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By J. Alexis, G. Ye, E. Burström

Over the past twenty years the 3 MW DC arc furnace at MEFOS has been frequently used for development of new processes. These processes include recovery of valuable metals from slag, sludge and dust from steel and other metallurgical industry, treatment of ashes from power plant and incinerators, smelting reduction of minerals and zinc recovery from EAF dust. The process characteristics of the DC arc furnace operation in terms of: ? selective reduction, ? total reduction, ? process stability and flexibility, ? dust carry-over, ? thermodynamic conditions provided in the hot spot area, ? precision in composing slag products These are analysed and described in this paper based on technical results from selected test campaigns over the years and thermodynamic considerations. The electromagnetic properties of DC arcs beneath the electrode have been studied by CFD simulation. The calculated result enables us to understand some interesting technical phenomena observed. The heat balance has also been considered based on data obtained from test campaigns and heat balance calculation.

Jan 1, 2004

By F. Patisson

During exothermic gas-solid reactions, heat generation makes temperature rise and modifies the rate of the various mass transfer processes, namely the chemical reaction itself, the pore diffusion and the external transfer. We have investigated this thermal effect during the oxidation of zinc sulfide porous pellets in a thermo balance furnace, between 550 and 900°C-and under O2-N2 atmosphere. The results have been' analyzed by using, firstly, the law of additive reaction times derived from the isothermal Grainy Pellet Model, and, secondly, a new numerical model taking into account non-isothermal conditions. Both the models can satisfactorily simulate conversion versus time, but the numerical model also depicts the temperature evolution within the pellet. Finally it is shown that owing to the heat generation the zinc sulfide oxidation takes place under diffusion control (3/4 internal, 114 external) in all the cases studied. During the course of reaction, the. pellet undergoes strong temperature variations, with thermal gradients confined to a shell oxide layer.

Jan 1, 1996

By S. K. Sahoo, S. K. Sharma, U. K. Singh, G. S. P. Singh

This research focuses on the strata control issues in a Bord and Pillar depillaring working under the influence of dead load condition of voluminous and fragmented softcover of overburden dump material. It reports the modeling of a mine working through the FLAC 2D software under the Indian geo-mining conditions. The modeling results of an actual mine working under softcover were compared with that under the intact overburden condition to assess the influence of the soft overburden over the depillaring working. The modeling work involved progressive caving of the strata and the cyclic goaf filling following the modelsimulated occurrence of main fall and periodic caving. Mohr-Coulomb Failure criteria along with a simplified strain-softening (MCSS) model was used to study the failure and caving mechanism. Salamon’s compaction model was used to simulate compaction and resultant stress recovery in the goaf material. Comparison of the model findings was done in terms of load on supports, abutment stress, and convergence, apart from the stress redistribution and failure mechanism. The load transfer mechanism of the soft overburden was also studied for an overall understanding of the strata behavior in such workings.

Jun 16, 2020

By Alper Kirmaci, Taghi Sherizadeh, Dogukan Guner, Samuel Nowak, Khaled Mohamed, Morgan Sears

Coal ribs present a major safety hazard in underground mines, and there is currently no unified approach for their design in the United States. To tackle this issue, this study investigated the stability of underground coal pillar ribs under development load. Utilizing over a thousand 3DEC models, a framework for calculating coal pillar rib rating (CPRR) was developed. A detailed step-by-step method was outlined for computing the CPRR based on a 3DEC analysis, which was then validated with various 3DEC models, demonstrating a strong correlation between the two models. The results demonstrated that the rib factor of safety (RibFOS) under development load is directly proportional to CPRR, coal mine roof rating (CMRR), and floor strength, and inversely proportional to the overburden depth and rib height. Moreover, a regression equation was formulated to predict the RibFOS based on the aforementioned parameters. Furthermore, empirical relationships were developed between the RibFOS and the applied primary rib support density (PRSD) in U.S. coal mines. To ease the calculations, a stand-alone application, Design of Rib Support (DORS), was developed. This application can be used to assess rib stability and easily calculate CPRR, RibFOS, and PRSD.

