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By AIME AIME

IT IS impossible in this short sketch to give a detailed description of each part of the plant at Bethlehem, therefore, only such facts will be touched on as are necessary to give a general idea of the works. The extent of the plant, and the fact that the units making up the various departments are located in different parts of the works, make it impracticable to mention the departments in any regular order with regard to their location. They are, therefore, mentioned approximately in the order of their relation to each other with reference to their functions in the making of the various products.

Jan 1, 1924

By Michael T. McCaffrey

The wide range of potential feed materials, process steps, and products in metallurgical facilities means that standard equipment might not be available to adequately meet the project technical and economic needs. Custom designed equipment should be considered only after rigorous research precludes purchasing standard equipment. However, the decision to use custom equipment introduces a new element of risk into the project. To manage the risk, custom equipment design should be developed through the same front end loading (FEL) phases as project development. If more than incremental development of custom equipment is required, appropriate test work or pilot trials are required to test key uncertainties. Important activities during custom equipment design include maintaining clearly defined performance objectives, conducting appropriate reviews, carefully crafting commercial and intellectual property agreements with design and fabrication partners, and assembling a multidisciplinary team with sufficient development expertise.

Jan 1, 2015

By W. R. Chambers

A wide variety of mining conditions exists within the South Midlands Area and across this range of conditions more than one half of the mines are highly susceptible to spontaneous combustion. Two thick seams in which the greatest risk exists are described and illustrated. The different heatings which take place are categorized by the locations at which they occur in the mines: additional special cases not easily categorized by location are discussed separately. The discussion for each category of heating follows the pattern of: (i) the reasons why it occurs; (ii) when it arises the means by which it is fought, and (iii) the preventive measures taken in an attempt to avoid its occurrence. Relatively new factors which may affect the incidence of heatings are highlighted and suggestions are made which may assist in reducing the number of incidents in the Area. A new method of continuous sampling, analysis and recording is described and mention made of an original method of interpreting carbon monoxide results with the aid of the computer. The first results from this work show that an early warning is given of an adverse change in trend several weeks earlier than with the present methods. Lastly, suggestions are made about the direction in which research might proceed to assist in reducing the special hazards created by several features inherent in the present methods of mining.

May 23, 1905

By M. Westendorf, T. Banerjee, S. Kaushik, D. Tinney

"Cyclones are one of the most extensively used pieces of equipment within the mineral processing industry because of their simplistic operating and maintenance philosophies. They are commonly used as classifiers within the comminution circuit to control the grinding product particle size for satisfactory performance of downstream operations.Cyclones are a key contributor to the effective operation of the plant and have a significant impact on the mineral processing plant operations. If the cyclones are not performing as they should, the results are often a combination of lost recovery, grade, capacity and reduced throughput. Similarly, an inefficient cyclone operation may also lead to low or high recirculating loads that impact the efficiency of the comminution circuit. This highlights the importance of having proper stability in cyclone operation while implementing any plant-wide optimization strategy.One of the key challenges in cyclone operation is that cyclones are highly sensitive to changes in operating conditions and are affected by process fluctuations such as feed pressure, solids concentration and flow rates. Fluctuations in cyclone feed characteristics lead to unstable cyclone performance which affects mineral liberation. For such an impactful unit operation, cyclones have historically been under-instrumented in an otherwise highly instrumented process plant. Traditionally, mill operators have relied on visual observations of the apex discharge to determine the operating state of the cyclones. Visual cues corresponding to the different cyclone operating conditions have been discussed by Neesse et al. (2004) as shown in Fig. 1."

Jan 1, 2014

By P. Tracy

An advanced real-time monitoring system, called a "Tapblock Diagnostic System" is under development to help furnace operators manage the operation and maintenance of their tapblocks. The life of a water-cooled tap block in a smelting furnace ranges from several months to several years, depending on the operating conditions. Tapblocks are typically replaced at regular maintenance intervals; a strategy based largely on historical records and not on the actual condition of a particular tapblock. The Tapblock Diagnostic System monitors the tapblock throughout its life and accumulates probable wear events to help the operator assess the residual integrity of the tapblock. Benefits of this system include the ability to provide early warnings of tap block wear to provide improved safety and maintenance planning. Using cooling-water flow together with copper and water temperature measurements, the system performs calculations that compare the present tapblock performance with the expected operating envelope using a multivariate statistical method (Principle Component Analysis). The operating envelope is pre-calculated for a wide range of operating conditions using transient thermal modeling (Computational Fluid Dynamics). A state indicator in the form of a green, yellow and red light is used to inform operators of the tapblock performance and health status.

