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By Richard Franchot

From an efficiency viewpoint, the greatest loss of energy to the blast furnace is in its failure to convert more than about a third of the coke carbon from carbon monoxide to carbon dioxide. This result has usually been ascribed to a necessity of a 2:1 excess of CO in order to reduce iron. It has, however, been proved that iron is completely reduced by equal volumes of carbon monoxide and carbon dioxide. Hence there is room for the hypothesis that vaporization, as cyanid, of accumulated alkalis is a serious primary factor limiting the ratio of ore to coke. Observed cyanid vapor concentrations and those measured by the variations of the nitrogen-oxygen ratio in the hearth gases form the basis for a quantitative explanation of the furnace action. As EVERYBODY knows, the blast furnace is a gas producer. As to the reason for this, people are not so well agreed. The significance of the fact is obvious, for the extent to which the fuel leaves the furnace as combustible gas measures poor economy in iron smelting; while good efficiency in this respect means poor gas. The furnace thus works at cross purposes. The present trend of the steel industry is toward. a primary use of the blast furnace as a gas producer with pig iron as a byproduct. Needless to say, this trend is away from improvement in iron making. The production of more and better iron in a given furnace consuming a given amount of coke would seem, at least, to involve a decrease in the relative proportion of the combustible gas. The possibility at the same time, however, of making more and better gas need not necessarily be excluded. (The more the furnace acts as gas producer, the bigger is the sulfur problem.) Whatever the object, it would seem desirable to have a, clear, comprehensive, mathematically exact estimate of why and how the blast furnace functions, to the large degree that it now does, as a gas producer. The literature does not give a definite answer to the question. That for which explanation is sought is the fact that only a minor part, usually not more than a third, of the coke carbon burned is oxidized to carbon dioxide; that the development in the furnace of the fuel energy is thus limited usually to little more than 50 per cent.; that it requires about twice as much fuel coke to make a ton of iron as is indicated by the rela-

Jan 7, 1925

By Paul M. Tyler, Carle R. Hayward

DOES it pay to do really good work? Quite likely the practical millman will answer that it does not. The preparation of ores for market is primarily a business enterprise, and by and large the individual operator does not bother his head about squandering our national resources or making easier the job of the smelterman. Having accepted such ore as he may get fro111 the mine, his job is to make the best possible showing with his mill fro111 the standpoint of financial return. His success is measured in dollars and cents, and he has no rightful reason to expect more than scant acknowledgment of any other achievements from the stock- holders of his company who in the last analysis are his employers.

Jan 1, 1936

By Arno C. Fieldner

PROBABLY no large industry in the United States is in greater need of technologic research leading to economic improvement than the coal industry. It has suffered severely from increasing substitution of petroleum and natural gas for coal and its products in the fuel markets. Part of this substitution is due to the greater convenience and suitability of liquid and gaseous fuels for special purposes, and part of it has been due to the extensive research programs conducted or sponsored by the petroleum and allied industries in the past 2 decades. A recent estimate1 places these expenditures at $100,000,000 a year.

Jan 7, 1951

By HILAND BATCHELLER

COMMENT on the economic significance of the special alloy steels seems inevitably to reduce itself to an attempt to peer into the future of the industry in which we are interested. We are all familiar with the historical development of iron and with the almost complete replacement of iron by steel. Those who have been connected with the industry since its .early days have had the satisfaction of witnessing the greatest industrial development the world has seen. As the cartoonists of the muck-raking decade liked to picture steel as an ogre armed with a spiked club, his hands reeking with blood and with golden coins dripping from his pocket, fiercely seeking for more widows and orphans to devour, I choose to call on my imagination to create a gigantic but beneficent robot of such marvellous mechanical skill. that it quickly transforms millions of tons of otherwise worthless material into the infinite variety of useful products which are so largely responsible for our present civilization.

Jan 1, 1931

By AIME AIME

AT the end of September, ' the metal-producing industries were almost prostrate, the production of fuels was largely curtailed, there was a fair degree of activity in general manufacturing, while retail trade was moderately good. Looking at industry on the whole, there was a large percentage of unemployment, the degree of which has increased, progressively, month by month since the beginning of 1921. There is the prospect of much destitution and misery this winter; yet while' in some, quarters, idle workers are already being fed from, commissaries; in other quarters profligacy; in "spending continues, unabated. Amid this confusion in conditions there is;' much that appears paradoxical, but in fact it is not so and indeed everything is running pretty true to form: Such activity in production as there is to be seen is mainly in textiles; - leather goods, foodstuffs, etc., i.e., consumption goods for immediate use. Even in hard times 105,000,000 people must buy a good deal of clothing and food. Besides this there is indispensable repair work and- maintenances. Thus, the good business of the year in white lead for painting. The chief uses for the metals, however, are in the production of capital goods, and except for occasional and special reasons nobody in his senses is capitalizing anything at present prices for labor. Hence several millions of men are idle. The impoverishment of Europe and the exhaustion of her credits adds to this by curtailing our export trade.