Jul 1, 2023

By W. C. McClain

In the design of underground excavations, rock mechanics considerations are nearly always based on an elastic behavior of rock. Most rocks do exhibit a certain amount of elasticity, and the application of principles and concepts of elasticity to rock mechanics problems has been largely responsible for progress in the field over the past 10 or 15 years. No doubt the theory of elasticity will remain the most useful analytical tool available for both the design of underground openings and the interpretation of phenomenological data.

Jan 1, 1967

CONTENTSIntroductionNorthern ExplorationDrive ConceptionGeneralDriving CrewDrive Cross Section and Track DetailsVentilation by Electrically Driven FanTemperatures and HumidityFan PerformanceRock Drill Carriage and Rock DrillsStandard Drilling RoundElectric Firing from Power MainsExplosives and DetonatorsCharging and FiringMechanical Loading and Electric HaulageOperating CycleStatisticalEquipmentAcknowledgementINTRODUCTION.The driving project described in :this paper is one of greater magnitude than usual for the Broken Hill field, and in the execution of the work a departure was made from long-established local practice by the introduction of mechanisation. The primary object of the drive is to provide sites for gaining information regarding the behaviour of the ore-bodies well beyond the limits of the present exposures.Due to thermal conditions, the major portion of the work was done on a six-hour shift basis, in contrast to the normal one of seven hours, with a five-day week.

Jan 1, 1946

By O. G. Olvera, L. S. Quiroz-Castillo, P. J. Valenzuela-Guerrero, D. G. Dixon

The effect of sulfuric acid concentration on the extractions of arsenic and copper in the catalyzed batch leaching of an enargite concentrate was studied. The acid concentrations studied were 60, 45, 30 and 15 g/L. The experimental series yields maximum copper extractions of 96 to 98% in an interval of 81 - 185 h leaching time for 60 - 15 g/L initial sulfuric acid concentration; all the copper extractions plateaued after these values; the rates and plateaus of copper extraction are increased with higher acid concentrations. Arsenic extractions reached maximum values of 89% in 57 hours, 57% in 49 hours, 33% in 25 hours, and 25% in 112 hours respectively; these maximum values were followed by a steep decrease in arsenic concentration, which indicates a precipitation event occurs in the process. According to the literature and process conditions, the arsenic precipitates obtained are iron arsenates similar to scorodite. The stability of the residues was tested using the Toxicity Characteristic Leaching Procedure (TCLP) from EPA; the residues for the four concentration levels passed the TCLP test, reporting arsenic leaching values below 1 mg/L.

Jan 1, 2014

By P. F. Stratton, M Huggahalli, N Saxena

"Several studies have been carried out to determine how the optimum atmosphere conditions in the heat treatment of metals can be established for a given product by using different gas injectors and varying atmosphere flow rate and composition. The most common approach taken to gain insight into furnace atmospheres has been to use commercial computational fluid dynamics codes and examples of their use are shown. However, the complexity of these codes, the difficulty in establishing boundary conditions, their cost and computational demands limit their usability in solving day-to-day production problems.A simplified, web-based model of a furnace atmosphere is described where the conservation equations are solved to determine the composition profiles of the atmosphere in the furnace. Although the model is restricted in scope to certain types of furnace, it is shown to give better results than CFD when boundary conditions are uncertain. The application of the model to the understanding of existing furnace conditions and to determining ways of optimising the use of gases are discussed. IntroductionThe important role of protective atmospheres during heat treatment of metals, furnace brazing of assemblies and soldering of printed circuit boards is well established. The atmosphere in the furnace prevents air ingress and oxidation of the parts, helps flush away any flux or binder from braze and solder pastes and provides an important mode of heat transfer [1]. In a batch furnace having typically one or two gas injectors, the gas utilisation and process can be optimised by minimising air leaks and mantaining atmosphere homogeneity with fans or other atmosphere circulation techniques. In a continuous furnace, however, atmosphere optimisation is more difficult as furnace inlets and exits can also let in air. The atmosphere requirements of different stages of heat treatment, brazing or soldering vary [2]. Achieving these atmospheres in different sections of the open-ended furnace is a relatively complex task. Methods such as atmosphere zoning and the use of physical curtains and gas injectors have evolved with time, though it is hard to predict how effective these techniques will be for a given furnace and process. Experts in the field tend to rely on experience and rules-of-thumb rather than scientific method to achieve the required results."