Jan 1, 2007

By W. P. DYKEMA

This report gins the results of a study conducted hy the Ilnreau of Mines for the purpose of informing the petroleum industry on the recent progress in the de,·elopment nncl application of the absorption process for recO\·ering gasoline from natural gas. The work has been undertaken entirely with regard to plant practice and for the purpose of describing the features and the operation of units of the plants now in use, the improvements that have been made, and the reasons for any ehanges eontemplated by the engineers in eharge· of the plants studied. Throughout the United States the impro,·ements in the absorption process that are under consideration by engineers not only widen practice so as to include gases at all pressures and percentages of gasoline content, but seem to be dewloping definite standards as to dimensions of towers, l"elocities of flow, saturation of oi~ areas of eooling surfaces, and quantities of menstruum to be circulated. Although perfect practice has by no means been attained, the writer belie,·es thnt a description of the current practice at ,·arious plants, including those ob,'iously more efficient features that each plant hns <le\"eloped and uses at one or another stage of treatment, will intere;; t and possibly help all persons operating or designing absorption plants.

Jan 1, 1919

By Paul Gottlieb

This paper reviews the status of automated applied mineralogy today and describes the history and fundamental theoretical and practical bases underpinning the development of automated systems. Details are given of the technical challenges that were faced in creating the new technology and in applying it to a range of applications. In recent years, automated mineralogy has become established as an essential enabling technology for the reliable acquisition of statistically sound comprehensive mineralogical and metallurgical data. This has had a revolutionary effect on the industrial use of such data in the study of geology, mining and mineral processing. Previously, using manual methods, it was not feasible to attempt this work because the large data sets required could not be assembled in a realistic timescale. There was a reliance on individual expert mineralogists and this was not scalable. The speed, reliability, detail and repeatability of the modern automated measurements has now made this type of analysis routine. Automated Applied Mineralogy has come of age! More than 100 systems have been installed around the World. Automated mineralogical analysers such as QEMSCAN® were originally developed as diagnostic metallurgical tools to improve mineral processing plants using samples drawn from plant surveys, bench and pilot-scale tests. They were used mainly for the assessment and auditing of size fractions of mill products, such as concentrates and tails. Subsequently, they began to be used for concentrator design and optimisation where ore characterisation was used to help understand the relationship between the feed ore and its subsequent behaviour in the plant. They are now widely used to measure exploration cores and drill chips from drilling programs to predict eventual metallurgical performance. Ore samples can be classified into metallurgical, as well as geological types, by combining mineralogical features in the ores with metallurgical properties related to grade control, separation, comminution, flotation and leaching behaviour. Three-dimensional block models of ore deposits are now being created based on processing response in addition to geological and mining properties. The development of automated systems began in Australia, the United Kingdom and Canada in the late 1970s and early 1980s. There were many technical challenges. Mathematical theories of randomness, sampling theory, image analysis and stereology were developed to ensure sample representivity so that meaningful information could be obtained. Sample preparation, presentation and measurement methods were developed to ensure that the random sampling was preserved during the measurements. Methods of automatic measurement and mineral identification evolved from the use of electron microscopes, fitted with backscattered electron brightness and energy dispersive X-ray detectors. Operational procedures were required to ensure that these instruments could accommodate a large number of samples and operate unattended for long periods of time. The new technology was progressively applied to a range of commodities and applications and new analysis methods, such as liberation measurement, were needed for metallurgical interpretation of mineralogical data.

Jan 1, 2014

The original manuscript of section 2 of this series of miners&apos; circulars devoted to accident prevention in bituminous-coal mines was completed in September 1944. At that time roof bolting had been tried with some success in the lead-mining district of south-eastern Missouri, but information on the subject was so fragmentary that it was not included as a method of roof support. References to roof support in bituminous-coal mines, therefore, were confined almost entirely to conventional timbering methods. In 1947 the Bureau instituted a research program and intensive study of the general problem of roof control, which emphasized roof-bolt application. The rapid increase in mechanized mining following the close of World War II provided the impetus for the Bureau&apos;s roof-control investigations, because the vertical supports used with conventional timber restricted the maneuverability of mechanical face equipment, and the industry wanted to explore every possible method of eliminating interference with the production cycle to gain full advantage of mechanized mining. Moreover, the accidental dislodgment of vertical supports greatly increased the roof-fall hazard. As roof falls have killed and seriously injured more mine workmen every year than any other cause or classification of injury since records have been kept, the Bureau assumed this investigative leadership with the prime objective of substantially reducing the annual toll from falls of roof, including falls of rib and face.

