Search Documents

By P J. Fairfield

This paper reflects on the author’s experience working in site-based technical and management roles over a 29 year period, and the past 12 years in internal and external consulting roles. It discusses the author’s experiences and observations of operations management, and the significant value of the technical specialist’s role in providing management with information on what to base tactical decisions, which may or may not be part of a defined strategy.The landscape of mine management changes with the cyclical nature of commodity prices driving operating and capital prudence, as operations change their focus from expansion and growth to staying in the game. The role of the mine manager and management team in navigating through these changing times, attitudes and stages of the project life can influence the success or otherwise of many projects.Technical knowledge is one of the key drivers in realising or destroying the value of a project or operation. As managers focus on people management, management systems and processes, recognising and understanding value in underlying technical knowledge, and getting back to the fundamentals/basics, can be overlooked. In reaction to the fluctuating commodity cycle, managers implement changes through optimisation, fast tracking or parallel streaming, expansion projects and changes in the application of technology. These responses occur against the background of changes in the appetite for risk, acceptance of project uncertainty and changes in personnel which result in a loss of knowledge and experience – often at critical times.This paper shares the author’s experiences and lessons learnt in dealing with and observing these issues. The author questions whether we really understand our projects and are valuing the most important asset, our people and, in particular, the technical specialist and their experience and knowledge.CITATION:Fairfield, P J, 2016. Staying in the game – the importance of engineering-based decisions, in Proceedings International Mine Management Conference, pp 67-74 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

By John V. Hamme

ONE of Tungsten Mining Corp.'s Vance County, N. C., mill near Henderson was the installation of a new crushing plant with a capacity of 45 to 50 tph. During 1953 the milling rate was jumped from 650 tons to 800 tpd simply by expanding existing facilities, eliminating bottlenecks, and making changes in the existing and new circuits. Previous expansions in 1951 and 1952 raised mill capacity from 300 tons to 650 tpd. In its latest move, Tungsten Mining decided that expansion of existing facilities would be more economical than building that normal production was uninterrupted. For the engineering and design of the new crushing plant and mill expansion the services of the Southwestern Engineering Co., Los Angeles, were obtained. The Southeastern Construction Co., Charlotte, N. C., carried out construction, alterations to existing facilities, and the installation of equipment

Jan 10, 1954

By M. C. Leverett

THE dynamic behavior of a multiple fluid system is completely describable in terms of driving forces and resistances to flow. The latter are proportional to the vis-cosity of the fluid under consideration and inversely proportional to a property of the system termed the " effective permeability" to that fluid, a property therefore defined by this relation. Since three phases are usually present in oil reservoirs, it is essential to know the effective permeabilities to the several fluid phases, and the relationship between the composition of the fluid in the pore space and that of the flowing stream, in order to handle satisfactorily certain problems of oil production. In this regard, there are many unknown factors and parameters, and many that can be evaluated only indi-rectly. However, it is expected that work along lines similar to this present under-taking will help materially in solving these problems. Previous workers in this field have inves-tigated the two-phase systems, water-gas,1 water-oil2 in unconsolidated sands, and water-gas3 in consolidated sands. The ex-tension of the study of the flow of hetero-geneous fluid systems from two to three phases involved only slight changes in technique. The apparatus used in the present work, except for slight changes to be described, was that used by Leverett in his water-oil experiments.2 Correlation and interpretation of data were made by methods analogous to those used in two-phase work. The relative permeability to a phase-the effective permeability divided by the permeability of the system to a homogeneous fluid-was employed through-out in correlating the rate of flow of that phase with the composition of the pore space. Quantitative measurements of two inde-pendent physical properties of the system were required to determine the composition of the pore space. As in the two-phase work, the fraction of water was determined electrically. The gas fraction was deter-mined by measuring changes in volume accompanying measured pressure changes. Suitable account was taken of the solubility of the gas in the liquid phases, and of the vapor pressure of the water phase. Since this work was exploratory in nature, no attempt was made to obtain highly accu-rate numerical results. Reasonable precision and reproducibility were sought.

