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By A Dennis, T Hunter, R Coleman

For metallurgical plant design, it is necessary to progress through successive phases of test work, piloting and process development before involving all the other engineering disciplines and “freezing” the process design criteria and flow sheet. This process usually relies upon the experience, skills and personal preferences of various technology providers, study and engineering entities, test work and metallurgical laboratories and, most importantly, the owner’s team and its operators. Current industry trends include lower grades, more complex orebodies, geometallurgy in defining orebody variation and design envelopes, more common “hybrid” plant processes and the market demands for more reliable, timely and predictable early plant performance.This paper will discuss interaction of these trends and provide guidelines for the level of detail and technical complexity required for a number of different “typical” examples. The paper will pay particular attention to the study definition level translated into the required detail and certainty needed by the overall process “owner” and original equipment manufacturer (OEM) equipment suppliers to ensure the best real plant performance. Some recent case studies will be discussed. In many projects, at a late stage of project definition, it has become common practice to undertake a “value engineering” phase. Although it could be argued that this should be undertaken earlier, it is largely driven by an overall need to reduce capex and “optimise” the perceived “fat” built into the project during the detailed design process. This value engineering can be very counterproductive to project timing and operational performance and warrants discussion.The paper is intended to promote discussion on a topic of wide interest. The authors’ diverse backgrounds and experiences are integral to the views in this paper.CITATION:Dennis, A, Coleman, R and Hunter, T, 2017. Critical process design considerations from test work to operations, in Proceedings MetPlant 2017, pp 12–30 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 11, 2017

By José Fagundes Jr., Juliano Braz Possatti, Bruno Câmara Vieira, Gabriel Godinho Alves, Bruno Bastos da Silva Murad, Cristina Maria de Oliveira Roque

Driven by market trends, increasing environmental accountability, government regulations and fostered by the Company’s strategic plan, ArcelorMittal Tubarão has developed new steel products to deliver better solutions to fit each customer’s needs. This often translates in higher strength, more complex and dimensionally challenging (thinner and wider) steels to attend a broad array of goals, such as reduction of vehicles fuel consumption and carbon emissions, increase in fatigue performance of heat treated parts, higher load capacity per net weight in vessels or wagons and lower supplying lead time as ArcelorMittal Tubarão establishes itself as a domestic option for so far imported grades. Based on the annual Product Development Plan, a structured workflow involves technical discussions from an operational point of view about safety issues, metallurgical project, steel grade family definitions, offline simulations prior to field trials, deformation resistance and process parameters adjustments and scheduling strategy. As a result of the increasing synergy between the areas, the share of new materials developed in recent years has been sustainably increased up to 15% in 2018, adding value to the final product without impact on hot rolled coil output and with a low cobble index.

Oct 1, 2019

By R. Gray, B. Hebblewhite

Experience from Australia had identified what is referred to as nonconventional surface subsidence behavior. This occurs under irregular surface topography, resulting in valley closure, valley floor uplift or “upsidence,” and far-field horizontal movements, occurring even beyond conventional “angle of draw” limits. This paper discusses such behavior recently observed in Pennsylvania and focuses on the 2005 case of Duke Lake Dam in Ryerson Station State Park. In July 2005, there was a significant increase in water leakage through a number of growing cracks in the dam, leading to the dam being breached to avoid an uncontrolled failure. An underground longwall mine was located approximately 900 ft to the north, mining at depths of 330 to 720 ft. Investigations, including a subsequent ground movement monitoring program, found a range of evidence in the vicinity suggesting that valley closure and farfield horizontal movements may have occurred, resulting from the adjacent mining. Besides discussing the phenomenon of nonconventional subsidence behavior and the Ryerson State Park case study, this paper includes an assessment of the mining, geology and subsidence impacts and suggested ground behavioral mechanisms.

