Search Documents

By Andreas Siegmund

During the decade of the nineties the conventional method of primary lead smelting (sinter machine/blast furnace) was successfully challenged by the introduction of novel direct and continuous smelting processes. In combination with a significant shift in market structure, as well as more stringent government regulations these modem technological innovations like the QSL, Kivcet, and Isa/Ausmelt processes became more than major competitors. They have proven to be economically and environmentally viable. The intensification of the metallurgical reaction by applying oxygen enriched or pure oxygen bath or flash smelting principles resulted in cost savings and a higher flexibility with respect to raw materials and additives usage. By synchronizing individual auxiliary plant sections with the smelting process a virtually waste- free production and low-emission mode of operation with nearly optimum energy exploitation is achieved. The primary lead industry will gradually substitute the sinter -blast furnace operation with novel high-energy efficient technologies in the new millennium.

Jan 1, 2003

By N Clarke, A Barros

Preconcentration of run-of-mine subgrade and marginal ore by screening has the potential to substantially improve the economics of mining, particularly for large, low-grade orebodies, and to reduce environmental impacts. It has recently been the subject of a major research effort by a joint public-private research body, CRCORE. Yet despite this, there appears to have been only one fully commercial installation, at Bougainville Copper Limited in the late 1980s. Two reasons for the limited application are that not all ores have suitable properties and the economics of all pre-concentration processes on low-grade materials are highly sensitive to the precise balance of mass and value recovery and to the pre-concentration process cost, including materials handling. These factors make it imperative to have good test data on the process response of feedstock across the orebody. Collecting that data presents major challenges, which differ for green and brownfields operations. This paper first discusses the approach to preliminary evaluation developed by CRCORE, which relies on testing of coarse rejects or drill chips available from exploration drilling programs. This method is an efficient first step in evaluating an orebody which is deemed geologically to be potentially amenable to screen upgrading, but it does have limitations and must be followed by larger scale work. A suite of methods have been developed by the authors as a result of test work since the 1990s on several projects, supplemented by published data, which aim to provide statistically robust data at lower cost than large scale bulk sampling tests. For greenfields projects, the upgrade response measured on material crushed to -53 mm has been found to correlate closely with ROM ore, with no scale-up required for material with upgrade responses in the range of commercial interest. Large diameter whole drill core, such as PQ, is expected to be suitable for this method. As drilling such core is costly, the aim should be to establish relationships between upgrade performance and proxy measurements such as multi-element chemical or hyperspectral analyses. This approach was successful at the Gramalote gold project in Colombia. The method is not applicable for ores with thick vein material comparable with the crush size, but such material is not suitable for upgrading by screening and would be eliminated by the preliminary testing. For brownfields projects where blasted material can be sampled, the upgrade response can be accurately measured by sampling only the finer fraction of the ore, selecting a top size which represents 30–50 per cent or more of the ROM size distribution. This is likely to be between 50 and 100 mm. The much finer size compared with the full ROM ore greatly reduces the sample mass required to achieve a given intrinsic sampling error and enables sample preparation to be undertaken with large-scale laboratory equipment rather than mobile crushing plant. The accuracy of the method can be improved by measuring the approximate mass of oversize rejected during sampling. Some ores do show a systematic deviation from the assumed model fit which results in this method slightly underestimating the upgrade response, and it would therefore still be recommended to take one or two full bulk samples to confirm results before a final investment decision.

