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By John J. Simmons

There is considerable interest in the iron and steel industry in the development of technologies that can reduce carbon dioxide emissions, as the iron and steel industry is the third largest producer of carbon emissions in the world, after automobiles and the power generation industry. The E-Iron Iron Nugget Making Process, invented by Dr. Komar Kawatra and Dr. Tim Eisele, provided a major breakthrough in the iron making process as the process uses biomass in the form of hard wood or soft wood as the reductant in the place of coal. Dr. Kawatra recognized that biomass is rich in both carbon monoxide and hydrogen, two important reducing agents. This resulted in initial experiments conducted by Dr. Kawatra and Dr. Eisele in the laboratories of the Chemical Engineering Department of Michigan Technological University (Michigan Tech) that prepared self-reducing pellets with wheat flour as the reductant and limestone/dolomite as the flux. Initial results were encouraging so they extended their work to include hardwood, which is in huge supply in the forests of Michigan and Minnesota, as the reductant. Dr. Kawatra has also applied the E-Iron Technology to other iron bearing minerals to produce pig iron grade iron nuggets. He used the E-Iron Process to convert red mud, a high iron waste product of the aluminum industry, into pig iron nuggets with the rare earth elements reporting to the slag. This work resulted in a patent with Dr. Kawatra and Dr. Michael Archambeau named as the inventors. Dr. Kawatra then extracted the rare earth elements as a separate high value bi-product using oxalic acid, which he produced from carbon dioxide. Dr. Kawatra also conducted a test program that produced pig iron nuggets from New Zealand beach sands. The vanadium in the beach sands was retained in the iron nuggets, recoverable as a valuable bi- product in a separate process. The titanium dioxide in the beach sands reported to the slag. This demonstrates the potential use of the E-Iron Process to convert the large ilmenite reserves in Northern Minnesota into pig iron and titanium dioxide. Another use of the E-Iron Process discovered by Dr. Kawatra was its ability to produce iron nuggets from manganiferous ores. Dr. Kawatra was able to direct the manganese into either the metal or slag by adjusting process temperature. The above discoveries are included in several patents that were assigned to Carbontec Energy. This presentation will only address the use of the E-Iron Process to produce pig iron nuggets from steel mill waste and un-pelletized, mid-grade iron ore. Carbontec Energy Corporation agreed to sponsor additional research directed at improving this new technology that would later be trade named, The E-Iron Process. Carbontec Energy conducted further work that proved that the E-Iron technology could also convert steel mill waste into metallurgically acceptable iron nuggets. Carbontec also collaborated with the Lawrence Livermore National Laboratory and Purdue University Northwest to conduct a Department of Energy (DOE) sponsored program that would use their high performance computer capability to both verify and model the E-Iron Process. Purdue University Northwest reported that the E-Iron Process can produce pig iron nuggets with 85% less carbon emissions than a blast furnace. The E-Iron Process is similar to the ITmK3 process, developed by Kobe Steel, that also produces iron nuggets but uses coal as the reductant.

Feb 1, 2025

A comparison of gold, platinum and sulfide ion selective electrodes was made in this investigation for determination of Eh in solutions containing sulfide ions as a model system. The comparison was made in terms of the accuracy of the measured response, response time, pH dependence, and reproducibility of measurement. In addition, the sensitivity of each electrode towards changes in sulfide ion concentration was measured in terms of the change in measured Eh per decade change in concentration of sulfide ions. On the basis of a detailed investigation of the electrode processes occurring at the surface of gold and platinum electrodes, it was postulated that within the pH range investigated these electrodes respond to changes in the hydrosulfide ion, HS-, concentration in solution. In comparison, the sulfide ion selective electrode is known to respond to changes in the sulfide ion, S-, activity in solution. Although the potentials measured with gold and platinum electrodes were mixed potentials, pretreatment procedures can be used to obtain a signal suitable for process control. For control of sulfide ions in flotation pulps, the use of a gold electrode pretreated at 1.0 V with respect to a standard hydrogen electrode is recommended.

