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By M. Sagedahl

The off gas from a smelter is cooled and dust removed in an electrostatic precipitator before approximately 95% of the sulphur dioxide (S02) is converted to sulfuric acid. However, the tail gas may need to be polished to remove the rest S02 to meet demands. A flue gas desulphurization (FGD) system, as usually applied to S02 removal on coal and oil fired Power Station, is suitable for polishing tail gases from copper smelters. The ALSTOM Seawater FGD process makes use of the alkalinity in the seawater to absorb and neutralize S02. Before being returned to the sea, the seawater is treated to comply with environmental regulations. As the ALSTOM Seawater FGD process uses no reagent and produces no byproduct, it is extremely cost-effective for coastal installations. The first SWFGD plant started operation in 1968. Over 60 of these units have been installed worldwide. The ALSTOM Seawater FGD process removes S02 from flue gas flows corresponding to a total of 70,000,000 Nm3 /h. Suitable for thermal power stations, smelters and oil refineries, ALSTOM Seawater FGD plants efficiently treats flue gases in the range of 300,000 Nm3/h to 2, 700,000 Nm3 /h per FGD plant, containing 20 - 6,500 ppm of S02.

Jan 1, 2007

By Patrizio Damiano

Competitiveness in Electric Arc Furnace production is pushing steelmakers to increase the throughput at the lowest expenditure. The technological challenge is therefore to operate the existing facilities at their top capabilities and to exploit materials and energy sources at the upmost yield and efficiency. Moreover, seizing the opportunity offered from the price variability of metallic feedstock calls for flexible practices, versatile equipment and tools to rapidly tune the melting profiles without hindering steel quality and equipment lifetime. The innovative Danieli Q-MELT Automatic EAF system addresses these aspects implementing a centralized control system which interacts with multiple technological packages. Each of these cutting-edge technologies focuses on one aspect of the EAF cycle, increasing machine availability and resource efficiency, by means of electrode regulation and foamy slag control, charging optimization, off-gas analysis and closed loop injectors control. Moreover, these modules provide the process supervisor application (Melt Model) with important information regarding the process status, thus allowing the adoption of a unified control strategy. The supervisor implements a robust statistical approach to identify process deviations in real time. The first results and technology perspectives inferred from the field immediately after the start-up are described in this paper.

Oct 30, 2017

By William K. Tolley

The U.S. Bureau of Mines (USBM) is currently investigating the electrochemistry of mineral flotation. A significant need in this area is greater reliability of sensors. The USBM is testing electrolytic methods to clean and condition redox-sensing electrodes to improve the reliability and extend the service life of these instruments in the harsh physical and chemical environment of mineral processing slurries. A novel method for removing scale from fouled electrodes has been developed that includes anodic polarization to 1.2 V versus the Ag/ AgC1 reference potential, followed by brief potentiodynamic conditioning. Laboratory results show that this technique removes calcarious deposits from gold sensing electrodes and returns the electrodes to useful service within approximately 10 min. Mechanical abrasion to remove the scale is thereby avoided.

Jan 1, 2010

By R. G. Johnston

Minerals have many uses in paint systems. These roles include use as primary and extender pigments, sheen control, film durability enhancement, and rheology control. These and other uses of minerals in paints, and the effects of mineral quality variations on coatings performance are discussed. As coatings performance requirements become more demanding, tighter consistency of important mineral properties, such as particle size distribution and purity, is becoming increasingly vital. Future directions of mineral use to meet projected environmental restrictions and performance demands on coatings, including the use of advanced minerals technologies, are examined.

Jan 1, 1993

By Stefan Mede

Robot Supported Moulding—this is the name of Herrenknecht Formwork’s entry to the world of automated segment production. What had been considered impossible for a long time, has been achieved by Herrenknecht experts together with the Swiss company Marti AG: unmanned segment production on the working line. The moulds open and close autonomously with the help of a hydraulic system. A robot cleans and greases the moulds at one work station and inserts the injection sockets at another. The next step will include further automation and digital networking of all processes from production to installation in the tunnel.