Jan 1, 1940

By A. Della Rocca, P. Jonker, B. Henning

Successful prediction of the collection efficiency of cyclone separators is a necessary step in cyclone design and verification. Aside from standard empirical relations, CFD modelling is widely adopted to supplement the design of cyclone units in relation to the desired separation performance. Nevertheless, effective adoption of numerical modelling is sometimes prevented by large modelling errors, especially for small size particles which are more subject to turbulence effects than larger particle classes. In the past, this motivated the adoption of more refined turbulence modelling approaches, such as large-eddy simulations. These approaches provide greater insight into time dependent behaviour, while leading to larger computational cost with respect to more standard approaches. In this paper, an effective Eulerian-Lagrangian Reynolds-averaged Navier-Stokes (RANS) approach is investigated, which is able to predict the complete separation efficiency curve with satisfactory accuracy, without requiring prohibitively long computational times. An assessment of the proposed approach is carried out against experimental data from large laboratory scale cyclones, in the form of mean and fluctuating velocity profiles from LDA measurements (Hoekstra, 2000), as well as with respect to the experimental separation curve (Zhao, 2005). The final application to a full-scale industrial cyclone unit is then carried out with the aim of tuning the cyclone design to the separation efficiency curve as required by downstream processes. Keywords: Cyclones, separation, CFD, RANS, RSM, Lagrangian

Jan 1, 2020

By MARK J. VANARELLI

Estimating groundwater inflows in rock deep tunnels is critical to the safety of personnel constructing the tunnel and the cost of construction. This paper presents two case studies for estimating steady-state groundwater inflows into deep rock tunnels. The case studies included the Chattahoochee and Nancy Creek tunnels. In this paper, statistical methods were applied to packer test data obtained from exploratory borings during geotechnical site investigations. A semi-empirical procedure was utilized for estimating groundwater inflows into these deep rock tunnels. The Chattahoochee and Nancy Creek tunnels are deep rock tunnels which exhibit radial flow conditions. For the radial flow condition, a statistical analysis presented in this paper indicates that the semi-empirical procedure works well; however, variations in the procedure and/or an insufficient amount of testing could lead to underestimations of the inflow quantities. Packer test data plotted in histograms were observed in all cases to be log-normally distributed for the radial flow condition. Modeling using Monte Carlo simulations was observed to be an effective tool for removing irregularities in the distribution of the data and incorporating high-end permeability data to derive reasonable groundwater inflow estimates.

Jun 13, 2021

By Tom W. Pfeifle, Paul E. Senseny

INTRODUCTION Engineered structures such as mines, shafts and tunnels, and storage caverns for hydrocarbons, chemical s and brine are being built in natural rock salt formations in increasing numbers. In addition, salt formations are being considered as potential hosts for mined, nuclear waste repositories. The popularity of these formations for engineering purposes stems from the many favorable commercial, physical, and thermal characteristics attributed to the material itself. Not only have the formations been stable and free of dissolution for hundreds of millions of years, but the salt is fairly easily mined and has very low permeability, low water content, and high thermal conductivity. Another characteristic of salt is its tendency to flow or creep when subjected to a shear stress. Although this behavior may be desirable in certain instances, it may be detrimental in other instances since the creep rate may be large enough to produce deformations that tend to reduce the volume of storage caverns or to restrict access to mining operations. In either case, the engineer is faced with the problem of accurately predicting the long-term structural deformations under various combinations of stress and temperature and is required to compare these deformations with long-term design criteria. In the laboratory, deformation-versus-time curves obtained at constant stress and temperature show that creep of salt is similar to creep of many other crystal line solids. Figure 1 shows a typical deformation-versus-time curve for salt. When a shear stress is first applied, the rate of deformation is high, but decreases monotonically. This initial behavior is called transient or primary creep. At some time, the deformation rate no longer decreases but continues at a constant rate. This behavior is called steady-state

Jan 1, 1982

A powerful, interactive metallurgical process simulator for use on micro- computers has been developed in the Department of Metallurgy and Materials Engineering at the University of the Witwatersrand. MICROSIM presently allows simulation of all ore-dressing flowsheets and a selection of hydrometallurgical unit operations, and is extendable to all such processes. MICROSIM is written in Pascal. This modern language provides very versatile data structures which can be effectively used to solve the major problem in generalised simulation programs, namely storage and transmission of data relating to liquid and solid phases. Dynamic memory allocation allows optimal utilisation of computer storage space. The simulator utilises very efficient precalculation algorithms that determine the tear streams for optimal sequential modulator calculation convergence. Microcomputer graphics simplifies flowsheet specification, and form-filling data capture with supplied default values eliminate most common input errors.

Jan 1, 1987

By D. Gupta

Rates of autothermic reactions are sensitive to temperature variations to the extent of potential extinction of the reaction. Such reactions, when carried out in the countercurrent mode with feed-back of energy between reacting phases, may result in the possibility of multiple steady-states. In regions of great sensitivity, minor variations, especially feed-temperatures, are an important criterion for such instabilities. Mathematical models have been used to delineate the parameter-fields in which instabilities might occur. The metallurgical system chosen to experimentally verify the above theoretical findings was the exothermic oxidation reaction of magnetite to hemitite.

