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By Mark Kruzynski, Srinivas Garimella, James T. Wiswall

"A flue gas recirculation (FGR) system for a combustion fired aluminum melting furnace is experimentally investigated. The FGR system flows combustion air in a turbulent jet within the flue gas stream, and the turbulent jet flow is collected in a tube at a distance from the jet exit. Entrainment of the flue gases as well as heat transfer between the flue gases and the jet occurs over the length of the exposed jet. Heat transfer between the flue gases and the jet, and the amount of flue gas entrained into the jet (derived from temperature, flow rate and oxygen fraction measurements) were measured as a function of nozzle exit velocity and the distance between the nozzle exit and collection tube. In addition to flue gas entrainment, a fuel savings of up to 7%, due to heat transfer over the length of the jet, was projected from the measurements obtained.IntroductionFlue gas recirculation can be applied to aluminum melting furnaces to control combustion temperature. When coupled with a device to improve furnace efficiency by recovering heat from the furnace exhaust, flue gas recirculation provides a control technique that is integral to achieving the goals of reducing fuel consumption, increasing product yield, increasing the longevity of infrastructure, and reducing pollutant emissions. In particular, combustion temperature control can help reduce reactivity of the products of combustion with the molten metal surface and furnace refractory materials. Combustion temperature control can also help improve the life of heat exchangers used to recover energy lost to the environment in the flue gases, and reduce NOx formation in the combustion process. Flue gas recirculation can also dilute oxygen used in oxy-fuel combustion to reduce reactivity.Flue gas recirculation has been used since the 1970s to control flame temperatures in the automotive industry [1-3] and has successfully reduced NOx emissions. Many different flue gas recirculation approaches for high temperature melting such as melting aluminum and glass have been patented since the 1980s [4-12]. There has also been academic interest to determine the fundamental performance characteristics of flue gas recirculation in high temperature furnaces and in combustion [13-15]."

Jan 1, 2014

By J. Seifert, L. Hunter, P. W. Conrad, S. Rosenthal

"The goal of the protocol for reclaiming in-pit tailings ponds to exceed federal and state regulations was to develop a series of steps that can be followed to design, operate, and reclaim a tailings disposal pond that will develop into grazing land with a wetland for open pit sand mines in warm dry climates. By incorporating a wetland into the reclamation design, the post mining land use gives back to both the wildlife as a source of water as well as providing for a diverse range of post mining land use including but not limited to livestock grazing and ranch land use. An example design was completed using this protocol to demonstrate how the protocol can result in in a well-designed, reclaimed tailings disposal pond. BACKGROUND In an industry plagued with decaying historic mine sites, the public’s perception of mining appears to be poor. While modern mines are closely monitored and generally managed by ethical professionals, history still influences how the public perceives the mining industry. From collapsing abandoned underground workings to historic tailings dam failures, the failure to account for the environment in the past seems to affect public perspective on mining today. In a 2013 “Opinion Former Survey,” a survey conducted through interviews with a diverse range of stakeholders in various gold companies, it was noted that the most serious challenges facing the mining industry were environmental concerns and the permitting challenges associated with them (Council). In another article, this time focusing on Australian citizens and their perspectives of the mining industry, it was found that the majority of those surveyed had a big concern over the environmental impacts of mining especially when it comes to water quality and quantity (Scan). The statistics portrayed in these articles illustrate that today’s mining engineers needs to make more of an effort to change the public’s perspective of mining by being more environmentally aware. These engineers should be continuously asking themselves what they could be doing better from an environmental perspective to ensure that history is not repeated and that natural resources are used as efficiently as possible."

Jan 1, 2018

By Joseph Chalmers

Stimulative methods of production, whereby the total recovery of oil from natural reservoirs is increased, have come into considerable prominence during the past 15 years. In many oil-producing areas properties considered ready for abandonment by ordinary producing methods have responded to some form of stimulation, and their economic lives have been extended. The stimulative method having widest application is the injection of air or gas into the reservoir formations through selected input wells and is commonly referred to as the "gas drive." As a result of the many successful "gas-drive" operations operators are depending more and more upon this method for increasing the ultimate recovery of oil from their properties. A number of factors influence the efficacy of different gases as propulsive agents in recovering oil from sands. Gases of high density and viscosity show a tendency toward a slightly higher efficiency than those of lower density and viscosity. The solubility of the gas in the oil also affects the efficiency of oil recovery. Not only does dissolved gas decrease the viscosity of the oil, but dissolved gas that expands from solution in the oil tends to increase the effectiveness of a "gas drive." Interfacial tension between the oil and the gas and its effect upon the recovery of oil by gas injection are factors of which little is known. Dr. A. G. Loomis expressed the opinion that interfacial tension probably plays a minor role in the recovery of oil, except under conditions that produce a gas-oil foam. In connection with the above physical properties that influence the action of a pressure medium, control of the injected volume of the pressure medium is perhaps the major factor. The rate of gas injection determines to a great extent the amount of slippage and the resulting efficiency of the operation. The importance of volume control is realized when one considers that frequently it is the only factor that is under complete control of the operator.