Jun 13, 2021

By S. R. Krom

In connection with perfecting a system of pneumatic concentration I had in view the improvement of machines for crushing and pulverizing ores. A study of the whole subject convinced me that the principle upon which the construction of the Blake crusher, and that of rolls, is based, possessed the mechanical elements which, if perfected and simplified, would make these machines the successful rivals of every other device. It is well-known that until very recently the stamp-battery held undisputed possession of the field; and mill-men and mill-builders almost universally believed that stamps would not be superseded by any other machine for fine crushing. The first step to drive stamps from the field was the introduction of rollers in the Bertrand and the Mt. Cory mills. In both of these mills the great superiority and economy of a system of crushing with rollers instead of stamps has been fully demonstrated. While perfecting the rollers, I had the fact confronting me that they had frequently been tried without success. In fact, the universal opinion prevailed that rollers could be used only for coarse, and not for fine crushing. The secret of the difficulty I discovered to lie in the imperfect and weak character of the rolls heretofore used, due to a misconception of the requirements for a machine for such work, and a failure to appreciate the advantages of continuous, rolling, crshing- surfaces, operating on the toggle-lever principle, which gives the greatest crushing pressure with the least power. expended, and the minimum of wear.

Jan 1, 1886

By Craig T. Jones, Zachary Q. Maassen

"Jet grouting is a method of ground improvement that relies on the erosive capacity of high-speed jets to cut and mix the ground in place with a cementitious grout. A continuous return flow of cuttings, called jet grout backflow or spoils, is expelled to the surface during the grouting process. Data from projects completed in Toronto and Ottawa is presented where BOS Solutions’ services provided significant savings compared to the traditional spoils treatment utilizing vacuum trucks for spoils disposal. These traditional treatment methods are cumbersome and expensive by nature. BOS Solutions provided an alternative solution that is environmentally friendly and capable of handling full flow to process these jet grout spoils utilizing a tank system paired with centrifuges and flocculation additives to remove the ground soils and grout product from the spoils slurry. BOS’ process produced a clean water for reuse in the project while reducing the overall waste volume by producing a dry, stackable solid that could be hauled to a landfill. Benefits observed by using the BOS process were disposal waste volumes decreased over 30% and at least a 19% reduction on disposal costs.SCOPE OF WORKJet grouting is a method of ground improvement that relies on the erosive capacity of high-speed jets to cut and mix the ground in place with a cementitious grout. A continuous return flow of cuttings, called jet grout backflow or spoils, is expelled to the surface during the grouting process. The backflow, or spoils, is a mixture of grout, water and soils. Traditionally, the spoil would be collected in in-ground pits and allowed to solidify for a few days prior to hauling to a final disposal site. For the projects completed in Toronto and Ottawa, the jet grouting work was performed at street level, in high traffic congested areas, presenting the challenge of insufficient space for the contractors to process the jet grout spoils in the traditional way. At first, attempts were made of using vacuum trucks to collect and haul the wet spoils to an off-site location where the spoils would be allowed to solidify. However, this method proved cumbersome and expensive due to the high volumes of spoils generated daily and the high number of vacuum trucks required to support the jet grouting operations, respectively."

Jan 1, 2017

By John Wall

The use of electronic detonators in civil tunnelling applications, to reduce vibration is small firings has been successfully utilised for a number of years. As part of the mining industry’s commitment to reducing blast damage during the development cycle in underground mining applications, a series of development blasts using eDevTM electronic detonators in typical mining applications was conducted in North Queensland, Australia.

Jan 1, 2012

By J. A. M. Cano

An extensive research work was developed by Samarco Mineracao S/A to study the quality characteristics of blast furnace pellets produced with high content of MgO. Comparative blast furnace simulation tests were conducted both in Samarco and foreign laboratories. The objective was to evaluate the behavior of high MgO and normal Samarco pellets in the blast furnace operation. Additives such as dolomitic hydrated lime, dunite and magnesite were used for increasing pellet MgO content. The test results showed that pellets produced with high MgO content are similar in quality to normal Samarco Pellets.