Aug 24, 2022

By John V. Beall

Since the U. S. Metals Refining Co. works was established, around the turn of the century, near the town which is now called Carteret, N. J., it has grown to be a major producer of refined copper and the main source of that special brand known as "oxygen-free high-conductivity copper." Owing to the complex metallurgical problems arising from handling a variety of raw materials such as copper concentrate from Matahambre, Cuba, copper and brass scrap from the New York area, and domestic blister copper, the organization is geared from top management down through its 2000 employes to maintain a high degree of flexibility in plant operation. The Company is a subsidiary of The American Metal Co. Charges for the smelter furnaces, one reverberatory furnace and one blast furnace, are made up in. bedding bins so that they may be tailored to the production of a constant grade of blister copper. The reverberatory furnace smelts the .sulphide charge, which may be a blend of ten different materials but principally the Cuban concentrate, and the matte from the process is poured into a converter. This reverberatory is 80 by 20 ft, silica lined with a slag bottom, fired by pulverized coal, and continuously side-charged from the top by bottom-dump cars which keep the side walls covered. It produces a 40 to 50 per cent copper matte. The fuel-charge ratio is 4.35 tons of solid charge per ton of coal. The furnace has a capacity of 10,000 tons of charge per month and produces from 5000 to 6000 tons of slag per month which must be disposed of. About 5000 tons of converter slag is produced monthly and returned molten to the reverberatory furnace. The converter gases go through a spray chamber to a Cottrell precipitator and thence to the flue system. Smoke from the

Jan 1, 1948

By T Sprague, D Pateman

"The Gosowong Gold Project is owned and operated by PT Nusa Halmahera Minerals (PT NHM), an Indonesian company 75 per cent owned by Newcrest. It is located on Halmahera Island, in the North Maluku Province of the Republic of Indonesia, approximately 2450 km north-east of the national capital, Jakarta (Newcrest, 2017).Kencana is one of two underground gold and silver mines at the Gosowong Operation where ground conditions vary from competent to very poor. Development headings occurring in poor rock mass conditions require high capacity ground support including long tendon cable bolts. Manual installation of cable bolts in these development headings has been a time consuming process due to borehole collapse, blockages requiring subsequent re-drilling and a minimum eight hour grout curing time interval. The installation of cable bolts including the setting, plating and tensioning can impact the critical path for development heading advance resulting in development cycle delays.A review was conducted by PT NHM on current industry practices for alternatives to manual cable bolting. PT NHM subsequently approached Minova to assist with the development and trialling of self drilling anchors (SDAs) installed using jumbos with a rapid setting pumpable resin, CARBOTHIXTM. A series of system development trials were conducted and a reliable bolting system was developed utilising the existing jumbo drilling fleet with minimal required modifications.The system developed was a ‘one pass’ bolting process to install and grout SDAs using a two component resin with a remote, mechanised system. Improvements achieved from the system include: eliminating hole closure issues and more immediate support in poor rock mass effectively reducing personnel exposure to poor ground conditions by removing the requirement to access the drive backs reducing grout set time with full installation times for 6 m SDAs averaging 25 min.The resin grouting system has now been successfully implemented to effectively manage areas of poor ground conditions and to accelerate advance rates in high priority headings.CITATION:Pateman, D and Sprague, T, 2017. Development and implementation of a long tendon bolting system utilising resin grouting technology, in Proceedings 13th AusIMM Underground Operators’ Conference 2017, pp 79–84 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 16, 2017

Lead Tariff.--The full House Ways and Means Committee approved H.R. 6089 which will have the effect of reducing the tariff on unwrought lead to 3% ad valorem, with a floor duty of 1.0625 cents per pound, compared with the currently effective rate of 3.5% ad valorem. Consideration is also being given to tariff rates on imports of red lead and litharge from Mexico. A consortium of domestic producers has appealed to the Office of the Special Trade Representative (STR) requesting a return to tariff schedules which were in effect prior to the concessions made effective on January 1. Mexican producers have filed a proposal in favor of lower duties, and the matter now awaits a ruling by the STR. Ferrous Scrap Exports.--After holding public hearings and receiving public comments in May, the Department of Commerce announced that it would not institute formal monitoring of ferrous scrap exports, as requested by the Ferrous Scrap Consumers Coalition. The Department said, however, that it would follow the trend of scrap exports and prices. Ferrous scrap prices are currently low and supplies are reported to be adequate.