Jan 1, 1930

By Earl M. Frizzell

Investigation of mined land characteristics, evaluation of irrigation systems and evaluations by the mining industry determined that irrigation is a feasible method for aiding the revegetation of coal mined lands in the western arid and semi-arid regions (Sherman, et al. 1980). The various regions studied displayed a commonality of characteristics which enables, independent of the site or region, the recommendation of solid-set irrigation. Irrigation should be supplemental by complimenting natural precipitation and should be implemented on a temporary basis. For germination, the vegetation requires application of small amounts of water in a gentle, frequent, and timely manner. For the establishment phase of growth, moisture should be applied and stored in the soil either through pre-irrigation or deep irrigation.

Jan 1, 1985

By Naiyang Ma

Along with steel production, various steelmaking slags are constantly generated at considerably high rates. In general, steelmaking slags are not categorized into hazardous materials and do not cause any environmental issues. Therefore, recycling of steelmaking slags is often aimed at creating values by using the slags to replace high-cost raw materials. Chemical compositions and particle size distributions of slag products from steelmaking slags will determine what raw materials the slag products can replace. Consequently, maximizing the values of steelmaking slags will require to produce slag products with the highest values and to process the slags with the lowest costs. In this paper, several slag processing processes are assessed based on maximization of the values of the steelmaking slags.

Mar 1, 2017

By M. A. Clayton, D. Kinakin

The Mitchell Creek Landslide is a large, structurally controlled, complex bedrock instability located in northwestern British Columbia. Characterization of the landslide using aerial photograph, exploration geology, and geotechnical investigation data has been completed allowing the development of a three dimensional conceptual model of the landslide domains and slope behaviour. Three domains have been identified in the landslide, from top to bottom: the Sliding domain, a relatively intact slab slowly sliding into the valley; the Transition domain, located in the mid slope of the landslide and showing evidence of significant extension and continuing to subside and displace into the valley; and a Toppling domain, at the toe of the landslide in an area of overturned foliation. Movement is greatest in the Toppling domain, with long term estimated rates of movement up to 4 times that of the Sliding domain; the Transition domain exhibits the greatest range of displacement rates, with average long term values approximately double the slower Sliding domain. This paper documents the results of numerical modelling of the Mitchell Creek Landslide with variation in geomechanical properties, basal rupture surface configuration, structural fabric, and pore water pressure conditions. The locations of internal shear surfaces within the landslide have been estimated from surface scarps, structural fabric orientation, and borehole monitoring data. The performance of each numerical model was evaluated against observed behaviour of the landslide. The configuration and properties of the basal rupture surface were identified as critical to model behaviour, as was spacing and location of internal structures.

Jan 1, 2015

By D M. Verster, P L. Gillot, A Kone

Randgold ResourcesÆ MorilaÆs gold leach plant is subjected to uncommon æoxygen stressesÆ. Feed ores exhibit very high oxygen demands, primarily caused by iron sulfides. In addition, ore oxygen demand varies significantly over time, as well as between different feed ore sources. The inability of the Morila gold leach plantÆs oxygenation system to cope with these high and fluctuating oxygen stresses manifested itself in variable gold residue grades, and cyanide consumption rates.Management launched a Morila oxygen system review project during September 2009, with the objective of auditing the performance of the then current oxygenation system, against required performance parameters as calculated from oxygen demands of the various feed ore types and targeted dissolved oxygen levels in the leach train.This paper describes the systematic changes made since 2009 to the Morila oxygen system in four main areas: O2-supply plant, O2-volumes, O2-controls and oxygenation equipment. Data are provided on corresponding improvements in leach plant performance. Theoretical, as well as practical aspects of gold leach oxygenation systems are covered.CITATION:Verster, D M, Gillot, P L and Kone, A, 2013. Oxygenation system upgrades and leach plant performance improvements at Morila Gold Mine - 2009 to 2012, in Proceedings World Gold 2013 , pp 215-224 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

