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By E. Lehtila, J. J. Talja, R. Jahila

Kopar Oy is acknowledged for engineering and manufacturing of robust systems for bulk material handling, especially at power plants and non-ferrous smelters. We have over thirty years of experience with systems specifically designed for hot and abrasive conditions, aiming at low cost of ownership, low operational expenses and high availability. Although Kopar has numerous applications in mechanical conveying, there is an increasing number of pneumatic conveying applications at copper smelters. They relate to conveying of concentrate, and primary and secondary flue dusts. Challenges of pneumatic conveying for concentrate are mechanical and do relate to broad particle size distribution and high abrasivity of the concentrate and the silica. Therefore, special attention shall be paid to system design and ceramically lined bends in the pipeline. Challenges of pneumatic conveying of primary flue dust relate predominantly to material stickiness and poor flowability which are mainly due to fine particle size and formation of sulphates and furthermore, crystalline water. Additional challenges of secondary dust, the white converter dust, are primarily due to the extremely fine 0.1–1.5 µm particle size and problems which come with this. Effect of material characteristics like size distribution, morphology and chemical composition in pneumatic conveying are discussed in detail. INTRODUCTION Fine materials like concentrate, feed mix, flue dusts (from waste heat boiler and electrostatic precipitator) and secondary dusts need to be conveyed at smelters. Both horizontal and vertical conveying and combination of those are used. For the purpose, both mechanical and pneumatic conveying are applied. Most widely used equipment are drag chain conveyors and various combination of pneumatic systems, e.g. air lift, dense-phase and dilute phase pneumatic conveyors. Kopar has 30 years’ experience with multiple material handling systems. Furthermore, acquired companies like Elmomet Oy and SITE Oy (both currently fully merged and integrated into Kopar Oy) have even longer history, especially in pneumatic conveying. It is commonly known that the finer the dust the more difficult it is to be conveyed pneumatically. Sulfates with crystal water makes it all even more difficult, if not ineligible. Challenges related to pneumatic conveying of various fine materials is discussed in detail in the paper.

Jan 1, 2019

By L. A. Vermeulen

A simple argument shows that it is impossible for the flight of a rod in contact with a litter bar in a rotary mill to be initiated at that point on the upside of mill rotation when all the forces acting on the rod are in equilibrium. The argument was confirmed experimentally in a study showing that the lift of litter bars is a function of their height, that the rod velocity at the point of departure has a significant radial component, and that the subsequent flight of a rod is along a parabolic trajectory as predicted by elementary mechanics. A quantitative account of the observed effects, which is based on a dynamic theory of the sliding interaction between rods and litter bars, revealed interesting properties of the motions of rods down the surfaces of litter bars when the latter are in uniform circular motion during the rotation of a mill.

Jan 1, 1985

By C. A. Fleming, K. W. Sarbutt, P. K. MacPhail

The SART process has been developed for Teck to treat bar­ren solution from the cyanidation/CIP process that has been developed for the Lobo-Marte project in Chile. The objective of the process is to recover cyanide in a form that is suitable for recycling to the leaching part of the process. The Marte and Lobo ore bodies require a dosage rate of about 2 kg/t NaCN, of which only 0.5 kg/t is truly consumed (as thiocyanate, cyanate and ferrocyanide species). The remaining -1.5 kg/t is present as cop­per cyanide (-1 kg/t) and free cyanide (-0.5 kg/t), and is poten­tially recoverable and recyclable. SART is an acronym that describes the unit operations in this cyanide recovery process; namely, .. Sulphidization .. Acidification .. Recycling of precipitate " Thickening of precipitate The basic chemistry has been applied previously, and has also been the subject of two patents (American Cyanamid Company, 1965, Potter et al., 1986). The process involves the conversion of all free and WAD cyanide in solution to hydrocyanic acid by acidification of the tailings solution to pH :s,4, and the conversion of all copper in solution to cuprous sulphide (synthetic chal­cocite) by the addition of a sulphide salt:

Jan 1, 1998

By A. J. Rigby

Current practices employing porous plugs to inject nitrogen into molten copper during primary smelting are described. Nitrogen stirring increases heat transfer to the bath, eliminates temperature stratifications, and improves efficiency during the steps of desulfurization and deoxidation. The opportunity to use porous plugs as the means to introduce reducing gases to deoxidize copper is also discussed. Previously reported laboratory results using porous plugs, which point to very high utilization efficiencies of hydrogen when used as the reducing gas, are again reviewed. Advances in the design of the porous plug, and the introduction of a system enabling external replacement of plugs is also discussed.