Jan 1, 1980

By Scott Rosenthal, Dave Gilkey, Theresa Stack, Daniel Autenrieth, Ciara Kremer

Jackleg drill operators are exposed to harmful levels of hand-arm vibration (HAV). Anti-vibration handles and gloves provide modest reductions in HAV exposures and forearm muscle exertion from the use of anti-vibration handles and gloves by jackleg drill operators. The goal of this pilot study was to investigate changes in HAV with the use of anti-vibration gloves and handles compared to forearm muscle exertion experienced by operators and measured with surface electromyography (EMG). Five subjects operated the drill under four different cases: no anti-vibration controls, anti-vibration gloves only, anti-vibration handle only, and simultaneous anti-vibration handle and glove use. Muscle exertion was expressed as a percent of maximum voluntary contraction (%MVC) and was compared using Welch’s ANOVA with Games-Howell post hoc comparisons. The case with both anti-vibration controls in use simultaneously (largest grip diameter) was associated with a mean %MVC of 36.13% during operation for all forearm muscles combined, which was significantly higher than that of the other cases (p < 0.05). There were no statistically significant differences in mean HAV exposures. The anti-vibration handle with anti-vibration glove case only increased the maximum allowable exposure time by 8 min as compared to the control case without any anti-vibration controls. These results suggest that the modest HAV exposure reductions from the use of anti-vibration handles and gloves may pale in comparison to the increased muscle exertion resulting from their use, and this trade-off among jackleg drill operators is a potential concern that warrants further investigation.

Jul 12, 2021

By K L. Olzard

At the WMC Resources Phosphate Hill operation, monitoring the quality of the ore delivered by the mine to the beneficiation plant is of prime importance to ensure the fertilizer is produced cost-effectively through the various stages of production and meets customer quality requirements. P2O5 and Fe2O3 are among the critical-to-quality elements. Fe2O3 is a key performance driver as it is an impurity that adversely impacts some of the chemical processes. The ore is supplied to the plant on a conveyor belt that is equipped with an automatic sampler. Increments are taken off the flowing ore stream at regular time intervals. A variographic experiment was conducted to investigate sampling strategies capable of estimating ore properties over a 12-hour shift to a nominated level of precision. The combination of individual increments into a shift composite was included among the strategies that were assessed. The experiment involved collecting data at regular time intervals and preparing variograms to characterise the feed-grade variability on the conveyor belt. Duplicates were also collected to assist in quantifying the precision of the subsampling stages of the sampling protocol and assay accuracy was monitored with matrix-matched standards. Various sampling schemes were evaluated by combining geostatistical techniques and the sampling theory of Pierre Gy. The following parameters were varied: the number of increments, the increment-size reduction leading to the composite, the masses of the subsequent sampling stages and the number of analytical determinations. This paper describes the planning of the variogram experiment, the various phases of data collection and the methodology used to process the data. It discusses the development of some of the sampling schemes that were considered.

Jan 1, 2005

By L. Tikasz

The primary purpose of ore hauling model studies is to capture the variability of the ore delivery ? stockpiling process in order to improve the estimation of equipment capacities and achievable throughputs. The operation of a mine-to-site ore delivery system is the subject of a number of challenges. Typically, ore is hauled by a given combination of trucks, conveyors and trains. In addition, ore loading, ore transferring to another means of delivery, stockpiling, reclaiming, and further deliveries involve many other types of equipment. The concurrent operation of all these units is scheduled; nevertheless, they are subject to planned maintenance and random breakdowns. To support our engineering design work on ore hauling operation, discrete event type models were built for each specific task. Then, due to recurring demands, an ore hauling library was gradually compiled. The now available model library allows fast and efficient simulation of various mine-to-site hauling arrangement, adaptable to various mining and mine construction operations (e.g. bauxite, iron ore, copper ore and coal).

