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By J. Pereyra, M. DeMarco

"INTRODUCTION It can be vital that bolted joints holding subassemblies together remain secure. Bolts should resist the loosening effects of vibrations and dynamic loads yet need to be easily removable during maintenance. When a threaded fastener is subjected to vibration, the rapid movement causes a lowering of friction against the threads and a subsequent loss of preload. The loss of preload allows the fastener to vibrate loose and possibly fall out. As the diameter of fasteners increase desired preload becomes increasingly more difficult to achieve. Input torque requirements for achieving proper bolt preload is exponentially related to any given fasteners diameter. This means that specialized tooling or bolting practices are usually required to attempt the tightening of fasteners to reach their required preload. Traditional methods can cause problems with joint integrity and do not provide consistent bolt load across the bolted surface. BOLTED CONNECTIONS A failed critical bolted joint can lead to high maintenance costs, machine downtime, and risk to worker safety. Control of the clamp load in a bolted joint is vital. However, when faced with a problem joint, it is not surprising that the design engineer will not have an answer if asked about the clamp load. Torque calculations must always be based on the existing conditions that often are vague. Unless all parameters are correct, the calculation will be unreliable. Examples of parameters are: • Thread condition of the fasteners • Hardness of contact surface • Material (steel, aluminium, copper, etc.) • Extra friction from a locking fastener • Extra friction from an adhesive • Lubricant on the thread • Type of bolt head (flanged, regular or serrated) • Surface coating of the bolt • New or reused fastener During tightening, bolts are subjected to both tensile and torsional stress. The total stress in a bolt can be calculated using the formula: Total stress = vsx2 + 3txy2 In order to maximize the desired tensile stress (sx) it is vital to minimize the torsional stress (txy). Tensile stress (clamp load) is achieved when the bolt is axially elongated. Unwanted torsional stress (twisting) in bolts arises during tightening due to thread friction. High thread friction increases torsional stress and causes yielding at lower clamp load levels than normal. A lubricant is necessary to minimize the malign torsional stress. However, many commonly used bolt-locking systems are based on increased thread friction (deformed nuts, adhesives, etc). To minimize thread friction and concurrently safely secure the joint has often incorrectly been considered impossible. The use of locking systems that increase thread friction is the single most common reason why the full capacity of bolted joints is not utilized. The following example illustrates the problem."

Jan 1, 2015

By M. van de Vijfeijken

This paper will first give a short overview of the Copper Mountain project in British Columbia, which just has started commercial operation earlier this year. The grinding process with one 34' x 20' SAG mill and two 24' x 39.5' ball mills will be briefly discussed. All three mills are gear driven by a ring gear, dual pinion and two low speed synchronous motors. Copper Mountain has installed on all three mills, the new state-of-the art dual pinion mill drives. All the inherent operation and maintenance features of this drive technology will be discussed, as well as the advantage of having variable speed control also on the ball mills. The installation and commissioning of the mills and drives at Copper Mountain will be briefly reviewed. Finally the first field measurements on these low speed mill drives will be presented, with the main focus on the low mechanical stress impact of these mill drives on the pinion and ring gear, as well as the accuracy of the load sharing between the two motors.

Jan 1, 2012

By S. Steinlechner, G. Schneeberger, J. Antrekowitsch

The recycling of steel mill dusts is getting more and more important. The costs and requirements of land filling are rising and companies are interested in new recycling strategies. The rising of sustaina¬bility hand in hand with the high rate of valuable metals in these residues supports new research activities on the recycling sector. Especially zinc but also iron and lead are economical factors due to the treatment of steel mill dusts. This paper gives a small overview of fundamental studies concerning the chemical and physical composition of these dusts. Furthermore aggregates for the reduction of these dusts in the liquid phase are introduced and compared. The Flash-Reactor, the TBRC-Technology (Top Blown Rotary Converter) and submerged arc furnaces and there use for melting and treatment of these dusts are in the center of interest of this paper. The final conclusion gives an overview of possibilities for reduction of filter dusts in the liquid phase.