Jan 1, 1990

By R. M. Wilson

Concentrating plants, in common with other types of industrial plants, cannot operate without lectric power. The elctric distribution system and utilization equipment; therefore, must be carefully considered in all phases of plant design. Two important aspects of proper distribution and usage of electric power are the selection of voltage levels and the methods of system grounding. These are not necessarily the most important design considerations, but are perhaps more controversial than other major points, Modern plants demand increasing amounts of power which, since electric power is the product of voltage and current means higher voltages or currents. Higher voltages require more insulation, higher currents more conductor. The equipment designer?s problem is to obtain in his transformer, cable, switchgear, controller, motor, etc a balance of insulation and conductor to obtain a satisfactory design at lowest cost. To provide the most economical system, both in initial and operating costs requires the system designer to select the proper voltage level. Adequate voltage also permits expansion to meet future requirements, and results in better operation of utilization equipment, Relatively little advancement has been made in recent years in improving conductors; however, great progress has been made in improving insulation. Thus modern plants, in general, now find it more economical to use higher voltages than they did previously. For example plants which only a few years ago would have used 2400 volts as a system voltage often find nowdays that 4160 volts is their proper choice. If the plant requires 10,000 kva br more, then an even higher voltage, such as 13,800 volts, will prove economical. However, for the average concentration plant, with less than 10,000 kva demand, the choice of distribution voltages is between 2400 and 4160 volts, and 480 volts will be used for the low voltage utilization system.

Jan 1, 1958

By Jaeheon Lee

"Biooxidation of gold ores or concentrates could be a very attractive alternative to pressure oxidation (POX) or roasting to liberate the gold grains from various sulfides. Crushed heap bioleaching was successful in US and many operations using tank bioleaching of gold concentrate are currently running around the world. Many parameters need to be considered during the project of sulfidic refractory gold ore process. Capital and operation costs are among the most important ones. Run-of-mine heap biooxidation could be very inexpensive and the smaller the crush size (particle size), the more expensive the capital and operating costs for biooxidation application are expected. The capital cost of biooxidation could be a fraction of the cost for building POX plant or roaster and the operating cost could be 1/3 of POX or roasting depending on the method utilized. A new biooxidation process, Sand Farming, is introduced as an alternative to POX and tank biooxidation process. A relatively coarser particle size (P80 = 650 µm) of the process benefits the low cost of grinding against the conventional grinding size (P80 = 75 µm) for other options. The cost of Sand Farming is less than 40% of that of pressure oxidation with comparable gold recovery from the downstream process. This paper will review the laboratory scale testwork for various biooxidation process of sulfidic refractory gold ores and concentrates and provide the economic evaluation showing the biooxidation could be the most economic method without much sacrificing the overall gold recovery. INTRODUCTIONThe decreased availability and lower grade of raw materials has motivated industries to consider recovering values utilizing low cost process options. The process may treat high grade concentrates or submill grade ores that cannot be processed economically by conventional milling-flotation or leaching. Sulfidic refractory gold ores/concentrates have been economically processed by roasting, pressure oxidation, and biooxidation in stirred tank reactor. The process selection is based on a series of studies including multi-year long ore characterization and metallurgical investigations."

Jan 1, 2016

By Priscilla P. Nelson

Many concepts concerning equipment selection, performance prediction, and evaluation of support requirements for tunnel construction in soil or hard rock tunnels cannot be extrapolated directly for application in soft rock (compressive strength between 1.0 and 35.0 MPa). Case histories for small diameter (less than 3.5 m) tunnels in Austin, Texas, are analyzed to gain insight into particular problems encountered during tunnel excavation in weak sedimentary rock, and the performance of different excavation systems are compared.

Jan 1, 1987

By G. H. Lind

This paper discusses the traditional costing approach currently used in the underground coal mining industry. Activity Based Costing (ABC) is identified as being a potentially more effective manner in which to cost underground coal mining systems. With the use of a costing framework developed by the author incorporating new thinking to eliminate the shortcomings identified in the traditional costing approach, a comparison of two types of underground coal mining systems, viz. continuous miner and longwall, is conducted. It is found that under certain criteria, in all cases, irrespective of the way in which the systems are costed, the continuous miner system is currently the better investment. It is also observed that when a system is costed using ABC that better investment decisions result when compared to costing the same system using traditional costing techniques. It is further seen that traditional costing techniques tend to overestimate the total costs of a mining system. This paper shows one application of ABC that can be incorporated as a management tool.

