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By Michael Schmitz, Eugene Ahrenholtz, William A. Heitbrink, Jeanne A. Zimmer, Andrew B. Cecala, Ernest S. Moyer, Earle H. Andrews, Chris C. Coppock, John A. Organiscak

Many different types of surface mining equipment use enclosed cabs to protect equipment operators from health and safety hazards. The overburden removal and mining process can be extremely dusty and can cause excessive dust exposure. To study this issue, a cooperative research effort was established between the National Institute for Occupational Safety and Health, U.S. Silica Co., Clean Air Filter Co., and Red Dot Corp. in an effort to lower respirable dust levels in an enclosed cab on an older surface drill at a silica sand operation. Throughout this research effort, a number of modifications were incorporated into the drill's filtration and pressurization system, as well as in other areas, to improve its design and performance. An average cab efficiency of 93.4% was determined with gravimetric sampling instruments when comparing the outside with the inside cab dust levels on the final design. Although this study considered just one operation, the goal was to identify cost-effective improvements that could be implemented on all types of enclosed cabs to lower respirable dust concentrations. Two critical components for an effective enclosed cab system are having a properly designed, installed, and maintained filtration and pressurization system, along with a method for maintaining structural cab integrity, which allows the cab to be positively pressurized. Another important component is maintaining cab cleanliness. Although this research was originally directed toward the mining industry, it is also applicable to agricultural or construction equipment.

By Atsushi Shibayama, Toyohisa Fujita, Luo Lin, Toshio Miyazaki

A novel process is developed in this study for separation of tungsten and vanadium from a leach solution of tungsten alloy scraps. Specifically, a magnesium salt combined ammonium solution is employed to precipitate vanadium and impurities in the purification of the leach solution. This separates vanadium from tungsten by rejecting tungsten in aqueous solution. Finally, tungsten is recovered as the form of ammonium para-tungstate (APT). Vanadium is recovered as the form of ammonium meta-vanadate(AMV).

Jan 1, 2003

By R C. A Minnitt

This paper illustrates the use of variography and moving average plots as an aid to analysing variations in the process that can be used to direct the improvement efforts. The hydrometallurgical processes used in manganese metal production consist of sequential unit operations that include milling and reduction of manganese ores. Leaching of the reduced ore, is followed by solid-liquid separation, residue disposal, solution purification and electrowinning of manganese metal completes the process. The nearly 250 integrated process control loops rely on reports of pH, flow pressure, level, temperature and chemical analyses. Metallurgical accounting, reconciliation and process control is achieved through monitoring of the chemical and mass balances within the manganese reduction plant, requiring approximately 50 000 analyses of solids, powders and liquids each month. The largest numbers of samples are taken in the cell house. Changes and variations monitored by sample statistics ensure that the manganese products comply with predetermined specification limits. Optimising the information-value of the approximately 50 000 samples in the manganese plant is carried out in tandem with ongoing process optimisation. Variographic analysis of daily sampling data suggests that the cyclical behaviour evident in the moving average plots is only a reflection of random residual variability and not a reflection of true underlying variability related to cyclical phenomena. Low resolution in the variogram of daily sampling data masks the short-range variability that emerges when hourly data are analysed. Hourly samples collected over a 39-day period (giving 941 sample data), helped identify short-range cycles in the process. The relative distribution of variability for daily sample intervals, indicate that 57 per cent arises from V[0], 18 per cent from V[process] and 16 per cent from random residual variation. V[0] includes all the uncontrolled sampling error arising from a poor sampling protocol, the fundamental error (FE), the grouping and segregation errors (GSE), the delimitation error (DE), the extraction error (EE), etc. This confirms the suspicions regarding the suboptimality of the sampling protocol and the way it is implemented. The absence of long-term trends in the leach suggests that short-term variation (less than one day) dominates the process. While the control charts indicate that the overall processes are maintained above the lower specification limits and the target values, there is nevertheless a considerable amount of variability in the system that overhangs the processes and threatens to impact them negatively. Although the variability in the leach is above the prescribed limits, the volatility is a matter of concern because it seems to be uncontrolled. The comparison of the various sources of variability in data collected on an hourly basis suggests that the short-term random variability (V[0]) accounts for almost 50 per cent of the variability in the process. The main source of this variability is due to errors in the sampling protocol and is probably related to the size of the fundamental error (FE), the grouping and segregation errors (GSE), the delimitation error (DE), the extraction error (EE), etc. Remediation of FE and GSE will probably lead to a reduction in V[0], whereas V[process] could be mitigated by reducing the biases associated with DE and EE in particular.

