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By Edward L. Vickers

When I was originally asked to give this talk, I had certain preconceived ideas of the mining industry's reaction to Operations Research. It seemed at the time to be a rather simple task to collect these ideas for presentation here today. Jotting down these notions, I became concerned that overexposure to this activity called OR perhaps had clouded my outlook on what was actually being done on a nation-wide scale. I felt, to have a better cross section, a questionnaire of current industrial activity was in order. I solicited the response of some 75 mining companies varying in sizes and operating characteristics, and I am pleased to report that the response was good. I received answers from 51. The questionnaire was intended to measure the degree to which their concerns were actually engaged in OR efforts. With all due respect to the people who were so gracious as to answer the questionnaire, I feel that there is a tremendous misconception as to the designed purpose of OR. This is not to imply that there are no active OR groups in the mining industry. But by in large, the majority of the companies sampled appear to be somewhat confused as to what OR really is.

Jan 1, 1962

By Frank D. Hoyt

BY far the most conspicuous of the Pennsylvania slate districts is that extending from the New Jersey line at the Delaware Water Gap westward almost to the Schuylkill River. This covers parts of three counties in east-central Pennsylvania: Northampton, Lehigh, and Berks. The most important development, both in geographic size and product importance, is in Lehigh and Northampton counties. The greater part of the region is underlain by only one formation-the Martinsburg, consisting of slates, clay slates, and sandy shales, all of the Ordovician period. The slate-bearing Martinsburg formation is underlain by Cambro-Ordovician limestones. Immediately overlying the Martinsburg formation is the Tuscarora quartzite of the Silurian period. The Martinsburg formation itself is divided into three distinct divisions, termed simply: the upper, the middle, and the lower members. Commercial slate has been extracted from all of these members, but the formation of greatest importance is the upper member, representing 2600 ft of the total formation thickness of nearly 11,000 ft. The upper member is commonly referred to as the "soft slate" and consists of three facies: 1) beds of blue-gray, very sandy, almost quartzitic slate, in many places, approximately a medium-coarse sand- stone with calcareous cement; 2) blue-gray sericitic slat-the dominant rock type of this member-with occasional chloritic beds; and 3) dark gray or virtually black, highly carbonaceous beds, referred to locally as "ribbons."

Jan 8, 1958

By Guo Chen, Xuefeng Liao, Tu Hu, Shengzhou Zhang, Hongying Xia, Jinhui Peng, Libo Zhang

Pine nut shell is as raw material for preparation of high surface area activated carbon (HSAAC) by microwave induced KOH activation. The effects of microwave power, activation duration and KOH/C mass rate (R) on the iodine adsorption capability and activated carbon yield were investigated. Additionally the surface characteristics of HSAAC were characterized by nitrogen adsorption isotherms and SEM. The operating variables were optimized utilizing the response surface methodology and were identified microwave power 738W, activation duration 17 min, and R 4, corresponding to a yield of 46.28 % and an iodine number of 2154 mg/g. The key pore structure parameters of HSAAC such as the Brunauer–Emmett–Teller (BET) surface area and total pore volume were estimated to be 3819 m2/g and 2.09 mL/g, respectively. The findings strongly support the feasibility of microwave heating for preparation of HSAAC from spent pine nut shell by microwave induced KOH activation.

Jan 1, 2016

By Brian E. Travis

Recent Developments in the utilization of polymer grid structures for Longwall Shield Recovery operations are discussed. Specifically: various Longwall screen designs and the numerous methods employed during installation. Also discussed is the role of polymer grid structures in head and tailgate mf and rib control and their role in controlling soft bottom often associated in shield recovery operations.

Jan 1, 1993

By Monica Stuckert

Field studies were made at an Appalachia coal stripping operation to evaluate the differences in cost and performance between blast casting with pre-split dewatering versus conventional coal overburden blasting.

Jan 1, 1985

By J. Armitage, J. Erskine

Feed level and thickness measurements are essential in the optimization of an electric arc furnace. A precise measurement of the feed thickness and level gives operators the ability to increase the smelter efficiency and reduce the maintenance cost. Hatch has developed a radar system which is an affordable, low maintenance, and accurate level measurement system. The radar units can be installed across the furnace to measure the feed level and the feed thickness can be calculated with one slag level sounding. The present paper describes the development of radar systems as a process optimizing tool by furnace controls. The authors will discuss the challenges involved in installing eight radar units on the roof of a six-in-line electric furnace.