Jan 1, 1991

By Sebastian Fischer, Rolf Katzenbach, Steffen Leppla

"The risk management in the case of liquefaction is one of the most serious and also difficult issues in geotechnical engineering because failure caused by liquefaction is always a sudden failure without ahead indication. For that reason ground improvement technologies for the prevention of liquefaction are necessary. The paper explains the responsible and effective risk management. Methods for the risk management and stabilizing the soil sustainably are described in detail.1. INTRODUCTIONDue to population growing more and more settlement area is needed, which is often including improper regions (e.g. mountain and coast regions) with raised risk of various kinds of disasters. But also in densely populated areas the risk of disasters like landslides can occur. One reason for the raising of risk in densely populated regions can be the opencast mining for raw material production. An essential element of the opencast mining is the loose deposition of the removed overburden, the so-called “overburden dump”. When an opencast mining is running out of the raw material, an opencast hollow remains in landscape. The slope areas of these hollows mostly consist of loose bedded material of the overburden dump. Due to the end of groundwater conservation these loose bedded slope areas are flooded. In consequence the slopes are in extreme danger of becoming liquefied. The result of a liquefaction in these slopes will unavoidably be a slope slide. Such a slope slide can extend up to several hundred meters into the landscape and can move several million cubic meters of material. An upsetting example for such a landslide is the slope failure in the German city of Nachterstedt on July, 18th 2009, which made necessitate remedial measures and also prevention works for the further utilisation of the region. The phenomena of liquefaction is not limited of slopes in series of opencast mining. Especially in regions with a highly appearance of earthquakes the phenomena of liquefaction is well known.2. RISK MANAGEMENTAn essential part for the stability assessment of slope systems is the investigation of sensitivity against liquefaction. In the case of given sensitivity against liquefaction there is no calculation method according to soil mechanics to determine the factor of safety against slope failure. Just for the case that sensitivity against liquefaction is not met, a comparison of the load (effect) E and the resistance R which is the traditional verification of stability against slope failure, can be calculated (Figure 1)."

Jan 1, 2015

By C R. Fountain, W R. Cannings

The zinc-lead-silver mineral resource at Lady Loretta ranks amongst the worldÆs richest when measured in terms of in situ metal grades. However, the project remains undeveloped 28 years after its discovery in 1969. The primary obstacle to development has been the fine and complex grain structure of its ores, which make flotation concentration inefficient even with fine grinding. The size and remote location of the deposit have also hindered exploitation. BUKA planned to directly fume the volatile target metals from the ore when it acquired the project. Intensive, post-acquisition modeling showed the innovative processing route to be uneconomic, notwithstanding high metals recovery and low waste content in fume product. Progressive modifications and supplements to the underlying fuming process enhanced economics and resulted in a new mine-to-metal processing route for zinc-lead-silver ores. The proprietary, three-stage BUKA Zinc Process offers technical, economic and environmental advantages. It is expected to find widespread application in the treatment of ores and residues. However, neither continued R&D nor application to Lady LorettaÆs currently delineated resource can be justified under prevailing market conditions. The objectives and results of each step in the process development sequence are outlined with reference to their impact on the commercial viability of the Lady Loretta project.