Jan 1, 2008

By M I. Pownceby, S Hapugoda, V Nunna

Deposits of low-grade iron ores containing abundant goethite are distributed across the world. A common difficulty associated with beneficiating goethitic-rich ores is the poor liberation characteristics of the iron-bearing minerals which often contain finely disseminated gangue minerals such as kaolinite, gibbsite and quartz. Microwave-assisted heating has been proposed as an effective way of inducing dehydroxylation and associated mineral transformations in order to beneficiate low-grade goethitic ores. In this research, the mineral transformations occurring in a low-grade goethite-rich sample using microwave radiation was studied. Roasting conditions (up to 1000°C and under various CO/CO2 gas atmospheres) were designed to generate a magnetic product from a goethite-rich, reject waste stream sample sourced from an iron ore processing site in the Pilbara, Western Australia. Conditions (T, pO2) for transforming the raw material from hydrated goethite to hematite and eventually to magnetite are presented. Chemical and mineralogical characterisation of the raw material and roast products were conducted using X-ray fluorescence, X-ray diffraction, optical microscopy and scanning electron microscopy techniques to identify the mineralogical and chemical changes occurring during the heat treatment. Further steps are suggested to optimise the microwave-assisted magnetising roasting and correlate it with the application of magnetic separation techniques to maximise the efficiency of upgrading the iron content in low-grade iron ores.CITATION:Nunna, V, Hapugoda, S and Pownceby, M I, 2017. Study of microwave-assisted magnetising roasting and mineral transformation of low-grade goethite iron ores, in Proceedings Iron Ore 2017, pp 575–582 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By Wesley, Worner H

During the meeting of the Institute last year at Port Pirie, the opportunity was taken to sample the lead bullion coming from the blast furnace and various stages during the refining process. Also, in the desilverising section, the upper zinc rich phase was sampled as the silver content built up and in the cupellation operation a series of samples was taken as the silver content of the bullion increased. In these two cases, the samples were taken under the supervision of a member of the staff of the Broken Hill AssociatedSmelters.In the following account of the microstructure of the samples taken, only the main phases present have received attention. In this connection deduction from phase diagrams of binary alloys has been used in conjunction with the assays carried out on duplicate samples taken at the same time as those for micro examination.

Jan 1, 1938

By J Samosir, L Snyman

Northparkes was the first mine in Australia to use block cave mining method which relies on gravity and natural rock stresses to fragment and recover the ore. It was also the first hard rock mine to use hydraulic fracturing, in conjunction with CSIRO, to promote caving of E26 Lift 1. The technique was later used on E26 Lift 2 wedge and E48 prior to undercutting.Northparkes production is currently sourced from the E48 Lift 1 block cave mine and E26SLC. The E48 block cave contains economic ore to the north and south of the current cave footprint. To recover this ore the footprint has been extended on the north and south with two extraction drives and one extraction drive, respectively. Modelling of cavability above the additional drives indicated that the cave would not readily propagate to a sufficient height of draw to mobilise the ore and tended to arch over into the existing cave. To address the modelling results and to reduce the risk of the project, rock mass preconditioning was adopted.This fracturing campaign was performed from surface drill holes adjacent the subsidence zone angled to intersect the higher grade and higher elevation ore zones.Optical televiewer surveys, run prior to fracturing, picked intervals and fault zones to be avoided. Holes were resurveyed post-fracturing to detect newly created fractures and as a measure of success of the program.During fracturing operations water and gel fractures were run at varying depths and pumping pressure was logged for each fracture. The mine seismic system monitored significant events and dye in the fluids utilised for tracking water inflow locations during underground inspections.Towards the end of the project, guar fibres from gel were detected within the mill circuit and required treatment to resume optimum processing.CITATION:Webster, S, Snyman, L and Samosir, J, 2016. Preconditioning E48 cave extension adjacent to an active cave, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 471–478 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By Robert C. Horton

The Getchell Mine is located on the east flank of the Osgood Mountain Range in the Potosi Mining District, Humboldt County, NV. Mining in the area first began in 1883 for copper, lead and silver in skarn-related deposits. Tungsten was discovered in the skarns in 1916 and was mined sporadically until 1957. The first major discovery was made in 1933 when two Winnemucca prospectors, Edward Knight and Emmett Chase, found gold at the present site of the Getchell gold mine. In 1934, after a small amount of preliminary prospecting, the claims were purchased by Noble H. Getchell of Midas, NV. The Getchell Mine Inc. was organized and exploration and development work began on a broad scale. Major funding was provided by George Wingfield and investors he assembled. Laxalt described Wingfield’s immediate history prior to his financing of Getchell as follows.