Jan 1, 1999

By Joel N. Van Sant

An investigation was conducted to study possible sources of Utah refractory and structural clays that could be used for the manufacture of refractories and light or buff burning heavy-clay products. A field study was made and the clay samples tested to determine their firing characteristics. Results of the Bureau's work indicate many small noncommercial deposits of hypogenic clay occur in igneous rocks. Commercial hypogenic deposits are mostly halloysite clay developed by hydrothermal replacement of limestone. The high firing shrinkage of halloysite precludes its use as a refractory, however, halloysite produced at the Dragon Mine south of Eureka, is used for making oil catalysts. Clays and shales suitable for low heat duty refractory products are found in the Manning Canyon shale, in shales associated with coal bearing rocks, and in the Dakota formation. Some of the clays from the Dakota formation are also suitable for high-duty refractory products.

Jan 1, 1964

By J. M. Mutmansky

This paper outlines patterns of methane emission in both longwall and room-and-pillar operations and the effects that these patterns have on the decision as to whether the methane is most economically handled by ventilation alone or by means of a methane drainage system in addition to ventilation. The costs of handling the methane in the ventilation system and the costs of implementing the methane drainage system will be discussed as well as the costs related to the production of coal. The important issue of production slowdowns and gas outs will also be discussed as well as the proper response of mine management to such a situation. Suggestions concerning the keeping of production records related to methane problems will be made as well as justification for more intensive economic analysis of coalbed methane extraction and utilization.

Jan 1, 1998

By Arthur F. Taggart

The quality of aggregate materials is. of major importance in governing durability and permanence of concrete structures. The problem of selecting suitable aggregate materials is two-fold. Geological factors include the type and character of the aggregate source, presence of known or suspected reactive constituents, and presence of thermally incompatible materials. Laboratory investigations include petrographic studies, soundness and reactivity tests, and tests of thermal properties. The importance of each factor in the selection of satisfactory aggregate material is considered in detail.

Jan 1, 1950

By B. J. Arnold, F. F. Aplan

Prior laboratory work has demonstrated that much of the fine ash forming minerals entering a flotation froth are there as a result of water carryover- from the bulk contents of the flotation cell (Arnold and Aplan, 1986a). Using a bank of four 8.5 m3 (300 cu ft) Wemco flotation cells cleaning a well-liberated Lower Kittanning seam coal, test results show that the sulfur and ash content of the froth is directly related to the water content of the froth (or inversely related to the percent solids in the froth). Reagent changes that result in a watery froth produce a higher ash content in the froth. A direct comparison of laboratory and plant results show that the standard laboratory flotation test produces a product higher in sulfur and ash than that produced in the plant. Caution should be exercised when extrapolating laboratory test results to the plant situation. A method of estimating coal flotation product quality in the plant based on laboratory tests is given.

Jan 1, 1991

By J. A. Finch

The use of pneumatic methods for measuring interface level in flotation columns is analysed. It is shown that errors can vary over a wide range (e.g. 40 cm. in one industrial application) depending on bubble size, particle size, bubble loading, liquid hold-up and bulk slurry density. Accurate measurements (+ 5 cm) can be obtained by measuring intensive properties of the froth near the interface. Methods based on the measurement of temperature and conductivity are described and analysed. Control of the interface level using these measurements subject to various disturbances is demonstrated.

Jan 1, 1988

People in the work environment (and often elsewhere) are seen as a commodity (we use them for our purposes).The general accepted view of a Company is that shareholders are "The Company" and that they employ people to utilise their money in a particular field to generate more money to give a return on investment. To achieve this, capital equipment is purchased to fulfil a task and people are employed to use this equipment. Equipment and people are commodities purchased with money.The focus of this approach is MONEY. The equipment and people, and the use of them, determines the amount of money that can be generated. In this approach people are motivated by financial concerns. The harder the times the more money becomes the focus.

Jan 1, 1998

By Julijan Bratun, Joze Kortnik

Production of technical stone is an important economic branch in Slovenia. In 2009, we had 95 dolomite quarries, 27 limestone and 6 silicates quarries, according to the Ministry of Economic Affairs. Together they produced nearly 15 million tons of aggregates. The production in quarries is mostly performed with drilling and blasting method and only a minor part with other method like mechanical mining method.

Jan 1, 2011

By C. Coetzee

Additives are commonly used in copper electrowinning to improve cathode morphology. Polysaccharides such as guar are generally favoured as additives due to their compatibility with solvent extraction. Polyacrylamides are, however, being considered as possible alternatives. Understanding the influence of the structural chemistry of additives on electrowinning performance is critical to utilise them efficiently. This paper investigated polyacrylamide additives which are structurally different; their effects on copper electrodeposition were characterized and compared to that of guar. Electrochemical impedance spectroscopy (EIS) were used to characterize the effects of molecular weight and ionic charge of the polyacrylamides on electrodeposition. The findings were compared against results obtained with an industrially used guar product. Equivalent circuit modelling of EIS data indicated that an increase in polyacrylamide concentration and a decrease in additive molecular weight increased the overall system resistance.

