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By R. Melley, P. Wissner

The paper looks at the basic theory of tri-bological wear and the role played by the lubricant and its additives. It presents the argument that the “real cost of lubrication” is not the purchase price of the oil or grease, but rather the costs associated with not using the correct lubricant. A number of examples are presented, covering oils, greases and additives, in which a detailed evaluation of the application has shown that when all of the benefits of using the best lubricant/additive are evaluated, the savings achievable greatly surpass the incremental cost of the superior lubricant. One of the emerging classifications of costs in industry today are those associated with environmental protection. Two of the examples used describe the replacement of more conventional lubricants with environmentally acceptable products, compounded to compete in all aspects of serviceability, but which have the added bonus of being not only biodegradable but also of being of low toxicity.

Jan 1, 1997

By J. Phillip Mackey

A whole new group of non-ferrous pyrometallurgical processes with the ability to utilize tonnage oxygen and capture sulphur dioxide were developed and commercialized over the period 1940s–1980s. Many of these earlier process developments were undertaken with limited knowledge of the process chemistry and influence of key process variables; in many cases, piloting helped provide much new physico-chemical data, but gaps remained. The second generation versions of these technologies of today provide all the primary copper, nickel and lead produced worldwide by pyro-metallurgical smelting. Further, process development has continued and a new generation of copper and lead smelting technologies have also been developed in China since the 1990s. The older reverberatory and blast furnaces have been progressively replaced by the newer technologies—a good example being the introduction in 1992 of the copper IsaSmelt technology at the Mt. Isa smelter in Australia where the former fluid bed roaster and reverberatory furnaces were replaced by a single new smelting unit, together with an acid plant for sulphur dioxide collection. The development of these new technologies was made possible by investment in fundamental and applied research. The lesson for the future is, in order to sustain these improvements, continued investment in research and development capability is required—to do otherwise is to risk obsolescence and lack of competiveness in the world market. Dr. Peter Hayes at The University of Queensland is one of the many researchers and process engineers who have contributed to the fundamental understanding of metallurgical processes over this period of rapid change in technologies. The present paper briefly outlines some of the many contributions Peter Hayes has made to the understanding of kinetics, mechanisms and phase equilibria in metallurgical systems, and metallurgical process development.

By M I. Roberts

Corporate and workplace culture, as many owners, directors, executives and managers know, is by far the most powerful determinant of productivity. It’s much more significant than buildings and equipment. Yet although no one today would build a building or machine without a plan, few leaders have a plan for building and sustaining a safer and more productive culture.Using practical ways, culture can be planned and shaped as desired. Success requires implementing a project plan for changing the systems that drive behaviours that in turn shape attitudes. The combination of behaviour and attitude together with leadership largely shape culture.To improve performance, leaders need to:1. improve the organisational systems that drive behaviour2. action a project plan for improving specific performance metrics 3. demonstrate leadership that is conscious, disciplined, committed and passionate for purposeful use of human energy.This paper explains all three factors in practical ways with operational and corporate examples. It details understanding and applying the power of fundamental statistical analysis tools to recalibrate, focus and drive proactive leadership that takes responsibility for process improvement, supporting people and ensuring accountability.Experience and practical understanding of human and organisational behaviour confirm that the Measurement ? Analysis ? Reporting system combined with conscious leadership is by far the most powerful driver of behaviour. This wisdom produces profound changes in leadership style and behaviour. It develops outstanding leadership to create and sustain a safe and highly productive culture reliably producing consistently high quality products. It is the key to developing accountability, employee retention and a sustained competitive advantage.CITATION:Roberts, M I, 2016. Building safe, productive cultures and leadership, in Proceedings International Mine Management Conference, pp 163-178 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

By J. Paraszczak

Underground metal mining involves many challenges. Economic slowdown, tough international competition and sometimes volatile metal prices put constant pressure on mine operators to increase productivity and to reduce production cost. At the same time, countries such as Canada, the United States and Australia are experiencing skilled labor shortages that might even stall development of certain mine projects. Furthermore, some stages of underground production take place in particularly hazardous environments where the safety and health of miners is at risk. Automation of some processes in underground mining is one of the promising avenues to alleviate some of these problems. Loading and haulage are among the most critical operations and areas where implementation of autonomous vehicles has been targeted. However, although health and safety issues are a primary driver to opt for automation, the latter should ensure an acceptable level of productivity and pro?tability. With this in mind, this article focuses on the factors affecting operational effectiveness of autonomous underground loading and haulage equipment and the means to maximize it.