Jan 1, 2015

By R. L. Bailey

"The Acheson D-3 Pool was discovered in August 1950, and contains 88 producing oil wells on 40 acre spacing. Initial oil-in-place was 118 million stock tank barrels and initial well potentials averaged 2,000 barrels per day.In early 1956 studies of hydraulic interference between the Acheson and Leduc D-3 Pools were conducted on the Carter Petroleum Reservoir Analyzer. These studies indicated that the natural water drive to Acheson would be incapable of replacing reasonable withdrawal rates over the life of the pool. To avoid shrinkage losses a scheme of pressure maintenance by water• injection was therefore instituted in March 1957.This pressure maintenance scheme is notable because pressure is being effectively maintained by high volume injection through one well located on the flank of the pool. Close control on reservoir behaviour is maintained by regular bottom-hole pres-sure surveys and observation of water cuts on producing wells. No evidence of pressure gradients or channelling of the injected water has been observed to date, and the water-oil contact has remained level over the whole field. It is possible to control the average reservoir pressure within very close limits by varying the rate of fresh water injection.Ultimate recovery estimated from the rise of the oil-water contact and calculated water influx to December 31, 1958, is 335 barrels per acre foot, or a total of 91.4 million barrels from the pool. This compares to 217 barrels Per acre foot or a total of 59.4 million barrels indicated from laboratory test data."

Jan 1, 1961

By William H. Pomroy

This report describes research leading to the design, prototype fabrication, and successful in-mine proof-of-concept testing of two improved stench fire warning systems for underground noncoal mines. The stench system, widely used in underground noncoal mines to warn of fire or other emergency suffers several serious shortcomings, including the toxicity of the odorant leading to debility in miners; reactivity of the odorant with iron oxide, resulting in unreliable warning because the odor may fade when transported long distances in steel pipe; lack of control over the rate at which agent is released into the air-stream, resulting in some work areas receiving unbearably high stench concentrations and other areas being missed altogether; lack of visual indication of system status, valve positions, or proper system operation; and excessively long stench transit times. In 1979, the Bureau of Mines, U.S. Department of the Interior, began research to upgrade the stench warning system. Two systems were subsequently developed which offer significant advantages over current systems.

Jan 1, 1984

By Paul F. Grundy

The ever changing conditions in the coal-mining industry and the increasing competition of other fuels such as oil, natural gas, wood refuse, etc., have made it imperative that the coal operator be in a position to supply a constantly uniform and clean product. The old idea of putting on the market "anything so long as it's black" no longer holds good. Today's users of fuel have to consider the amount of heat per dollar they obtain from the fuel they buy. Burning of coal has become largely mechanical, at least so far as industrial coal is concerned, and industrial coal is the kind the bituminous operator is for the most part called upon to supply. When we get into things mechanical, the matter of precision has a mighty bearing on efficiency. Precision in coal means standardization of quality, or uniformity of preparation in size and also in ash and moisture content. The trend of coal mining is ever towards more and more mechanization. Mechanization means coal-cutting machinery, loading machinery, conveying machinery, etc. Although such methods cut the cost, the cleanliness of coal so mined and loaded is not controllable to the same extent as when each operation is by hand labour. The operator has therefore the problem of mining his coal as cheaply as possible, but at the same time preparing a product which will to the utmost satisfy his customer. The answer is a mechanical cleaning plant. Before installing a cleaning plant, however, the operator must take into consideration the cleansability of the coal from his particular mine. This is accomplished by taking representative samples of the seam or seams to be treated, and subjecting these to screen tests, followed by float and sink tests on each size product. From these tests, it can be readily found to what degree of cleanliness the several sizes can be prepared advantageously, and also what will be the percentage recovery of cleaned coal. The accompanying tables give the results of representative tests on Michel coals of minus-2-inch size. All coal over 2-inc.h was intended to be hand cleaned. The coal-cleaning plants in general use at the present time come under two broad classifications, namely, wet and dry.