Jan 1, 2001

By S C. Dominy

Gravity amenable gold ores are those that after comminution produce liberated particles, composites and/or carriers that can be recovered by gravity separation means. Recovery depends upon mineralisation type and the comminution and concentration method used. Any in situ ore with more than 20 per cent of gold greater than 100 µm in size is likely to have a strong gravity recoverable component. A less traditional approach is where the gold is sulfide-locked and the gold carrier plus any liberated gold is recovered via continuous gravity recovery following fine crushing. Specific tests are undertaken to determine the level of gravity amenable gold within a deposit. The principal methodology is the gravity recoverable gold (GRG) test, which consists of three sequential liberation and recovery stages. For continuous gravity recovery (CGR), the sample is fed over a laboratory Wilfley table to simulate continuous recovery of the gold. Tails from the feed can be progressively re-ground and re-tabled to develop a grade-recovery curve. Primary geology and gold particle size-distribution have a strong effect on the mass of sample required to provide representative results for both tests. Where low-grade ore contains very coarse gold, substantially larger sample masses are required. Experience has shown that GRG and CGR values can vary throughout an orebody, particularly within different geological-grade domains. A testing regime must consider sample frequency and support.

Sep 5, 2011

By P. R. Taylor

Three refractory gold concentrates have been tested to evaluate the effect of roasting with hydrated lime followed by cyanidation. The results indicate that it may be possible to roast in such a manner as to contain nearly all of the sulfur, arsenic and antimony in the roaster calcine. Cyanidation results indicate that the gold recoveries are greater than 80% for all three concentrates.

Jan 1, 1993

By James Dickson

Brief History of Discovery and Early Development In the first half of the nineteenth century, the only authority on the Pacific coast between the Columbia river and Alaska was exercised by the Hudson's Bay Company, who had established a series of forts and trading stations on the coast from the Columbia north to Millbank sound. The Hudson's Bay Company were chiefly interested in the fur industry, and the large influx of settlers from the eastern United States into the territory now known as the States of Oregon and Washington, about 1840, not only interfered with the fur business but involved the question whether the territory should be under the British or the American flag. Anticipating the possibility, later realized, of losing control of this area, the Company, in 1845, established their main fort and trading centre on the southern end of Vancouver island under the name of Fort Camosun; shortly afterwards changing the name to Fort Victoria. Realizing that their former policy of discouraging all attempts to develop any other business than the fur industry had lost them several hundred thousand square miles, the Hudson's Bay Company now set about encouraging settlers in the vicinity of Fort Victoria by disposing of lands to suitable parties and also to those in the employ of the Company. The usual pioneering stage was passed through with the starting of small sawmills, grain mills, etc., and the incidental work accompanying such efforts. Any coal required for blacksmithing or other purposes was brought from England around Cape Horn by the few ships that visited the Pacific Coast. About 1849, an Indian who was having his gun repaired by a blacksmith in Fort Victoria asked about the "black stones" used in the fire and, on being told that the "black stones" had to be brought a great distance, he informed the blacksmith that there was plenty of the same stone where his people lived. This information was immediately given to an official of the Hudson's Bay Company who talked with the Indian and told him that if he would bring some of the "black stones" he would get his gun repaired free and a present of a bottle of rum. Nothing more was heard of this coal until April of the following year, when the Indian came into Fort Victoria with his canoe loaded with coal, which was tested and found to be of good quality. It is reported that the Indian got his bottle of rum.