By A. G. Loomis

Although secondary-recovery methods have not been applied widely in California, it is apparent that increasing attention and effort must be given to this phase of recovery if the State is to maintain its high rank as a petroleum producer. Steadily increasing demands for petroleum products and decreasing rates of discovery of new oil fields and rapid depletion of existing reserves emphasize the prospect of an adverse situation of supply and demand in the not-far-distant future. If the trend of discoveries becomes more favorable or if more complete economic recovery of the oil in place can be obtained by secondary recovery, this situation can be averted. Not only are these reserves of economic importance to the petroleum industry to meet increasing market demands, but economic reclamation of such reserves is an important conservation measure, which will prolong the productive life of many fields" Accordingly, progressive operators in California are alert to the possibilities of secondary recovery and have done much to implement such operations wherever feasible. Most of the operations are of the pressure-maintenance type} in which the reservoir pressure is maintained or partly maintained by injecting natural gas to increase oil recovery. The possibilities of recovering additional oil from stripper fields by gas drive and water flooding (including water disposal) also are being tested in experimental field projects. Table 1 summarizes gas and water-injection projects in California.

Jan 1, 1952

Real gross national product increased at a larger-than- expected annual rate of 8.3 percent in the first quarter of 1984, with both consumption and investment spending increasing significantly in real terms (table 1). Residential and nonresidential fixed investment increased at annual rates of 25.7 and 14.6 percent during the first quarter of 1984, and investment in nonresidential structures, which declined in 1983, also increased during the first quarter of 1984, nearly attaining its 1982 level. The annual level of personal savings increased $27.7 billion, while the personal savings rate (the ratio of personal savings to disposable income) increased to 5.8 percent during the first quarter. The increase in the personal savings rate comes as welcome news to analysts concerned over the flow of loanable funds to the private sector and the impact on interest rates in 1984 of increased private and Government demands. U.S. Minerals Industry Performance A major upswing in the performance of the metal mining sector occurred during the first quarter of 1984, with production increasing almost 11.2 percent from January to March, The recovery of the metal sector is also reflected in the performance of primary metal industry profits, which were positive during fourth quarter 1983 following seven consecutive quarterly losses (table 1). Two thousand nine hundred more metal mining production workers were employed in February 1984 than in February 1983.

Jan 1, 1984

By Mitchell L. Spencer, Viswanathan Panchanathan

"Bonded magnets are important category in permanent magnets. They are made by one of the following processes: compression bonding, injection molding, extrusion, calendering. An overview of the various bonded magnet processes and properties of products made with different magnet materials along with their applications are discussed. The main emphasis will be on the use of bonded NdFeB and ferrite magnets.IntroductionBonded magnets are a major growth area in permanent magnets. Bonded magnets are made by any one of the following processes: Compression bonding; Injection Molding; Extrusion and Calendering [1,2]. Compression and injection molded magnets are rigid magnets. Materials used in calendering process produce flexible magnets. Only the extrusion process makes both rigid and flexible magnets. The binders used for the bonded magnets vary depending on the processes. Thermoset, thermo-plastic and elastomeric binders are respectively used in compression, injection and the calendering process. Extrusion molding uses elastomers or thermo-plastic materials. The most co=on magnetic materials, Ferrite, SmCo, Alnico and NdFeB can be used in any of the above processes either alone or in combination as hybrid magnets. Another material that has been developed for co=ercial application is SmFeN. Making the material has been challenging and it is being used in niche market applications in limited quantitiesIn the extrusion process, a highly loaded compound is used to produce strip or sheet and is continuously extruded through a die. In calendering the granulated compound is rolled to produce a continuous wide sheet. In the compression bonding process a uniaxial pressing force is used. These magnets have higher loading compared to injection molded magnets. In injection molding the material is forced into a mold cavity and has lower loading compared to compression molded magnets [2,3]. Most of the flexible magnets are made using extrusion and calendering processes and the most co=on magnet material is inexpensive ferrite. Flexible magnets have been made using rare earth materials, but on a very limited basis.The major advantages of magnets processed by extrusion and calendering are as follows: inexpensive tooling, automation; practically any 2D geometry; fast production rates; no chipping or breaking; a wide range of properties; on-line magnetization; easy to convert (e.g. cut, punch or shape).Compression bonded magnets are inexpensive to manufacture. They have higher magnetic properties compared to injection molded magnets; however lower than their sintered counterparts. The magnet shape is restricted to simple geometries and they require careful handling. Their isotropic nature allows complex magnetizing patterns."