Jan 1, 2015

By George Schore

Radiation grafting of ion exchange structures contains ion exchange groups but may consist of neutral groups. High energy grafting of monomers on to polymers has-been known since 1950 (1.2); manufacture on an industrial level was-begun in 1970.(3) Proper choice of substrate and monomer will produce various ion exchange membranes with differing physico and chemical properties. Grafting a selected monomer to the proper polymer will provide selective ion exchange with assured chemical protection of the substrate. Ion exchange systems utilizing radiation grafted structures to polymers have been fabricated to "capture" gold from drag-out and rinse water and silver from cyanide rinse water. Other ion exchange systems can feasibly be produced to remove other precious metals. Rotating Cathode Technology is used to recover the metals from their concentrated eluating solutions as pure metal foil.

Jan 1, 1984

By S. M. Mustakim

Red mud is the major waste material produced during digestion of bauxite ores with caustic soda in alumina production following the Bayer?s process. Its disposal remains a worldwide issue in terms of environmental concerns. A lot of research and developmental activities are going on throughout the world to find effective utilization of red mud, which involves various product developments. At present, building materials, industries are fast growing industrial sector where the need of various raw materials is enormous. The use of red mud in building material production is one of the options for conservation of natural resources and reduction of environmental pollution. A cost-effective and energy efficient mineral cementation process has been developed at CSIR-IMMT, Bhubaneswar for use of red mud in manufacture of building brick, block and aggregate. The red mud is an alkaline material, which contains both leachable and non-leachable soda along with different mineral constituents of alumina, iron and silica. The effort has been made to use the mineral constituents of red mud to develop cold setting building brick by mineral cementation process using a binder specially prepared from Portland Slag Cement, Lime, Gypsum and Alkali metal sulfates. The red mud has been used from 40 to 70% by weight along with fly ash and binder in development of cold setting building brick conforming to the specification of IS:12894:2002.

Sep 1, 2012

By Taner Kavas

The refractory bricks of a rotary cement furnace containing of alumina and magnesium chromite were studied in order to determine whether they could be used in the concrete production as aggregates. Three mortars were prepared by mixing 1 part cement, 3 part aggregate materials, 0.5 part water by weight and mechanical, chemical, thermomechanical and microstructural characteristics were evaluated. The compressive and bending strength of samples were determined after 2 and 28 days curing. Resistance to chemicals were established by calculating the weight gain of mortars stored in 2 % HCl solution for 1 h and 24 h. Thermomechanical characteristics were determined by measuring the compressive strength of heat treated specimens at temperatures of 400 °C, 600 °C and 800 °C. Consequently, magnesium chromite containing waste brick aggregates have given the best results.

Jan 1, 2006

By D. R. Hack

The complexity of commercial mining software has gained rapidly over the past decade as hardware developments have surpassed software capabilities at a staggering rate. Software users, recognizing the limitations of off-the-shelf applications, have adapted embedded scripting languages. Custom programming has always had a vital role in mine computing innovations, yielding a dynamic research environment in industry and academia. Fields such as industrial minerals can benefit from customization of existing software, since the majority of mine planning software was designed for large metal mines. Different customization approaches utilizing embedded scripting languages are presented, with examples of sand and gravel applications in development. Following implementation by Surpac and development of the Surpac Command Language, Tcl has been widely applied. Mintec introduced Python, also extensible and portable amongst various operating systems, for use in their MineSight products. In early 2000, Gemcom introduced the use of Microsoft Visual Basic for Applications, widely used customization tools for a decade. Datamine implemented a flexible multi-language approach, with all program commands and processes available through the COM Server Interface. This extends customization from the existing macro language to scripting in HTML, JavaScript, or any language that supports COM.

Jan 1, 2003

By H. M. St. John

LIKE every present-day manufacturer, the brass foundryman is faced with the necessity of reducing the cost of his finished product without impairing its appearance or quality. He must use every economy that the progress of art and science puts at his disposal and should also be alert to profit by any peculiarity in his own situation or the nature of his product that may give him an exceptional advantage. Much can be accomplished by the adoption of labor-saving equipment and improved methods of melting, molding and handling. Control of pouring temperature, study of defective castings and their causes, laboratory control of molding sand and core mixtures, the use of less expensive alloys, all contribute to the desired end. Assuming that the composition of the alloy is already as inexpensive as the character of the casting will permit, still further savings can be made by the intelligent purchase and utilization of the metals needed to produce the desired analysis.

Jan 1, 1929

By James Cudworth

THE Birmingham district of Alabama has utilized the slag from its blast furnaces consistently since the earliest development of the slag industry. Today there are producers of slag cement who started business in 1900, and who have, under a progressive policy, expanded the number of their products to meet present demands. There are producers of slag aggregates and other crushed slag products who have been successful for periods of over thirty years. There are at the present two companies, Cheney Lime and Cement Co. and the Southern Cement Co., manu-facturing puzzolan cement; three companies, Birmingham Slag Co., Woodstock Slag Co., and Swann Chemical Co., making slag aggregates and by-products; one company, Tennessee Coal, Iron and Railway Co., a subsidiary of the U. S. Steel Corporation, producing ground open-hearth basic slag for soil conditioning. Two companies, the Sloss Sheffield Steel and Iron Co. and the Woodstock Slag Co., make slag concrete in ready-mix plants and one company, the Superock Company, manufactures fine and coarse slag aggregates under a new granulation process. No Portland cement is made with slag as an ingredient, because dolomite is used so extensively as a blast-furnace flux that the magnesium content of the slag is excessive.