Jan 1, 1958

By W. C. Phalen

During the search for deposits of soluble potash salts in the United States, carried on by the United States Geological Survey, much information was collected on the salt resources and industry of the United States. The more important features of the information thus gathered, compiled, and digested may be classified under five headings, as follows: 1. Geology of the salt deposits of the United States. 2. Theories relating to the origin and formation of salt deposits. 3. Chemical composition of saline materials in the United States, principally rock salt and natural and artificial brines. 4. Statistics of salt production in the United States. 5. Technology of salt production. The first four items are not discussed in this report, but their treatment will comprise a separate report published by the Geological Survey,a which will supplement this report, relating to salt-making processes, and will describe comprehensively the salt resources of the United States. Persons desiring a copy of that report should apply to the Director of the United States Geological Survey, Washington, D. C.

Jan 1, 1917

By Harold J. Bennett

This study was performed by the Bureau of Mines to evaluate the potential supply of primary copper from domestic resources. A tonnage-price relationship was developed indicating the quantity of copper that could be produced economically from known deposits at various copper prices and at various rates of return on the required capital investment. Costs of production are based on estimated capital and operating costs for mining, concentrating, smelting, and refining the copper. Total known recoverable copper resources are 189 million short tons of which 83 million tons could be economically recovered assuming a price of $0.50 per pound of copper, credit for the recovery of byproducts, and a 12-percent rate of return on capital investment. The quantities of recoverable byproducts associated with the 83 million tons of recoverable copper are molybdenum, 1.8 million tons, gold, 43 million troy ounces, and silver, 740 million troy ounces.

Jan 1, 1973

By Nilufer Kursunoglu

Despite being crucial for meeting the world’s energy demands, coal mining operations present considerable health risks, especially when it comes to exposure to coal dust. Longwall coal mining, an advanced technique, has considerably enhanced production but made dust control more difficult. Due to its explosive nature, coal dust continues to be a serious and dangerous concern in the industry despite developments in safety technology. This study aims to comprehensively assess the risk of coal dust explosions by integrating fuzzy risk matrix and Pareto analysis methodologies, offering precise risk ratings for various root causes. A fuzzy risk matrix was developed to assign exact risk ratings to identified root causes. Additionally, a Pareto chart was used to identify the main reasons and suggest particular preventive measures. 17 significant causes were determined for underground coal mines based on the study’s methodology, and some preventive measures were suggested. In accordance with fuzzy risk rating values, root causes were divided into six categories. The root hazard with the highest risk rating was identified as ‘accumulation of inflammable gas/gases’. The proposed approach was used to examine incidents caused by coal dust explosions in Turkish coal mines in order to demonstrate the effectiveness of combining the fuzzy risk matrix and Pareto analysis for assessing coal dust explosions. This study gives not only a solid framework for risk assessment but also critical information for classifying the risks associated with coal mine dust explosions. The results highlight the critical necessity for proactive and preventive actions to reduce the hazards of coal dust explosions and protect the safety of mining workers.

Nov 16, 2023

By Ed McConaghy, P. LaRochelle

The Ambatovy Nickel Project comprises the development of mine, hydrometallurgical processing facilities and necessary infrastructure in Madagascar, positioning Ambatovy as one of the world’s largest producers of nickel and cobalt from lateritic ore. SNC-Lavalin successfully provided comprehensive Engineering, Procurement, Construction Management (EPCM) services for this major capital project which, apart from its sheer size, scope, and engineering design, represented significant location, infrastructure, labour, environmental and climatic challenges. Today, the project has reached 90% of its nameplate capacity and is in its final performance optimization stage. This paper will discuss the significant project management effort that was required to successfully address the complexity of this major project. It will cover the main project management control systems and the engineering tools and processes used during the detail engineering, procurement, and construction phases to achieve optimum project execution.

Jan 1, 2015

By R. M. Sweetin

Detailed descriptions by operating area of the Kidd copper smelter are presented, together with accounts of complement staffing, training, and preparation activities for smelter start-up in June 1981. Concentrate tonnages smelted in the first twelve months of operation were constrained by the capacity of the furnace off-gas system. However, modifications designed and introduced over that period, plus sustained efforts by operations and maintenance personnel have resulted in stepwise improvements in smelter performance.. Consistent operation at design feed rates has been well demonstrated over the third and fourth smelter campaigns and efforts continue on further improving the continuous smelter on-line times and increasing campaign life. In November 1982., following a seventeen month preproduction period, the Kidd smelter attained full operating status.

Jan 1, 1983

By Elmer W. Pehrson

OPINION seems widely divergent as to where we stand with respect to future mineral supply. From some quarters we hear that the United States is about to become a "have-not" nation and about to experience the evil consequences such a situation would entail. Others claim that we are still a treasure house of stored-up mineral wealth, the surface of which barely has been scratched. The data to be presented here support the conclusion that neither of these viewpoints is correct and that we are far from exhaustion of those mineral resources that are basic to our industrial economy. However, exhaustion is well advanced in a number of important subsidiary minerals so that we can no longer drift along with the easy-going philosophy that the earth will provide. The time has come when we must recognize the true situation and do something about it.