Jan 1, 2013

By Elwyn H. King, Thomas R. Kuesel

I. CONCEPT MARTA's Peachtree Center Station is being mined out of hard rock, directly beneath Atlanta's central business district, with minimal surface disruption during construction. Its cost is competitive with that of a conventional cut-and-cover alternative owing to its design concept, which utilizes the rock as a primary structural and architectural material. II. PLANNING The station was originally planned for cut-and-cover construction. However, Peachtree Street is unusually narrow for a main business street (generally 78 feet (24 m) between building lines) and cut-and-cover construction would therefore be very disruptive to surface traffic and severely restrict access to adjacent buildings, including Peachtree Center, Atlanta's showcase business/commercial complex. (See Fig. 1.) Tunneling had been considered, but was initially thought [ ]

Jan 1, 1979

By B. M. Harra, O&apos

Zinc smelting is frequently termed a backward art. The term is hardly true, for great progress has been made in recent years in the design and in the thermal efficiency of the retort furnace, in the quality of retorts, in the recovery of zinc, and in the ability to treat more impure and complex ores. The fact remains, however, that the peculiar physical and chemical properties of zinc have delayed such immense advances-large smelting units, high recovery, low-unit costs, and ability to treat low-grade ores-as have been made in the metallurgy of lead and copper. In current retort-smelting practice, the ores, if carbonates, are calcined to remove carbon dioxide; or, if sulphides, are roasted to remove sulphur. The sulphur must be eliminated as completely as possible, usually to less than 1 per cent. This means that the roast must be continued for a long time at a high temperature, with resulting high cost and small capacity per furnace. The roasted ore is mixed with about 50 per cent of its weight of reducer, which may be fine coke, anthracite, or nonbituminous coal. This mixture is charged into horizontal fire-clay retorts. The retorts used in this country are about 8 inches in internal diameter by 4 feet in length and hold 50 or 60 pounds of ore. The diameter of the retort is limited by the time required for the heat to penetrate to the center of the charge; the length by the strength of the retort, which at the high temperature employed can not support the weight of the charge if the span is more than about 50 inches. The retorts are heated externally by coal, natural gas, or producer gas to a temperature of 1,200° C. or more. The zinc oxide is reduced to zinc, which is volatile at this temperature, and passes into a conical fire-clay condenser attached to one end of the retort, where it condenses to liquid zinc and is removed. Twenty-four hours are required for distillation, and because of the low heat conductivity of the retort walls and of the ore charge itself, the heat efficiency even of the most modern regenerative furnaces is only about 12 per cent. The retorts have a short life, 30 to 60 days, at the high temperature required; zinc

