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By James A. Commins

Accurate engineering predictions of energy needs for pollution control equipment used in surface mining operations is critically important to sound management selection of control alternatives. This paper will describe a procedure for evaluating two control alternatives with different energy needs. Three steps are involved: an analysis of the pertinent regulations, a determination of the size distribution of the particles being emitted, a calculation of the energy needs and costs of the candidate control systems as a function of these regulations and emission characteristics. The principal air pollutant to be controlled in surface mining operations is particulates, or dust, some of which is already on the material introduced into the primary crusher and other dust which is generated by the various steps in the subsequent processes. The requirement for control stems both from regulations concerning workers at the operating site, and the community surrounding the operations. In order to speak quantitatively about the need for control we will use regulations that pertain in Pennsylvania although it must be borne in mind that such regulations vary according to juristiction.

Jan 1, 1975

By C. M. Rule

Energy efficiency is currently a significant area of interest due to the Eskom power situation, which led to severe power impacts to the PGM, and indeed whole SA primary industries, in early 2008. Anglo Platinum has focused on energy efficiency for a number of years, especially in the concentrator operational area. New comminution technologies have been aggressively developed, which have shown real metallurgical efficiency gains as well as significant energy efficiency and saving potential for Anglo Platinum?s total electrical consumption as the company expands into a growing PGM demand market. This paper illustrates this programme?s activities, potential and considerable achievements to date.

Jan 1, 2009

By O. E. Polter, W. J. N. Fernando

Smelter-grade alumina is usually produced by the calcination of gibbsite. The ideal energy requirements for the calcination of gibbsite have been analysed and compared with the actual energy consumption of some industrial calcination processes. The consumption of most of these is considerably in excess of the ideal. Methods suggested for calcining dry gibbsite feeds which claim energy savings of 10-14% consume 26-34% more than the ideal energy requirement for dry feeds. This study indicates that it should be possible to recover appreciably more energy, giving further improvements in fuel efficiency, both in existing gibbsite calcination processes and in methods that have been proposed for the stagewise calcination of dry gibbsite

Jun 13, 1905

By H. B. Merlin

"The past demands for energy and the contributions by the major sources are shown for the world and regions, and for Canada. Three forecasts of future demand are presented. By the year 2000, the world will be consuming energy at a rate of 670-700 x 1015 Btu/year. Canada's rate is estimated at 20 x 1015 Btu/year. Electricity will increase its portion of energy from 7.5 per cent to 15 per cent, and more than 40 per cent of the primary energy w1ll. be required to generate 1t. World, regional and Canad1an forecasts are g1ven for total electricity generated and for electricity generated in nuclear stations. The integral world requirement for energy by the year 2000 will be over 12 x 10 18 Btu. Current recoverable fossil and hydro reserves are about 18 x 1018 Btu. The total reserves are estimated to be seven times greater.World production of electricity in nuclear stations by the year 2000 will be almost three times the electricity produced in the world today. The amount of fuel consumed in generating this electricity will depend upon the types and mix of reactors installed. The heavy water reactors, alone or in conjunction with fast breeders and liquid fuel reactors, are the most efficient users of uranium and thorium resources. The heavy water reactors are also the most efficient producers of plutonium which will be required as fuel for fast breeders."

Jan 1, 1969

By P. T. Kane, O&apos

Capital and energy are the dominant cost factors in nickel production from laterites. Since the 1973 energy crisis, pyrometallurgical developments have been oriented towards lower cost sources of energy and higher grade ores and hydrometallurgy towards higher recoveries and greater flexibility in types of ores treated. Energy recuperation offers some potential, but at a price. 'The lower energy acid leaching process is indicated to have the greatest potential, particularly with its inherently high cobalt recovery.

