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By G Harbort, V Lawson

Mount Isa Mines Limited operates one of the worldÆs largest underground mines in North West Queensland. ItÆs mining and smelting complex produces copper anode, crude lead bullion (containing silver), and zinc concentrate. Copper is recovered in the Copper Concentrator from chalcopyrite ore, converter smelter slag and rotary holding furnace (RHF) slag via grinding and flotation operations. During 2002 a project to optimise cleaner circuit capacity was commenced. Its aims were to minimise copper losses and minimise slag/chalcopyrite cross contamination by reconfiguring existing flotation equipment and the addition of new flotation capacity. To minimise cross contamination a Jameson Cell was installed and dedicated to cleaning of slag concentrates, which had formerly been conducted by three flotation columns operating in series. The flotation columns were re-configured to operate in parallel and dedicated to upgrading chalcopyrite concentrate. In addition a Jameson Cell was installed to reject entrained copper from a prefloat concentrate consisting of talc and carbonaceous pyrite. This paper discusses the logic behind the cleaner circuit expansion, recent test work relating to the Jameson Cell and the installation and commissioning phases. Difficulties relating to the commissioning are reviewed and the solutions to problems are highlighted. The benefits the reconfigured circuit has provided to Mount Isa Mines are also discussed.

Jan 1, 2003

By J. E. Gill

THE 1938 season was marked by a distinct lull in exploratory activity in the Province of Quebec. Quebec was not unique in this respect, but the condition appears to have been more acute here than in most other parts of the Dominion. Various causes may be suggested to account for this. The general disturbance in political and economic conditions throughout the world has certainly had an adverse influence. Uncertainty induced by changes in the mining laws of Quebec in 1937 contributed. A third cause was the belief, now held by many, that the easily accessible deposits in the main producing belt extending eastward from. the Rouyn district have now all been found and that new discoveries in this field will henceforth come more slowly and more expensively. A fourth is the lack of conspicuous success by companies and individuals who have interested themselves in less accessible areas to the north, notably the Chibougamau district. A fifth, the unattractive appearance, as viewed on published geological maps, of the vast area extending northward to Ungava bay and Hudson strait. A sixth, the attraction of such speculative funds as were available to the Northwest Territories, where spectacular finds were reported in the fall of 1937. Whatever may be the relative importance of these causes, languor in exploration will ultimately be reflected in production returns. This appears, therefore, to be an opportune time to take stock of the general position of the Industry in the Province and to consider ways and means of counter-acting those conditions which are now impeding, or will in the near future impede, its expansion. At the request of the Institute Secretary, Mr. Carlyle, I have prepared a brief summary of accomplishments to date and a discussion of some of the geological aspects of the problem.

Jan 1, 1939

By S. J. Thiele, T. Newton, W. Magalhäes, T. Takayama, J. Welsh

Companhia Paraibuna de Metais (CPM) is presently pursuing a zinc production expansion project. Besides increasing production, the goal of the project is to address existing problems while providing a platform for a proposed twofold increase in production in 2003/2004. Therefore, the current expansion strategy was formulated to address present and future requirements. Computer simulation modeling and full scale plant testing are being used to generate data to optimize the operating conditions and to perform a sensitivity analysis. The initial phase of the project, which will boost CPM's capacity to 86,000 t/y of marketable zinc, is to be completed in September 2000.

Jan 1, 2000

By H. Kurokawa

Sumitomo Metal Mining decided to expand copper production capacity of Toyo Smelter and Refinery to cope with the recent copper demand growth in Asia, and to survive by reducing cost. The expansion plan is promoted to increase electrorefined copper production capacity from 270,000 metric tons in 2001 to 450,000 metric tons in 2007. The major changes in smelting section are introduction of the rotary steam dryer, renewal of the feeding system for flash furnace, improvement of the concentrate burner, modification of the flash furnace cooling materials, renewal of the slag cleaning furnace, modification of the flash furnace waste heat boiler, installment of a new converter furnace, enlargement of two anode furnaces. In addition, the gas cleaning system was upgraded and the second acid plant was installed. In the refinery section, the existing tank houses have been operated at high current density of 300A/m2 using the conventional starting sheet cathode technology and moreover a new tank house utilizing the permanent cathode technology was constructed. Although the copper production capacity has been increased, SO2 emission has been kept the lowest in the world through consideration of influence on the environment by expansion project.