Jan 1, 1923

By P. J. Mackey

A whole new group of non-ferrous pyrometallurgical processes with the ability to utilize tonnage oxygen and capture sulphur dioxide were developed and commercialized over the period 1940s–1980s. Many of these earlier process developments were undertaken with limited knowledge of the process chemistry and influence of key process variables; in many cases, piloting helped provide much new physico-chemical data, but gaps remained. The second generation versions of these technologies of today provide all the primary copper, nickel and lead produced worldwide by pyro-metallurgical smelting. Further, process development has continued and a new generation of copper and lead smelting technologies have also been developed in China since the 1990s. The older reverberatory and blast furnaces have been progressively replaced by the newer technologies—a good example being the introduction in 1992 of the copper IsaSmelt technology at the Mt. Isa smelter in Australia where the former fluid bed roaster and reverberatory furnaces were replaced by a single new smelting unit, together with an acid plant for sulphur dioxide collection. The development of these new technologies was made possible by investment in fundamental and applied research. The lesson for the future is, in order to sustain these improvements, continued investment in research and development capability is required—to do otherwise is to risk obsolescence and lack of competiveness in the world market. Dr. Peter Hayes at The University of Queensland is one of the many researchers and process engineers who have contributed to the fundamental understanding of metallurgical processes over this period of rapid change in technologies. The present paper briefly outlines some of the many contributions Peter Hayes has made to the understanding of kinetics, mechanisms and phase equilibria in metallurgical systems, and metallurgical process development.

By R. A. Friedel

THE IMPORTANCE of infrared and ultraviolet-visible spectrometry in studies of the structure of coal and similar substances is described. Special experimental techniques have been developed for these studies. Thin sections of coal are preferred, but halide pellets are easier to prepare. Information obtained from infrared spectra on chemical functional groups has been discussed; the importance of both intensities and wavelengths of absorption bands has been emphasized. Functional groups assigned include aliphatic and aromatic CH, methylene and methyl groups, hydrogen-bonded hydroxyls, hydrogen-bonded and chelated carbonyls, phenolic structures, minerals, and aromatic structures that are benzenoid or polynuclear. Infrared studies of structures of coal extracts, distillates, and reaction products of various processes, both chemical and physical, are discussed. Coallike infrared spectra of chars of model compounds have been utilized extensively in studies of coal structure. Ultraviolet-visible absorption spectra of coals show a lack of fine structure and low spectral intensities. These results have been applied to the questions of the chemical and physical structure of coal, particularly the question of polynuclear aromaticity of coals. The color of coal is also treated. The physical-chemical origin of the color of coal may be due to free radicals, as interesting correlations of ultraviolet-visible spectra with electron paramagnetic resonance have been obtained. The optical color of coal has been explained and simulation of the color changes observed in thin sections has been carried out, The spectra and structure of coal derivatives and other carbonaceous materials are also discussed. Possible sources of error in absorption spectral measurements are pointed out. Limited measurements of the ultraviolet-visible reflectance spectra of coal are described.

Jan 1, 1967

By Han Jie

The results of full scale plate load tests on stone columns on soft clay in coastal areas are presented in this paper. Four load tests were made, two of which were performed on the ground treated with stone columns, one on an isolated stone column and the last one on the untreated ground. For a given stress range, the settlement of the rigid plate, the stress concentration factor, and the excess pore water pressure were measured. It is found that the distribution of vertical stress beneath the rigid plate supported by the composite ground of stone columns is very different in shape from the one by the untreated ground, that the stress concentration factor has a relation with the stress level and time, that the stone columns increase the bearing capacity up to by 2 times, and that the ground stabilized by stone columns is of great advantage to keep the foundation stable.

Jan 1, 1991

By A. G. Fonseca

The effects of coal cleaning, coal combustion and flue gas particulate removal systems on the partitioning of 12 trace elements were investigated. This study was prepared to help document the fate of trace elements in modern coal preparation plants and coal-fired utility boilers. The coal cleaning data were obtained from several coal preparation plant operations. The CONSOL 1. 5 MM Btu/hr pilot combustion and electrostatic precipitator (particulate removal system) test facility was used to develop the combustion systems data. A comparison with the very limited amount of published data from utility boilers is presented.

