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By David Bequette, Ray D. Peterson, Cynthia K. Belt

"With a need to cut production costs in the metals industry, cost savings from energy efficiency improvements are critical. Opportunities can be found by reviewing furnace systems and practices so that the melting and holding processes operate at the highest energy efficiency. Many of the changes can be implemented with a minimum of expense or capital investment. This paper will review several low cost methods to optimize energy efficiency on reverberatory melting or holding furnaces. These five methods (furnace utilization, idle procedures, fire rate, controls, furnace pressure) will be explained and information given to implement these changes. Included are several rules-of-thumb and benchmarks for aluminum reverb furnaces.IntroductionEnergy can be a significant portion of the total manufacturing costs for metals and materials manufacturing involving thermal processing such as heat treating, melting, and high temperature processing. Natural gas prices have dramatically varied over the last few years. While no one can foresee the future, prices are expected to increase from the current low prices. More recently, emphasis is being put on the reduction of greenhouse gases with the potential of additional costs to industry.One of the first steps in an energy management program is to measure the energy usage of the process [1]. The results are typically understood in relation to the mass melted in kWh / mT [BTU / lb]. For the purposes of this paper, furnace energy efficiency is calculated over a month or even a year and thus includes hold times. This efficiency is typically different from the values quoted by furnace manufacturers. Those values are for limited short term tests at highutilization.Once you know the performance for your furnaces, these should be compared to industry benchmarks. For aluminum melt furnaces with cold air burner systems, a benchmark value or goal is 1800-2000 BTU/lb [1160-1290 kWh/mt], though some of the best have reached 1600 BTU/lb [1030 kWh/mt]. Furnaces with regenerative burners can attain 1100-1200 BTU/lb [710- 775 kWh/mt]. There are some designs of multi-chamber furnaces or oxygen furnaces that have improved on these numbers, perhaps as low as 950 BTU/lb [615 kWh/mt]. Typically, as the degree of sophistication and energy efficiency of the furnace increases, so does the cost."

Jan 1, 2010

By J. Hendry, K. Brady, J. Yorzyk

Drawing from the experience of nickel, copper, aluminum and mineral borates, this paper illustrates the business value that the mining, minerals and metals industry as a whole can gain from applying life cycle assessment (LCA) to products and operations. Through the use of case studies, the paper explores how companies and industry associations have used LCA to their advantage: from evaluating capital investments, meeting customer information needs, supporting new product applications, and developing credible marketing information on the environmental performance of their products. It also explores the dynamics of LCA adoption and integration within companies, and provides recommendations to further strengthen institutionalization of LCA.

Jan 1, 2010

By T. Gollaher

The use of paste thickeners for mineral tailings has gained increasing acceptance by the mining industry throughout the world and in the U.S. during the last five years. Advantages of water recovery and environmental sustainability are the driving forces for paste as an alternative to conventional thickening and the slurry pond. This paper presents a summary of the differences between paste and conventional tailings thickeners, along with recent examples of full-scale paste thickener installations.

Jan 1, 2010

By A. S. Azman

The mining workforce experiences high rates of hazardous noise exposure and hearing loss. However, previous studies have identified specific behavioral and attitudinal barriers that keep miners from effectively acting to prevent their own hearing loss. NIOSH has developed several new hearing loss prevention tools and interventions that specifically target these barriers to prevention. The NIOSH Hearing Loss Simulator addresses motivation to take action and knowledge about the consequences of noise exposure. The QuickFit earplug test device and QuickFitWeb online hearing protection tester address barriers to effective earplug and earmuff use by verifying at least 15 decibels of protection. The NIOSH Roll-Pull-Hold technique helps miners obtain better protection through an easy-to-remember set of steps that improves attenuation by 9 decibels. The ?Inquiring Ears Want to Know? fact sheet helps miners to understand audiograms and to use them to maintain their hearing health. Each of these interventions can be used within the context of a comprehensive hearing loss prevention program.