Jan 1, 2006

By T. Maruyama

Tamano Refinery started its operation in 1972 with the cathode production capacity of 84,000 tons per year. After several expansions, the production capacity increased to 228,000 tons per year in 2001. In this paper, we are introducing our next expansion projects starting October 2006. The project expands the production capacity of cathode from 228,000 tons to 260,000 tons per year. The main modification of this project is the conversion to the ISA process and the installation of additional seventy-two cells in the No.2 Tankhouse. The No.1 Tankhouse remains the same, using the conventional process. Half of our starting sheet cells are converted to commercial cells. The other expansions are to enlarge our purification plant. And the incidental facilities are enlarged, for example, circulation tanks, heat exchangers, filtration system, etc. Finally, this paper describes those improvements to our refinery performance and preparing for future expansions.

Jan 1, 2007

By Howard Scott

INVAR is the preeminent low-expansion metal by virtue of the fact that it can be prepared with a zero coefficient of expansion at atmospheric temperature. This fact suggests that there is little room for improvement in the expansion properties of the low-expansion nickel steels. The inference is true, however, only so far as the expansion at and near atmospheric temperature is concerned, because the expansivity of invar starts to increase rapidly on heating above 100° C. and soon reaches the value of copper. Guillaume1 met this situation by increasing the nickel content above that of invar. By that expedient, alloys having low expansivity under higher temperatures were obtained, but not without a large increase in minimum expansivity. The increase in minimum expansivity with increasing nickel content severely limits the technical applications of these alloys at high temperatures. Prospects of improving the expansion characteristics of the nickel steels is offered by alloying. Search for an advantageous alloying addition by analogy with other alloy systems, however, is not productive because the low-expansion characteristic is unique with that system. The rule of mixtures usually gives a fair value of the expansivity of other solid-solution alloys, but in the iron-nickel systems gives a value of 18 X 10-6 per deg. C. whereas the actual value is 1 X 10-6 per deg. C. Apparently suitable additions are not to be deduced from such ingenuous considerations. Recognition of the fact that the temperature range of low expansivity in nickel steels is terminated with loss of magnetism affords a more promising basis for the selection of an advantageous element. One may expect from that fact that additions of nonmagnetic elements to the iron-nickel alloys are detrimental to the low-expansion characteristic. Indeed, carbon, manganese, silicon, copper and chromium are detri-mental to the expansion properties and no nonmagnetic element is reported to be beneficial. From the same viewpoint, the addition of a magnetic metal offers prospects of improvement. As two of the three ferromagnetic elements are already present in the

Jan 1, 1930

By Jaime Tumialán

El presente texto describe el planeamiento y ejecución del proyecto Expansión Casapalca realizada a través de la gerencia de operaciones de CENTROMIN PERÚ. En este sentido, el objetivo del texto es incrementar la producción de 2,150 TCS por día utlizando una explotación racional de las reservas probadas del yacimiento. Asimismo, refiere los antecedentes, estudios de factbilidad y las características generales del yacimiento.

