Mitsubishi Process were in their infancy, while flash smelting (which was first commercialized in 1949 at Harjavalta, Finland) had made significant in-roads in boosting copper output, with some 22 new flash smelters licensed by 1976. Computer technology and associated process control techniques were rudimentary compared to systems today, available physico-chemical data remained largely in tabulated format and needed to be manually entered into the main frame computers of the era, while modeling techniques common today had not yet been developed. The copper industry has therefore seen immense changes since the time of this textbook: world tonnage of smelted copper has risen from 7.34 million tonnes/year in 1976 to 16.7 million tonnes/year in 2012, over a two times increase. Technologies such as the El Teniente Process, or Top Submerged Lance technologies, typified by the ISASMELTTM, not commercialized at the time, now treat large tonnages of copper concentrate in a single furnace. Advanced heat and mass balance software and thermochemical modeling are now used extensively to examine chemical and physical characteristics for process design and to support process optimization. These changes in the industry have been chronicled in subsequent editions of the book. This paper looks at the issues and problems seen in 1976 and over the intervening years, and compares this with the challenges facing the industry with the available tools and technologies today. Some ideas looking into the future are also discussed in the paper.

Jan 1, 2014

By E S. Bernard

Steel fibre reinforced shotcrete (SFRS) is increasingly being used as ground support in both civil and mining applications. In recent years, methods of assessing the performance of SFRS have been developed. These include the beam test such as that prescribed by ASTM C-1018 and the panel test prescribed in the EFNARC European Shotcreting Standard. The panel test has gained popularity in recent times due to the two-way action modelled in the test. However, some difficulties have been noticed. Shear failures sometimes occur and there appears to be a rather high degree of variability in the panel test results. A new method of testing panels has been proposed. A circular panel supported on three symmetrically arranged points has been assessed at the University of Western Sydney. This paper describes the new test which may be the basis of a new specification for the testing of toughness of SFRS and summarises research work which has been carried out to-date.

Jan 1, 1999

By J. Bacho

The modern drilling fluids industry is a dynamic, evolutionary environment. It is continuously striving to satisfy and anticipate the ever-changing needs of the oil and gas industry. The predominant driving forces in the industry over the past decade have changed dramatically. Health and environmental issues, coupled with economic and performance requirements, demand innovation and change from the drilling fluids industry. Emerging drilling fluid technologies will demand environmental considerations from mined components with additional emphasis on cost and performance criteria. Drilling fluids providers continue to search for and identify environmentally sensitive components which meet or exceed the performance of their more toxic predecessors. These changes have and will impact the components of drilling fluids that are mined.

Jan 1, 1994

The original and most basic relationship between mining company and explosive supplier was a simple one of consumer and product supplier. The divide between the two was quite clear-cut with neither taking much interest in the activities of the other. The explosive supplier had little understanding or share in the outcome, efficient rock breakage and therefore impact on mining and milling. Likewise, the mining company did not encourage the improvement or development of products. The transactions were limited to product and funds. This environment does not encourage any form of knowledge sharing, trust or optimisation of the mining process.Conversely, there are now a variety of relationships to the point that the mining company may simply be an asset manager whereby all æoperationalÆ aspects are contracted out. For the drill and blast aspect this takes the form of a æRock-On-GroundÆ contract whereby the explosives company takes on design, drill, load and fire responsibilities and is paid a rate per volume of broken rock. This removes the majority of risk to the mining company derived from having to produce broken rock and guarantees the cost of a portion of the overall unit cost of mining. The onus is now on the explosives supplier to break rock to a specification as efficiently as possible.There exist a number of variations between the æbasic supplyÆ and æRock-On-GroundÆ. These contracts may also include value sharing to encourage the explosive supplier to optimise the mining operation to maximise profit.This paper looks at some of the drivers for the change in explosive supplierûconsumer relationships and examines the æprosÆ and æconsÆ of a few of the options.

Jan 1, 2004

By S. S. Sephton

Sintering as applied to agglomeration of ferrous fines has shown little growth in the United States in recent years. The general concensus was that most of the existing facilities would remain in production at a reduced tonnage to dispose of and recover solid waste from steel plants. Further growth for ferrous sintering technology was not in sight in the United States and in the early sixties expansion came to a virtual standstill, however, we witnessed a rapid emergence of a tremendous pelletizing industry. On other continents, due to different raw materials supply and capital structure, sintering technology continued to grow, with a more cautious development of pelletizing installations. In the U.S. the diminishing supply of good quality, high grade coarse ore resulted in eventual disappearance of high grade ore fines for sintering. The finely divided concentrates produced from lower grade ores were not amenable to this type of agglomeration, but were more suitable for pelletizing. Furthermore, pellets seemed to possess all the features of an ideal blast furnace feed; namely pellets are free flowing, uniform in size, strong, with extremely uniform chemical composition and good reducibility. Importance and demand for such well stabilized furnace feed further increased as size of newly installed blast furnaces continued to grow. The in- creasing demand for a uniform, stabilized burden coincided with the effort to produce a fully beneficiated burden for smelting, thus reverting the blast furnace to its primary function of smelting.

Jan 1, 1973

By R. O. Burt, D. J. Ottley

"SYNOPSISRecent developments in the use of the Bartles-Mozley table and the Bartles CTS screen are described for the gravity preconcentration of fine heavy mineral and metal particles present in low grade pulps. The B-M table is a relatively new device used for the recovery of particles of up to 100 micron size down to 5 microns or in the case of gold and platinum, down to 1 micron. The CTS screen is a wet screening device used for feed preparation ahead of the Bartles-Mozley table and will size effectively down to about 300 mesh. Results and operating data for a number of different materials are given including outline flowsheets; the effects of the major variables on the performance of the table are briefly discussed. The potential of the B-M table to treat a variety of different ores, coal, tailings, and waste products are considered. The utilization of the B-M table in association with other unit processes to improve overall results as well as to improve the economics of design and performance of plants are also mentioned.INTRODUCTIONA number of new gravity concentration devices have been developed in recent years for the recovery of fine heavy mineral and metal particles but for reasons which include low capacity, high capital or operating costs, competition from other and better processes, the absence of simplicity or reliability in operation etc., only a few which include the Bartles-Mozley table, have been proved to be of commercial application.The name of the machine is derived from the inventors name, Richard Mozley, who developed the B-M table at the University of Bristol in England. The table was subsequently taken up and patented, world-wide, by the National Research Development Corporation a British government agency. An exclusive license to manufacture the table was granted by NRDC to Bartles (Carn Brea) Ltd. in Cornwall, England."

Jan 1, 1973

By B. J. Elliot

The Outokumpu Oy flash smelting furnace was designed for a capacity of 69,5 mtph of concentrate. The history of developments on the flash furnace, from the original operating capacity of 55 mtph to a proven capacity of 115 mtph of concentrate, is summarised. The new feature of operation at BCL Limited is ?the use of screened lump coal reduction in the settler region of the furnace. This paper considers the effects of settler bath reduction on the furnace smelting capacity, the condition of the furnace ?lining and bath, and ,the slag losses generated from the flash furnace and ultimately to discard. By using the settler bath reduction technique the capacity of the furnace for smelting new concentrate has been increased by 15% and hearth accretion has been eliminated by direct reduction with coal, which has also allowed the generation of a substantial protective lining on the furnace walls and roofs. As a result of improved slag losses from lump coal charging the metal recoveries on the flash furnace have increased from 70% to 87% for nickel, 68% to 82% for copper, and 28% to 45% for cobalt.

Jan 1, 1983