Jan 1, 2010

By W. A. Wilkinson

Mine planners are under pressure to evaluate the impact of changing economic times and newly acquired data on their mine plans. Incorporating changes such as commodity prices, customer sales, fluctuating cost assumptions and newly acquired geologic data requires quick turnaround for model building and planning to keep mine plans on pace with changes as they occur. Because of the length of time required to perform some of the geologic modeling and mine planning tasks, planning frequency may not be keeping pace with the frequency of change. To meet these challenges, one leading North American mining company successfully increased the frequency rate and accuracy of its mine plans to stay current with incoming data, ensuring its mine plans reflect the latest information, thereby minimizing or eliminating production cost variance.

Jan 1, 2010

By Dale Preece, Joergen Pilz, Zavis Zavodni

An overland conveyor was constructed at a surface coal mine to reduce the truck haul distance and make the operation more efficient. An important element in this system is a truck dump facility to transfer coal from truck to conveyor. Mechanically stabilized earth retaining walls were employed to accommodate the coal processing equipment, including the crusher, in this facility. These retaining walls are close enough to the pits being mined that blasting induced vibrations must be considered in analyses of the wall structural stability.

Jan 1, 2010

By Jr. Wilkinson

Mine planners are under pressure to evaluate the impact of changing economic times and newly acquired data on the mine plan. Incorporating change, such as commodity prices, customer sales, changing cost assumptions, and newly acquired geologic data into the mine plans requires quick turn-around for model building and planning to keep the mine plan on pace with changes as they are occurring. Because of the length of time required to perform some of the geologic modeling and mine planning tasks, planning frequency may not be keeping pace with the frequency of change. This paper discusses how one company has increased the frequency rate and accuracy of mine plans to keep current with incoming data, ensuring mine plans reflect the latest information, thereby minimizing or eliminating production cost variance.

Jan 1, 2010

By Stephen C. Tadolini, Peter A. Gray, Robert Hawker, Andrew Sykes

"Self-drilling rock bolts (SDRBs) that use pumpable cement grout to anchor bolts have been used successfully in the tunnelling and civil engineering industries for many years. Pumpable cement grout offers a considerable advantage in that the SDRB can be fully encapsulated right down to the bearing plate, including filling cracks and cavities in the borehole. However, cement grout cannot provide the immediate rock support required for the coal industry. This paper describes a new SDRB system that uses pumpable resin to anchor the SDRB in a borehole, which not only provides all the advantages of a pumpable grout anchoring system, but also provides immediate roof and rib support as required in the coal industry. This paper further outlines the latest developments in SDRB technology including (1) extendable self-drilling rock bolts, which can almost double in length during the installation process and are particularly suited to low seam heights and rib support and (2) pre-tensioned SDRBs, where a pre-tensioned load can be applied during the installation process. These new SDRB systems offer both considerable advantages in rock support and improvements in mining productivity.INTRODUCTIONThe mining industry is continually striving to develop more efficient methods to support the roof and walls of roadways and tunnels, and rock bolting has proven to be one of the most significant improvements in ground support over the last 50 years. Rock bolting is now almost universally used in the underground mining industry worldwide, and there are many different rock bolts available.Rock bolts are traditionally made from steel or fiberglass and are anchored into a borehole with a friction-anchoring device, such as an expansion shell mechanism; cement grout; or chemical resin. Friction-anchored bolts are widely used in the Australian metal mining industry, predominantly as short-term support. They are used in conjunction with resin-anchored bolts where there is a requirement for longer life. Resin-anchored bolts are used in the coal mining industry.Friction-anchored bolts provide immediate rock support, but their load transfer capacity is poor compared to resin or cement anchored bolts. In addition, friction-anchored bolts are more susceptible to corrosion than resin or cement anchored bolts."

Jan 1, 2010

By L. Bomvisinho

As a result of today?s requirements for larger mills with higher power demand, and in order to cope with maximizing throughput, and optimize grinding efficiency, the minerals industry is increasingly relying on the robust Gearless Mill Drive (GMD) solution. This paper describes the new features introduced with the revolutionary ABB drive controller for Gearless Mills, and explains the benefits this can bring to the operation. Extensive surveys have been performed with GMD users to gather suggestions and understand the market wishes. As a result the new driver controller capabilities and functionalities focus on safety, high availability, operational flexibility and remote diagnostics.