Jan 1, 1998

By B Smith, R Gelson

Springvale Colliery is an underground longwall mine situated approximately 10 km north-west of Lithgow in the western coalfields of New South Wales. Following a full-scale review of the mineÆs ventilation system in mid-2010, it was clear that the mine by early 2013 would become ventilation constrained as a result of the increasing size of the mine workings, the predicted worsening tailgate conditions and plans to introduce a fourth continuous miner unit. This realisation led Springvale to embark on a major upgrade of the mine ventilation system that would meet short-term and life-of-mine (LOM) requirements.Included in the upgrade project was the installation of a new high pressure centrifugal main exhaust fan that is capable of overcoming the high resistances imposed frequently on the circuit by restrictions in the tailgate airway. The new fan featuring a 2.5 MW motor is designed to be capable of operating at a quantity of 250 m3/s at a pressure of 7.9 kPa, a substantial improvement over the previous system, which had an operating duty of approximately 145 m3/s at 1.9 kPa. The new fan is of a centre hung design and features a backup diesel motor to maintain ventilation in the event of a power outage.Structural engineering analysis determined that under the operation of the new main fan the existing standard of ventilation control devices (VCDs) at Springvale would not be adequate to withstand the increase in differential pressures. As such, an upgrade of critical VCDs was undertaken utilising a novel high flexural strength (9 MPa) shotcrete and thin spray-on liner, which help serve to safeguard the structural integrity of the appliances and prevent increased leakage as roadway conditions at VCD sites deteriorate over time (a serious problem in many areas of the workings at Springvale).In addition to the main ventilation system upgrade, a separate upgrade focusing on improving development face ventilation was also undertaken. This upgrade included the purchase of two high capacity (22 m3/s) variable inlet vane (VIV) auxiliary fans to facilitate comfortable development face ventilation.The upgrade of the mine ventilation system at Springvale has been three years in the making, but has removed a major business risk in that it has afforded mine planning and operational flexibility (a fourth unit can now be introduced) for the LOM, and importantly provided unprecedented levels of comfort to operators at the working faces where previously ventilation and heat issues were frequently reported. The impact of this on the morale of the workforce, and hence their output, should not be underestimated.CITATION:Gelson, R and Smith, B, 2013. Life-of-mine ventilation system upgrade at Springvale Colliery - A case study, in Proceedings The Australian Mine Ventilation Conference , pp 79-86 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 1, 2013

By M. Buxton

Sensor derived data can add value across the mining operating chain ranging from resource definition, extraction, pre ? concentration, mineral process monitoring and assessment of product quality. Most documented studies on the use of sensors in mining focus on specific technologies for specific applications. These studies do not take into account different aims, objectives and operating conditions at different steps in the value chain. The first part of this contribution assesses key physical performance and discriminatory requirements of sensors applied in each portion of the mining value chain. The second part proposes a framework of methods for quantifying the value added by additional sensor information. Integrating the sensor based technology and the economic value quantification allows for both, designing an economically optimal sensor monitoring network along the whole mining value chain and optimizing efficiencies. Illustrative studies demonstrate the significant economic benefits, in particular in reduction of exploration expenditures, increase in extraction efficiencies, increase in ore product quality and improvement of processing efficiencies.

Feb 27, 2013

By Raja V. Ramani

As the new millennium approaches, it is appropriate to assess the progress that has been made in mine health and safety, a matter of concern to management, labor and government. One can hardly look at the major events of the last century — from the birth of the US Bureau of Mines through the enactment of the modern health and safety laws — without realizing that the march has been relentless toward eradication of health and safety threats in mining. The progress is spectacular in mine safety and significant in mine health. In looking at the future, it is safe to assume that societal demands will increase for improved health and safety conditions in the workplace. So will the demands for greater technological leaps. The standards will for measuring success and the expectations of progress in creating a safer and healthier mine environment will grow. The possibilities are enormous of meeting these exacting requirements in the 21st century.

Jan 1, 1999

By M. R. Shahan, W. R. Reed, S. Klima, T. W. Beck, Y. Zheng

Testing was conducted to determine the ability of foam to maintain roof coverage in a simulated longwall mining environment. Approximately 27 percent of respirable coal mine dust can be attributed to longwall shield movement, and developing controls for this dust source has been difficult. The application of foam is a possible dust control method for this source. Laboratory testing of two foam agents was conducted to determine the ability of the foam to adhere to a simulated longwall face roof surface. Two different foam generation methods were used: compressed air and blower air. Using a new imaging technology, image processing and analysis utilizing ImageJ software produced quantifiable results of foam roof coverage. For compressed air foam in 3.3 m/s (650 fpm) ventilation, 98 percent of agent A was intact while 95 percent of agent B was intact on the roof at three minutes after application. At 30 minutes after application, 94 percent of agent A was intact while only 20 percent of agent B remained. For blower air in 3.3 m/s (650 fpm) ventilation, the results were dependent upon nozzle type. Three different nozzles were tested. At 30 min after application, 74 to 92 percent of foam agent A remained, while 3 to 50 percent of foam agent B remained. Compressed air foam seems to remain intact for longer durations and is easier to apply than blower air foam. However, more water drained from the foam when using compressed air foam, which demonstrates that blower air foam retains more water at the roof surface. Agent A seemed to be the better performer as far as roof application is concerned. This testing demonstrates that roof application of foam is feasible and is able to withstand a typical face ventilation velocity, establishing this technique’s potential for longwall shield dust control.