Aug 1, 2013

By Scott W. Hazen

This Bureau of Mines report presents the results of a study and statistical analysis of part of the initial exploration churn-drill sampling and some of the subsequent underground diamond-drill-core sampling in the North are body at the San Manuel copper mine, Arizona. These data were derived from regular exploration and mine sampling, not from special samples obtained solely for statistical analysis. The study was conducted as part of the Bureau&apos;s continuing program on sampling-methods research. The major objective of the study was to investigate the feasibility of using the techniques of statistical analysis in evaluating sample and assay data and computing grade and tonnage of Ore from porphyry-type copper deposits. It was recognized that using existing data acquired over a period of several years by different methods would introduce problems and limitations for precise comparisons. However, it was expected that the study would provide some general conclusions and certainly a number of preliminary conclusions on the nature of the mineral characteristics and their effect on sampling procedures, the requirements for sampling deposits of this type, and the comparative results of churn-and diamond-drill sampling in the same area of the deposit. All of this information would be essential for future sampling-methods research for computing grade and tonnage of ore.

Jan 1, 1963

By K. Bunney, R. Pleysier

The deportment of a suite of elements through representative gold ore processing unit operations in cyanidation has been investigated. Chromium and lead are not soluble in alkaline cyanide solutions. Arsenic, antimony, cobalt, molybdenum, selenium, tellurium and vanadium are soluble, but typically do not adsorb onto activated carbon to any appreciable extent. Silver, copper, cadmium, mercury, nickel and zinc to varying extents report along with the gold to the carbon eluate. Cadmium, mercury and zinc can report to the carbon regeneration kiln off-gases. Strontium is soluble and adsorbs on carbon where it remgins.

Jan 1, 2011

By William Gleason

"When Dr. Joseph A. Holmes was named the first director of the U.S. Bureau of Mines in 1910, the challenge in front of the mining industry was urgent and profound. Just three years before the Bureau was formed, the United States’ coal industry saw a spike in fatalities, as 3,242 miners lost their lives, including 918 miners killed in 18 major disasters. Holmes, who is often called the Founding Father of Mine Safety, was charged with researching and finding new and safer methods to conduct mining activities as well as more efficient ways to conduct mine rescue to educate miners.The U.S. Bureau of Mines was dissolved in 1996, but the mission of the Holmes Mine Rescue Association remains intact, although the challenges have changed greatly.During the 102 years between its formation and the 2018 Joseph A. Holmes Safety Association & Holmes Mine Rescue Association Annual Meeting and Training Seminar in Denver, CO June 5-7, the mining industry has evolved to become one the safest industries in the United States, with an injury rate on par with school teachers and better than retail workers. The work of Holmes and the Bureau of Mines plotted a course for others to follow, and the fatality rate has plummeted to historic lows. However, those who work in the mining safety and health sector remain diligent to their cause and are slow to celebrate too much the accomplishments of the past century, focusing instead on the work that lies ahead.“The nature of mining accidents has changed and it is very difficult to make changes when you get down to the asymptotic part of the equation,” David Zatezalo, assistant secretary of the U.S. Mine Safety and Health Administration (MSHA) told Mining Engineering. He was the featured speaker at the Joseph A. Holmes Safety Association annual meeting’s banquet dinner and presented a thorough overview of the mission of MSHA and his goals as its top man.Nominated by President Donald Trump, Zatezalo was sworn in as the ninth assistant secretary for MSHA on Nov. 30, 2017 and brings with him a lifetime of experience in mining. During his presentation, he displayed the chart (Fig. 1) showing the dramatic improvement in safety that the industry has achieved during the past century, but he noted that, as the industry gets closer to its end goal of zero fatalities, it has become increasingly more difficult to cross the finish line."

Jan 8, 2018

By Joo Hyun Park, Soo Sang Park

The distribution behavior of Pb between molten copper and FetO-SiO2 (-CaO, Al2O3) slags was investigated at 1473 K (1200 oC) and p(O2)=10-10 atm in view of the reaction mechanism of Pb dissolution into the slag. The distribution ratio of Pb (LPb) decreases with increasing CaO content (~6 mass pct) irrespective of Fe/SiO2 ratio (1.4~1.7). However, the addition of alumina into a slag with Fe/SiO2=1.5 linearly decreases the LPb, whereas a minimum value is observed at about 4 mass pct Al2O3 at Fe/SiO2=1.3. The log LPb continuously decreases with increasing Fe/SiO2 ratio, and the addition of Al2O3 (5 to 15 mass pct) into the silica-saturated iron silicate slag (Fe/SiO2 < 1.0) yields the highest Pb distribution ratio. The log LPb linearly decreases by increasing the log (Fe3+/Fe2+) value. The Pb distribution ratio increases and the excess free energy of PbO decreases with increasing Cu2O content in the slag. However, from the viewpoint of copper loss into the slag, the silica-saturated system containing small amounts of alumina is strongly recommended to stabilize PbO in the slag phase at a low Cu2O content.