Jan 1, 2011

By Nick Hazen

Many successful actions are required to bring a profitable extractive metallurgical operation into production. Competent process development performed within the project development schedule increases the chances of obtaining project financing and decreases the risk of engineering design errors being built into the commercial plant. The general sequence of steps in process development is well known: technology review, desktop studies, scoping studies, prefeasibility, and so on, with an increasing requirement for experimental evidence as the studies advance. This paper suggests principles for guiding process development work so that the efforts stay on track toward a smooth startup and a profitable commercial operation. It emphasizes closely aligning the research with the corporate goals of the mining company management, understanding the mineralogy and variability in the deposit, and guiding by flowsheet and material balance. Examples of hydrometallurgical process development leading to the early use of solvent extraction in the mining industry are given.

Jan 1, 2014

By R Araya, G Harbort, D R. Seaman, L Huynh, P D. Munro

In today’s operating environment many conventional cleaner circuits struggle to produce final grade concentrate with acceptable levels of non-sulfide gangue and/or penalty elements. This is primarily due to poor selectivity and the entrainment of gangue, and is further exacerbated by the processing of lower grade ores with more complex mineralogy that require finer grinding for liberation. In new concentrators, the standard approach to cleaner circuit design is to define the number of stages of mechanical cells required to achieve the desired concentrate grade. Residence time is the primary factor to size cells and to determine the number of cells required to attain target recovery. While it is required for recovery, a bank of mechanical cells is not the ideal solution to maximise concentrate grade. Relatively coarse bubble size means slow flotation of fines, requiring long residence times. The combination of long residence times and no froth washing means higher entrainment as the pulp becomes more barren and froth stability decreases down a bank.In recent years, the Jameson Cell technology has been retrofitted into a number of concentrators around the world to solve both cleaner circuit capacity and concentrate grade issues. Jameson Cells have been installed at the head of conventional cleaner circuits to produce final grade concentrate in a single step of flotation using a single cell (referred to here as ‘cleaner scalping’ duty). The experience gained from these installations has provided the platform for the design of improved and simpler cleaner circuits that will perform better and be more robust to operate. This paper analyses traditional cleaner circuit designs and explains the philosophy behind new hybrid cleaner circuits, which use Jameson Cells to produce final concentrate and mechanical cells for a ‘cleaner scavenger’ duty. The advantages of the new cleaner circuit design are demonstrated by a case study from an operating plant. Engineering studies show that the better metallurgical performance can be achieved with less equipment than conventional cleaning designs, reducing capital cost, operating cost, and with more than 30 per cent energy savings.Finally, the paper describes simple modifications to the standard laboratory flotation test procedures which accurately simulate this new cleaner circuit using routine equipment.CITATION:Huynh, L, Araya, R, Seaman, D R, Harbort, G and Munro, P D, 2014. Improved cleaner circuit design for better performance using the Jameson Cell, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 141–152 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By Jheison Lopes dos Santos

Sistemas de blindagens multicamada têm sido estudadas pela sua ótima capacidade de proteção, devido à combinação de diferentes materiais que constituem seus componentes. A primeira camada é constituída por um componente cerâmico, cujo objetivo principal é fragmentar o projétil, dissipando grande parte de sua energia. A camada intermediária compreende tecido de aramida ou matriz polimérica com fibras naturais, que também dissipa energia tanto do projétil quanto do cerâmico e opera retendo os fragmentos cerâmicos. Neste trabalho, pela primeira vez, o sistema cerâmico Al2O3-Nb2O5-LiF tem seu comportamento dinâmico avaliado balisticamente. Este composto cerâmico foi submetido a impactos balísticos de projéteis 7,62 mm, para testar este cerâmico do primeiro componente de um sistema de blindagens multicamadas. Os resultados obtidos mostraram que a adição de LiF ao composto cerâmico Al2O3-4%p. Nb2O5, sinterizado a 1.300 ºC, obteve desempenho comparável ao obtido por Al2O3-4%p. Nb2O5 sem LiF, sinterizado a 1.400 ºC. Os resultados revelaram que, ao serem submetidos a esses impactos balísticos, apresentaram valores comparáveis aos esperados de pressão e de velocidade de partícula na interface de impacto projétil-cerâmico. Dessa forma, a adição de fluoreto de lítio ao composto cerâmico alumina-nióbia possibilitou a redução em 100 ºC na temperatura de sinterização, sem comprometer o desempenho balístico e exibindo parâmetros de choque comparáveis, e redução de custo.