Jan 1, 2017

By M. R. Shahan, W. R. Reed, S. Klima, T. W. Beck, Y. Zheng

Testing was conducted to determine the ability of foam to maintain roof coverage in a simulated longwall mining environment. Approximately 27 percent of respirable coal mine dust can be attributed to longwall shield movement, and developing controls for this dust source has been difficult. The application of foam is a possible dust control method for this source. Laboratory testing of two foam agents was conducted to determine the ability of the foam to adhere to a simulated longwall face roof surface. Two different foam generation methods were used: compressed air and blower air. Using a new imaging technology, image processing and analysis utilizing ImageJ software produced quantifiable results of foam roof coverage. For compressed air foam in 3.3 m/s (650 fpm) ventilation, 98 percent of agent A was intact while 95 percent of agent B was intact on the roof at three minutes after application. At 30 minutes after application, 94 percent of agent A was intact while only 20 percent of agent B remained. For blower air in 3.3 m/s (650 fpm) ventilation, the results were dependent upon nozzle type. Three different nozzles were tested. At 30 min after application, 74 to 92 percent of foam agent A remained, while 3 to 50 percent of foam agent B remained. Compressed air foam seems to remain intact for longer durations and is easier to apply than blower air foam. However, more water drained from the foam when using compressed air foam, which demonstrates that blower air foam retains more water at the roof surface. Agent A seemed to be the better performer as far as roof application is concerned. This testing demonstrates that roof application of foam is feasible and is able to withstand a typical face ventilation velocity, establishing this technique’s potential for longwall shield dust control.

Jan 1, 2018

By George W. Little, John Councilman

"The selection, evaluation, and modification of contractor mix designs for self-hardening seepage barriers, completed by the slurry trench excavation method, can be one of the most critical and challenging tasks to ensure the cutoff wall meets the design performance criteria. Contractor mix designs should incorporate all available geotechnical data, including subsurface soil characteristics, groundwater information, and potential site contaminates. However, the pre-construction mix design can have limitations if subsurface data is limited or shows variability from initial investigations. Placement of the seepage barrier material needs to be evaluated during construction to identify in-situ performance. In one particular case study, the self-hardening cutoff wall mix design was evaluated over a one year period followed by a year and a half installation period, in which, a number of adjustments were made to the laboratory mix design during construction due to performance in the field. Installation for the selected mix was monitored on a real-time basis, using quality control data, as well as early strength and permeability results to determine if adjustments to the self-hardening mix were necessary. Evaluation of early results and relationships between strength and permeability were used to make adjustments prior to achieving the final test results for 28-day strength and permeability. Test results of the installed mix illustrated a direct correlation between strength and permeability. Achieving a minimum unconfined compressive strength was necessary to meet the minimum permeability of the seepage barrier. Other determinations conclude that the thorough development of a pre-construction mix design can have limitations even when all geotechnical data and site conditions are taken into account. Understanding early indicators and key strength and permeability relationships are necessary to determine seepage barrier performance and limitations.IntroductionThe evaluation of contractor mix designs for self-hardening seepage barriers was reviewed for one particular case study where a mix was developed using available geotechnical background information, including considerations for impacted groundwater. Following development of the laboratory mix design, the seepage barrier wall was installed over a one and a half year period, where the contractor mix design was evaluated and modified to accommodate field conditions affecting performance. The objective of the project was to cutoff and collect impacted groundwater and prevent the migration of contaminants to the creek running adjacent to the project. The self-hardening seepage barrier wall was installed using the slurry trench excavation method along 4700 ft of alignment and extended to depths ranging from 20 to 85 ft below ground surface, where it tied in with a low permeability stratum or competent bedrock."