Jan 1, 1921

By Walter Renton Ingalls

IN SEVERAL papers and addresses during the past two years, I have dwelled upon some of the economic consequences of the war. The fundamental thought that I have sought to convey is that the world became immensely poorer by the war, not only in material wealth and population, but also in the psychology and morale of the people. I do not see how there can be any intelligent dissent from that statement. All the ideas of post-war prosperity were manifestly fallacious, manifestly fallacious from the outset. If there had been any truth in them it would have followed logically that a great war, with all its destruction of wealth, health and life would be a good thing. Therefore, let us have a great war every ten years or so. Such an idea would be both monstrous and absurd. Assuming then the acceptance of my premise, I have tried to show that the losses by the war could be made good in a short time, i.e., in a relatively short time, only by doing things a great deal better than formerly, and that the accomplishment of such a result called for greater transparency in industry, for industrial cooperation, for thinking in terms of industries as a whole, and for the greater exercise of engineering functions. All of this introduced, of course, the position and psychology of labor. I say frankly that I do not look for labor to contribute any constructive thought to the upbuilding. I neither expect it nor hope for it. This is a pity, for it could do so much for its own economic advancement if it would. However, it never has done so, but rather has benefited only from the exercise of the talents of the few, and the main hope now is to bring it into a passive state, dispelling the resistive fallacies that developed during the war. Let us briefly examine the nature of these.

Jan 1, 1921

By Thomas V. Fame, William E. Porter

"As geological and mining conditions become more complex, and as overall mining economics become more marginal, short- and long-range decision-making regarding multiple-seam surface mining becomes more difficult. The decision-making problem involves a study of economics, cut-off grades and ratios, equipment capabilities, sequencing and selective mining practices.This paper is concerned primarily with multiple-seam mining of bituminous coal. The research has led to the development of an economic decision-making model for use as a day-to-day tool to aid mine operators and pit geologists to decide what and how to mine.The model is designed as an aid for feasibility decision-making in multiple-scam situations and for situations where selective mining is needed or desired. In effect, a simulation of the feasibility and preliminary mine planning phases has been developed. The model is divided into four separate segments: decision-making, simulated mining, cost calculations and the determination of the discounted cash flow return on investment."

Jan 1, 2014

By W. A. Forbes

OUR present-day geological surveys show that 36 of our States are underlain with bituminous coal, covering a total area of 496,709 square miles. The North American continent possesses 69 per cent of the world's coal reserves, with the United States alone having an estimated 55 per cent. The American coal reserves, in tons, are calculated to he about 3,500,000,000,000 tons, of which we have exhausted about 1 to 1 1/2 per cent. If this coal were mined at the rate of the 1918 production-a record output of 579;000,000 tons-it would not be depleted for 4,000 years. The more easily accessible and high-grade coals would obviously be consumed much before this; some estimates are 100 years. The natural progress of the nation's industries up to 1910 encouraged on every hand the development of new mines, especially where cheap and easy access to coal measures was coupled with short hauls to the consumer. Over-development resulted, which is perhaps today one of the fundamental causes for the many difficulties faced by the coal industry, which is highly competitive; about 70 per cent of the production cost is labor. Salient statistics for 1930, recently issued by the U. S. Bureau of Mines, follow:

Jan 1, 1932

Economic Sustainable Power for Mineral Processing

Sep 13, 2010

By Joseph E. Pogue

NEW economic forces are at work in the petroleum industry.. In order to visualize these forces and clearly see their bearing on the producer, refiner and marketer, it is necessary to see in perspective the economic evolution of the business. For several decades prior to 1913 the outstanding feature of the petroleum industry was a trend toward integration, culminating in a huge combine, the Standard Oil Co. An important aspect of this integrative trend, however, was its concentration on the combination aid control of refining and marketing, leaving crude oil production, for the most part, to the exigencies. of small-unit competition. It is a noteworthy coincidence that during this era the law of oil and gas was formulated and applied, whereby these substances had to be reduced to possession to establish ownership; and the forces of competition in crude oil production were thereby intensified. It was to the interest of an industry, safeguarded in its control of manufacturing and markets, to have supply stimulated by legal convention as well as by individual initiative in order that the growing demand could be met without interruption. And so over-production of crude oil during this era was no handicap, but rather an aid, to the progress of the industry.