Jan 1, 1977

By C W. "Mickey" Bradley

Thunder strikes terror in the hearts of man and has since the advent of time. We all fear the unknown; even the Greeks created a god, THOR, to be responsible for the thunder and rain. Thunder, by itself, can't hurt anyone; it is simply hot air moving very fast. Thunder, however, is caused by lightning and lightning is what we need to fear and rightfully so. Annually, lightning kills hundreds of Americans, injures another 2,000, damages or destroys approximately 30,000 structures, 1 starts thousands of forest fires and strikes mine properties over 100,000 times.

Jan 1, 1992

I find that during the short time I have been in this district, the majority of boilers are, and have been, receiving very bad usage owing to the difficulties which they have to contend against, viz., oil and bad water. Oil on the heating surface of a boiler is of a highly dangerous nature inasmuch as it allows the surface to become overheated, owing to the water not coming into direct contact with the plates, and it naturally follows that when the crown sheets of a flue or firebox become overheated, you lose a considerable amount of the strength of the plate, and the flue or crown comes down. Referring to the oil question, I find that too much care cannot or exercised on the part of engine drivers in order to minimise as much as possible the internal lubrication of the various engines under their control. For I consider that it is here that the most of the trouble is caused. My reasons for stating such to be the case, are:-That the majority of enginedrivers before coming to this field have been used to driving engines that have been exhausting into the atmosphere, and probably they have been taught that it is far better to use a little extra lubrication than to have a hot bearing. So far so good. But one thing that must not be overlooked is that on these fields the conditions are altered in this respect, as the majority of engines in this district are not exhausting into the atmosphere, but are condensing their exhaust steam and using the water so condensed for feed purposes.

Jan 1, 1901

By A. R. Harrington

BEFORE discussing some of the technical aspects of the steam generating plants of Nova Scotia Light and Power Company, Limited, it might be of interest to go back through history and see the development of steam generation in this public utility. Back around 1902 Nova Scotia Light and Power Company, Limited, had three slide-valve engines in-stalled at its Water Street, Halifax, generating station for a total capacity of 1,800 kilowatts. The plant remained at about this size until 1910 and in 1911 a 2,000 kilowatt steam turbine was installed to raise the total capacity of the plant to 3,800 kilowatts. In 1916, a 3,000 kilowatt turbine was installed and one of the slide-valve engines was removed to make a total plant capacity of 6,200 kilowatts. The total demand in the Company's service 8rea was at that time 4,000 kilo-watts.

Jan 1, 1958

This paper describes a steam outburst in a metal mine which occurred in December 1992 in Japan, resulting in two fatalities. The outburst occurred just after blasting in a heading face 600 m below surface (SL-50 m), 1664 m from a mouth of the mine. The scale of the outburst was large and the fragments of the outburst spread up to 34 m from the face, the total volume of the outburst was estimated to be 206 m3. The outburst materials were mostly clay originated from the typical surrounding rock of sulfide ore and basalt. The shape of the larger outburst fragments were slabs with a thickness of 10 to 20 cm. The victims were found in a main ventilation air shaft, 175 m and 380 m from the face, respectively. The mine mainly produces copper, lead and zinc. The face was ventilated by a 560 mm diameter duct with a fan and the strata temperature of the rock was estimated to be in the range of 120 to 140¦C. There is a famous hot spring near the mine. A thorough investigation into the unprecedented accident was made including an on-site inspection and investigation of rock characteristics in laboratories.

Jan 1, 2005

By R. D. Leitch, W. P. Yant, R. R. Sayers

In 1924, the United States Public Health Service was requested to undertake a special study of stream pollution. The Public Health Service asked the United States Bureau of Mines to take up the study because the training and experience of the personnel of the former was considered not to be as well suited to this type of investigation as that of the Bureau of Mines. Under H. Foster Bain, then Director of the Bureau, field investigations were begun in the spring of 1925. Along with mine-drainage wastes, the problem of gas-house and coke-oven waste was investigated in the laboratory and a method of treatment by sodium hydrate and benzol was found to be promising. The idea was obtained by A. C. Fieldner, chief engineer of the Bureau Experiment Stations, on a trip to Germany in 1924. He saw a practical application of the process, but obtained no information as to definite chemical or mechanical processes. Because of the then pending American patent applications by the German firm, we made no attempt to develop our findings further. Shortly afterward, a similar method of treatment was developed in the United States,' and since that time we have devoted our attention entirely to mine drainage. This paper is a presentation of some general facts and information gathered during the past five years on coal-mine drainage. Scope of Work There was such a diversity of opinion at the time this work was begun, on the whole subject and apparently so little accurately known, that it was decided to undertake a basic study from which first, certain definite information might be evident, and second, what might be considered