Jan 1, 1945

Jan 1, 1993

Minerals are vital to any industrialized civilization. Annually, the United States uses more than 4 billion tons of new mineral materials, or about 40,000 pounds per person-about half being mineral fuels and the other half metals and nonmetallics. Stable and economic domestic mining, mineral, metal, and mineral reclamation industries are essential to the economy. The value of United States energy and processed materials of mineral origin exceeds $200 billion annually. Although a number of minerals are imported, especially some designated as "strategic and critical," most U.S. mineral supplies are derived from the domestic mines and processing facilities that you will be seeing, reading about, and visiting as you use this visitor guide. We hope you enjoy your experiences. This pamphlet, a guide to mining and mineral operations that may be observed or visited and some other points of interest relating to minerals, is intended to aid tourists and students who are interested in mining. Some may wish to study our Nation&apos;s romantic past; others may plan to enter the minerals industry as a career; still others may have a primary interest in conservation practices. The pamphlet is also intended to aid State and local officials, Chambers of Commerce, and mining firms in answering some of the many questions of tourists and students.

Jan 1, 1977

By J. C. Loretto

The philosophy and detail of mill design in developing countries, where it is frequently difficult to obtain experienced, qualified supervision to operate the plant, are discussed. The resulting design suggests the desirability of simple units, with maximum visibility of equipment operation and material movement, which allow the minimal technical supervision to see the plant conditions prevailing. Information on plant conditions during periods of lesser supervision can be provided by the use of simple, low-maintenance recorders. Where the mill is intended for operation in a developing country, it is insufficient for the flowsheets and plant layouts merely to be drawn: the process metallurgist must pay meticulous attention to details that could ordinarily be left to the design detailing group. The design of this type of mill requires a knowledge of human engineering—of the type of individual who will operate and supervise the plant; probable changes in personnel should be taken into account. Details are suggested for coarse-ore handling, screens, feeders, secondary and tertiary crushers, conveyors, dust collecting, fine-ore feeding, grinding mills, conditioners, flotation, thickeners, filters, reagent systems, sand pumping, sampling, instrumentation, safety and construction

Dec 1, 1971

By Albert H. Fay

This glossary is published by the Bureau of Mines as a contribution to the mining literature in the belief that it will fill a long-felt need. It contains about 20,000 terms; these include both technical and purely local terms related to metal mining, coal mining., quarrying, petroleum, and natural gas, and metallurgical works; names of useful, important, and common minerals and rocks; and geological terms. It presents in one comprehensive volume the available standard, technical terms relating to the mining and mineral industry, as well as provincialisms that have been or are now in use in English-speaking countries. The glossary also includes many terms relating to ceramics and. the clay industry, glass making, foundry practice, railway and building construction, electrical installation and power-plant equipment, and chemical terms relating to metallurgical practice. Complete lists of terms for each of these allied industries are beyond the scope of this glossary. Paleontological terms, although closely associated with geology, are far removed from mining and metallurgical operations, and for this reason have been omitted.

Jan 1, 1920

For 11 years, under authorization of the Synthetic Liquid Fuels Act of April 5, 1944 (30 U.S.C. 321-325), and amendments, the Bureau of Mines has carried on an extensive research and development program to establish methods for producing oil from coal and from oil shale. This act was passed by the 78th Congress primarily because of the stress of wartime demands for liquid fuels to supply our armed forces during World War II. The act was progressively extended by the 80th and 81st Congresses, as later peace-time demand for oil and oil products continued to increase.

Jan 1, 1956

By David R. Wilburn

The U.S. Bureau of Mines investigated the resources, costs, capacities, market relationships, and short-and long-term supply of bauxite, alumina, and aluminum. The 45 evaluated mines and deposits in 14 market economy countries (MEC&apos;s) have a demonstrated resource of 8.4 billion mt of bauxite and an aluminum content of approximately 2.1 billion mt. Developed world bauxite resources and existing primary aluminum smelting and refining capacity are sufficient to satisfy demand through at least 1995, when additional properties (with higher cost levels) would need to be developed to satisfy future demand levels. It is anticipated that new alumina or aluminum production most likely would occur in developing regions with large bauxite potential, low-cost energy sources, and a close proximity to refining and/or smelting capacity. An increase in aluminum recycling capacity would help meet future demand increases. A series of network model supply analyses was performed for the period 1988 through 2000. Based on announced future production levels and assuming demand grows at the level outlined in the analyses, model results indicate there is sufficient material available to meet demand until 1998, where-upon an aluminum shortfall is projected. Additional analyses investigated the effect of a reduced growth rate of demand and regional production variations in Venezuela on the international aluminum industry.

Jan 1, 1993