Jan 1, 1929

By Rahul Sharma

Although, mining of minerals such as polymetallic nodules and sulphides from the deep sea floor has been delayed due to the combination of factors such as current availability of Cu, Ni, Co, Mn (and other metals) on land and their fluctuating prices; these deposits are still considered as the alternative source for metals in the 21st century. Exclusive rights for exploration in the ?Area? (beyond the national jurisdictions of any country) given to eight countries and consortia by the International Seabed Authority and the estimated resource of 300 million tonnes in a typical area of 75,000 km2 is expected to yield about $17.5 billion (at December 2008 metal prices) in 20 years life span of a single nodule mine-site. In order to recover 3 million tonnes of nodules, an area of 300 sq km only will be mined annually (i.e. <1 km2/day) for an optimum abundance of 10 kg/m2. However, during mining, large quantity (22 tonnes/day) of sediments associated with nodules would be resuspended that could lead to certain environmental impacts on the benthic ecosystem. Several small-scale benthic impact experiments in the Pacific and Indian Oceans, have given some insight into the possible environmental impacts and the restoration processes, but the possibility of extrapolating these findings to a commercial mining scale remains an issue to be considered. An estimated capital expenditure of $1.05 billion and operating expenditure of $4.2 billion for a single deep-sea mining venture will have to be weighed against the availability of mineral ores on land as well as the metal prices in the world market. None-the-less, development of technologies for mining and metallurgical processing, as well as formulation of regulations and guidelines for potential ?contractors? to mine these minerals have been progressing consistently. These coupled with recent efforts by certain ?entrepreneurs? to initiate mining of seafloor massive sulphides in the EEZ of certain countries, indicate the continuing interest and support the perception that such deposits could well be the future sources of metals. This paper analyzes the current status and discusses the economic, environmental, and technical issues that need to be addressed for sustainable development of deep-sea minerals.

Jan 1, 2010

By Bedrand L. Johnson

THE phosphate-rock industry is built upon natural deposits of rocks and minerals in which the element phosphorus is present as a phoshate. The term ?phosphate rock? is a general one, applied to certain rocks of different degrees of consolidation and of diverese origin, charater and occurrence, composed of intimate mixtures of several phosphate minerals, largely submicrocrystalline, usually calcium phosphates, in commerical quantities, with various impurities. This term includes phosphatized limestones, sandstone, shales, and igneous rocks; nodular phosphates ; residual weathered phosphatic limestones ; vein phosphates ; and phosphatic sediments, both consolidated and unconsolidated.

Jan 1, 1944

Mining is a high risk, high capital and potentially high reward undertaking. A large proportion of the risk comes from a lack of definition of the orebody (which also provides some of the potential) and the unpredictable nature of the market. This makes the planning process difficult but encourages the development of a robust yet flexible mining system. The system should be capable of absorbing some deviation from the anticipated concept without a significant impact on profitability. The mine planning process tends to consist of a series of related but discrete stages. For instance, the pit shells are designed, a schedule for the pit shells is created, a plant fleet is chosen to achieve the schedule and a financial analysis is carried out on that scenario. It is likely a few iterations are carried out using various mill throughputs to produce a favoured financial result. The problem is that handing results from stage æBÆ for use in æCÆ doesnÆt encourage a flexible system. æCÆ is likely to be built for exactly æBÆ. Unfortunately, in mining, æAÆ (the orebody) has the highest potential for variability and impacts everything else downstream. æDÆ the market also has high potential for unplanned variability. These variations can spread and æreverberateÆ through the whole mine process. For example an unexpected increase in ore oversize impacts all downstream mine processes to the primary crusher which may in turn create problems back æupstreamÆ by restricting throughput rate. Also an unexpected drop in demand or price could require modifications to the planned production rates. This paper looks at how mining process simulation can be used to support the development of strategies to counteract unforseen circumstances or alter production to match fluctuations in demand and price.