Jan 1, 1934

"4.1. IntroductionThis chapter reviews the geochemistry of the platinum-group elements (POE) in sulphur-poor silicate rocks, and the limited data on POE in silicate, oxide, sulphide, arsenide and sulpharsenide minerals. The earliest geochemical studies of POE in silicate rocks, minerals and meteorites were carried out mainly by Goldschmidt, the Noddacks and their co-workers, and are reviewed in Crocket (1969). These researchers established the siderophile character of the POE, emphasized the common association of the group with sulphides in ultramafic-mafic rocks and suggested that very low concentrations of POE are typical of sulphur-poor silicate rocks and minerals. Much of these data were for Pt and Pd only and are more than 50 years old. Because of the poor sensitivity typical of the available analytical methods, few reliable data were obtained on silicate rocks in these early studies. Surveys of POE geochemistry demonstrate that the data base for sulphur-poor silicate rocks is very restricted, although considerable highquality data for Pd and Ir have been accumulated (Wright and Fleischer 1965, Yushko-Zakharova eta/., 1967, Mertie 1969, Crocket 1969, 1979, Keays 1981).Two recent publications, Vol. 71, No. 7 (1976), of Economic Geology (An Issue Devoted to Platinum-Group Elements) and Vol. 17, Part 2 (1979), of The Canadian Mineralogist (Nickel-Sulphide and Platinum-Group-Element Deposits), are of special interest. These volumes are clear testimony to the impressive progress made in the last decade toward describing the mineralogical and geochemical aspects of POE ore deposits, but at the same time demonstrate the constraints in modelling POE ore genesis due to our meager knowledge of the. POE content and distribution among minerals in the source rocks of ultramafic and mafic magmas. It is clear that the phases hosting POE in mantle source rocks are poorly understood. Nevertheless, Naldrett and Duke (1980) have shown that the absolute and relative concentrations of POE in magmatic sulphide ores are related to the degree of partial melting of mantle peridotites, and subsequent processes of batch equilibration and fractional segregation of sulphides."

Jan 1, 1979

By Mike Ghassemi

It is clear that precise overground and under-ground mapping is an important factor for all designers. Due to rapid changes in underground construction, tunnel designers are increasingly in need of updating project information. This article explains the latest techniques for detecting under-ground utilities as well as underground mapping. Global Positioning System (GPS) is a very ac-curate and popular navigation and mapping system that has been used extensively above ground, but is not used for underground mapping as signals are not strong enough to pass through ground or water. Most underground techniques were developed for military applications during the first and second world wars. Later, the techniques became public. For example, ground penetrating radar was developed for the military in 1970 to be used for locating tunnels under the demilitarized zone between North and South Korea. Later, the same technique was used for detecting unexploded ordinance such as plastic land mines.

Jan 1, 2011

By Chris Groccia, Damodara R. Chinnasane

Vale is in the process of resuming mining in the lower 810 ore body (810 OB) below 4130L at Copper Cliff Mine – South Side. Production in the lower 810 OB had continued until it was temporarily ceased in 2017 to allow for the execution of activities associated with Copper Cliff Mine Phase 1 project. While mining the stopes in both the lower and mid part of the 810 OB, a seismic response was experienced that resulted in rockbursts and challenging mining conditions. The majority of the rockbursts experienced in the past were associated with stopes mined in a bottom-up mining sequence under a diminishing pillar situation between 3350L and 3540L. The current mining plan is comprised of both top-down and bottom-up mining fronts using a center-out chevron sequence of long hole open stopes to manage induced stresses. Numerical modeling assessments have been carried out to forecast the response of the rock mass due to the planned mining. Seismicity and stress induced damage surrounding excavations are anticipated, and areas requiring extra attention have been identified. A tactical approach is being used to prepare the area for production, including replacement of ground support elements that are damaged or have insufficient residual capacity, and installation of dynamic support in areas anticipated to experience bulking and/or dynamic loading that would exceed the current support system’s capacity. A series of monitoring programs are being put in place to confirm current conditions, and to monitor the response of the rock mass to proactively implement ground control tactics should the need arise. This paper provides a summary of the approach used to forecast, monitor, and manage the behavior of the 810 OB rock mass response to continued mining at depth.