By F. Garcia, J. Cervik

Recent advances in the commercial separation of gases using membranes have renewed interest in the possibility of applying this technology to the recovery of methane ( CH4 ) from mining operations . This Bureau of Mines report briefly reviews the history of the development of membranes for gas separation , the theory of how they work , and their application to the separation of methane from air and associated problems . However , methane -air mixtures are difficult to separate with membranes because the pertinent gas couples , 02 - N2 , 02 - CH4 , and N2 -CH4 , have poor separation characteristics , as indicated by their separation factors of about 3 or less . Even if these separation factors were substantially higher , there is doubt that methane could be recovered economically from the low concentrations in mine ventilation exhaust ( 2 vol pct or less ) . The exhaust pressures are not sufficient for adequate separation . The power cost of compressing the methane recovered . these mixtures would far exceed the value of New discoveries could make separation of gob hole methane - air mixtures practical . These mixtures have much higher concentrations of methane (from 30 to 100 vol pct ) ; however , for safety reasons , be limited to gob gas with 60 vol pct CH4 or more .

Jan 1, 1988

The development of a robust belt sampling strategy and protocol inunderground gold mines is a fundamental requirement for effective grade quality control, ore accounting and mine-mill reconciliations. As part of the ore management system, a belt sampling system has been developed by the author, which is used to predict monthly gold grade and its error for underground/belt/mill reconciliation and grade control. This paper presents the step-by-step development of the belt samplingstrategy and sample preparation protocol at Target, an underground gold mine in South Africa. The belt sampling system at Target consists of an underground belt transporting run-of-mine material into an underground transfer point, a weightometer, a two stage crushing system, a tube splitter and a catchment device. The design allows run-of-mine ore on the belt to be sampled automatically by a go-belt sampler. GyÆs sampling theory of particulate materials forms the basicframework of the belt sampling strategy. The theory is used to quantify the optimum sample mass of broken material to be taken from the belt and to predict its reliability. It is also employed to determine the Fundamental Sampling Error (FSE), time interval between samples and particle size requirements of the final underground belt sample. Further, GyÆs sampling theory provides the means of analysing the crushing processes, splitting, segregation error, analytical variance, and the best sample preparation protocol. Although the belt sampling strategy developed in this study was forWitwaterstrand gold ore, the process is entirely general and may be very successfully used in any underground or surface mine.

Jan 1, 1999

By M. Sengupta, A. A. de Gast

"With rapid deterioration in the urban environment caused by air pollution, the possibility of chemical reaction between dimension stone and the industrial waste gases present in the ambient atmosphere remains. The chemical reaction can cause expensive damage to building stone; it is essential that a stone evaluation for use in construction should assess the possibility of this type of decay. This paper endeavours to develop testing procedures for evaluating stone decay in polluted environments. Such tests can accompany other standard tests used in dimension- stone evaluation."

Jan 1, 1972

By R. V. Lundquist, H. Leitch

Sodium aluminate is the principal aluminum compound formed in the sinters prepared by the lime - soda sinter process for recovering aluminum from silicate source materials . The properties and characteristics of this compound were studied to improve the efficiency of the process . Crystalline sodium aluminate was prepared by sintering stoichiometric quantities of soda ash and calcined alumina for 1 hour at 1,250 ° C. The extent of aluminum extraction from sodium aluminate was determined in water and in solutions of NaOH and Na₂ CO3 . Nearly complete extraction of aluminum from sodium aluminate was achieved only in solutions containing free NaOH in excess of that supplied by the salt through hydrolysis . About 42.2 to 68.8 percent of the aluminum was extracted in water or in solutions of Na₂ CO . The precipitation of alumina trihydrate from sodium aluminate solutions was shown to be part of a continuous , reversible reaction according to the equation Al (OH ) A1 (OH )3 + OHThe reverse reaction dissolves alumina trihydrate in NaOH solutions to produce sodium aluminate . Approximate equilibrium concentrations were determined for the reaction at 30° , 50 ° , and 70 ° C. False apparent equilibrium conditions for the dissolution reaction appear when only a small excess of alumina trihydrate is present in the NaOH solutions . A large excess of alumina trihydrate must be present before the true equilibrium point is assured . The engineering significance of the data is summarized , showing controls that should be exercised for a successful and efficient process .