Jan 1, 2003

By Sean Cassady, Jason Liu, Sanja Zlatanic, Taehyun Moon, Chris Devery

"For the Hollywood International Airport Runway Expansion Project at Fort Lauderdale, Florida, the structural fire durability analysis was completed for a series of tunnels formed by roadway and railroad cells located under the runway structure. A systematic design approach was developed to mitigate structural damage during a fire event and arrive at a practical method to structural fire engineering that is compliant to NFPA 502. To ensure the NFPA 502 requirements are satisfied, the performance based approach was implemented and the engineering analyses were performed for the adopted design fire event. The analyses considered the facility’s unique features including its fire safety systems to determine applicable design fire curves for structural durability analyses. The paper also outlines the process of defining the project specific fire curves for a specific design fire scenario and summarizes the results of heat transfer and structural fire durability analyses. This approach was aimed to assist the owner and Authority Having Jurisdiction to achieve practical decisions to the tunnel facility fireproofing.INTRODUCTIONFort Lauderdale–Hollywood International Airport (FLL) in Broward County, Florida is a major hub facility serving more than 23 million passengers annually. As part of the Airport Expansion Program, the South Runway (9R-27L) Expansion project aimed to meet ever increasing service demands via an increase to runway lengths. This necessitated the placement of one of the reconstructed runways on bridge structures over the existing U.S. Route 1 (US 1), a major north–south U.S. Highway that serves the East Coast of the United States, and the Florida East Coast (FEC) Railway, thus effectively creating multiple tunnel cells beneath the subject runway. For this project, HNTB suggested a tunnel fire damage mitigation system that would protect the runway major structural elements from the design fire event that may happen within the tunnel cells. This paper addresses the issues related to the fire event originating within the tunnel encompassing the US1 highway only, and deals with requirements of NFPA 502 [5] exclusively. Therefore, while approaching the structural fire protection issues for the specific tunnel cells beneath the runway structure, the requirements of the American National Standard NFPA 502 (Standard for Road Tunnels, Bridges, and Other Limited Access Highways, 2008 edition) were followed. Per this standard, regardless of tunnel length, all primary structural concrete and steel elements shall be protected in order to:"

Jan 1, 2016

By Seppo Lähteenmäki, Pertti Koivistoinen, Jaakko Levanaho

"This paper describes the benefits and disadvantages of fully autogenous grinding when compared to grinding with steel grinding media. The study is a real case study based on a low tonnage, high grade mining project in a remote location in a developing country. The study compares the capital and operating costs of using either SAG mill, Ball mill, Crusher (SABC) or fully autogenous (AG) grinding circuits and produces an economical analysis of the project for both options. The economics have been developed for the overall project, including mining, processing, environmental and the infrastructure as well as for the additional cost of constructing a fully autogenous grinding circuit instead of the original plan of a SAG Mill, Ball Mill circuit.The paper also describes the development of the autogenous grinding circuit at Outokumpu Oy, Pyhäsalmi mine. This experience was used to design the autogenous grinding circuit for the case study. Pyhäsalmi Concentrator has over 30 years of experience in operating autogenous grinding circuits and therefore provides a sound base for the new circuit design.INTRODUCTIONGrinding of ore using steel grinding media is currently the most commonly used method in the mining industry. Autogenous grinding, ore replaces iron media, is also common especially in Europe and Africa. Iron ore industry in North America uses autogenous grinding in primary and/or secondary stages extensively. In gold, copper and other base metal industries, autogenous grinding is not as common, although there are operations where pebble grinding is or has been used in the secondary grinding stage. There are many variations of autogenous grinding in use in the mining industry. These variations include different mill sizes, mill length to diameter ratios, ore lump sizes, screening and pebble crushing configurations."

Jan 1, 2000

By C. L. HUNTZINGER

THE mine here described is in the Witbank district, a coal area of the Transvaal, about 100 miles north- east of Johannesburg. and is owned by the Witbank Colliery, Ltd. The plant has a capacity of 4000 tons per eight hours, and prepares five sizes of coal. The coal seam lies at a depth of about 200 ft. below the surface, and is reached by an inclined shaft sunk at an angle of 18° with the horizontal. Although the thickness of the coal seam varies from 10 to 14 ft. or more, only about a 7-ft. bench is mined. Mining is by the hord and pillar system. Bords are driven 18 ft. wide, with pillars measuring 18 ft. square. The mine is laid out into four sections, each sewed by a main haulage way from the shaft. Arc-wall machines are used for cutting the coal. but all loading is done by hand. Native labor is employed under the supervision of white miners, who do the required blasting. The workings are practically free from gas and water, and very little timber is needed.