Nov 8, 1984

By Kathleen M. Kowalski-Trako?er

National Institute for Occupational Safety and Health re­searchers conducted a study to investigate the human response issues related to wearing a self-contained self-rescuer (SCSR). The goal was to develop training to educate miners on what they could expect from their units during an escape. Subjects included miners who had experience wearing SCSRs, manu­facturers, and researchers. Results identified nine key areas of concern: (1) starting the unit, (2) unit heat, (3) induction of coughing, (4) unit taste, (5) difficulty in breathing while wearing the unit, (6) quality of the air supplied, (7) nose clips, (8) goggles, and (9) the behavior of the breathing bag. In addition, researchers reviewed the literature on human response under duress. This article describes the expectations training program, which comprises the findings of the SCSR study and what is known about the normal human response in an emergency. The authors present background on SCSRs and the SCSR switchover procedure mandated in the recent federal Mine Improvement and New Emergency Response Act of 2006, which provided the impetus for the expectations training. Keywords disaster, escape, mining, self-contained self-rescuer, training

Jan 1, 2008

By Launa Mallett, Charles Vaught, Michael Brnich, ROBERT PETERS

Interviews of 48 miners who escaped underground coal mine fires revealed that none of them had ever, before that incident, worn their self-contained self-rescuer (SCSR) either in training or in a real emergency. Consequently, they were ill-prepared to use this emergency breathing apparatus. One persistent problem stemmed from the fact that miners had no notion of breathing resistance, nor of the fact that it would get more difficult to breathe the longer they wore their device. As a result, many of those who were interviewed had simply removed their mouthpieces and breathed ambient air. This is obviously behavior that should be trained out of the workforce. Unfortunately, because of high costs and difficult logistics, miner training is unlikely to ever include donning and wearing an apparatus on a regular basis. In order to give workers a better idea of what to expect from their devices, therefore, the National Institute for Occupational Safety and Health researchers developed a tabletop (paper and pencil) simulation based upon actual predicaments evacuees had reported encountering. The simulation is designed to emphasize important points related to donning and wearing a self-contained self-rescuer in a mine fire escape, and, by doing so, to bring miners' expectations more in line with what their actual experiences would be. The simulation was field tested in six training classes at three different mining operations. In all, 99 individuals were involved in completing the exercise and rating its properties. In their ratings 88% of the respondents indicated they thought the scenario could definitely happen in real life, and over 80% agreed they had learned something new. From the field test data it was concluded that the simulation had authenticity and potential value as a teaching tool. The simulation was therefore used in a pre-test/post-test control group experiment to determine whether it led to improvements in miners' scores on a true-false test of their SCSR's functional capabilities and proper usage. Eighty-three miners were included in this part of the study. As expected, miners who had participated in the training exercise scored significantly higher on their post-test than miners who had not.

By Mark L. Blanford, Roger M. Zimmerman

INTRODUCTION Volcanic tuffs on and adjacent to the Nevada Test Site (NTS) are being considered by the Department of Energy (DOE) for the possible geo- logic disposal of high-level radioactive wastes. The Nevada Nuclear Waste Storage Investigations (NNWSI) project was established in 1977 to evaluate such disposal. Sandia National Laboratories (SNL), one of the participants in the NNWSI project, has as one of its responsibilities the development of a rock mechanics program for the Nevada site. SNL conducted three small-diameter heater experiments in welded and nonwelded tuffs in G-Tunnel on the NTS, to investigate the thermal (heat transfer) and hydrothermal (thermal- induced water migration) behavior as part of the rock mechanics program. These two aspects were investigated to increase knowledge about the behavior of tuff so that predictive capabilities are available for use by repository designers, waste-package designers, and performance analysts. Also, knowledge of the behavior of the tuff is invaluable for planning and designing future in situ experiments at Yucca Mountain, the candidate site for the repository. The evaluations of these three experiments is the subject of this paper. Designers, analysts, and experimenters are seeking a better understanding of the behavior of tuffs under the influence of thermal loads expected from radioactive-waste storage, because of two physical features peculiar to tuffs. First, tuffs are inherently porous because of the manner in which they are deposited (Smith, 1960). Tuffs utilized in G-Tunnel testing have porosities ranging from 15 to 46%, which cover the ranges of expected porosities in the target horizon at Yucca Mountain. It has been established that the G-Tunnel tuffs have similar bulk, thermal, and mechanical material properties to those at Yucca Mountain (Zimmerman et al., 1984), thus, G-Tunnel testing can be used to evaluate the effects of porosity on the thermal and mechanical behavior. The second feature is that tuffs above the water table contain pore water that influences the thermal properties of the rock; displacement of the water must be accounted for in repository designs and analyses. For example, G-Tunnel tuffs, located some 600 m above the static water level, have saturations in excess of 60%. Similar percentages are expected at the target horizon in Yucca Mountain (Zimmerman et al., 1984). The presence of and the removal of the pore water affects the thermal behavior of the tuffs, and these three experiments were designed first to determine the phenomenological behavior and then assess influences on predictive capabilities. The focus in this paper is to present the results and evaluations of the experiments as they apply to improving predictive capabilities. The thermal aspects are emphasized by comparing the measured temperatures (in and around heater emplacement holes) with calculations of predicted temperatures using numerical models, so that the effects of significant parameters can be evaluated and integrated into future predictive models. Observation of the hydrothermal aspects is needed to assess the effects of loss of pore water and subsequent migrations on the temperature fields during the heating, and also to define the expected environment in the vicinity of the outer metallic surface around the waste. The metallic boundary can be either the outer shell of the waste package system, which is the main engineered barrier for waste containment, or the borehole liner. A final decision has not been made as yet about the necessity for lining boreholes; thus, the emphasis is on predicting the characteristics of the environment around the outer metallic surface. Two aspects that limit the scope of this paper are (1) the experiments were performed at a smaller than canister scale for the purpose of