Jan 1, 1931

By Stanley F. French, Bruno F. Koch

Although the amount of dust that will be actually recovered in the six main dust-control systems cannot be accurately stated until the tests mentioned previously are carried out, it is estimated that the average air entering the wet collectors will contain around 5 grains of dust particles per cubic foot. This means that the six systems handling a total of about 133,000 cu.ft. of air per minute will return about 68 1/2 tons of dust to the concentrator per day and since the copper in this dust will average around 2 per cent, the total recovery is approximately 1.37 tons of copper every 24 hours. This important copper recovery is not due entirely to the dust-control system since in a plant without control only the duct that is dispersed to the atmosphere represents a loss. A conservative estimate of the recovery of copper solely due to the dust control system would be about half of the total or approximately 0.70 tons of copper per day.

Jan 1, 1942

By U. A. Peuker

"Steam Pressure Filtration (SPF) is a modified cake filtration process and is characterized by both washing and excellent de-watering of the filter cake. Compared to conventional gas differential pressure filtration, the filter cake is treated with saturated or superheated steam replacing pressurized air. Invented in the early last century, Steam Pressure Filtration has reached technical maturity in the 1990ies for inorganic particle systems, fine chemicals and coal. Especially the de-watering performance for fine particles systems below 50 µm make Steam Pressure Filtration an excellent option for the processing of fine tailings streams, to produce a stable material, which can be described by the methods of solids mechanics instead of paste rheology. The washing, which is due to the condensing steam, is able to reduce the ion load of the solid. This additional effect is able to generate a dry tailings material, which shows a reduced leaching potential of mobile ions, which originally derive from the process water. INTRODUCTION Steam Pressure Filtration is a process concept especially of hyperbaric filtration, which started its market entry in the 1990ies (Bott 1996, Bott 2002). Even though there have been many attempts to apply steam on filters before, the success story began with the combination of hyperbaric filtration and steam application and the technical solution to limit the steam treatment to a defined zone on the filter. This resulted from the scientific findings that steam mainly enhances the de-watering during the mechanical filtration (Gerl 1999). There are no or minor positive effects of steam application to a filtration process during cake filtration and after the steam breakthrough has occurred. Furthermore that time a sufficient control technology to regulate the steam consumption as well as suitable filter cloths became available. There is a growing need for de-watering technology in the mining industry, not only for the concentrate but also for the tailings streams. Several reasons argue against the established solution of damping the tails as suspension or paste into tailings ponds. There are ecological, political, societal and economic reasons, which question the tailings ponds more and more. Due to the increasing costs in the building and monitoring of tailings dams, which contain the tailing ponds, the concept of dry stocking using filtration technology comes into the game (Jansson 2016). Dry stocking converts the tailings stream form the suspension or paste state, into a material, which can be stockpiled. The latter typically is a moist flowable disperse particle system. The conversion involves a de-watering step, in which different types of filter equipment can be used, e.g. filter presses, membrane filter presses, automatic press filters or hyperbaric filters. For coarse products also vacuum filter can be applied. Due to its excellent de-watering performance and the easy scale-up properties Steam Pressure Filtration is further option for dry tailings stacking."

Jan 1, 2018

By W. H. Schacht

IN THE Lake Superior District, the air indoors must be heated continuously during eight months of the year and occasionally during the remaining months. Incident with mining in this district, therefore, there is need for heating many of the buildings connected with these operations. In addition to the mine buildings, that is, shops, engine, houses, offices, change houses, etc., such public buildings as schools, library, and theater, when close to the mines, are often supplied from the mine heating mains. At the Copper Range Company's mines, Champion, Trimountain and Baltic, the heating surface thus supplied from the mine mains is over 50,000 sq. ft. (4645 sq. m.) which requires a steam consumption, at times, of 18,000 lb. (8165 kg.) per hour, or the equivalent of a rate of over 50 tons of coal per day (were live steam used). This figure is based on a consumption of 1/3 lb. per square foot of heating surface during the coldest weather, and provided the system is not wasting steam by blowing it to the atmosphere or into the return line on account of leaky traps, which so often is the case. Under the latter conditions, steam consumptions of three to four times the above rate are not uncommon. This shows that the cost of heating is of enough importance to be given serious consideration, especially at this time of rising prices of fuel. The power and heating value of exhaust steam are appreciated by most engineers, and its application for such purposes is general. At our stamp mills, the exhaust from the stamps is used to operate low-pressure turbines, thus reducing the former water rate per horsepower developed by more than 50 per cent.