Jan 1, 1999

By W. K. Gowans

The Sullivan Concentrator treats a complex sulphide ore consisting mainly of galena, marmatite and pyrrhotite. The ore carried minor values in silver, antimony, bismuth, indium and tin. The products of the concentrator are lead, zinc, iron and tin concentrates. The minor metal values other than tin are recovered from the concentrates by the refining processes in the smelter at Trail.The concentrator was completed in 1923 and first operated with a capacity of 2,500 tons per day. In the years 1926 to 1929 changes to equipment and buildings brought the operation up to 5,500 tons per day and then, in the years 1935 to 1945, the daily tonnage was raised to 8,500 tons. After 1945, the rising insoluble content of the ore made it necessary to consider the construction of a Sink-Float plant. At this time consideration was also given to the construction of a new crushing plant underground to replace the rolls crushers and cone crushers located at the concentrator. By 1949, construction of the Sink-Float plant was completed along with a new underground crushing plant, and an electric haulage way between the underground crushing chamber and the Sink-Float plant. The ore was hauled in forty 14-ton car trains which discharged into a 3,000 ton receiving bin by means of an air operated five car rotary dumper. With the start up of the,Sink-Float plant, a 1 ½ ft. by 12 ft. Hardinge rod mill was also brought into operation. The Sink-Float plant made it possible to treat 12,000 tons/day of mine run ore with up to 40% of this being rejected as float.

Jan 1, 1975

By J Law, S Jahanshahi, R Holmes

Iron ore is AustraliaÆs largest commodity export and is vitally important to AustraliaÆs current and future prosperity. However, while major expansions are currently in progress to satisfy demand, the industry is also undergoing major transformations. Reserves of traditional high-grade Brockman ores that have underpinned the Australian iron ore industry since its inception are slowly being depleted and alternative ore types such as Marra Mamba bedded iron deposits, Yandi and Pannawonica channel iron deposits and magnetite deposits are now being developed. However, the impurity levels in some of these alternative ores are higher and they require blending and/or upgrading as well as an advanced knowledge of their downstream processing characteristics to facilitate cost-effective utilisation by overseas customers. The research challenge is to use advanced techniques for mineral exploration, ore characterisation, mineral beneficiation, agglomeration and sustainable processing to identify and develop innovative and breakthrough options for locating, unlocking and enhancing the value of AustraliaÆs iron ore resources. Furthermore, to sustain the steel industry and hence secure the demand for iron ore, there is a growing need to enhance the environmental and business performance of the industry through reductions in wastes and emissions. Therefore, cost-effective breakthrough and enabling technologies that massively cut waste generation, CO2 emissions and water consumption are also being developed. These include the use of renewable fuels and reductants, waste heat recovery and conversion of by-product slag into a saleable substitute for Portland cement. A number of examples of recent developments in the above areas are provided in this paper.CITATION:Holmes, R, Jahanshahi, S and Law, J, 2013. Research and innovation for the iron ore to carbon steel value chain, in Proceedings Iron Ore 2013 , pp 3-6 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

By N. Simpson

Low carbon 11.5% chromium stainless steels are finding increasing use in industry as square or rectangular tubing material for the construction of structures by welding. During processing, resistively welded circular pipes are bent into square or rectangular shapes. During this process longitudinal cracks can sometimes develop atone of the inner corners of the section. An investigation has shown that the processing of round into square tubing with very sharp corners can cause excessive cold working at the inner corners of the squared tube. This, together with the high tensile residual stresses and a susceptible microstructure due to the presence of grain boundary carbides, can result in brittle cleavage cracking. Measures that can be used to reduce the problem are described.

Jan 1, 2003

By K. K. Kershner

Sulfide ore concentrates containing cobalt, nickel, copper, lead, and iron were salt roasted and leached on a laboratory scale. More than 95 percent of the cobalt, nickel, and copper was recovered. Heating patterns for salt roasting different concentrates were established. More cobalt, nickel, and copper were recovered from a bulk concentrate composed of a mixture of copper concentrate and iron concentrate. This mixture corresponded roughly with the mixture of these materials in stockpiles in southeastern Missouri. A temperature range of 375° to 400° C. was best for salt roasting. Metal chlorides were leached at a pH of 1 from chloridized charges of concentrates, Although the amounts of cobalt, nickel, and copper extracted were high, the amount of iron dissolved simultaneously interfered with subsequent separation and recovery of these metals. The amount of dissolved iron was reduced substantially by steam treating chloridized charges of bulk concentrate at 300° C. In this way, the ratios of cobalt, nickel, and copper to iron in leach liquors permitted satisfactory separation and recovery of these metals. INTRODUCTION The Federal Bureau of Mines is experimenting with chloridizing reactions.4 5 6 7/ Salt roasting of sulfide ores and concentrates, or their calcines, to form metal chlorides has certain advantages. Chlorides of