Jan 1, 1937

By Joseph C. Mead, James R. Cudworth

THE Birmingham district of Alabama has utilized the slag from its blast furnaces consistently since the earliest development of the slag industry. Today there are producers of slag cement who started business in 1900, and who have, under a progressive policy, expanded the number of their products to meet present demands. There are producers of slag aggregates and other crushed slag products who have been successful for periods of over thirty years. There are at the present two companies, Cheney Lime and Cement Co. and the Southern Cement Co., manufacturing puzzolan cement; two companies, Birmingham Slag Co. and Woodstock Slag Co., making slag aggregates and by-products; one company, Tennessee Coal, Iron and Railway Co., a subsidiary of the U. S. Steel Corporation, producing ground open-hearth basic slag for soil conditioning. Two companies, the Sloss Sheffield Steel and Iron Co. and the Woodstock Slag Co., make slag concrete in ready-mix plants and one company, the Superock Company, manufactures fine and coarse slag aggregates under a new granulation process. No Portland cement is made with slag as an ingredient, because dolomite is used so extensively as a blast-furnace flux that the magnesium content of the slag is excessive. Sources Of Slag In the Birmingham district there are 22 blast furnaces, of which the majority are in blast. The present production is 165,000 tons of pig iron monthly; the production in 1935 was 1,297,960 gross tons1. There are also two blast furnaces at Gadsden and one ferroalloy electric furnace at Anniston. From these two sources is obtained slag to approximately 1.1 tons per ton of pig iron.

Jan 1, 1937

By B. Rai

Aluminum is produced by the Hall-Héroult process, which involves passing a current through a molten mixture of alumina dissolved in cryolite (Na3AlF6) to reduce the alumina to aluminum. This process occurs in an electrolytic cell comprising a steel shell lined with a carbon cathode and refractory bricks. After a certain period of operation, the carbon cathode deteriorates and is removed from the cell along with the refractory bricks. These removed materials are referred to as spent pot lining or ?SPL?. Typically, 30 Kg of SPL waste is generated for every ton of Aluminum produced. Globally aluminum smelters produce more than 500,000 tons of SPL each year. Even though SPL has a high fuel value (8000 to 9000 BTU/lb) and contains valuable metals, it is classified as a hazardous material due to its cyanide content and leachable fluorides. Various disposal/recycle techniques have been developed over the years for SPL but none of them is satisfactory. Thus, large quantities of SPL are still being dumped in landfills. In some countries, even the land filling of SPL is not permitted. The safe disposal of SPL thus remains a challenging problem to the aluminum industry and the search continues to find methods of converting SPL into a non-hazardous waste and/or recovering the valuable materials contained in the SPL. We have developed a process to produce hydraulic setting cements (eco-cement) containing a novel fluoride rich cementitious phase, from SPL by an energy efficient, low temperature clinkering route. A raw mix blend of SPL, lime/limestone, calcium sulfate and tailings sands based on a set of design criteria developed by us, is clinkered in a two stage process; 2 hours soak at 800 °C followed by clinkering at 1000 °C for another 2 hours, to produce a soft clinker. The SPL eco-cement is made by grinding the clinker to a fineness of 5000 cm2/g Blaine with 1% by weight borax as a set retarder. A good quality cement having as high as 20 % by weight of SPL in the raw mix (28 % by weight in the cement clinker) is thus produced. The physical properties of the SPL cements are found to be comparable to the Indian standard (IS) specifications for Ordinary Portland Cements (OPC). We have produced the cement in a few Kg batches and tested the reproducibility of results from batch to batch for further scale up. Once commercialized, this process has a potential of converting SPL into value-added cement products. Keywords: cement, spent pot lining, clinkering, fluoride, aluminum, ordinary portland cements

Sep 1, 2012

By S. Shrivastava, R. G. Reddy

Spent potliner is generated in the electrolytic process of reducing alumina to make aluminum metal using molten fluoride electrolytes. Spent potliner (SPL), obtained at the end of the pots life contains a small amount of cyanide and fluoride which present environmental problems. SPL became a listed hazardous waste under RCRA (KO88) in July, 1990. One of the possible uses of spent potliner is as a substitute for Calcium Fluoride (CaF2) as a fluidizer in iron- and steelmaking and in the glass industry. A low viscosity and a low melting point are prime requirements for accomplishing the above. In the present study, viscosity measurements were performed. Effect of various additives, such as sand, limestone, dicalcium silicate dust, and MgO baghouse dust on the viscosity of SPL was studied. The results showed that with the addition of sand and limestone, very high fluidity of SPL melt can be obtained at significantly low temperatures. The results suggest that spent potliner mixed with additives could potentially be used as a substitute fluidizer.