Jan 1, 2010

From a distance, the 0.75-km (0.5-mile) rail line that sits in the shadows of Vale-Inco?s Stobie Mine outside of Sudbury, Ontario could be mistaken for a standard conveyor belt hauling ore from the nearby mine. But with its large, yellow-painted loop and interconnected green rail cars that invert themselves on the loop before correcting with a smooth rollover further down the track, one might assume that this is some sort of test track for a new roller coaster. The fact of the matter is that it is the proving ground for Rail-Veyor technology, a technology that the company hopes will one day change the face of ore transportation in surface and underground mines around the world. With a line of linked, low-profile rail cars that are capable of carrying up to 1 t (1.1 st) per car of ore by way of simple, above ground, lightweight rail track, the technology is not groundbreaking. In fact, it was developed in the 1960s for the French State Railroad. A demonstration plant for the Florida Institute of Phosphate Research was installed in 2000 and the first commercial under-ground installation was in 2007 in South Africa at Harmony Gold?s Phakisa Mine. There, a 4.7-km- (2.9-mile-) long tram between two shafts operates three Rail-Veyor trains on a shared track. The difference is that the application that is being tested day-and-night in Sudbury is getting closer to wide production, thanks to the use of computer controlled automation that has helped turn an old idea into a cost-effective modern solution.

Jan 1, 2010

By J. Drimmer

The past several decades have seen the rapid expansion of multinational mining companies? exploration and production activities around the globe. This trend has resulted from a number of factors, including increased demand for resources as a result of worldwide economic growth, the diminishment of known and proven reserves, rising commodity prices, technology improvements, and the liberalization of investment regimes in developing countries with significant natural resources. With those opportunities, however, come associated risks and significantly increased legal compliance obligations that may be imposed by various bodies. That includes domestic regulations, as well as foreign civil and criminal laws with extraterritorial reach. A failure to adhere to those laws can have dire consequences, including substantial monetary fines and penalties, severe damage to a company?s reputation, and even jail time for individual company employees.

Jan 1, 2010

By Randall Head

The drilling at the Taum Sauk Reservoir was a unique compilation of the latest technology and everyday common sense. This site is comprised of rhyolite, which is 30 times harder than limestone in comparison. Using some of the most state of the art drills, coupled with GPS guidance, angular drilling systems, and an ordinary piece of string, some of the most amazing drilling feats were accomplished. By constructing the new dam on top of a mountain that had been blasted once before nearly 50 years ago treacherous conditions for the drills and crew were a challenge. The drills had to be flown in by cranes to get to their locations, where they then drilled anywhere from 2.5 to 6 inch (6.4 to 15.2 cm) holes at angles up to 24.4 degrees. Custom drill bits were designed by the drilling crew to tackle feats such as drilling holes up to 120 feet (36.6 m) deep. A main challenge was the shape of the reservoir, as it is not in a straight line, but rather round, so no technological way was readily available to use to drill. Common sense came in and an ordinary piece of string was used to aide in drilling the hole. A revolutionary step was that our drill was used to core our own samples. By using our own equipment, we were able to complete this task for one-third of the cost of having a third party contractor obtain the core samples. On this unmatched jobsite, it has been established that technology has come a long way, but when all else fails, a piece of string will do just fine.

Jan 1, 2010

By T. M. Ruff

The U.S. Bureau of Mines has developed a portable, inexpensive teleoperation system for mobile hard-rock mining equipment. The system was tested on a compact loader-trammer in a simulated stope. The teleoperation system includes radio remote control and computer-assisted navigation. A recent enhancement includes video cameras mounted on the machine to provide visual information to the operator. This system allows the operator to remain in a safe location while operating the machine from a distance, thus increasing both operator safety and mining productivity.

Jan 1, 2010

By Michael J. Pazuchanics

This report documents the current status of the U.S. Bureau of Mines ongoing investigation of the use of adaptive signal discrimination (ASD) systems to distinguish between cutting coal and cutting rock. Cutting-tool forces and vibrations were measured in the laboratory using both conical bits and roller cutters in a linear-cutting apparatus for several material samples and two cutting directions. A number of ASD systems consisting of one or more signal classifiers were trained and tested to study how data window size, type of signal feature, and combining (polling) of classifier results influence system performance. The results show that ASD system recognition rates can be improved by increasing data window size, removing air-cutting portions from the signal data, overlapping data windows, and combining (fusing) information at various levels of ASD system operation.