Jan 1, 1964

By J. C. Underwood

"The wear performance of grinding balls under conditions of impact and abrasion is affected by their chemical composition and structure. The selection of appropriate analyses and heat treatments that will provide both abrasion and impact resistance takes into account the effects of certain elements on structure and harden-ability, as well as the over-all effect of composition and hardness penetration on the residual stress pattern developed through heat treatment. Direct quenching from forging temperatures substantially increases hardenability over that obtained in reheat-quench practices, and can be done without undue risk of damage to the ball provided that the harden-ability bears the correct relationship to ball diameter.Average volumetric hardness and percent hardened volume are convenient parameters for quantitatively expressing the response to heat treatment and indicating anticipated wear properties. A number of factors which can lead to reduced wear life as a result of material or processing problems are reviewed and illustrated."

Jan 1, 1959

By L Dubron

This study details a mineralogical and textural characterisation of West African iron ores with an emphasis on their behaviour during mineral processing. By means of both qualitative and quantitative characterisation, a simulation of the beneficiation process applied to these iron ores is performed. A series of different analytical tools are used, including:X-Ray Diffraction (XRD) for qualitative mineralogical analysis;• qualitative optical microscopy (phase identifi cation, description of micro-textures) and (semi)• quantitative optical microscopy (counting of particles, phases and textural types); and• chemical analysis.All the information provided by these analytical methods are combined into a quantitative mineralogical and textural analysis, here called ‘modal analysis’, which enables us to simulate the capability of West African iron ores to be benefi ciated by magnetic and gravimetric separation techniques.On one hand, both qualitative XRD and optical microscopy have revealed the presence of the following mineralogical phases: magnetite, haematite, goethite and quartz. On the other hand, the chemical analyses provide us with quantitative inputs expressed as oxides. We have converted the oxides into mineralogical contents expressed as magnetite, haematite, goethite and quartz. In this way, we build a simple quantitative mineralogical analysis.Beside this, the semi-quantitative approach of the characterisation by optical microscopy also provides us with a liberation study, enabling us to split the gangue-bearing content between two types of particles:1. liberated gangue-bearing particles, and2. composite particles composed by both iron (oxhydr) oxides and gangue-bearing minerals.We have assumed that we could anticipate the behaviour of these two kinds of particles through a mineral process, by simulating the removal of at least the liberated particles of gangue. Optical microscopy also revealed a trend in the weathering profi le of the Tokadeh ore horizon with a decrease from bottom to top of magnetite and an increase of both goethite and martite showing a higher level of oxidation and hydration in the upper ore horizon.We have applied this removal extent upon the quartz content of the mineralogical quantitative analysis and we have re-calculated the quantitative mineralogical analysis considering the expected decrease in the quartz content. Finally, by converting the re-calculated (oxhydr) oxides contents into iron grades and summing them, we do obtain a fi nal simulated iron grade for the upgraded products.

Jul 11, 2011

By D Brennan, S Jahanshahi, F Jorgensen

The recycling of metals can be very efficient with careful selection of the material being recycled. The volume and value of recycled ferrous scrap has lead to the development of steel mini-mills which in turn has caused major changes to the steel industry. Although much smaller in volume, the recycling of lead is very significant, with battery recycling accounting for 60 per cent of annual world production. This high recycle rate can be attributed to the relatively uniform feed-stock from lead-acid batteries. The recycling rates of other metals are considerably lower due to longer use and non-uniform product usage that results in less efficient segregation and processing. It is clear that recycling of metals has advantages but its sustainability is uncertain. What are the key benefits of metal recycling? Metal recycling has technical, economic and social impacts. It is relatively easy to assess recycling on a technical basis, but the social impacts are harder to evaluate. This paper examines some of the issues in evaluating the sustainability of metal recycling.

Jan 1, 2002

By D. R. Wilburn

his summary of international mineral exploration activities for the year 2011 draws upon available information from industry sources, published literature and U.S. Geological Survey (USGS) specialists. The summary provides data on exploration budgets by region and mineral commodity, identifies significant mineral discoveries and areas of mineral exploration, discusses government programs affecting the mineral exploration industry and presents [ ] analyses of exploration activities performed by the mineral industry. Three sources of information are reported and analyzed in this annual review of international exploration: 1) budgetary statistics expressed in U.S. nominal dollars provided by Metals Economics Group (MEG) of Halifax, Nova Scotia; 2) regional and site-specific exploration activities that took place in 2011 as compiled by the USGS and 3) regional events including economic, social and political conditions that affected exploration activities, which were derived from published sources and unpublished discussions with USGS and industry specialists.

Jan 1, 2012

By Lloyd W. Trevoy

Commercial production of heavy minerals from plant tailings streams is undergoing study by Syncrude Canada Lrd. When tar sand from an open pit mine is processed and up- graded to synthetic crude oil, heavy minerals can be recovered from the extraction circuit and can be upgraded to provide concentrates of zircon and titanium minerals. The titanium minerals concentrate consisting of a mixture of ilmenite, leucoxene and rutile, could be utilized as recovered or could be upgraded to synthetic rutile. With the construction of further synthetic crude oil plants in Western Canada a large reserve of heavy minerals will become available for utilization.