Jan 1, 1993

By H. W. Gillett

Unlike most previous Howe lecturers, I had not the good fortune to be associated with Henry Marion Howe, nor to be directly one of his students. Yet, through his writings, he has been my teacher, as he has of all American metallurgists. Instructive as his writings are—I use the present tense because Howe thought so keenly and reasoned so surely, seeing clearly, as if by intuition, what was hazy to lesser minds, that his writings are still vital—it is not those books and papers, nor even the minds he trained in his classes, that were his most outstanding service. It was the spirit of Howe in his approach to the problems of metallurgy, his broad-mindedness and fairness, his recognition of the need for theories and hypotheses to explain metallurgical phenomena, his willingness to use them as servants, as well as his questioning attitude—his refusal to accept them as masters—that comprise his greatest service. This most thoroughly warrants the honor the Institute pays each year to his memory. These traits I so respect and honor in any man that I glory in this opportunity to do reverence to him in whom they were so notably united. Howe's Discussion of a Creep Problem I have often wished that Howe were still with us to turn his keen insight upon the problems of the use of metals at high temperatures, a field much studied but still very hazy. Indeed, 53 years ago, in a paper1 before this Institute, Howe stated a problem closely allied to some that still perplex metallurgists and engineers dealing with the high-temperature field. Howe was intrigued by a report2 from another old master, Robert Henry Thurston, on the behavior of annealed vs. cold-drawn iron wire, and in order to broaden the foundation for metallurgical generalization, Howe made experiments of his own on copper and silver. In these tests by Thurston and by Howe, the wires were rapidly loaded to determine the

Jan 1, 1939

By L. C. IlsLey, H. H. Clark

In various publications relating to safety in mining the Bureau of Mines has called attention to the hazards attending the use of openBame lamps. An open-flame lamp is a potential source of danger in any coal mine. It may start a fire in a dry mine or an explosion in a gaseous mine. The type of open-flame oil lamp now used in mines is the product of long evolution; its principal merit is simplicity. That such a light is unsafe in an atmosphere containing gas (methane) is evident, and Sir Humphrey Davy immeasurably increased safety in coal mines when he found means of protecting a lamp flame so that it would not readily ignite gas. The safety lamp, however, gives less light than the open-flame lamp, is not as simple in construction, is more cumbersome, and must De carried in the hand .. Consequently, some miners are reluctant to abandon the open-flame lamp for the safety lamp, and risk their own lives and the lives of their fellow workers with the one rather than to be hampered by the other. When small electric bulbs, with their clear, white light, and small electric storage batteries became available, the advantage of combining these elements for a miner's lamp seemed manifest. The combination looked simple and safe, but was soon found to have elements of danger and weakness peculiar to itself. The Bureau of Mines showed, in 1911, that the breaking of a miniature electric bulb in an inflammable mixture of gas and air might ignite the mixture, so that only the fragile glass of the lamp bulb might stand between the miner and injury or death. There Was also a possibility that sparks from the small battery would ignite gas, and the accidental spilling of the contents of a battery on the miner's clothing or skin was a possible source of injury. The first portable electric miner's lamps that were carried in the hand, or with the battery strapped to the back and the light carried on the head, were exceedingly crude and were designed without appreciation of the sources of danger. The possibility, however, of producing a safe and practical miner's lamp by the proper combination and design of the elements available promised to increase safety so greatly that the Bureau of Mines attemr>ted to stimulate better design and construction by careful investigations and the establishment of an approval system that would be an assurance to the miner and an advantage to the maker of the lamp. As a result various manufacturers submitted types of lamps, cords, and bulbs for test and cooperated with the bureau in efforts to so improve the safety features of these devices that the lamps would P&$ specific tests for approval.

Jan 1, 1917

By David W. Tongue

This report describes the engineering work leading to the design of an underground coal mine piping system to transport approximately 2,000,000 cubic feet per day of methane gas to the surface from degasification holes drilled horizontally into the coalbed in existing coal mines. Safety instrumentation for detection of gas leaks and provisions for automatic emergency shutdown are included in the design. It also includes specifications for a safe system of handling gas, water, and drill cuttings during drilling of the horizontal holes and recommendations for compressor and metering facilities at the surface. The main pipeline is recommended to be constructed of polyethylene plastic pipe joined by a butt fusion method while lateral lines and separator and meter piping at the horizontal holes are recommended to be screwed steel piping. The materials used are to be resistant to the forces of impact exerted by falling rock. The pipelines are to be suspended from the ceiling with pipe hangers. All steel components are protected from chemical corrosion by applying protective coatings and the vertical casing to the surface is protected from electrolytic corrosion by a rectifier station. Methane gas detectors monitor the mine atmosphere to detect the presence of gas leaks and a pneumatic plastic tubing line provides for control of the safety shutdown system. Both the recommended design and the required construction procedures are in compliance with the applicable Federal codes for coal mine safety.