Jan 1, 2014

By Emanuelle Garcia Reis, Gustavo de Sousa, Rodney Pardo Alves

Gerdau Ouro Branco´s plate mill started the operation in 2016 with high level technology. In general, national and international plate markets are every day more rigorous about final product quality. Suppliers must be aware about dimensional accuracy, surface quality and flatness of the plates, independent of the quality standards. To guarantee the best service to this increasingly demanding and competitive market, it is extremely important to guarantee the original project conditions executing the right maintenance of the rolling mill main components. In order to maintain the product quality and avoid the production and maintenance cost increase, it is important to find ways to control the mill and the main process variables, through daily measurements of the equipment performance. This paper aims to present the influence of the main equipment variables that affect the mill operational stability and how to control and evaluate the mill performance.

Oct 1, 2019

By R. Karl Zipf, Z. T. Bieniawski

"Abstract. Based on the premise that understanding the fundamental mechanics of fine fragment formation in coal will lead to reducing coal dust problems in mines, a thorough study of the mechanics of crack propagation in coal was undertaken. Two approaches were considered in an attempt to understand and quantify the fracture process as it relates to fine fragment formation.In one approach, theoretical models are used which describe the size of the fracture process zone which may relate to the amount of structural damage and fine fragment formation on the new crack surface. The other approach is based on the relationship between crack tip stress intensity and new surface appearance for mixed mode crack propagation. Preliminary observations with a scanning electron microscope support the premise that fine fragment formation is related to fracture surface appearance and fracture initiation conditions.An experimental program designed to supply the input parameters for these approaches is presently underway. The experimentation features mixed mode fracture toughness testing, using a special mixed mode testing rig, and fracture velocity measurements with a crack propagation gage. The interpretation of this data via the approaches discussed will provide further understanding of the mechanics of fine fragment formation in coal."

Mar 1, 1989

By Mogens Henriksen

In the past decade, numerous urge scale drilling projects have made use of reverse circulation air lift methods. Reverse air lift pumping can be established by injecting gas into a column of liquid; the subsequently decreased density of the gas-liquid mixture allows atmospheric pressure outside the lift conduit to establish flow. The rate of flow can be controlled by varying the gas to liquid ratio. A typical reverse circulation air lift system is depicted in Figure 1. Allen1 has described a number of reverse air lift drilling projects. Although cited examples are generally related to large diameter holes, the method has seen use in other applications such as sand dredging, chemical pumping, water well pumping and continuous coring. One particular benefit obtained with enclosed reverse circulation drilling is elimination of lost circulation. The required air/water ratio for pumping at a given submergence and lift has been established experimentally by Gibbs2. His data, however, do not reflect sensitivity of flowrate to air/water ratio. Further, in Gibbs&apos; work, air apparently is injected continuously along the column of water. This configuration differs from that used in reverse air lift drilling where air is injected at discrete points only. Gas lift theory has received considerable attention over the past decades. Orldszewski3 defined flow regimes in two phase flow. Griffith and Wallis4 determined relative velocities of gas to liquid. Two-phase flow has been studied extensively for oil transport in inclined and vertical pipes by Chierici et a15, Beggs and Brill6, and Gould, Tek and Katz.7

Jan 1, 1977

By AIME AIME

THE Petroleum Division will hold two meetings this fall, one on the Coast at Los Angeles, Sept. 29, with the technical sessions in the assembly room of the California Oil and Gas Association and a banquet Friday evening at the Richfield Cafe atop the Richfield building; the other in the Southwest, at Dallas, Texas, Oct. 6 and 7, with the Baker Hotel as headquarters. Dr. Frederick M. Becket, President of the Institute, and A. B. Parsons, Secretary, will attend both meetings. Arrangements for the meetings are not yet complete but the respective local committees, working in close touch with the officials of the Division are rapidly shaping up the programs and other detail.