Jan 1, 2001

Council for 2003/2004 President T.R. Stacey President-elect F. M. G. Egerton Vice-presidents Senior W. H. van Niekerk Junior R.P.H. Willis Immediate Past-president S.J. Ramokgopa Honorary Treasurer J.A. Cruise

Jan 1, 2004

By J. R. Cole-Baker

An independent technical audit by a consultant is part of the accountability process of publicly owned or publicly quoted companies when raising finance through share issues or loans or the sale of equity, and of banks or development funds when granting loans. Africa is undergoing a renaissance in investment in its mining industry. It is forecast that capital investment, in major mining projects in Africa, will be over US$ 4.4 billion, in the next few years. Most, if not all, of the capital to be raised will require an independent technical audit. The aim of this paper is to assist the management of mining companies seeking finance in appreciating the role of such technical audits. The reasons for such audits, especially to attract international investment, are listed. The role of the audit is explained in assessing the underlying robustness of the company as ?a going concern? and the viability of any ?expansion plans?. Its use is emphasised in establishing the underlying value of the company based on the mine life as supported by the mineral reserves. The independent consultant role is stressed as a representative of the parties in a finance deal who cannot, in practice, carry out their own detailed and specialized technical due diligence. The various components of a typical audit are examined with examples of critical matters which may require resolution. The definitions, which are used commonly in audits, in respect of competence and reserves and resources, as stated by various regulatory bodies, are compared.

Jan 1, 1998

By G. Winkel

"Safety conditions in industry have greatly improved over time. However, around the world, in Canada, and in each province or territory, people are still the victims of serious industrial accidents. The increasing safety of people at work then continues to be an imperative in industry today. In addition to protecting people, safety has been shown to make good business sense in any industry.The road to safety improvement is built on establishing a culture of safety that forms the basis for how work gets done in a company. Most importantly, an effective safety culture is built on the full engagement and participation of workers and leaders alike, who share in a vision for safe work performance where “no one gets hurt” and “everyone is a leader in safety.”Let’s learn together on how we can make a safety culture happen. The resulting bias for safety will ultimately save lives, and fulfills our moral objective to strive for safety excellence. IntroductionWe have the good fortune of living in democratic countries where freedom and the value of human life are key beliefs. These beliefs translate into the moral obligations and laws that we value and uphold in our society and life today.A minesite or workplace is simply a necessary part of our society where people earn a living. It is a place where our moral obligations and laws equally apply, a place where human life is of ultimate importance and value. In the early years of industry, this value has not always been evident. Take this description of a tragic accident reported in a coal mine on December 8, 1879:“Oliver Thompson, shaftman, aged 35— While taking wooden partitions out of a ventilation shaft, he fell off the work platform a distance of 100 yards, there did not appear to be anything unusual to account for this accident.”"

Jan 1, 2004

The control of AG mills fed by ores with harder and softer components can be challenging due to the sensitivity of the mill to the ratio of hard to soft components. The mills at LKAB?s iron ore operations are generally well controlled, but there are periods when the throughput falls off dramatically, due to a loss of mill filling. As the ore is upgraded in the sorting plant through magnetic separation prior to milling, this presents an opportunity to manipulate the feed blend in advance. In order to assess this opportunity, a fullscale mill charge was dumped and assayed by size to quantify the build-up of competent waste in the mills. This was supplemented by pilot and locked-cycle laboratory tests at a wide range of feed blends in order to facilitate the development of an appropriate multi-component AG mill model. This paper reports the experimental campaign requirements and methodologies, as well as the major outcomes from analysis and modelling exercises using the industrial, pilot and laboratory multi-component data.