Jan 1, 1935

By Cyril Wells

THE diffusion of carbon in gamma iron plays an essential role in many metallurgical processes. In carburizing, in graphitizing, in homogenizing, in the formation of pearlite from austenite, and in other processes, migra-tion of carbon in gamma iron occurs.1,2 A full understanding of the rate at which these processes occur obviously requires a knowledge of the rate of diffusion of carbon. In carburizing, for example, the depth of carbon pentration is determined by the carbon concentration in solid solution at the surface, and by the rate of diffusion inward of the carbon. Until reliable data on the rates of diffusion of carbon are available it is unlikely that a full quantitative description of this process will be obtained. In the formation of pearlite from austenite, the segregation of carbon and alpha iron from the austenite obviously requires the diffusion of carbon; the rate at which pearlite nodules grow is evidently controlled at least in part by the rate of diffusion of carbon; it is unlikely that we shall understand the factors that determine the rate of growth unless data on rates of diffusion of carbon, and the variation of these with com-position, grain size, and temperature are available. Accordingly it was decided: (1) to determine, more accurately than hitherto, the diffusion coefficients of carbon in austenite over a wide temperature and a wide concentration range, (2) to study the influence of grain size and impurities on this diffusion coefficient, and (3) to study the effect of manganese and nickel on the rate of diffusion of carbon in the austenite of manganese and nickel steels, respectively; the influence of carbon on the rate of diffusion of manganese and of nickel will be made the subject of later papers. The rate of diffusion of carbon in gamma iron has been studied by Runge3 by Tammann and Schönert4, by Bramley and co-authors,5-14 and

Jan 1, 1940

By Lv Guozhi, Ren Xiaodong, Liu Yan, Dou Zhihe

"This paper investigated a new desulfurizer, dolomite and ferrosilicon. Magnesium vapor produced by silicothermic reduction of dolomite and ferrosilicon in an immersion tube of molten iron was injected into the molten iron by carrier gas through the underpunch of the tube and desulfurization reaction occurred. In order to explore the desulfurization process of molten iron by the new desulfurizer, the thermodynamics, and experiments of magnesium vapor production and desulfurization have been studied. Through thermodynamic calculation, the reaction temperature of magnesium vapor production by 75ferrosilicon and light-burned dolomite is 1838K in the standard state and decreased with the decreasing partial pressure of magnesium vapor, PMg· When PMg=25kPa, the reaction happens at 1673K. From experiments of magnesium vapor production, reduction efficiency of Mg vapor is about 60 % in 15 minutes at 1673K. From hot metal experiments, the desulfurization efficiency is 89.35%, and the lowest sulfur concentration after desulfurization is 46ppm.IntroductionPretreatment desulfurization of hot metal has become a necessary step in modem optimizing steelmaking process for its cheap cost, which can not only liberate of blast furnace productivity and reduce the burden of produce steel, but also effectively improve overall economic efficiency of the iron and steel system[l-ZJ_ At present, injection magnesium particle is one of the two main methods of desulphurization in hot metal owing to its strong affinity for sulphur, low amount of slag produced, low iron loss in slag skimming and low equipment investment[3l. However, there are still some insufficiencies on the hot iron pretreatment with magnesium particles at present[4-5l"

Jan 1, 2013

By Allan E. Hall, Stephen G. Hardcastle, Lucien D. Nel, Jean-Paul Saindon

A description is given of the investigation conducted at Sherritt Gordon's Ruttan Operation in Manitoba during 1986. Gas and dust concentrations were measured in the exhaust air of the major working sections to assess the potential for recirculating exhaust air into the intake air in winter to reduce heating costs. The results indicate that there is excellent potential to significantly reduce winter heating costs by controlled recirculation of exhaust air. Gas and dust concentrations vary significantly during the working shifts but have consistent trends from shift to shift and day to day. The variations in gas concentrations have similar trends but no single gas could be reliably used to predict the variation of the other gas or the dust concentrations. Dilution and the other effects which reduce pollutant levels as the exhaust air returns to surface indicate that recirculation should take place as close to surface as possible, subject to the economic constraints of the airway construction required and the extra fan energy required for the longer recirculation path. Recommendations are made for the choice and positioning of air and dust monitoring sensors and the logic of a control system. Economic analysis of the results indicates that controlled recirculation is viable at an existing mine with a pay back period of approximately two years. Incorporation of a system into a new mine at the planning stage would significantly shorten the pay back period.

Jan 1, 1987

By M. Nambiar

Due to the remote locations of mining projects and the need for long transmission lines to provide electrical power, mining sites often operate with poor network power quality and low short-circuit capacity. To cope with this situation, more and more mining operators are considering the installation of appropriately designed synchronous condensers together with power factor correction and harmonic filter systems (PFC & HFS). The installation of such power quality equipment is viewed as a technological advancement in the mining application. An adequate level of short-circuit power is essential and has to be ensured for the safe and reliable operation of especially large cycloconverter-driven gearless mill drive systems (GMDs) used for grinding. This paper explores the impact, technical advantage and reasoning for the selection of this advanced hybrid technology to cope with the power system challenges of future mining projects. It also delves into the potential problems and how to address them.