Jan 1, 1961

By S. Merjan

Three papers were presented for discussion at the conference: 1) Instrumented driven steel tube piles at Canary Wharf; author: A. R. Gaba, United Kingdom. The author described the Canary Wharf development in the London Docklands, and in particular, the decision to build over the water by driving open-ended steel piles 25m in length into the sands below the soft estuarine deposits. The tubes were then filled with concrete above the sand plug (usually 17m below pile head). Three trial piles were instrumented with: a) resistance strain guages on the inside of the tubes; b) vibrating wire guages on the re­inforcement of the concrete. The trial piles showed elastic behaviour in five cycles of lateral loading, while the verticle load tests showed a definite bi-linear load-settlement behaviour. The initial stiff portion was a result of frictional staff resistance, both inside and outside the tube, with the soil at the base contributing at higher settlements. Loads were taken to three times working load, with no imminent signs of failure.

Jan 1, 1991

By C. E. Gerity

Near Bunker, Mo., in the New Lead Belt, Ozark Lead Co. operates a 6000 tpd lead-zinc mine. Mined ore is transported to the surface in three mechanized and automated steps. The mine is developed by a rectangular-shaped sublevel haulage drift 15 ft high by 28 ft wide, driven on strike below the ore zones. Ore transfer raises were driven from the sublevel at locations near the shaft, 1500 ft distant, and on subsequent 1000 ft centers. These 6 x 5-ft raises are slashed to obtain maximum storage below dump points. These dump points are located on each mining level and are of steel and concrete construction. Spiral 12 X 24-ft inclines driven from the sub-level provide access to these levels for equipment and mine utilities.

Jan 11, 1972

By C. Jay Hodgson, P. J. MacGeehan

"The gold ore zones of the Campbell and Dickenson mines occur within a km-wide, 2 km-long zone of highly altered and anomalously fissile and deformed volcanic and subvolcanic intrusive rocks, cut by a series of mainly post-deformation mafic and quartz-feldspar porphyry felsic dykes.Three main periods of gold ore-forming hydrothermal activity are recognized. In the first, the mine rocks were extensively altered and gold and arsenic enriched; syn-volcanic auriferous veinlet and low-grade chemical sedimentary ores were deposited in what was a major discharge zone of a submarine hydrothermal system. The chemical sedimentary ores are closely associated spatially and temporally with domal rhyolitic extrusions. Because of its mechanical and chemical properties, this synvolcanic alteration zone became the locus of later deformation, and the site of the generation of auriferous hydrothermal solutions, perhaps by pressure solution processes at depth. These solutions deposited, synchronously with deformation and metamorphism, the second and most economically important type of ore zones in the mine: large foliation-parallel and foliation-oblique banded carbonate- 'chert' Rssure-filling veins.In the third and final mineralizing event, high-grade, pipeshaped zones of siliceous replacement-type mineralization, and quartz-arsenopyrite-gold veins, were superimposed on the previous mineralization types after most of the deformation, but before the emplacement of the late dykes. The source of heat and also possibly the fluids for the third mineralizing period may have been the dyke-forming igneous activity. The textures and mineralogy of the banded carbonate- 'chert' veins suggest a near-surface (<3 km) environment of deposition, but their relationship to the fabric of their host rocks indicates they were emplaced in an environment, presumably at considerable depth (5-10 km?), in which the rocks were undergoing intense penetrative deformation. This anomaly is unresolved."

Jan 1, 1982

By G. Taylor

A 21st Century worker is one who works less with his physical power and more with mental ability. Such a worker is more skilled than a labourer and is consequently rewarded accordingly. A21st Century supervisor is one who ensures that workers are constantly supported so that they can maximize safety and productivity. A 21st Century manager is one who constantly searches for ways to maximize returns for the various stakeholders. Given the well-known constraints in narrow reef mining, all of the above is meaningless unless a mining method is found which provides conditions which support the 21st Century initiatives. [ ] The identified mining method is a continuous non-explosive stope breaking system using rocksplitter technology. Rocksplitting is defined as: The fragmentation of rock through high energy pulse wave transmission in a fluid-filled hole or hydro fracturing. Shotholes are effectively filled with a water-based geland 30 grams of explosive after which the hole is closed off with a ?rocksplitting gun?.