Oct 30, 2017

By J. V. Scalera

Because of U.S. dependency on imported critical metals, the Bureau of Mines has conducted research to evaluate the possible substitution of nitrided low-alloy steels for higher chromium-containing alloys. The corrosion data for nitrided steels are limited primarily to the Soviet literature. The objective of this study was to determine the corrosion properties of six commercially nitrided low-alloy steels in a 5-wt % NaCl solution at pH 4. Weight-loss tests indicated that, in deaerated test solutions, most of the nitrided steels were less corrosion resist-ant than nontreated steels. However, electrochemical tests indicated that under more oxidizing conditions, nitrided materials are converted to a passive state with a significantly reduced corrosion rate. Elec-trochemical tests performed in an aerated environment confirmed the passivity of the samples in an oxidizing environment.

Jan 1, 1984

By R. C. Emmett

The industrial practice of concentration of solids and production of clear solution by gravity sedimentation is an old technology. Through the years, many devices have been designed and built to aid this process. One of the more significant developments was a revolving rake mechanism to convey settled material to a central discharge point of a circular tank, patented in 1907(1). In recent years, clarification systems employing parallel inclined plates have appeared on the market; the original device utilizing this principle was patented in 1886(2). Numerous other methods have been invented, tested, discarded and sometimes re-invented, all with the specific intention of improving the capacity of a particular settling area. Sedimentation theory, as expressed in Stokes' Law, shows that the rate of settling of a particle is directly proportional to the difference in density between the particle and the surrounding liquid and, more significantly, proportional to the square of the particle diameter. Anything that can increase the latter will greatly assist sedimentation and, as a result, flocculation always has been an integral part of sedimentation. Most materials suspended in aqueous media are naturally flocculent to some degree and, hence, are readily concentrated by sedimentation, although sometimes very slowly.

Jan 1, 1978

By F. N. Siddiquie, Mohd Shaif, Rajiullah Khan, Juned Alam

Manganese ore bodies of Banswara Mn belt were classified into stratiform and stratabound types, based on their mode of occurrence, distribution, and their chemical characters. These ore bodies generally composed of braunite, pyrolusite, cryptomelane/ psilomelane, wad, etc. The stratiform-type Mn ore bodies are conformable with the associated host rocks (Mn phyllite, etc.) and occurred in the form of layers, bands, etc., which are variable in their shape and size. These ore bodies are also strongly folded with the enclosing host rocks. The others, which are stratabound-type Mn ore bodies, also showed an intimate association with the associated host rocks. These types of ore bodies occurred in thin layers, pockets, lenses, stringers, etc. The classified ore bodies are confined with Kalinjara formation of Aravalli Supergroup of Paleoproterozoic age. The ore bodies are structurally controlled and well associated with phyllite, schist, limestone, quartzite, etc. The stratiform-type ore bodies constitute a marginal to low Mn grade and are also characterized by lower Mn content (26.19–39.24%) along with the Mn/Fe ratio of 7.16–12.23, while the stratabound-type Mn ore bodies are rich in Mn (35.92–49.64%) along with the higher Mn/Fe ratio of 14.15–23.97. However, the poor Mn grade along with high siliceous impurities of Banswara Mn deposits is subjected to them for intermittent mining activities in the past and, consequently, did not attract the scientific and industrial community for the evaluation of these resources. Therefore, the authors attempted this study in a scientific and systematic manner (mode of occurrence/distribution and possible methods for evaluation/exploration) to evaluate the potential of existed and newer Mn deposit resources in the Banswara Mn belt. The whole findings would be very much helpful for exploration/ mining geologist along with other concerned, to completely evaluate these Mn deposits in the future.