Jan 1, 2012

By Richard G. Stearns

Extensive thick lignite apparently lies within 250 feet of the land surface in Dyer, Lake, Lauderdale, Obion and Tipton counties. Information on geology, land use, soils, groundwater and instability is compiled, along with a bibliography. A test and monitoring site was investigated at Fort Pillow Prison in Lauderdale County. Analyses were made of lignite, overburden, associated water and leachate. Lignite has high BTU (about 7800) and low sulfur (1.1% avg.). A year or more of data are presented on rainfall, water levels, and chemistry of surface water, groundwater, leachate and water from test pits. Main potential environmental problems are quality of surface water, and possibly shallow groundwater. The main aquifer of the region will likely be un-affected by mining. Low transmissibility of shallow aquifers will minimize lowering water levels of wells. Soil reclamation and conservation should be readily accomplished, Dangerous earthquakes have a low probability and mines are not significantly more hazardous than steep bluffs.

Jan 1, 1981

By Christopher Mark

This proceedings volume contains papers presented at W U.S. Bureau of Mines (USBM) technology transfer seminars on New Technology for Longwall Ground Control. These seminars were conducted in Washington, PA, on April 12, 1994, and Denver, CO, on May 10, 1994. The papers herein describe several new, highly practical USBM technologies now available for ground control in longwall mines, including lie Coal Mice Roof Rating (CMRR), cable bolts, the MULSIM/NL model, and the Wood Crib Performance Model. Other significant topics addressed include longwall panel layout, coal pillar design, horizontal stress in longwall mines, roof support selection for gate entries, and ground control monitoring.

Jan 1, 1994

By J. Hoover

"IntroductionThis chapter will discuss the operational and maintenance aspects of a heavy media cyclone circuits as applied to coal processing and using magnetite as the media. It deals with heavy media bath separators in terms of types of media, equipment, circuits, media recovery, maintenance, and product handling. It will detail heavy media cyclone operation and supplement the previously described topics.The heavy media cyclone was first developed in the Netherlands by the Dutch State Mines in 1945. A cyclone plant was not built in North America until 1961. Traditionally, heavy media cyclones have been used to treat size fractions between 1lz in. (12 .6 mm) and 35 mesh (0.5 mm). High maintenance related to heavy media bath separators has recently prompted some plants to crush all raw coal to minus 2 in. for treatment in heavy media cyclones.The heavy media bath separators utilize only the force of gravity to make the separation between heavy and light particles. This requires lengthy retention time which can lower capacity and also is inefficient for finer particles. A heavy media cyclone utilizes centrifugal forces which are 20 to 200 times greater than the force of gravity. This means the separation between coal and the impurities occurs very quickly, therefore a low retention time is required allowing cyclones to have high tonnage capacities. Also these greater forces allow better separation for the finer particle sizes.Heavy media cyclones are now widely used to produce both metallurgical and thermal coal. Work is in progress to reduce magnetite consumption, extend wear life, increase tonnage capacity, improve separation efficiency and automatically control these cyclone circuits."

Jan 1, 1989

By R. O. Burt

The original flowsheet of the TANCO mill consisted of a simple two-stage gravity circuit for the recovery of the tantalum concentrates. With decreasing grade and grain size of the tantalum minerals, considerable modifications to the circuit have been required. This paper discusses the various recent improvements carried out 011 all stages of the flowsheet, which have resulted in a 10% increase in recovery. Future improvements, including on stream analysis, and the possibility of tantalum flotation , are also discussed.

Jan 1, 1979