Jan 1, 2000

Traditionally, the gravity cleaning of coal has been evaluated in pilot plant tests. Attention is now turning to the development of empirical models of gravity cleaning equipment that can be used for the design and evaluation of circuits. This paper presents some preliminary information for spirals and water-only cyclones treating fine coals. Also discussed is how such information gives a better understanding of the operating and performance characteristics of this equipment, how realistic comparisons can be made between different types of equipment, and how small mobile plants could be designed for treating the fine coals &apos;stockpiled&apos; at many NZ mines.

Jan 1, 1985

By Jerry F. Parola

In current practice, pile foundation design is based on a general under-standing of pile-soil interaction during installation and superstructure-pile-soil interaction after construction. The pile design is a reflection of experience, precedent and judgment for normal piling practice of working load capacities up to approximately 100 tons with corresponding ultimate capacities up to 200 tons. For higher capacity piles, pile design is even less predictable. In particular, the feasibility of pile installation is an important design consideration that must be given the proper attention. An installation capability that is not given the required emphasis can cause unnecessary problems.

Jan 1, 1986

By L. Villa, O. Suarez, D. Arias, L. G. Corretge

The deposit comprises two vertical, lenticular bodies emplaced in the allochthonous block of a Variscan thrust. Epigenetic mineralisation occurs as replacement of carbonated volcaniclastic rocks of Cambro-Ordovician age. The dominant sulphide minerals are sphalerite and galena with minor chalcopyrite; the main non-metallic mineral is quartz and there is hydrothermal silicification, chloritisation and sericitisation. Sulphur isotope values for sphalerite and galena are heavy and reflect the fundamental relationship between delta-34S in ZnS and in PbS, suggesting isotopic equilibrium. Four sphalerite-galena pairs yield temperatures between 163 and 218 degrees C, in good agreement with the 187-207 degrees C estimated by the Ga/Ge-sphalerite geothermometer. The ore sulphide was leached by the hydrothermal solution from diagenetic pyrite in the host rocks and disseminated sphalerite and galena in Cambrian carbonates

Jun 19, 1905

By R A. Binns, S Murao

The PACMANUS and Jade deposits are two active hydrothermal fields that are forming massive sulphide deposits at the Pacific rim margin. Both are associated with felsic submarine volcanic rocks and both occur in back-arc settings. However, PACMANUS is associated with almost sediment-free dacites and lies on the crest of a volcanic ridge, whereas Jade occurs in a heavily-sedimented tectonic depression associated with a basement of pumiceous rhyolite. The PACMANUS deposit is richer in Cu and Au, and Jade in Pb. Zinc, Ag, As and Sb contents are similar. Sulfide textures at PACMANUS suggest formation of Cu and Zn sulfides by simultaneous double-diffusion involving inwards-moving seawater mixing with outwards-moving hydrothermal fluid. By contrast, at Jade there is a more complex history of formation where initial growth of barite on the sediment surface, probably associated with microbial activity, formed an impervious cap which trapped higher temperature hydrothermal solutions. &nbsp;

Jan 1, 1995

By Jan W. Merks

"The settlements between mines and smelters are based on the mass of metal contained in concentrate lots. The mass of contained metal is a function of the wet mass of a lot, and its moisture content and metal grade while the variance of the mass of contained metal is a function of the same variables and their variances. Uncertainties in the measurement procedure applied to estimate each variable are quantified in terms of precision and bias. The absence of bias and an acceptable degree of precision are the keys to effective risk analysis and loss control.ISO Technical Committee 183-Copper, Lead and Zinc Sulfide Concentrates, has developed standard methods for sampling and weighing, estimating precision and testing for bias, the determination of mass loss on drying, the calculation of the mass of contained metal and its variance, and various analytical methods for major and minor metals. The variance for wet mass is calculated from the precision of the scale while the total variances of moisture and grade are estimated from pairs of interpenetrating primary samples. The variance of contained metal can be calculated either from mine data or from smelter data but the risk associated with the settlement is largely determined by the absence or presence of bias and the variance of differences between exchange assays.ISO/TC 183 does not deal with precision and bias for exchange assays but is developing guidelines to determine realistic splitting limits. Given that the exchange of assays between mines and smelters accounts for a large part of the risk associated with the settlement, precision and bias for exchange assays should be measured and monitored. The need for umpire services can be reduced by applying statistical quality control (SQC).Calibrating static scales, moisture balances and analytical balances, bias testing of sampling methods and sample preparation procedures, estimating the variance of a single variable or the variance of a function that a set of variables defines, and monitoring precision and bias for exchange assays, are the quintessence of metrology, the science of measurement, when applied in mining and metallurgy."

Jan 1, 1995