By J. A. Drozdiak

In this paper we examine, through pilot-scale testing, the possibility of operating a circuit comprised of two stages of HPGR comminution, followed by grinding through a horizontal stirred mill. In order to assess whether the novel circuit design could achieve the reduced energy requirements indicated in the literature, two more-established circuits, a cone crusher / ball mill and an HPGR / ball mill, were examined using a combination of testing and flowsheet simulation. The results showed that, based solely on the specific energy requirements for comminution, the HPGR / stirred mill circuit achieved a reduction of 9.2% and 16.7% over the HPGR / ball mill and cone crusher / ball mill circuits, respectively.

Jan 1, 2012

By G. Ferrara

During several years of operation in Europe, South Africa and other countries, the Tri-Flo has demonstrated to represent a substantial improvement of the dense medium dynamic separation systems. The reasons are: (1) high sharpness separation due to the multistage system and the application of new concepts in designing the regeneration circuit and controlling the medium rheology; (2) the possibility of performing two cuts at different densities using a since separation device and a single regeneration circuit. The paper discusses in detail the above mentioned points, with particular reference to the multistage technology, based on the circuit analysis theory, and to the control of the medium rheology based on recent work in the modelling, and simulation of the rheological behavior of dense suspensions.

Jan 1, 1993

By J. E. Udd, L. P. Geldart, B. B. Dhar

"Solutions for the stress distributions around simulated underground openings have been limited to calculations of boundary stresses for simple openings in which the boundaries may be expressed in mathematical terms. Studies involving circles, ellipses and ovaloids are re-ported in the literature.The stresses on the boundary of an opening and those at a distance from it in the medium are of concern to the engineer. The former may be related to the greatest concentrations of stresses encountered; the latter have a bearing on the identification of the ""zone of influence"" of the opening.Recent advances, in the form of a derivation for the stresses at a distance from an opening of elliptical shape, together with a solution derived previously for stresses in depth around ovaloidal openings, have been combined with computer programming techniques to provide complete solutions for a wide range of cases and variables. Some typical results which, it is hoped, may have some application to the design of underground openings are given herein."

Jan 1, 1970

By Liming Yuan, Wei Tang, RICHARD THOMAS, DAVOOD BAHRAMI

The location and orientation of fire suppression nozzles is critical in suppressing mobile mine equipment fires. To effectively suppress such fires, optimization needs to be considered for the suppression nozzle locations and discharge angle. Detailed experiments were conducted to study the effectiveness of fire suppression agents with different nozzle configurations. A variety of fire suppression systems including dry chemical, wet chemical, dual agent (dry and wet chemical), carbon dioxide, and water mist were used. Six types of nozzle locations were studied, and their fire suppression effectiveness were compared. Results from this work highlight potential considerations when determining effective fire suppression designs.

Feb 1, 2025

The Particulate Mineralogy Unit has been established at the College Park, Maryland, Metallurgy Research Center. The Particulate Mineralogy Unit will have the responsibility within the Bureau of Mines for the characterization of particulate minerals which have potential for adverse environmental effects. The Unit will provide a focal point for identifying particulates in connection with environmental problems related to the activities of agencies such as OSHA, HEW, EPA, and MESA. The Particulate Mineralogy Unit is seeking to clarify the ambiguities surrounding the mineralogy of and terminology used for asbestiform minerals and other mineral particles. The Unit?s investigations of the morphology, composition, and structure of asbestiform minerals and their nonasbestos analogs have made its members recognized experts in this field. The information which it develops on the characterization of asbestos and other particulate mineral forms such as silica should provide a technically rational basis for decisions by regulatory agencies. Those desiring further information, contact Dr. W. J. Campbell, Program Coordinator, College Park Metallurgy Research Center, College Park, MD 20740, telephone: 301-344-4014. ALUMINUM: For over a month, domestic producers have priced 99.5 percent grade primary aluminum ingot at 48¢ per pound. In the same period, merchants raised ingot quotes by 1.5¢-2.5¢ to a range approaching 44¢-47¢ per pound.

Jan 1, 1976