By W. M. Tuddenham

It would be most difficult to place a date on the beginning of the revolution in analytical techniques that we have witnessed in recent years; but there is no question that the period since the end of World War II has seen a major change in thinking with respect to control and accounting analyses. For reasons relating to competition, much of this change was brought about in the chemical industries and only more recently has begun to affect directly the mineral industries. In considering the subject outlined in the title of this paper, one might well be tempted to discuss solely the more exotic methods of control and automation which have come into being in the past short while. In this paper, however, an attempt will be made to take a broader view and consider not only the application of newer purely physical methods of control but also those phases of chemical plus physical analyses that have bearing on our industry.

Jan 1, 1962

The implementation, during recent years, of the concept of distributing chilled water to improve cooling at the working faces represents a very important innovation for the mining world. In a logical extension to that concept it has been recognized that distribution of the cooling water at high pressure would provide a potential source of energy for driving water powered hydraulic machinery such as rockdrills, water jets for moving rock, and support props, in the workings. With this in mind, the Research Organization of the Chamber of Mines of South Africa is pursuing the development of such a dual system that will provide cooling in a deep mine and, at the same time, drive hydraulic machinery. A comprehensive design of such a system has been completed and has shown the concept to be entirely feasible technically using technologies currently available. A pilot system is working in a mine shaft 2000 m deep giving a pressure of 20 MPa at the bottom of the shaft and distributing the cold water into the workings at a pressure of 17 MPa. The system shows considerable potential for improving existing mining methods and will open the way for the development of new mining methods for deep mining operations.

Jan 1, 1986

By L. Yuan, J. H. Rowland III

"In 1995 and 2003, the Mine Safety Health Administration (MSHA) conducted surveys to determine the number of atmospheric monitoring systems (AMS) being used in underground coal mines in the United States. The survey reports showed data for the different AMS manufacturers, the different types of equipment monitored, and the different type of gas sensors and their locations. Since the last survey in 2003, MSHA has changed the regulation requirements for early fire detection along the belt haulage entries. As of December 31, 2009, point-type heat sensors were prohibited for use for an early fire detection system; instead carbon monoxide (CO) sensors are now required. This report will examine the number of AMS currently used in underground mines in the United States to see if there is a change in their use. The locations and parameters monitored by AMS are also discussed. INTRODUCTION The last survey conducted by the Mine Safety and Health Administration (MSHA) on atmospheric monitoring systems (AMS) used in underground coal mines in the United States (US) was in 2003 [1]. The survey report states that since 1995 there had been a steady increase in the use of AMS in underground coal mines as the technology of CO sensors was improved by manufacturers. AMS had become more reliable and some CO sensors could be purchased with the capability to discriminate between the CO produced from a fire versus CO produced from diesel equipment. This increase in reliability had reduced the number of false alarms and the response time. The faster response time to a developing fire allowed for the miners to take the necessary action to put out the fire or exit the mine. It should also be noted that at the time of last MSHA survey, some mines still used point-type heat sensors to detect the presence of a fire on conveyor belts. This detection method works by measuring the temperature of the air around the sensor. As a fire starts to develop, smoke and hot gases are produced from the combustion process, and the air is heated up. Once the air and gases reach a designated temperature detected by the point-type heat sensor, a fire alarm signal is generated. Studies have shown that the response times for detecting the presence of a fire using CO sensors are much shorter than using point-type heat sensors [2]. Finally, since the last MSHA survey, regulations have changed on the type of automatic fire detection systems permitted to be used in conveyor belt entries. As of December 31, 2009, point-type heat sensors are not permitted to be used for fire detection in underground coal mines in the US; instead CO sensors are required as a replacement (30 CFR 75.1103-4). This study will examine how the changing of the above regulations has impacted the use of CO sensors in underground coal mines in the US compared to their use based on the last MSHA survey. Importantly, in the previous MSHA survey, the data was recorded for producing and non-producing coal mines. In this study, only the data from the producing coal mines was recorded. Data was collected from a total of 235 coal mines for this study with the help of the MSHA district offices."

Jan 1, 2017

By John W. Brown

During the summer of 1994 the mining industry experienced numerous accidents involving blasting related incidents. The Tri-State Chapter of Explosives Engineers planned a meeting to discuss three of these accidents.