Aug 16, 2021

By Flavio Begazo, William A. Enrico

"Southern Peru Copper Corporation's Ilo Refinery, the largest in Peru, began operations in 1975 with a production capacity of 165,000 stpy. Southern Peru bought the Refinery from the state owned Minero Peru SA on June 1, 1994.The Refinery processes blister from Southern Peru's I/o Smelter. Blister copper is processed in an anode plant equipped with two 365 st tilting reverberatory furnaces, a 26 mold casting wheel and an anode press machine. Copper is electrorefined in a tank house equipped with 768 commercial cells, 44 stripper cells, and 40 liberator cells, utilizing two electrolyte circuits and a 21,000 Ampere rectifier.During 1989 through 1994 a program for improving productivity was carried out by increasing the number of cells and increasing current density to the total rectifier capacity. As a result, a capacity 215,000 stpy of refined copper, 2 million tr. oz silver and 6,000 tr. oz gold per year was achieved. In 1994 Southern Peru announced plans to increase capacity to 250,000 stpy of cathode with a US$ 18 million investment and a US$ 2 million investment in environmental improvement projects, as part of the purchase agreement with the Peruvian government.This paper outlines the scope of the SPCC lio Refinery modernization and environmental program. It describes the implementation of the Electrolytic Plant expansion based on instaliation of polymer concrete cells, a new rectifier, a new selenium roaster and a Precious Metal Plant upgrades."

Jan 1, 1997

By Subrata Dutta

Sindesar Khurd Mine is situated in Rajasthan, India, and operated by Hindustan Zinc Ltd, under Vedanta Group. The base metal mine is high in reserves of Lead, Zinc and silver and has been producing since 2007 with initial production of 0.3 mtpa. Recently the mine has gained prominence as a base metal underground mine in introduction of latest mining techniques and achieving high production at lowest costs. The promising Lead-Zinc reserves of Sindesar Khurd Mine (SKM) and high-tech exploration adopted by Hindustan Zinc Ltd (HZL), (Vedanta Group), raising the reserves and resources from a meager 9 Mt (1997) to 81 Mt (2012), has prompted HZL management to ramp up the mine production from 0.3 mtpa (2006-07) to 2 mtpa by 2013-14 with ambitious plans to reach 3.5mtpa subsequently (presently largest underground metal mine in India). The complete trackless system underground mine, recently equipped with latest leaky feeder communication system (unique in India), utilize modern drilling, mucking and hauling equipment aided with various utility/service vehicles. Excavation optimization and quality recovery maximization from the open and post filled stoping methods, continual expert analysis and feedback from International consultants like AMC (Australia) and SRK (UK), and involvement of renowned bodies in management excellence, have lead the mine towards highest productivity and lowest mine operating cost, earning the mine a prominent place in the global base metal industry. The paper deals with how the various challenges in mine planning and designing, mine development, operator skill, equipment introduction and maintenance, expertise availability, provide training and exposure to officials, prompt and effective communication/service, control of ground vibrations, maintain ventilation standards etc are faced in attaining high operational excellence and thus attain a record mine output/man shift (OMS) of 14 ton/man shift with targets to reach 20 ton/man /shift. Scientific designing using 2D/3D numerical mine-modeling techniques, faster stope sequencing with introduction of paste filling ( first time in India),latest leaky feeder communication system, control ground vibration to stringent standards using electronic delay system, faster raising techniques using raise borers to enhance development and ventilation, cavity scanners to monitor large stope voids, fast shaft sinking at 100 m/month(Chinese expertise) and maintaining adequate ventilation with close software monitoring are some of the highlights discussed in the paper towards achieving the targets.

Aug 1, 2013

By A. R. Javadi

Pyrite (FeS2), chalcopyrite (CuFeS2), sphalerite (ZnS) and galena (PbS) generate hydrogen peroxide (H2O2) when placed in water, with pyrite generating the most amount of H2O2. The order of these minerals for generating H2O2 in water is: pyrite > chalcopyrite > sphalerite > galena. In previous research, the methods of generation of H2O2 in the grinding mill were studied. In this study, data from experiments were included by using MODDE 9 software for six parameters composed of water, grinding media, particle size; adding collector to the grinding, and adding depressant and pH. Finally the optimal condition was achieved. According to the results, most of the recovery is related to the particle 75 μ size and when using processed water, adding 100% collector and without depressant and pH 10. The most recovery of lead in the case of the use of fresh water is in the case of 100% collector, without depressant, pH 10 and 150 μ particle size. Maximum recovery in fraction size 45 μ in the case of water process is 100% collector, without depressant and pH 10. Maximum depressant of pyrite will be the fraction size 75 μ, distilled water, without collector, 100 depressant. Keywords: Sulfide mineral, hydrogen peroxide, flotation, oxidation