Apr 26, 2022

By H. L. Willett

Wrapping up the symposium, covers incidence of spontaneous combustion in British mines, assessment of liability to spontaneous combustion, precautions, rate of advance, starting a line of a coalface, local heatings at roadsides, burying packs, coal headings, retreating longwall, detection and sealant coatings.

May 23, 1905

By R. Quintero

The HYL Direct Reduction Process was the first in the world to operate successfully at industrial scale. The results were so innovative and attractive that other steelmaking companies acquired licenses for the HYL Process. Now in its 40th year of commercial operation, the HYL process has evolved into a modem, highly efficient and economical technology -HYL III. The technology offers high productivity, minimum energy and water consumption, electricity co-generation, raw material flexibility, premium quality DRI/HBI, and is highly versatile for meeting the specific needs of each user. A historical review as well as recent developments and future plans are presented in this paper.

Jan 1, 1998

By J. Gibson

"INTRODUCTION As one of the most pressing and important political debates of this century, climate change has captured global attention and is forcing governments to take action towards decreasing GHG and carbon emission levels below what was previously thought to be necessary. With the ever-increasing price of diesel fuel accompanied by the popular topic of carbon taxes and greenhouse gas emissions, the mining industry is looking to industry specialists for assistance. The benefits of a no-idle policy reach far beyond carbon reduction and fuel savings, ranging from decreased maintenance to increased engine life. With products like battery powered A/C systems and diesel-fired heaters, going no-idle is easier today than ever before. With both systems being manufactured to withstand the harsh environments of the mining industry, the end user will see a seamless change from conventional, inefficient belt-driven systems to future, stand-alone mobile equipment HVAC. THE HISTORY OF GHGS AND CLIMATE CHANGE In 1896 Svante Arrhenius first claimed that the combustion of fossil fuels may eventually result in enhanced global warming, but not until 1955 did Gilbert Plass draw global attention to global warming by summarizing that adding carbon dioxide to the atmosphere would intercept infrared radiation and thus warm the earth. Then in the early 1960’s Charles Keeling developed modern technology to produce concentration curves for atmospheric CO2 (Figure 1). In 1988 the Intergovernmental Panel on Climate Change (IPCC) was founded by the United Nations after acknowledgement of a rising global annual temperature. The IPCC consists of over 2500 scientific and technical experts from more than 60 countries, and because climate change could not be solved by a single country, the Kyoto Protocol was negotiated in 1998 requiring all participating countries to reduce their GHG emissions by at least 5% from the 1990 levels. The Protocol was signed by 186 countries in 2001 (since then several countries have retreated from the agreement, including the United States)."

Jan 1, 2015

By D Carroll

Mining of the zinc, lead and silver deposit at the Broken Hill Southern Operations site has been occurring for over 100 years. As a result of this, a significant amount of high-grade ore is now taken from narrow remnant pillars left between old stopes and zones of previously mined ground. Stopes have been filled with either hydraulic fill (also known as ‘sandfill’), cemented hydraulic fill (cemented sandfill), waste rock backfill or a mixture of these fill types.In the last ten years, there has been considerable success mining through narrow pillars where sandfill is exposed in the development face and/or walls using a ‘shell’ support regime, wherein a layer of bolted mesh is sandwiched between two layers of sprayed fibrecrete (25 mm fibrecrete, then mesh and bolt, followed by a final 50 mm layer of fibrecrete). Shell support is also used in very poor, broken, relaxed ground conditions and in areas filled with cemented fill (sandfill with a minimum four per cent cement content).The next stage of innovation has been to develop a technique for mining through old stope voids filled with uncemented sandfill, known locally as ‘contours’ (old cut-and-fill working), an activity where unconsolidated sandfill can run at the face and from the backs. The challenge is to prevent exposed sandfill in the face and the backs from failing before it can be supported.To achieve this, the Southern Operations mine has implemented a technique in which 6 m long spiling bars are used to strengthen and stabilise the sandfill in front of the face. The hollow steel bars are driven in around the heading perimeter in a closely spaced pattern then pumped full of grout. The bars and the grout stabilise the sandfill in front of the face, preventing it from failing into the drive during excavation and prior to further support being installed.A final support system consisting of shotcrete, mesh, bolts and steel girders is installed as excavation progresses. Both the initial and final support systems are essentially passive support systems designed for a low-stress environment (as the stress originates mostly from the mass of unconsolidated sandfill).This process is slow and labour intensive. Fifteen separate cycles of people/machinery are needed to progress one equivalent heading cut (compared to six for a standard fibrecrete- and bolt pattern-supported rock face heading). This slow pace introduces scheduling challenges, but the process opens up parts of the orebody that were previously uneconomical to mine.CITATION:Carroll, D, 2014. Mining through sandfill using spiling bars, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 95–100 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By F. P. Haver