Jan 1, 2010

By M. A. Roberts

Oebswana's Jwaneng Mine (south-central Botswana) is the richest diamond mine? in the world and has been contributing substantial revenue to Botswana since the mine started operating in 1982. The resource consists of 3 separate volcanic pipes/vents namely North, South and Centre pipes (2 additional small kimberlite bodies have also been intersected within the mining pit) which erupted through Transvaal strata and the overlying Karoo sediments -245 million years ago. Although earlier drilling and geophysical surveys suggest that the 3 pipes extend to depths greater than 1 km below the surface, the resource is only at an indicated level of confidence to a depth of 400m, and mining activities will start exploiting the inferred resource material below 400m in 2014.

Jan 1, 2010

By Christoph Muller, Geoffrey Liggins, Mohan Hensman

Modern commercial blasting is as much a technical process as it is a business one. As with most processes both aspects of blasting are driven by and generate new data. The time-critical nature of commercial blasting in mining and construction projects, dictate the timely exchange of information so as not to impede production or commerce. Up-to-date information about the blast to be undertaken can help suppliers: meet customers’ expectations to address challenging ground conditions; react to a market where quickly changing orders occur regularly; and address as-drilled blast patterns as opposed to baseline plans. “Real-time” data exchange into and out of the blasting process supports the whole-of-mine data management that the industry is migrating to.

Jan 1, 2010

By H. Walqui

The Empire concentrator currently processes magnetite ore from the Empire pit which is approaching the end of its mine life. Over the past two years plant wide tests have been run to access the plant capability of processing ore from the neighboring sister Magnetite pit. The neighboring pit presents challenges to the Empire plant due to its higher feed grade, finer liberation size and higher percent silica which require additional secondary grinding and concentrating capacity to achieve concentrate grade. The following paper summarizes the results from the second full scale test, run during 2009 under a challenging market environment

Jan 1, 2010

By R. T. Swinderman

This paper discusses how many of the common practices in conveyor specification and design are out of date compared to the current expectations of users for safe, serviceable, reliable, and fugitive material-free conveyance of bulk solids. Ten of the most common mistakes made in the specification and design stages related to user expectations are reviewed along with the cost vs. price implications of those decisions. A general specification and design hierarchy that designers can use to improve conveyor design is included.

Jan 1, 2010

By S. M. Moore

Each year more than 400 coal miners are injured (fatal and non-fatal) by rock falling from between or around roof supports. Many of these injuries could be prevented by the installation of roof screen (wire mesh). However, many coal mines may be reluctant to use roof screen because of the added cost. The goal of this study was to determine the potential saving in workers? compensation (WC) premiums that could be achieved due to a reduction in rock fall injuries after roof screening. The WC rate-setting methods utilized by IL and KY were investigated in this study. Using actual data obtained from MSHA, national and state WC bodies and individual insurance companies (e.g. average cost per injury, loss cost rate, number of injuries per year, number of injuries preventable each year with roof screening), hypothetical mines (representing two mine sizes: 67 and 150 employees) were constructed with realistic ranges for estimates of injuries and WC premium costs. Using each state?s actual WC rate-setting formulas, total savings in WC costs after a three-year period were determined. Across both states, savings in WC premiums ranged from 1.8% to 14.6% when injuries were reduced by 10% to 20%. Additionally, an economic analysis was performed for an existing mine consisting of 67 employees. For this mine, the annual cost of a roof screening program was estimated at $240,000. If the screening prevented 13 ?struck by? WC claims over a 3-year period at this mine, the reduction in WC premiums alone could pay for the entire screening program.

Jan 1, 2010

By Rob Farnfield, Mark Pegden

Old Cliffe Hill quarry produces between 4 and 5 million tonnes of crushed granite per year and is located in the county of Leicestershire in the East Midlands region of England. Blasting is carried out with bulk emulsion explosives in combination with either shock-tube or electronic detonators.

Jan 1, 2010