Jan 1, 1999

By R. G. Reddy

Spent potliner is generated in the electrolytic process of reducing alumina to make aluminum metal using molten fluoride electrolytes. Spent potliner (SPL), obtained at the end of the pots life contains a small amount of cyanide and fluoride which present environmental problems. SPL became a listed hazardous waste under RCRA (K088) in July, 1990. One of the possible uses of spent potliner is as a substitute for Calcium Fluoride (CaF2) as a fluidizer in iron-and steel making and in the glass industry. A low viscosity and a low melting point are prime requirements for accomplishing the above. In the present study, viscosity measurements were performed. Effect of various additives, such as sand, limestone, dicalcium silicate dust, and MgO baghouse dust on the viscosity of SPL was studied. The results showed that with the addition of sand and limestone, very high fluidity of SPL melt can be obtained at significantly low temperatures. The results suggest that spent potliner mixed with additives could potentially be used as a substitute fluidizer.

Jan 1, 1999

By R. G. Reddy

Spent potliner is generated in the electrolytic process of reducing alumina to make aluminum metal using molten fluoride electrolytes. Spent potliner (SPL), obtained at the end of the pots life contains a small amount of cyanide and fluoride which present environmental problems. SPL became a listed hazardous waste under RCRA (K088) in July, 1990. One of the possible uses of spent potliner is as a substitute for Calcium Fluoride (CaF2) as a fluidizer in iron-and steel making and in the glass industry. A low viscosity and a low melting point are prime requirements for accomplishing the above. In the present study, viscosity measurements were performed. Effect of various additives, such as sand, limestone, dicalcium silicate dust, and MgO baghouse dust on the viscosity of SPL was studied. The results showed that with the addition of sand and limestone, very high fluidity of SPL melt can be obtained at significantly low temperatures. The results suggest that spent potliner mixed with additives could potentially be used as a substitute fluidizer.

Jan 1, 1999

By Jorge Armstrong, Sean Warren, JOSEF BOURGEOIS

The application of statistical analysis software programs has proven useful for the investigation of rockfall runout distance along a designed slope. Rockfall modeling programs are continually being upgraded with more sophisticated analysis tools, such as the use of the rigid body versus lump mass models. Engineers at mine sites utilizing the software may have varied experience related to these models, their associated input parameters, and how to interpret the generated results. To address this concern, researchers at the Spokane Mining Research Division (SMRD) of the US National Institute for Occupational Safety and Health (NIOSH) investigated the influence of slope height, slope angle, slope material, and rock size for both rigid body and lump mass models in a 2-D statistical analysis program. Based on a literature search and industry input, specific ranges common to that of an open pit mining environment were chosen for each of the input parameters to determine 90% rock runout distance as well as their sensitivity to change. Data collected from this numerical analysis and simulation will be compared to empirical rockfall data gathered through the duration of the Highwall Safety project conducted by NIOSH from 2022–2026.

Jun 18, 2023

By J. Armstrong, J. Bourgeois, S. Warren

The application of statistical analysis software programs has proven useful for investigation of rockfall runout distance along a designed slope. Rockfall modeling programs are continually being upgraded with more sophisticated analysis tools, such as the use of the rigid body versus lump mass models. Engineers at mine sites utilizing the software may have varied experience related to these models, their associated input parameters, and how to interpret the generated results. To address this concern, researchers at the Spokane Mining Research Division (SMRD) of the U.S. National Institute for Occupational Safety and Health (NIOSH) investigated the influence of slope height, slope angle, slope material, and rock size for both rigid body and lump mass models in a 2-D statistical analysis program. Based on a literature search and industry input, specific ranges common to that of an open pit mining environment were chosen for each of the input parameters to determine 90% rock runout distance as well as their sensitivity to change. Data collected from this numerical analysis and simulation will be compared to empirical rockfall data gathered through the duration of the Highwall Safety project conducted by NIOSH from 2022–2026.

Mar 2, 2022

By Jorge Armstrong, Sean Warren, JOSEF BOURGEOIS

The paper investigates the influence of slope height, slope angle, slope material, and rock size on rockfall runout distance in openpit mines. Using statistical analysis and simulation, the study aims to improve rockfall hazard assessment and catch bench design by identifying key variables affecting rockfall behavior.

Oct 1, 2023