Jan 1, 1986

By Keuncheol Choi, Yonghack Lee

"The new lead smelter based on the QSL technology was started operation from May 1992 at Onsan Refinery of Korea Zinc Co., Ltd. The smelter is designed to treat not only various types of lead concentrate but also secondary materials coming from the zinc plant without special pretreatment.Shortly after the start-up of the operation, it has demonstrated that the smelter have a capability to treat wide range of raw materials. Continuous modifications and improvements of the plant are still under way to increase the feed rate and also the ratio of secondary materials to the feed.In this paper, the operating experience and results of QSL smelter, especially the injection of gases and coal to the melt, will be presented with major operation parameters and data.INTRODUCTIONThe QSL lead smelter based on new injection technology was commissioned at the Korea Zinc's Onsan plant from May of 1992. After starting the operation, the QSL lead smelter faced various kinds of mechanical and metallurgical troubles. However, these were gradually worked out by the continuous improvements and efforts.At present, the QSL lead smelter is operated stably at the total feed rate of 57 tonnes per hour with an increased amount of secondary materials."

Jan 1, 1996

By Douglas M. Dwosh

INLAND STEEL COAL COMPANY'S experience with a gypsum cement, with and without fiber glass filler, indicates that the concept of utilizing standard rock dust equipment to dry handle and apply gypsum cement as a mine sealant is feasible, simple and economical. Prior to 1975, Inland had casually experimented with a few sealants and had discussed the advantages and shortcomings of other sealants with various users. Hower in mid-1975, Inland foresaw the need to seriously acquire a practical sealant system. There were nearly a dozen sealant materials on the market at that time: silicate-based materials, Portland cements, vermiculite cements, gypsum cements, and magnesium-oxysulfate cements, each with their own fillers and additives. The applicating equipment ranged from simple to complex: wet mix or slurry machines operating on either a batch or continuous basis, high viscosity pumps, and pneumatic, dry conveying machines with water nozzles. Compounding the selection process, two or more products could often be used with the same machine, or a given material could be successfully applied with more than one type of machine.

Jan 1, 1976

By Douglas M. Dwosh

Inland Steel Coal Co.'s system of applying a gypsum/fiberglass rib and roof sealant with standard rock dusting equipment will be outlined. The criteria for use included acceptability of results, flexibility of equipment, ease of application, and economics. Material is conveyed dry until the gypsum, fiberglass, and water are combined at the discharge end of the rock dust hose.