Jan 1, 2012

By C. S. Smith, E. W. Palmer

For several years an investigation has been in progress in the research laboratory of The American Brass Co. to determine the thermal and electrical conductivities of most copper alloys of commercial importance and several of scientific interest. This paper contains such data on the binary alloys of copper with silicon, aluminum, manganese and nickel, and on a large number of ternary or more complex alloys. Some interesting general relationships between the thermal and electrical conductivities for all copper alloys at all temperatures are pointed out. The data for the copper-zinc, copper-phosphorus and copper-tin binary systems have already been published1,2 † except for the electrical conductivity at 200" C., which is given in the appendix of this paper. Literature on Thermal Conductivity of Copper Alloys The papers referred to above contained a summary of the figures available in 1929 for the thermal conductivity of copper alloys. There is given in Table 1 herewith a selection of the data that have appeared since that time. The measurements of Hanson and Rogers3 are particularly interesting since they cover a series of alloys in the alpha solid solution range and show the effect of heat-treatment. Their alloys were tested as annealed castings, and are not therefore directly comparable to the worked alloys measured in the present investigation, although the difference is small. Bailey's determinations4 were carried out on the alloys used by Lees6 in 1906, and extend his results to higher temperatures. It is most unfortunate that the alloys were not analyzed, for the approximate compositions given are hardly sufficient identification of the material. It is equally to be regretted that neither Hanson and Rogers nor Bailey give data for the electrical conductivities of their samples. Sager6, using the heat-wave method of King, determined the thermal conductivity of copper, nickel and four alloys of the two metals. His results are included in Table 1.

Jan 1, 1935

By C. S. Smith, E. W. Palmer

For several years an investigation has been in progress in the research laboratory of The American Brass Co. to determine the thermal and electrical conductivities of most copper alloys of commercial importance and several of scientific interest. This paper contains such data on the binary alloys of copper with silicon, aluminum, manganese and nickel, and on a large number of ternary or more complex alloys. Some interesting general relationships between the thermal and electrical conductivities for all copper alloys at all temperatures are pointed out. The data for the copper-zinc, copper-phosphorus and copper-tin binary systems have already been published1,2 † except for the electrical conductivity at 200" C., which is given in the appendix of this paper. Literature on Thermal Conductivity of Copper Alloys The papers referred to above contained a summary of the figures available in 1929 for the thermal conductivity of copper alloys. There is given in Table 1 herewith a selection of the data that have appeared since that time. The measurements of Hanson and Rogers3 are particularly interesting since they cover a series of alloys in the alpha solid solution range and show the effect of heat-treatment. Their alloys were tested as annealed castings, and are not therefore directly comparable to the worked alloys measured in the present investigation, although the difference is small. Bailey's determinations4 were carried out on the alloys used by Lees6 in 1906, and extend his results to higher temperatures. It is most unfortunate that the alloys were not analyzed, for the approximate compositions given are hardly sufficient identification of the material. It is equally to be regretted that neither Hanson and Rogers nor Bailey give data for the electrical conductivities of their samples. Sager6, using the heat-wave method of King, determined the thermal conductivity of copper, nickel and four alloys of the two metals. His results are included in Table 1.

Jan 1, 1935

By R Young, D OÆSullivan

When Centaur Mining and Exploration produced nickel metal fromlaterite ore at its Cawse nickel project in January 1999, a new era in the nickel industry was heralded in. One of three new laterite projects commissioned that year, new technology and a unique process design has been combined at Cawse to launch what will be amongst the worldÆs cheapest nickel production. However, the road to success has proven to be long and challenging. This paper explores CentaurÆs approach to the Cawse start-up and discusses a number of issues that have been confronted and overcome. * Originally published in the Proceedings of the Seventh MillOperatorsÆ Conference, published by The AusIMM.

Jan 1, 2001

By Erdal Ünal

The computer program introduced in this paper is based on design guidelines developed for selection of support systems used in mine roadways. The support types considered include rock bolts as well as rigid and yieldable steel arches. Using the computer program, the design engineer can select the type, pattern and specifications of the support systems suitable for various roof conditions. The concepts utilized, assumptions made, support selection criteria and description of the computer program, developed for the PC, are included.