Jan 1, 2016

By V. Budinsky

In recent years the global mining industry has addressed its social and environmental responsibilities and numerous factors have contributed to this. Corporate Social Responsibility (CSR) is an important part of mining company strategy for practical implementation of the goals of sustainability, transparency, accountablity and good relationships with stakeholders:- investors, employees and communities. A key stakeholder for all mining companies is the local community which is affected by the mining operations. Companies must identify the emerging social and environmental trends, study the interests and concerns of various communities, address their needs and maintain a positive relationship. The CSR programmes of Czech coal mining companies are focused on surrounding community initiatives and sustainable responsible business. Mining in the Czech Republic is subject to strict rules and regulations and supervised by the State Mining Authority. Mining projects undergo rigorous approval procedures which encompass all operational measures at the different planning levels ? such as public participation in the authorisation process for mining projects, the application of the Environmental Impact Assessment Directive, environmental sustainability programmes, innovative solutions and flexible options offered by the mining company. One very important part is the preparation of the mining-technology preconditions and developing the integrated planning process in which all socially and politically relevant subjects in the mining operation surroundings are included. In an in-depth debate, all stakeholders may jointly develop the concept, in accordance with democratic principles. The optimally conducted dialogue process needs broad communication bases, including setting up theme-related joint taskforces, together with good moderation and the highly qualified support of technical experts. Using a case study of Severoceske doly a.s. Chomutov (SD Company) and the Czech Coal Group ? Czech leaders in the extraction of brown coal, this paper aims to examine the community development approaches and the CSR effectiveness of large scale mining companies. This paper brings a review of CSR and other such voluntary initiatives in the mining industry's proactive steps to contribute to societal well-being in a meaningful way. Key studies are provided by the projects ? Region with Better Perspective?, ?Stop Dust for Healthy Brezno Village?, ?Clever Heads for the North? and ?Coal Safari?. CSR issues are managed throughout all stages of the mine operation and beyond, long after the mine closes (e.g. post-closure programmes of new landscape, alternatives for reclamation including generation of lakes in former surface mines, conceptualization of industrial heritage). Communities need to be given the opportunity to help themselves through participation in CSR projects rather than being recipients of financial gifts from the company. A fair balancing of interests is the basis of any successful cooperation.

Aug 1, 2013

By M. Krasowska, W. Skinner, R. K. Asamoah

Understanding chemical interactions at solid-liquid interfaces have played a pivotal role in improving mineral flotation performance, increasing the rate of mineral crystallisation and profitable leaching of valued minerals and metals. This paper highlights gold leaching with links to surface and interfacial chemical processes occurring, and opportunities to maximise extraction while reducing usage of more recent scarce resources. From the review, there is a significant link between surface and interfacial processes and gold leaching performance. Evidently, gold leaching kinetics could be increased by changing leaching conditions, including manipulating the surface and interfacial interactions. Control of surface and interfaces during gold extraction could enhance rapid, smarter gold extraction and mitigate formation of passivation layers. Keywords: Surface and interfaces, refractory ores and concentrates, gold leaching, reaction mechanism and kinetics

Jan 1, 2020

By K. V. Raj, C. A. Berry, A. T. Weakley, A. L. Miller, P. R. Griffiths, D. A. Parks

Diesel particulate matter (DPM) has been classified as a carcinogen to humans by the International Agency for Research on Cancer. DPM exposure is therefore regulated by the U.S. Mine Safety and Health Administration (MSHA). The current monitoring process takes days or weeks for exposure levels to be known, and a real-time monitoring device is needed. It is believed that infrared spectroscopy has potential for use in a real-time, field-portable device. This paper presents a method for measuring organic carbon (OC) and elemental carbon (EC) in DPM for a broad range of OC/EC ratios.