Jan 1, 1978

By Patzen Wu

Taiwan is located in the orogenic belt of island arcs on the western rim of the Pacific Ocean. The structure of the Taiwan coal fields is much complicated as a result of active Cenozoic orogenic disturbance in Plio-Pleistocene time. The abundant faults and folds have created poor structural conditions of the coal seams and some peculiar safety problems in mining however, the domestic coal still played an important role in the economic development of Taiwan for the years before 1968. Because of increasing mining depth and a decreasing number of miners, the coal production dropped from nearly 5.1 million metric tons in 1968 to 2.45 million metric tons in 1981. There were 173 small active coal mines and about 22 thousand miners in 1981. The coal mining in Taiwan has a history of more than one century. Specific efforts have been undertaken in solving major coal mine safety problems such as gas outbursts, bad roofs and weak floors, difficulty in ventilation due to deep underground mining, spontaneous combustion etc. We have thus acquired much helpful experience which, we deem, is worth reporting at this meaningful meeting.

Jan 1, 1982

By P. G. Henderson

Coalbrook Collieries has produced approximately 2 million tons of coal by retreat longwalling since April 1976. Strata control. support. stone intrusions. coal conveyance, and the inflow of goaf and water between the face supports have been the major operational problems experienced to date. The progressive percentage availability of the total system (moves between panels excluded) for the first three panels mined was 40 per cent. Satisfactory solutions have been evolved for these problems. and the availability in the present panel (fourth panel) has increased to approximately 60 per cent. It is envisaged that longwalling will become the most economical method of ensuring optimum heat values, greater recovery. and reduced geographic expansion. as well as safer roof conditions. at Coal brook.

Jan 1, 1980

By Kennedy G. L

Operating experience with the pilot Lurgi carbonization plant at Morwell showed that under conventional operating conditions, although the thermal efficiency of the plant was very' high, the physical quality of the char produced was extremely poor. By variation of operating conditions to produce the slow drying rate developed by the laboratory research at the University of Melbourne, an improvement in the size of the char was achieved. A similar approach in the carbonization stage where severe breakage of the briquettes still occurred was not possible due to insufficient control over the heating in this stage. Theoretical analysis of the heat exchange process has shown that severe heating of the briquettes entering the carbonizer is a characteristic of the Lurgi system and cannot be controlled by modified operation. The plant has been closed down for reconstruction of the heating system to enable it to be used to produce hard char.INTRODUCTIONAn experimental carbonization plant was operated at the Morwell Works of the 'Gas and Fuel Corporation from November 1958 until July 1959. This plant was built as a pilot plant by the Corporation to designs supplied by the Lurgi Gesellschaft fur Warmetechnik and had the nominal capacity to carbonize 25 tons of brown coal briquettes and to produce 11 tons of char per day. The briquettes were supplied from the· normal production of the Yallourn briquette factory and the 2t in. I-type briquette was the largest size which the plant could handle.This carbonization plant represents the intermediate stage of development between the laboratory research at the University of Melbourne and the commercial production of hard char as a metallurgical fuel. It is intended in the first place for the study of the technical problems in the handling and...

Jan 1, 1960

By N. Giguère

Until recently, the heat treatment of pressure die cast parts has always been considered unpractical because the solution heat treatment resulted in unacceptable blistered parts. This was due to the presence of massive porosity associated with the die casting process where the inflow of metal inside the mold cavity is extremely turbulent. With the steady improvement of foundry practices and the generalization of vacuum die casting, porosity defects have been reduced to the point that a partial solutionizing heat treatment can be applied without any damage to the casting. However the solutionizing temperature must be lower than that applied to macroporosity free castings and for much shorter time. The object of the present study was to determine the optimum solutionizing temperature that can be applied to aluminum 383 die cast brackets along with the optimal temperature and time of aging resulting in the highest improvement in mechanical properties (both strength and ductility). This was done by testing strength and deformation on the casting itself using a specially designed jig; the crushing force to deformation curve was analyzed so as to quantify the improvement in both strength and ductility gained with the partial precipitation hardening heat treatment.