Jan 1, 1933

By G. France

The Blair Athol Coal Mine (BAC) is a large open cut operation in the Bowen Basin of Queensland, Australia. Current mine capacity is about 11 million tonnes per annum (Mtpa) of export coal. On-line analysis at BAC consists of two Coalscan 9500s installed directly on the output of the crusher plant and immediately before the product stockpiles, while a third Coalscan 9500 is installed on the transfer conveyor feeding the train loading bin. The two product Coals cans have a dual purpose. The first is to provide real time coal quality data directly back to the mining operations. The second is that of modeling the product stockpile with accurate on-line information. This modeling enables both production and coal quality personnel to accurately examine the coal quality of each stockpile with a degree of resolution which previously had never been achieved.

Jan 1, 1999

By Lyman C. Hitchcock

The objective of this program was to determine the minimum luminance requirements for underground coal mining work from the working face to the first transfer point. The resulting data encompasses 114 visual tasks from conventional continuous and longwall mining methods representing the salient visual tasks found in the jobs listed. Cutter Operator Roof Bolter Face Drill Operator Airdox Operator Longwall Jackman Shuttle Car Operator Loader Operator Shot Fireman Continuous Miner Operator Longwall Head Conveyor Operator Longwall Tail Conveyor Operator

Jan 1, 1973

By Rodney L. Williamson

Optimal estimation theory has been applied to the problem of estimating process variables during vacuum arc remelting (V AR), a process widely used in the specialty metals industry to cast large ingots of segregation sensitive and/or reactive metal alloys. Four state variables were used to develop a simple state-space model of the V AR process: electrode gap (G), electrode mass (M), electrode position (X) and electrode melting rate (R). The optimal estimator consists of a Kalman filter that incorporates the model and uses electrode feed rate and measurement based estimates of G, M and X to produce optimal estimates of all four state variables. Simulations show that the filter provides estimates that have error variances between one and three orders-of-magnitude less than estimates based solely on measurements. Examples are presented that verify this for electrode gap, an extremely important control parameter for the process.

Jan 1, 2001

By Tuanhui Wang, Qiwei Wang, Quanrui Liu, Jianhui Xu, Chao Wang, Yu Liu, Yuefeng Li

Rockburst is a highly destructive geological hazard that can cause casualties and equipment damage. To achieve highaccuracy discrimination of rockburst intensity, this article proposes an improved model that addresses the inefficient maximum membership principle used in traditional rockburst fuzzy evaluation models. The stress coefficient σθ/σc, brittleness coefficient σc/σt, and elastic deformation energy index Wet are selected as evaluation indicators for rockburst classification. Subjective and objective weights are obtained using the Delphi method and entropy weight method (EWM). Three types of membership function distribution forms are then used to obtain the membership degrees of each indicator to rockburst grades: trapezoidal membership function (TMF), normal membership function (NMF), and quadratic parabolic membership function (QPMF). Finally, six traditional models and six improved models are established using the maximum membership principle (MMP) and weighted average-maximum membership principle combination evaluation principle (WMP), respectively. Based on the analysis of 100 sets of rockburst field data, the accuracy, precision, recall, and F1-score of the improved evaluation model are increased by 11.3%, 0.097, 0.068, and 0.089, respectively, compared to the traditional model. The Delphi-NMF-WMP model is selected as the best model, with four performance indices reaching 97.0%, 0.979, 0.979, and 0.978. The best model is applied to evaluate the rockburst intensity of the Cangling Tunnel, Dongguashan Copper Mine, and Jiangbian Hydropower Station Diversion Tunnel, with evaluation results consistent with the actual situation, demonstrating the reliability and scientificity of the model.

Feb 28, 2024