The Bureau of Mines has investigated the electrochemical reduction of lead chloride as a method for producing lead without the pollution problems associated with smelting. It was determined that high-purity metal (>99.9 pct Pb) could be obtained, using PbC12 prepared by ferric chloride leaching of galena concentrate: PbS + 2FeCl3?PbCl2 + 2FeC12 + S°. Optimum results in small-scale electrolytic tests were achieved with a bath consisting of 40 to 70 wt-pct PbCl2 dissolved in KC1-LiCl eutectic, an operating temperature of 450° C, a current density of 2.5 amp/in2, and an electrode spacing of 0.5 inch. In large-scale tests made to develop a cell design for commercial application, the optimum electrode arrangement proved to be a bipolar configuration with horizontal plates. This gave a current efficiency of 86 pct with an energy requirement of 0.52 kwhr/lb lead. To determine the effect of impurity buildup in the bath, 1,200 lb of PbC12 prepared by ferric chloride leaching of galena concentrate was electrolyzed over a period of 2 months. Little deterioration of the metal quality occurred in that time; all of the lead produced had a purity equal to or better than corroding grade (>99.94 pct Pb).

Jan 1, 1976

By C. P. Mabie

This report summarizes studies by the Bureau of Mines in developing a simple method for estimating the phosphorus pentoxide (P205) content of finely ground sedimentary phosphate ores and beneficiated products. The method used involved leaching, filtration, and precipitation. The Bureau found that measurement of the volume of ammonium phosphomolybdate precipitate obtained from samples containing 16.8 to 37.7 percent P205 and the use of an appropriate calibration curve permitted estimates of percentage of P205 content accurate within ± 1.1 to ± 2.6 percent, respectively, at the 95-percent confidence limits. Incidental to mineral dressing and petrographic investigations of western phosphate ores in 1959, the Bureau of Mines undertook development of a simple process-control method for rapid on-the-spot evaluation of phosphate-mineral recovery. Because of the fine-grained and obscure character of western phosphate ores, chemical, rather than microscopic or petrographic, techniques were investigated. The described method involves acid decomposition of the ore or product, filtration, addition of ammonium molybdate reagent to the filtrate, and centrifuging and measuring the volume of yellow ammonium phosphomolybdate precipitate produced.

Jan 1, 1961

By S Viviers, G Ratner

Ventilation is part of all underground mine operations and is undertaken in order to introduce fresh, cool air to the workings and to remove stale, affected air. It is problematic to obtain efficient and accurate estimates of volume flow and static pressure in the installed operational configuration for the auxiliary axial flow fans.An empirical method was developed to estimate the static pressure and volume flow through a calibrated differential pressure port on axial flow fans. Prior to shipping, each fan is performance tested according to BS 848 (ISO 5801) to establish the fan performance curves. In addition to the standard required parameters captured to fully describe the performance, the differential pressure is measured across the fan rotor to enable correlation with the characteristic fan curve.The method was implemented on a ruggedised tablet PC platform. This compact platform is then used to calculate the volume flow rate from the differential pressure sensor measurement input via a USB port. The result is a real-time measurement of volume flow and operating point of the fan system. This can be used effectively in overall modelling of the mine auxiliary ventilation systems and calculation of system resistance could provide a health indication of the fan and duct system.CITATION:Ratner, G and Viviers, S, 2013. Underground auxiliary ventilation monitoring and diagnostic system, in Proceedings The Australian Mine Ventilation Conference , pp 57-62 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 1, 2013