Jan 1, 1989

By James M. Link

The first rule of mineral deposits always seems to be: the deposit is never close to the market. With gems and precious metals, this is not much of a problem. But with most of the mineral commodities used in today's world, transportation becomes a major part of the cost to the consumer. In Japan, for example, more than 60% of the cost of coal to the consumer may be attributed to transportation. The purpose of this article is to examine pipeline transportation, particularly mineral slurry pipelines, as a means of getting the mineral to market. Pipelines Today Regulated pipelines in the US totaled nearly 724 Mm (450,000 miles) in 1980 according to the Federal Energy Regulatory Commission (FERC). Worldwide, more than 210 Mm (125,000 miles) of new pipelines will start construction in 1982 at an estimated cost of more than $150 billion. According to the Bechtel Corp., the period between 1982 and 2000 will see major growth in pipelines of all kinds. In North America, major movements of crude oil from Alaska and synfuels from the Rocky Mountains will require the construction of nearly 16 Mm (10,000 miles) of new pipelines. Nearly 42 Mm (26,000 miles) of new gas transmission pipelines will be needed to tap both US and Canadian arctic gas fields and move the gas to major markets on both coasts. Other pipelines will be required to move additional quantities of natural gas from the Rocky Mountains to more populous regions. Bechtel says more than 24 Mm (15,000 miles) of slurry pipelines will be needed to transport coal from both eastern and western coal provinces to the Mississippi valley and coastal areas. In 1980, 125 companies delivered more than 1 km3 (6.5 billion bbl) of crude oil and 652 hm3 (4.1 billion bl) of products in the US. At the same time natural gas pipelines transported 498 km3 (17.6 trillion cu ft). The reported investment by these companies was nearly $20 billion at the end of 1980. Advantages of Pipeline Transportation The obvious success and vitality of the oil and gas pipeline industry is based, at least in part, on the fact that pipelines are a very efficient and low-cost method of transportation. This fact, coupled with the need for lower cost trans¬portation, has led to the marriage of oil and gas transmission technology and the bulk mineral solids transportation industry. The off-spring of this marriage is the mineral slurry pipeline. Slurry pipelines have a number of advantages over other transportation methods. One of these is the fact that they are buried-out-of-sight, out-of-mind. Second, they are relatively small users of labor because they lend themselves to automation and remote, or even computer control. Third, they offer an attractive economic alternative to other transportation systems. For example, for a 1000 km (621 miles) distance, rail costs of 1?/ km (1.7?/ton-mile) are about equivalent to slurry pipeline costs. But, as the distance increases, pipeline cost per t-km continues to drop while equivalent rail charges remain essentially insensitive to distance. Where existing rail, barge, or ocean ships are available, the cost of new construction associated with a slurry pipeline probably will render it noncompetitive. However, where new rail or other construction is needed, the cost of a slurry pipeline is very competitive. About three-fourths of the cost of a pipeline is in pipe, fittings, and construction. Nearly a fifth of the investment is in pump stations and the remainder is in right-of-way, surface facilities, utility acquisition, communication facilities, and other support areas. The fact that pipelines are capital intensive is, at the present time, a mixed blessing. For example, the delivered cost of coal in a hypothetical project doubles when the cost of money rises from 9% to 17.5% per year. The largest cost element for delivered coal in this example is in depreciation and finance charges. The next largest cost element is electricity to power the pumps, with labor making up the smallest increment of the delivered cost of coal. World Slurry Pipelines The idea of a slurry pipeline was probably first investigated in the latter 19th century, but the first ones were successfully built and operated in the US in the early 1900s. Today, they are fairly common worldwide. Table 1 shows a number of the world's slurry pipelines. An examination of these will further emphasize the fact that pipelines provide a cost competitive alternative where new construction of a transportation system is required. In each of the examples, the desired mineral commodity is located in a remote corner of the world, markets are at a great distance, value of the commodity is not great, and no other transport system is available.

Jan 10, 1982

By D. Tao

Froth flotation is widely used in the coal industry to clean -28 mesh or -100 mesh fine coal. A successful recovery of particles by flotation depends on efficient particle-bubble collision and attachment with minimal subsequent particle detachment from bubble. Flotation is effective in a narrow size range outside which the flotation efficiency drops sharply. A fundamental analysis has shown that use of picobubbles can significantly improve the flotation recovery of particles by increasing the probability of collision and attachment and reducing the probability of detachment. A specially designed column with a picobubble generator has been developed for enhanced recovery of fine coal particles. Picobubbles were produced based on the hydrodynamic cavitation principle. Experimental results with one metallurgical coal and one steam coal have shown that the use of picobubbles in a 2" column flotation increased fine coal recovery by 10-30%, depending on the feed rate, collector dosage, and other flotation conditions. Picobubbles also acted as a secondary collector and reduced the collector dosage by one third to one half.