Jan 1, 1979

By K. Trybalski

Facing the optimization activities, which purpose is to minimize the copper processing costs, the main sources of their occurring were presented. In this purpose, the costs analysis was performed, divided to individual standings, for one of the polish copper beneficiation plants. It was proved, that the main component of the copper beneficiation costs is energy consumption, generated mainly in grinding and classification node, particularly by operating mills. The technological system ? grinding and classification node ? in KGHM Polska Miedz S.A., ZWR region Lubin was then selected to investigation. To evaluate the grinding and classification node, the energetic factors W were proposed, calculated on the basis of the energetic-technological data of process, given by node monitoring system. The correctness of the energetic factors selection to evaluate the work of this node and their practical application in industrial conditions was experimentally proved in other technological object. The selected technological object ? grinding and classification node ? was then mathematically modeled and optimized. The calculated energetic factors were the basis to build mathematical models, identifying industrial copper grinding and classification process. The models described correlation and character of dependency between factors and energetic-technical data of the process. These were regressive and neural networks models. On the basis of factors models, the optimization tasks were determined, which purpose was to select the optimal points of grinding and classification node work. Also, the estimated economical effect, possible to achieve after introduction of given monitoring values to grinding and classification node optimization system, was presented.

Jan 1, 2014

By K. Adham

Iron chloride pyrohydrolysis (ICP) is used as an efficient way to fix iron as an oxide, for sale as a by-product or for safe disposal. Iron chloride is reacted with water at elevated temperatures to yield iron oxide and hydrogen chloride. Both the steel industry and synthetic rutile producers make extensive use of ICP. Two technologies are available for ICP: fluidized bed (FB) and spray roaster (SR). Both technologies are energy intensive. Here, fluid beds and spray roasters are compared with respect to their fuel and electrical energy consumptions. Roaster size and oxide product characteristics are also considered. Process models are prepared, using the METSIM® software, and specific energy consumptions are compared. The results will help the industry decide which technology best suits its goals and at what energy cost.

Jan 1, 2006

By K. Liddell

Current practice for the recovery of platinum group metals (PGM) from flotation concentrates is by energy-intensive smelting processes followed by separation and refining of the base and precious metals. Energy costs are rapidly increasing in South Africa and this trend is forecast to continue in future years. Moreover, the smelting operations are highly susceptible to deleterious constituents, particularly chromite; and the increasing tonnages of UG2 chromititic ore being mined results in an increasing chromite content of smelter feeds. Hence there is a substantial incentive to assess and implement alternative processes to smelting for the treatment of PGM concentrates. The Kell process is a patented hydrometallurgical alternative to smelting that is totally insensitive to the chromite content of the feed concentrate and comprises three commercially proven unit operations (pressure oxidation leaching of base metals and sulfur, roasting and chlorination of precious metals). The Kell process provides the opportunity for existing and new PGM producers to significantly reduce their energy consumption, and in particular their consumption of electricity, by removing the need to smelt PGM concentrates. Energy costs, greenhouse gas emissions and installed power requirements are also much reduced. Compared with smelting and refining these reductions are calculated as: ? Total energy consumption-50% reduction ? Electrical energy consumption-84% reduction ? Energy consumption costs-76% reduction ? C02 emissions-70% reduction ? Installed power requirement 92% reduction. The data obtained from simple laboratory batch amenability testing can be readily applied to the Simulus mass and energy balance simulation procedure to determine energy and reagent consumptions, equipment selection and process optimization. The applicability of Kell to treating low-grade 'dirty' concentrates with high UG2 content as well as to polymetallic concentrates containing base metals as the major payable metals with subordinate PGM means that these savings can also be expected when the process is used for treating a range of concentrate types and grades. Keywords PGM,UG2, Merensky, smelting, chromite, electricity, hydrometallurgy, Kell Process, Eskom.

Jan 1, 2011

By Nexhmedin Lohja

The production of high-carbon ferrochromium in a submerged electric furnace based on double-level technology has some advantages compared to close-type furnaces with one tap hole. These advantages include the reduction of the specific energy consumption for the overall process, good separation of ferrochromium from slag, an effective treatment of raw materials including lean chrome ores (low percentage of Cr2O3) etc. An outline of the operation of this furnace along with the production line of briquettes from fines of chrome ore by using organic and inorganic binders, will be followed by a description of the recent work carried out to improve the energy consumption in this furnace through a pre reduction process of Cr2O3 ores by the off-gas energy recuperated from the furnace and the use of SiC in the feed. A short theoretical analysis of the new work will also be given.