Jan 1, 1931

By Pfeifer H. C, Nicacio P. A D

Sinter has been used as part of the metallic charge in large-scale blast furnaces for many years with the well-known benefits in terms of productivity and fuel consumption. However, because of the high investment in a conventional sinter plant, small blast furnaces and the associated integrated mini steel plants have not taken the advantages of using sinter. Recently KTS Korf Tecnologia Siderurgica, a division of Mannesmann Demag Ltda in Brazil, has developed a mini sinter plant for which the investment is compatible with small blast furnaces. Consequently, it is of great interest to evaluate the economical impact of using sinter in such small-scale integrated steel plants. In order to compare two alternatives, ie 100 per cent ore and 70 per cent sinter in the blast furnace burden, mass and heat balances for the entire operation from sinter plant through the blast furnace and EOF-based melting shop, were performed to evaluate the final production cost of the liquid steel. It was found that, depending on the sinter feed price, substantial savings can be obtained with the use of sinter.

Jan 1, 1999

By Victor Azbe

Introduction Lime enters our daily life in many ways. Our building, chemical, agricultural, sanitary, and industrial endeavours depend on it to such a great extent that it could probably be called the most important inorganic chemical, and the extent to which it is used might be considered an index of industrial development. Industrial limes vary greatly in quality, due to internal structure and other characteristics. They may be good or bad, sensitive or slow to react. While improper manufacture may not greatly alter the appearance of the lime, it may affect its properties considerably and thus its suitability in the many processes in which lime is used. In some of the processes, one kind of lime is wanted, in others another. While the nature of the stone from which it is made has much to do with whether a lime is suitable or not, its burning and hydration are the crux of the matter. Up to not so many years ago, the knowledge of lime burning was rather imperfect and it is only relatively recently that its manufacture is approaching the state of a higher industrial art. This slow development was in part due to lime manufacture being scattered among many small concerns who, independently, either lacked the inclination or could not afford to strive for a higher technical development.

Jan 1, 1946

By Victor Azbe

Azbe System of Controlled Calcination To obtain good and cheap lime there are certain fundamental requirements that need to be satisfied. These are : (1) Proper combustion of fuel and steady supply of heat to the kiln. (2) Proper heat distribution in the kiln. (3) Uniform drawing of lime through the several shaft sections. (4) Complete cooling of the lime and recovery of the heat. (5) Temperature control of the hot zone by economical means. (6) Ample draft to obtain high capacity. (7) Arrangements to facilitate operation. Figure 17 shows diagrammatically one of the smaller kilns, intended for large stone. Such a kiln can be supplied with gas from a centrally located automatic gas producer, or, as shown, from an integral producer located snugly against the kiln. These producers make very good gas and have a gasification capacity of either 10 or 15 tons of coal a day. The producers have water-sealed ash pits, a rather thick fuel bed that is conducive to the making of high-CO gas, and are under forced draft. No steam is used. Clinkering is prevented by admixing some spent gas from the kiln with the air. Coal feeding is from a coal bunker through spouts into the hoppers over the producer. This is done, at proper intervals, by manual operation of slides, but it is planned to install mechanical feeders. Central mechanical gas producers have the advantage of requiring little labour, but the blowing of soot is a problem, as also is the proper distribution of the gas among several kilns. In the case of integral gas producers, soot from the centre burner is blown back into the producer to be burned, and the supply of gas to the kiln is controlled by regulation of air to the producer. In large plants, the mechanical producer may be preferable, but in small ones, the integral producer is cheaper, better, and more reliable. The kiln shown in Figure 17 is suitable for both systems of gas supply. It will be noticed that there are no side gas burners. All gas enters the kiln through the centre burner in a manner that permits any desired amount of gas to be directed to any of the kiln sections by the aid of regulating slides.

Jan 1, 1946

Develop a simple and economical technique for determining the absolute stresses and the change of stress on the surface of roofs, floors, or walls in miners. Approach Use a commercially-available, permissible, Whittemore-type gage to determine the stress at the surface of a mine opening and to monitor any stress changes that might take place. How It Works The following equipment is used: ? One steel templet (for laying out a 60° rosette on the: rock surface). See first photograph. ? One 3/8-inch rock drill bit for drilling holes for the rosette pins. ? Six stainless-steel rosette pins. ? One Whittemore-type mechanical strain gage. ? One drill (not shown). ? Epoxy for cementing the rosette pins. ? Tape to hold the pins while the epoxy sets. The following procedure is used to determine the absolute stress on the rock surface. 1) Spot the location of the rosette pins with the templet. 2) Drill the pin holes and set the pins with epoxy cement. 3) Measure and record the distance between the pins across three diameters of the rosette with a 10-inch Whittemore-type gage. See diagram. 4) Drill a 1 1/2-inch diameter hole in the center of the

Jan 1, 1981