Jan 1, 2006

By V. R. Degner

En las últimas décadas la declinación en los contenidos metálicos de los yacimientos mineros se ha constituido en un aporte para el desarrollo progresivo de máquinas de flotación de gran tamaño. En este sentido, las máquinas de flotación de las décadas del 50 y 60 fueron reemplazadas por máquinas de mayor capacidad, potencia y simplicidad en los controles del proceso, adquiriendo ventajas económicas y operativas que pueden ser aplicadas a los diseños de plantas de gran tonelaje en el futuro. Por ello, el objetivo del texto es revisar los procedimientos seguidos en el desarrollo sistemático de las celdas de 1000 pies3 de capacidad y la evaluación de su performance en el beneficio de minerales metálicos.

Oct 14, 1980

By J. F. Lupo

Heap and valley leach operations rely on solution collection piping placed within the heap to enhance both solution recovery and to assist overall solution management. The most common piping used in leaching operations is solid or perforated High Density Polyethylene (HDPE) pipe and Corrugated Polyethylene pipe (CPE). These pipes are widely used because of their low cost, ease of installation, durability, and flexibility. The typical recommended maximum design depth of burial for HDPE and CPE pipes is on the order of 30 meters (100 feet). However, ore heap heights at many facilities exceed 30 meters and some are now approaching 180 meters (600 feet) in height. At very high ore heap heights, the stability and performance of HDPE and CPE pipes becomes a critical issue for leaching facility design and operation. Failure of solution collection piping can lead to poor solution recovery, high hydraulic heads on the liner system, and in some cases, unstable ore slopes due to high solution pressures near slopes. This paper presents a review of methods that have traditionally been used to evaluate pipe stability under high normal loads. A common shortcoming of these methods is the inability to account for beneficial effects of ore arching around pipes and the time-dependent creep (stress relief) behavior of polyethylene (PE) materials. A new analytical approach is developed and presented which includes the effects of ore arching around pipes and creep of PE materials. The results of the new approach show that PE pipes will deform under high heap loads, but can remain stable and functional. Pipe stability is shown to be dependent on the type of pipe backfill and initial backfill compaction. The new approach represents a useful tool for designing applications for PE pipe under high normal loads.

Jan 1, 2001

By J. C. Taylor

The Rhodax inertial cone grinder, designed by France?s FCB Group Fives, is the result of three years, theoretical and mechanical research in the field of compression grinding by the research staff of FCB?s CRM minerals research centre. A number of potential uses have been assessed and will be discussed in the paper. The crusher is an inertial grinder that works on the pressurized bed fragmentation principle. The fragmentation force is caused by the rotation of unbalanced masses rather than by an eccentric mass, as is the case in a conventional crusher. This makes it possible to achieve very high reduction ratios. By controlling the speed of rotation of the unbalanced masses, the grinding force can be modified, thus changing the product size distribution. The paper describes the machine layout, operating principles, control parameters and will briefly describe the results obtained on reef, waste and ROM reject pebbles. Some comparisons are made with conventional crushing.

Jan 1, 1998

By W. D. Ludemann, E. A. Loria, E. A. Rowe

The isothermal recrystallization of electrorefined vanadium has been studied as a function of annealing time , temperature , and prior deformation . Specimens were cold- rolled from 30- to 75 - percent reduction in thickness , then annealed from 700 ° to 1,200 ° C at time periods ranging from 1 minute to 96 hours . The course of recrystallization was followed by means of hardness , metallographic , and X- ray techniques , and a recrystallization diagram was constructed . Interpretation of the data indicated that there was around 50- percent softening due to recovery ( first stage of softening) before recrystallization began . The defining of recrystallization limits with respect to the amount of deformation was precisely established for electrorefined vanadium . More than 30- percent reduction was necessary for recrystallization to occur at 850 ° C. With 60- percent reduction , it was initiated at 750 ° C and completed at 950° C. The activation energy for recrystallization , as derived from the data , was 95,300 cal per mole for 60 - percent reduction and annealing at 750 ° to 900 ° C. Recrystallization by the mechanism of nucleation and growth was the principal process during the second stage of softening . minor part of the second stage of softening took place as strain- induced boundary migration , which was observed in specimens reduced 30 percent , bent in L- shape , and annealed at 950 ° C. Grain size decreased significantly only with the largest reductions and annealing between 750 ° and 950 ° C. Grain growth was expressed by the empirical relation D = KKtt"" ,, the exponent being the same at 60- percent reduction and annealing from 750 ° to 900 ° C. Accordingly , the activation energy for grain growth was 75,000 cal per mole .

Jan 1, 1964