Jan 1, 2006

By E. G. Joe

The continuing increase in costs for power and fuel are affecting significantly the cost of milling Canadian ores. In order to ascertain the scope and source of energy consumption in Canadian mills for further energy conservation opportunities, CANMET, in cooperation with the Canadian Mineral Processors, carried out a detailed survey on the metallic mineral processing plants. Sixty-seven mills representing almost 300 million tons of annual capacity participated in the survey. The results indicated that, in general, copper and iron ore mills, representing the bulk of the tonnage, consumed relatively low levels of energy per ton. Nickel-copper, zinc-copper and lead-zinc .ore mills were moderate in energy consumption, and uranium and some copper-lead-zinc mills reported much higher energy consumptions due primarily to the increased heat requirements of the ore pulp. Although plant heating costs varied somewhat with location, it was apparent that the lowest heating costs were achieved by those plants built with proper insulation and energy conservation design. If the cost per million British thermal units is taken as $2.00, the mill energy costs generally ranged from 40ft to $1.20 per ton.

Jan 1, 1979

By E. G. Joe

"The continuing increase in costs for power and fuel are affecting significantly the cost for milling of Canadian ores. In order to ascertain the scope and source of energy consumption in Canadian mills for further energy conservation opportunities, CANMET, in cooperation with the Canadian Mineral Processors carried out a detailed survey on the metallic mineral processing plants. Sixty-seven mills representing almost 300 million tons of annual capacity participated in the survey. The results indicated that in general, copper and iron ore mills, representing the bulk of the tonnage, consumed relatively low levels of energy per ton. Nickel-copper, zinc-copper and lead-zinc ore mills were moderate in energy consumption, while uranium and some copper-lead-zinc mills reported much higher energy consumptions due primarily to the increased heat requirements of the ore pulp. While the plant heating costs varied somewhat with the location in Canada, it was apparent that the lowest heating costs were achieved by those built with proper insulation and energy conservation design. If the cost per million British Thermal Units is taken as $2.00, the mill energy costs generally ranged from 40¢/ton up to $1.20/ton.IntroductionEnergy consumption in milling has always been of significant interest to Canadian mineral processors who traditionally calculate their milling costs down to pennies per ton. Even the measure of an ore's grindability is expressed empirically by Bond in kilowatts hours per ton milled. Some of the mills located in isolated areas were obliged to generate their own electrical energy from fossil or petroleum-based fuel at a cost substantially higher than that obtainable from captive or public hydro-electric installations. These mills practiced energy conservation long before the advent of O.P.E.C. energy cost inflation. One example of this was the use of electric boilers to produce process and heating steam during off-peak electrical load periods."

Jan 1, 1978

By E. Forssberg, Y. Zeng

Fine crushing and rod grinding have been investigated using a laboratory-scale jaw crusher and a rod mill. The net energy consumption in both crushing and grinding was evaluated from torque measurements. An empirical relationship was established between energy consumption, particle size and operating parameters. When the mill feed size is reduced, through fine crushing, to about 80% passing 3 mm, the energy consumption will be minimized in a comminution chain of fine crushing and coarse rod grinding. The results in fine crushing were compared with a large-scale test.

Jan 1, 1993

By Dan Nilsson

Open pit mining is the strong sector of the American mining industry. In the middle of the 60's. 17-18% of the ore in metal mines was mined with underground methods. From the middle of the 60's to 1980 the production in open pit metallic mines increased from about 400 to close to 600 million short tons while at the same time the underground mine production decreased a little, from about 90 to about 80 million tons. Less than 15% of the ore prodction now come from underground mines. Large amounts of waste rock were also handled in the open pits. In the middle of the 60's about 600 milion tons were handled, in 1980 1,200 million tons were moved. This means that the average stripping ratio increased from about 1.5 to over 2.0 tons of waste rock per ton of ore, figure 1.