Jan 1, 2011

By G. Morin, F. Chiesa, B. Tougas, B. Duchesne, Jocelyn Baril, N. Giguère

"An aluminum A356 compressor impeller was sand cast using the Low Pressure technique. The casting was limited in size (170 mm in diameter, 1.2 kg in weight) and very intricate in shape thus making 3D mold printing particularly favorable; indeed, producing this part by the traditional pattern-core box route would involve mounting 12 cores inside the mold while stringent dimensional tolerances are required as the impeller blades are only 2 mm thick. Consequently the molds were produce on the X-One MFlex printer of Quebec Metallurgy Center - CMQ. A dozen castings were produced with different casting temperatures and filling times so that it was possible to assess under which conditions complete filling of the mold cavity would be achieved. Filling and solidification modeling allowed predicting misruns and metallurgical properties inside the A356 (AlSi7Mg04) casting.INTRODUCTION Recent advancements in additive manufacturing enable foundries to produce molds without the tooling (pattern and core boxes) necessary when conventional technology is used (Eyad, 2016). This is particularly advantageous when dealing with intricate shapes and/or when a limited number of parts must be produced within a few days rather than in 5 weeks. An additional advantage is gained when producing prototypes (Johnson, 2016) as changes are much less costly and time consuming when made on a numerical 3D drawing rather than on patterns and core boxes. 3D printing is normally economical for a small number of parts; however, if the part is not too big and very intricate in shape such as the part that will be studied in the present work, 3D printing can be economical even for an important number of castings to be produced. On the other hand, low pressure casting is a high integrity casting process in which the mold cavity is filled from the bottom via a transfer tube in which the liquid aluminum rises under the pressure applied at the surface of the melt as illustrated in Figure 1. The filling can thus be precisely controlled, eliminating the turbulence created when the mold is filled from the top (gravity casting). Also, the pressure applied on the melt during solidification results in excellent feeding of the casting when conditions of directional solidification are met. In the present work, the compressor impeller shown in Figure 2 will be sand cast by low pressure."

Jan 1, 2018

By Roberts T. J, Thomson I. A

Mill scale, which contains a high proportion of magnetite and wustite, was added to the feed to the Whyalla grate kiln pellet plant during the production of acid pellets for domestic consumption. Its addition resulted in increased production -rates together with reduced consumptions of bentonite, fireclay and fuel. Mill scale was particularly beneficial when treating feed containing difficult to process, earthy, high ignition loss iron ores. Test work in the laboratory and subsequent plant experience showed that the magnetite and wustite oxidised in the drying and preheat sections of the travelling grate. The additional heat reduced gas flows through the grate kiln system, aided the drying of green balls containing earthy ores and increased the preheat strength of the balls. These advantages were offset to some extent by higher power consumptions to grind the harder mill scale and process difficulties caused by the contamination of mill scale with oil and coke.

Jan 1, 1974

By C. S. Ha, H. S. Choi, D. Y. Shin

POSCO installed a new 100 ton oxygen bottom-blown converter in 2013 for the development of new steelmaking process named as PS-BOP which is reading POSCO-Saarstahl Basic Oxygen Process. This process was developed by the collaboration research between POSCO and Saarstahl AG in Germany that is based on substantial increase of CO post combustion in a converter by blowing hot air from the top of converter. The collaboration research has been finished successfully in November 2013 with 17% decrease in hot metal ratio (HMR) when hot air was blown from the top of the oxygen bottom-blown converter. After the collaboration research the converter has been tried to be operated as oxygen top and bottom-blown converter to reduce bottom wear and to decrease production cost with increased use of low cost Fe source by the help of increased CO post combustion. The presentation includes experience on the start up of oxygen bottom-blown converter, HMR reduction trials with hot air top blowing and transition from oxygen bottom-blown to top and bottom-blown converter operation.

Jan 1, 2015