Jan 1, 1995

By Hannu Penttila, Harrison R. Cooper, Olli Mattila

Two approaches to automated operation in metallurgical processes involve the conventional analog control or, more recently, digital control. The expanding use of digital controls applied to process automation is a comparatively new development. Several current technical reports describe digital control systems in concentrator grinding control, 1, 2, flotation, 3 and smelter operations. 4,5 The principle factors influencing trends to digital control are:

Jan 10, 1976

By Oliver Bowles

"The manufacture of asbestos paper began commercially about 40 years age but its principal development has taken place during the past twenty-five years. The asbestos used by the ancients, termed amiantus by Pliny was used for winding sheets, tablecloths and other fabrics. It was probably chrysotile fiber and was a woven and not a felted product, and there¬fore is not to be confused with asbestos paper. There are, however, some early references to paper manufacture that are of interest. Pontoppidian, Bishop of Bergen, in his Natural History of Norway, published in 1750, refers to paper made from asbestos found in the parish of Waldens. He states that this paper did not burn when thrown in the fire, but the writing on it totally disappeared. This indicates that the primary ob¬ject was to obtain an indestructible writing paper. About 100 years later, further efforts were made with the same object in view. In 1853, a patent was issued for a process of making paper from a mixture of asbestos and alum. Many experiments were made to manufacture suitable asbestos printing paper. Some such papers contained only about one-third asbestos, the remainder being of combustible material. Such papers would burn, but would leave a white residue which retained its shape and preserved the written characters. On account of the difficulty of obtaining a smooth and even surface, and the tendency for the material to absorb ink like blotting paper, asbestos paper is not well adapted for writing or printing purposes. Other early uses of asbestos paper were for ornamental wall-paper and carpet linings. None of the uses mentioned above have developed to anything of importance in a practical way, but the manufacture of asbestos paper has become a very important industry, and it has found extensive uses in ways that were never dreamed of by the early investigators.It is recorded that the first sheet of asbestos paper made in America was manufactured in 1876 by John Roberts & Son Company, in a mill near Waltham, Mass. The material first used was a long-fibered amphibole asbestos from Italy. About three years later, Canadian fiber was introduced and proved to be very satisfactory. The shorter grades of fiber which would otherwise be wasted were used for the manufacture of paper and board. For several years, the product of this mill was sold through Rice Kendall of Boston, Mass. From 1881 to 1900, the H. W. Johns Company, of New York, took the entire product which was 30C to 700 tons per year. The latter company built their own asbestos paper mill at Brooklyn in 1900. Keasbey & Mattison Company, of Ambler, Pennsylvania, began to manufacture in 1897. Other early manufacturers were: the Asbestos Paper Company, at Baldwinsville, Mass„ and Mr. B. S. Binney, at Shirley, Mass. The number of manufacturers gradually increased until at present asbestos paper is manufactured by the following ten companies:"

Nov 1, 1919

In the last five years, new iron ore pellet plants have been built with significantly reduced air pollution levels compared to the older generation of plants. European and American pollution controls are more stringent that in China and Brazil. The recent American plants have successfully employed circulating fluidized beds for sulfur control, baghouses for particulate control, activated carbon injection for mercury and a new design of specialized low-NOx burners.

Jan 1, 2015

By J. A. Theron

"This paper provides guidelines on performing mass and energy balance modelling involving coal and coal derivatives. Usually, the inputs to a pyrometallurgical process would be specified in terms of elements and compounds. Reliable thermochemical data is more widely available for species involving uniquely defined, relatively smaller molecules. However, in the case of coal, the molecules are extremely large and not uniquely defined. Consequently, modelling processes involving coal and its derivatives have several potential pitfalls. These are outlined in the present paper. The main findings are as follows:•,Coal proximate analysis should not be regarded as absolute; it could vary with several parameters, including heating rate •,For modelling, the use of ultimate analyses should be considered a preferable option to proximate analyses, where, ‘fixed carbon’ and ‘volatiles’ are not defined in terms of chemical composition •,Significant errors could be made if the larger molecules are neglected during calculation of the calorific value (CV) of coal gas (the gas liberated when coal is heated in the absence of oxygen) •,For elemental analyses, the oxygen content (which is calculated by balance) should be checked to ensure it is within the expected range •,For representation of sulphur in coal, double-counting due to SO3 in the ash analysis should be avoided •,Potentially, oxygen in coal could be represented as O2, H2O, CO, or CO2; however, use of some of these species without considering the experimentally determined gross CV results in significant errors in the energy balance. If coal enthalpy is calculated from elemental analyses without correction, representation of coal oxygen as H2O(l) gives reasonable accuracy (up to 6.9% error for a set of South African coals). Coal volatiles could be represented by a complex mixture of compounds, even using different oxygen-containing species than the abovementioned four, provided the enthalpy is corrected •,It is recommended that an ‘enthalpy correction value’ is incorporated in energy balances involving combustion, devolatilization, or conversion of coal and coal derivatives, e.g. coke, char, or tar. That would imply that proximate analysis, elemental analysis, as well as the gross CV would be required for all solid or liquid coal-derived substances being modelled. No other correction due to the form of carbon being different than graphite should be used, as that would imply doublecounting some effects."

Jan 1, 2014