Jan 1, 1983

By S. W. Marcuson, P. J. Mackey

The 1973 Oil Embargo and succeeding disruptions in supply had a profound effect on energy costs and consumption patterns in the developed world. This was especially true in the USA where post World War II growth, fueled by low-cost imported oil, left the country dependent on uninterrupted oil shipments from the volatile Middle East. In this atmosphere, Professor H.H. Kellogg of Columbia University, convinced of the necessity of good environmental stewardship by the writings of the era’s leading environmentalists, developed a methodology for evaluating energy and process efficiency of metallurgical processes and wrote a series of papers describing and applying the techniques. One of these, "Energy Use in Sulfide Smelting of Copper" is recognized as a seminal work which both described the state of energy usage in copper smelting in the mid-1970’s and portended future developments. The background to these papers is examined and the current and past Cu-Ni matte smelting practices in Canada are examined in the context of the results. Data from early 20th century publications describing reverberatory and blast furnace operation is employed to show that energy consumption for much of the century was several multiples higher than that calculated for best reverberatory operation in the 1970’s.

Jan 1, 2015

By S. F. Shaw

IT IS generally recognized that the natural gas absorbed in petroleum plays the leading r6le in moving the oil through the sands to the well and supplies the energy that delivers the oil to the surface when the wells are flowing. It is the purpose of this paper to note the amount of oil that could be lifted by this gas if 100 per cent. efficiency were obtained and the efficiencies actually obtained in the use of this gas. An article in MINING AND METALLURGY,' stated that in a Wyoming field, with a pressure of 300 lb. per sq. in., there would be absorbed 65 cu. ft. of gas per barrel, or 1.55 cu. ft. per gal. of oil. The writer does not know if data have been obtained, by experiment, for pressures beyond those indicated in this article, therefore, for the purpose of illustration, he has projected this curve to obtain figures for pressures greater than 300 lb., although probably experiment will show that the extended line is not quite correct.

Jan 1, 1926

By Wenkai Wan, Charlie C. Li

Strain burst can occur in underground hard rock excavation when the in-situ stresses are high enough. The prerequisite for rock burst is that the total energy released from the rock mass is higher than the energy needed for rock fracture. The total released energy is contributed by both the burst rock and the surrounding rock. The part of the energy from the burst rock is constant per unit volume of the rock, but the part from the surrounding rock is associated with the burst volume. A greater amount of energy will be released from the surrounding rock in the case of a larger volume of burst rock. The postulation for the energy conversion in strain burst is verified through a FLAC3D model in the paper. It is assumed that the strain burst occurs in a circular tunnel that is located in the hydrostatically loaded rock mass in the model. Six pairs of notches with different depths are created in the opposite walls of the tunnel to simulate the bursts. The energies released from the notch rocks and from the surrounding rock are calculated during the burst. The simulation results show that the percentage of the energy released from the surrounding rock in the total released energy increases with the notch depth. The numerical modelling confirms the postulation that the surrounding rock contributes more energy than the burst rock itself in large-scale strain bursts

Apr 26, 2022

By R. Leithner

The need/wish to sequestrate CO2is based on the assumption of the International Panel of Climate Change (IPCC), that CO2 maybe the major driver in climatic changes, i.e. especially the anthropogenic CO2emissions due to the combustion of fossil fuels like coal, oil and natural gas will increase the atmospheric CO2-content, which will lead to higher temperatures in the atmosphere. The 0.03% CO2in the atmosphere have a 22% share of the natural greenhouse gas effect of 33 K necessary for life on earth. The main share of 62% has the water vapour in the atmosphere. Only if one concentrates on the greenhouse gas effect of the gases beside water vapour, CO2 becomes most important with 58% influence. In addition there are other influences on the climate like: • Eccentricity of earth’s orbit, precession of orbital plane, obliquity and precession of earth’s rotation axis (Milankovitch’s theory) • Sunspots and magnetic field of the sun • Changing streams in the ocean • Volcanic activities • Distribution of continents on the surface of the earth • Impact of meteorites • Change of insulation by interplanetary dust [Muller, R.A. 2000] etc. To answer the question, if the CO2-content in the atmosphere has an important or exclusive influence on the earth atmospheric mean surface temperature, one should look into history. Figure 1shows the mean temperature of the atmosphere and the atmospheric CO2-content time histories 1 billion years back; no correlation can be found between them. Nevertheless a lot of countries have committed themselves to reduce their CO2-emissions.