Jan 1, 2020

By Zhao-feng Xie

A new process of recycling valuable metals containing in the slag of jamesonite smelting in the blast furnace was studied. In this process, the valuable metals such as Pb, Sb, Zn and In etc. were fumed and volatilized and enriched in the dust firstly and then the dust was leached by sulfuric acid. In the leaching procedure, Zn and In in the dust entered into the leaching solution and were separated from Pb and Sb which remained in the residue.The optimal operation conditions of the fuming procedure are as follows: the mass ratio of the blast furnace slag, coal powder and lime are 100:22:10 respectively and the fuming time are 1.5~2.5 h, the fuming temperature is not below 1200C and the volatilization rates of Pb, Sb, Zn and In are 95%, 92%, 86% and 75% respectively. The optimal conditions for the leaching procedure are also presented: the consumption of sulfuric acid is 1.15 times of the theoretical consumption, the ratio of liquid to solid is 4:1 and the leaching temperature, leaching -1time and stirring speed are 90, 1.5h and 300 r?min separately. The leaching rates of Zn and In are 98.5% and 95.2% respectively. The experimental results shows that the valuable metals in the dust can be recovered and separated effectively by this process and the?ir recovery efficiencies are as follows: Pb94%,Sb91%, Zn84% and In69%.

Jan 1, 2009

By O Omidi, P D. Katsabanis

The effect of delay time on fragmentation has been discussed for a long period but rarely in a satisfactory and unbiased way. Despite the efforts of many researchers, delay selection for fragmentation improvement or optimisation remains a controversial issue. Large-scale tests have been plagued with scarcity and scatter of observations, while small-scale tests have been associated with boundary effects and energy losses. Theoretical work is often used to produce explanations for available measurements or tries to simplify wave propagation and wave interaction to guide observation and practical work. The present work analyses results obtained from a relatively large number of small-scale experiments in blocks made of grout, and re-analyses results of previous experiments, to conclude on the effect of delay on fragmentation. It is shown that the main contribution of the delay is found in the fragmentation of the larger fragments of the blast, while the small fractions show almost no effect. Samples, where copper liners were used to inhibit penetration of detonation products in the rock mass, showed effect of delay only when short times were used and steady but poor fragmentation when long delays were used. Based on small-scale experiments, it appears that the fragmentation is optimised when a hole fires prior to the radial cracks, produced by the previous hole, reach the free face of the blast. Gas penetration may result in the development of few more fractures that affect the fragmentation of the largest particles of the blast.CITATION:Katsabanis, P D and Omidi, O, 2015. The effect of delay time on fragmentation distribution through small- and medium-scale testing and analysis, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 715–720 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By J. J. Fitzpatrick

"This paper deals with the methods used by Quebec Cartier Mining Company in the evaluation and selection of new haulage equipment and in increasing the productivity of the existing fleet.Selection of new equipment is based upon the comparison, for each model under consideration, of the capital investment required and the estimated operating costs and production rate. The calculation of the production rate is based on a widely used estimating procedure. Actual operating conditions considered in the method include: payload, haul distance, road grade, rolling resistance, loading and dumping times, and operational efficiency. A digital computer is used to handle the large volume of repetitive calculations required. Where a fleet of haulage equipment includes trucks of different size and performance characteristics, the problem exists of assigning each truck type to the different working locations to minimize total cost. Linear programming can be used in the solution of this problem."