Jan 8, 1920

WINDING engines are one of the most important units in the equipment of a mine. Upon the winding machinery depends not only the output of the mine, but it supplies in most cases the only means by which workmen enter and return from the mine, and consequently the utmost care and attention is desirable in its design. The efficiency of a direct acting winding engine, as a machine is very low. In other words, the proportion between the useful work performed and the actual work the engine is capable of performing (under the most favourable conditions) is very small. The reasons for this are:-1. The intermittent nature of the work; the engine is stopped from 20 to 25 %(or even more) of the time which would constitute a useful day's work.2. The large amount of power that is absorbed applying the brakes to bring the load to rest.3. That the net useful load raised is small in comparison with dead load to be lifted, and the parts to be set in motion.4. That, owing to the frequent stops, initial condensation in the cylinders is always greater than in a continuously running engine, whilst radiation from steam pipes, valve chests, &c., goes on whether the engine is running or...

Jan 1, 1911

Currently raw brown coal is fired in the Latrotx; 'ahcc th,iki~, Lanying with it two major penalties, (a) boiler efficiency of 65 - 70 per cent (in terms of GCV), (b) much higher boiler cost than for black coal. Drying the coal, in energy-efficient, and cost-efficient manner, opens the way to efficiencies of order 88 per cent and enables the lower cost black coal type boilers to be used. With the higher boiler efficiency goes much higher combustion temperatures and the effect of this on radiative heat transfer is a major factor in reducing boiler cost. In a fluidised-bed combustor the temperature is controlled to 800C - 900C. In a pulverised fuel combustor higher temperatures are however achieved and can increase boiler fouling due to the salt content of the coal. This is a problem which needs to be solved. Victoria has the prospect of lifting efficiency from 28/29 per cent to 35 per cent, of reducing carbon dioxide output correspondingly and reducing cost of power stations. So far as gasification is concerned, efficient removal of liquid water from the coal is important to the overall efficiency.

Jan 1, 1992

By H. H. Stoek

THE fundamental reasons underlying the choice of a method of mining a coal seam are safety of operation, cheapness of producing the product and the character of the product as a saleable article. From the standpoint of safety, open or strip coal mining is always preferable, as many of the dangers inherent to underground work are absent, such as explosions of gas and dust, falls of roof and coal, and also to a great extent those due to haulage and the use of explosives, thus eliminating three of the chief causes of accident from which about 75 per cent. of the underground accidents in coal mines occur. The conditions under which coal is stripped also make the work much safer than ordinary quarry work, as the depth. of the pit is usually comparatively slight. From the standpoint of low mining cost, there is much misapprehension and many of the costs given are misleading in that they do not take into account such items as the destruction of the surface for future use, the full cost of the removal of the overburden, depreciation, amortization, coal depletion, loss of time through floods and from bad weather in winter, etc. Coal is no doubt often put on the cars at less cost by stripping than by underground mining, but by no means always so, as is too generally assumed. In some cases coal must be obtained by stripping or not at all, due to the small amount of overburden that renders underground mining impossible.

Jan 9, 1917

Discussion of the paper of H. H. STOEK, presented at the St. Louis meeting, October, 1917, and printed in Bulletin 129, September, 1917, pp. 1385 to 1419. J. B. WARRINER, Lansford, Pa. (written discussion*).-The figures on costs given at the end of this paper. are of particular interest and it is unfortunate that they necessarily cover such limited periods, as figures giving the costs over a period of at least a year would be of much greater value; for instance, it seems hardly probable that the performances credited to the various shovels for the months for which the costs are given would represent the average of the performances of these machines over a longer period. It would seem to me that the maximum of 4000 cu. yd. (3058 cu. m.) per clay given for the 225 B shovel is much greater than could be maintained for an entire year's operation. On the other hand, the 1500-yd. figure for the 150 B shovel would seem a low average for this type of shovel. In connection with the drag-line excavators, it will be interesting to know that the Lehigh Coal, and Navigation Co. is about to install one of these machines on a clay stripping at their Nesquehoning colliery to excavate an average depth of. overburden of 65 ft. (19 m.), which, due to local conditions, will require that part of the excavated material be handled a second time and a lesser quantity a third time. The results of this operation will undoubtedly be watched with great interest.

Jan 1, 1918