Jan 1, 2004

By Jonathan G. Price

The 2011 report titled ?Energy Critical Elements: Securing Materials for Emerging Technologies? by the American Physical Society?s Panel on Public Affairs and the Materials Research Society surveys potential constraints on the availability of these elements and identifies five specific areas of potential action by the United States to ensure their availability: 1) federal agency coordination; 2) information collection, analysis and dissemination; 3) research, development and workforce enhancement; 4) efficient use of materials and 5) market interventions. Energy-critical elements (ECEs) are a class of chemical elements that currently are critical to one or more new energy-related technologies. A shortage of these elements would significantly inhibit large-scale deployment, which could otherwise be capable of transforming the way in which energy is produced, transmitted, stored or conserved. The report addresses elements that have not been widely extracted, traded or used in the past, and therefore are not the focus of well-established and relatively stable markets (such as carbon in coal or uranium as fuels, copper, aluminum, nickel and iron, all of which are clearly vital in energy applications).

Jan 1, 2011

By A. J. Lewis, P. J. Hutcheson, M. E. Robertson, P. A. Moir, K. M. Barfoot

With the content of gold and platinum in the vast majority of ore deposits typically averaging 6 parts per million and less, the accurate and precise measurement of these metals in samples of ore and mining process streams has proven very difficult to achieve by modem spectroscopic analytical techniques. Largely because no other technique has proven suitable, the basic fire assay process has become the accepted international standard for these metals. Fire assay, however, suffers a number of disadvan­tages in the modem, competitive, high technology, and increas­ingly environmentally aware world. It is a labour intensive technique that is difficult to automate, and requires high levels of skill to ensure accuracy and consistency of results. Potentially hazardous chemical reagents are employed, of which, lead, in particular, can be a serious source of contamination to both personnel and the environment if not effectively controlled. Other dangerous elements, such as mercury and arsenic, liberated in high energy furnace operations, are further sources of possible health and pollution hazards. n contrast, the energy dispersive K X-ray fluorescence (K­XRF) technique devised by K X Technology Ltd overcomes many of the technical constraints of conventional low energy X­ray analysis, and has the potential to revolutionise assay opera­tions in precious metal mining. The technology is simply automated, requires basic operator skills, uses no chemicals, consumes less than 20kW, and is capable of detecting gold and platinum to an accuracy of O .1 parts per million by mass. The new third generation design of AZTEC laboratory instrument, released in 1994, is the result of significant technical development. Capable of analysing over 1200 samples per day, and developed primarily for grade control sampling, its applica­tions have spread to gold ore accounting from on-line conveyor belt sampling; screening of exploration samples; measurement of gold in carbon granules for Carbon-in-Pulp process control; and for conducting rapid checks to support key managemen decisions. The economic, rapid, and non destructive analysis ofup to 80g of ore for large numbers of samples, reduces sampling and sub-sampling errors, and provides improved grade estimates for ore bodies. When interfaced to a LIMS, laboratory automation and cost-savings can be further enhanced. The AZTEC design is also being modified for the analysis of platinum. The GOLDSTREAM on-line analysis system is an important new application of K-XRF to the continuous monitoring of process streams in gold ( or platinum) plants and mills. Integrat­ing the technologies of K-XRF to measure total gold, and dissolved gold spectroscopy to measure gold in solution, the insoluble fraction of gold can be deduced, and the effectiveness of the extraction process determined. Slurries are sampled automatically from selected points of the plant and pumped to the system for analysis. The information produced forms the basis for plant control and optimisation.

Jan 1, 1995

By Ying Lu, Jeffrey C. Johnson, Chen-Luh Lin, Jan D. Miller, Sindhoora Puvvada

Energy dissipation and fragmentation of rock is of interest for mine-to-mill operations in order to understand breakage and to minimize energy consumption during blasting at the mine site, and comminution at the processing plant. In this regard, high velocity impact breakage of long granite cores, called bars, has been studied with instrumented strain gages to follow the energy dissipation gradient along the bar length resulting from the strain waves generated by impact. As a result of high velocity impact, three zones have been identified (fragmentation, fracture, and elastic) and these three zones have been characterized in 3D using X-ray tomography. The fragmentation zones of the granite bars were studied in detail to describe the particle size distribution and the particle shape characteristics. Finally, the experimental energy dissipation for the fragmentation zone was found to be in close agreement with the expected energy calculated from the Bond work equation, if the anisotropic granite particles are defined by length rather than by sieve size.