Jan 1, 1967

By R Long

The founder of social psychology is sometimes identified as Kurt Lewin. In a 1947 article, Kurt Lewin coined the term ‘group dynamics’. He described this notion as the way that groups and individuals act and react to changing circumstances. Lewin theorised that when a group is established it becomes a unified system with unique dynamics that cannot be understood by evaluating members individually. The discipline of social psychology really emerged out of World War II and tackled questions associated with human judgement and decision-making by the Nazis. For a comprehensive look at the development of social psychology look at Abelson, Frey and Gregg (2004).Social psychology is concerned with the way social arrangements affect human judgement and decision-making. What the author has done is apply the knowledge of this new discipline to an understanding of risk, safety and leadership. This paper will explain some of the developments in social psychology, such as the discovery of the bystander effect, Groupthink, bounded rationality, heuristics, risk homeostasis and the Milgram effect.The social psychology of risk tackles the way decisions are made about risk in their social context. Unless organisations understand that decision-making is socially conditioned, they are unlikely to be able to tackle the complexities of culture change or the development of risk maturity.The paper will offer a new understanding of why people do what they do, how risk makes sense and why a ‘dumb down’ approach to safety is dangerous. A model will also be presented that shows the pathway to risk maturity.CITATION:Long, R, 2016. The social psychology of risk, safety and leadership maturity, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 31–42 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By W Ludlow, C Harrington

This paper presents an overview of the design and construction challenges to implement capping systems on Tailings Storage Facility’s (TSF) based on recent projects in Australia. Key aspects discussed include the cover design and barrier system to encapsulate the tailings, designing for a service life of 1,000 years, water management considerations. construction on tailings, vegetation selection and agronomy of the available capping soils plus the Health, Safety and Enivornmental challenges faced in working on tailings. Lessons learned from experience in capping TSFs are also presented. CITATION:Ludlow, W and Harrington, C, 2018. Experience with Capping of Tailings Storage Facilities for Decommissioning Projects in Australia, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 157–165 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By C. T. Twort

As technology and economic conditions allow mines to operate at ever greater depths, increasing demands are placed on the environmental engineer to adjust the capacity of the installed mine . - refrigeration systems. At the same time the engineer must satisfy the changing legislation, which demands that developments are carried out in as an energy efficient and environmentally accept- able manner. Following the trends outlined above, this paper is written to give an overview of the current and potential future refrigeration technology available to the mining industry. The effects that may be produced by the adoption in mining applications of the new generation of 'green' refrigerants are examined both at the design stage and when considering the viability of retrofitting existing systems so that they comply with the Montreal Protocol. An introduction to the concept of Total Energy Warming Impact (TEWI) is provided, with an explanation of its use in optimising system design and performance, and its incorporation as part of an environmental audit strategy. The paper concludes with a discussion of innovative refrigeration techniques and the possible future developments in legislation.

Jan 1, 1997

More and more coal in Australia is extracted by underground mining methods especially by longwall mining. These methods can be particularly sensitive to relatively small-scale structural discontinuities and variations in roof and floor rock character. Traditionally, information on these features has been obtained through drilling. However, this is an expensive process and its relevance is limited to the immediate neighbourhood of the boreholes. The geological uncertainty remains. Seismic surveying, especially by 3D seismic, is an alternative tool for geological structure delineation with growing credibility. In fact, it is one of the most effective geophysical methods available for identification of geological structures such as faults, folds, washouts, seam splits and thickness changes which are normally associated with potential mining hazards. Seismic data even can be used for stratigraphic identification. The information extracted from seismic data then can be integrated into mine planning and design. In this paper, we demonstrate computer aided interpretation techniques for maximising the information from seismic data and illustrate the ability of seismic reflection methods to resolve localised geological features. Both synthetic and real seismic data obtained in recent 2D and 3D seismic surveys from Australian coal mines will be used. Compared with results obtained with drilling programs, the structural definitions from seismic are of unprecedented quality.

Jan 1, 2002

By Robert C. Weisner

Current production costs and market conditions in the potash industry of the Carlsbad area were studied to determine the potential values of the potash mineral resource that would be lost or foregone if the Waste Isolation Pilot Plant (WIPP) facility is constructed on the proposed site in that area. The purpose of the WIPP project is to investigate the possibility of developing a nuclear waste disposal plant in the salt formations at the site. Analyses were made of all potash deposits determined to be in the site. Mining and processing under the most favorable recovery systems were considered. Value determinations were based upon estimated operating and capital costs of current mine-mill operations in the Carlsbad area. This study was made for the Energy Research and Development Administration (ERDA) by members of the Federal Bureau of Mines Minerals Availability System staff.

Jan 1, 1979