By Roy H. Grau

Increased awareness of a healthy work environment is common to all industries and the stone industry is no exception. The presence of operating diesel equipment, welding, stone production blasting, and silica dust in a working environment all contribute to air quality issues in underground stone mines. Particularly recognized is the exposure of workers to diesel particulate matter (DPM). Recent regulations call for a DPM standard of 160TC ug/m3 (TC = Total Carbon). The National Institute for Occupational Safety and Health (NIOSH) has conducted research to improve the ventilation of these mines and consequently reduce the exposure of workers to harmful airborne contaminants. The results have shown that the ventilation of underground stone mines can be significantly enhanced using improved ventilation controls and techniques. Large-opening stone mines present specialized ventilation challenges because their entries are much larger than in other types of mines. Most stone mines have entries about 40 feet wide and up to 30 feet high, with bench areas that may extend even higher. These large entries present the positive opportunity to move large air quantities at relatively low mine fan pressures resulting in lower fan horsepower and reduced operating costs. However, the difficulty in ventilating large-opening mines is that even with large air volumes, the air velocity is often less than 100 feet/minute. Higher ventilation velocities more quickly dilute and remove contaminants from the face areas. Higher ventilation airflow velocities can be achieved by effective ventilation planning and proper choice of ventilation fans.

Jan 1, 2009

By Mark R. Pettitt

The charter of this investigation was to identify and promote the application of noise control technology to future longwall mining machinery. Intensive noise and vibration data were acquired on a typical longwall shearing machine, and the highest noise levels were shown to radiate from the cutter drums. Shearing machine cutter drum noise control techniques that take advantage of the nature of the dynamic forces generated during coal cutting were developed. These include both structural redesign and force isolation techniques. A reduced noise cutter drum was developed that achieved a 5 to 6 dBA system noise reduction at the operator's position. Its operational performance was verified by a six-month long in-mine test. It was evident from the data that additional noise reduction could be achieved by treatment of the shearing machine hydraulics. Noise control of secondary sources was also investigated. A method of reducing full or empty stage conveyor noise (and continuous miner conveyor noise) by 5 to 10 dBA was demonstrated through isolation techniques. Underground mine durability testing, however, is yet to be demonstrated.

Jan 1, 1986

Unfortunate occurrences resulting in injuries, loss of life, and destruction of property by explosion, fire, and other mishaps during shaft sinking focused the attention of the Bureau of Mines on the need for safety standards For such operations. Information Circular 7810 was published to meet that need. The current revision updates and replaces IC 7810. Several States have some rules and regulations applicable to local conditions, and several Bureau publications (including some now out of print) cover the hazards that may be encountered in shaft sinking. Certain requirements of the Federal Mine Safety Code and Federal Coal Mine Safety Act may be applied, but there are no definite, uniform standards that will guide those desiring to sink a shaft safely and bring about uniform safety inspections.

Jan 1, 1968

By Roy L. Grant

The Bureau of Mines investigated the up-and-down method with factorial designs to determine if shorter, and therefore less costly, trial sequences could be used. Although sequences of 50 trials are usually recommended, sequences of 20 trials were arbitrarily chosen for the experiments with permissible coal mine explosives described in this report. These explosives were fired from a cannon pointed into a flammable natural gas-air atmosphere at the Bureau of Mines Explosives Research Center gallery to ascertain their safety properties. The investigation demonstrated that the shorter sequences led to useful conclusions with a reduction in cost of the experimental program.

Jan 1, 1967