Jan 1, 1981

"The Metropolitan St. Louis Sewer District (MSD) in Missouri, the country’s fourth largest sewer system, is upgrading its storm and wastewater infrastructure in a 23-yearlong, $4.7 billion initiative called “Project Clear.” Historically, during times of intense precipitation, the current sewer system becomes overwhelmed. The primary goals of this project are to improve water quality and to alleviate many wastewater concerns in the St. Louis region by planning, designing and building community rainscaping, system improvements and an ambitious program of maintenance and repair.Part of the system renovation has focused on constructing underground tunnels for storm water storage, permitting controlled drainage of runoff, and preventing overflows into rivers and streams. Construction plans for these storage tunnels called for eight vertical intake and ventilation shafts to be bored from the ground surface. These shafts will then be intercepted in the bedrock at a depth of about 150 ft (45.7 m) during the excavation of the 3,000 ft (915 m) long underground tunnel that will be about 28 ft (8.5 m) in diameter. According to John Deeken , a geotechnical engineer with Black & Veatch Corp. and construction manager for the Maline Creek project, the drilling and blasting technique for creating the shafts was ruled out because the project was located in a residential neighborhood. “We could have used rock coring or a cutter head, but the drop shaft for this project is constructed within 10 ft (3.05 m) of an existing 108 in (274 cm) diameter sewer main,” Deeken said. “We had to take precautions to avoid damage to it.”A primary planning mandate of all MSD Project Clear phases requires minimized impact on traffic and residents. The canister drilling method enabled work to be confined to the median of a residential boulevard running perpendicular to the side street without detouring traffic. In addition, canister drilling offered a highly-precise means to create the shafts, leaving a smooth-sided borehole, right on target. Ground conditions in this 132 in (3.35 m) diameter intake shaft were wet due to the high groundwater levels and close proximity to the Mississippi River. “They’ve been finding shale in 2 to 6 ft (0.6 to 1.8 m) layers between weathered layers of Mississippian limestone,” said Dan Spiecher, technician at Center Rock (CRI). “The 2 ft (0.6 m) layers we can punch through. The 6 ft (1.8 m) layers slow us down.”"

Jan 1, 2017

By Brent C. Jellicoe, Phil Robertshaw, J. Murphy, Peter Williamson

Kimberlites and associated diamonds have been the focus of extensive exploration in central Saskatchewan since 1988. During 1989, Uranerz Exploration and Mining Limited identified 71 shallow magnetic anomalies in the Fort a la Corne area from detailed aeromagnetic surveys. By the end of 1991, 18 of these targets had been proven, by drilling, to be kimberlite bodies encased within Cretaceous sedimentary strata. From 1991 to 1997, the number of drill-confirmed kimberlite bodies increased to 69. Our current view, drawing on an integration of geophysical and geological information, is that the kimberlites are composed of individual bodies and multi-vent clusters of coalesced bodies, all apparently constructed of stacked, temporally distinct layers of pyroclastic crater-facies kimberlite. Diamond recoveries and geochemical results from associated heavy minerals at Fort a la Corne remain highly variable, although continued minibulk sampling is expected to improve the estimation of diamond grades for the most prospective bodies.

Jan 1, 2001

By M Lewis, A Cook

This paper is based on the technology and functionality of a Modular Mining IntelliMINE« system which is a real-time decision-making tool. The IntelliMINE« system, incorporating Dispatch, is a fully Integrated Mine Management System. Measuring, quantifying and analysing the performance of mining is considered a fundamental and strategic step towards changing the nature of technical and operational decision-making at the majority of international mining corporations. Successful implementation of electronic data capture devices and computerised tools have enabled many mining operations to improve their competitive position with an improvement in the utilisation of the key assets, mineral resources, capital mining equipment and human resources. Real Time Mine Management Systems are designed to direct the emphasis away from collecting data and focus decision makers on the real issues with well-presented and reliable information. The systems provide a common stream of information to enable senior management, operations, maintenance, technical and process plant staff to make complementary decisions based on reliable, accurate and timely data. The mine asset information tools focus all employees on performance and give them feedback on their area of responsibility. The resulting tangible benefits can be delivered in different forms depending on the mining method, ore type, workplace culture and the current competitive position. Typical areas of improvement reported by system users are:reduction in capital expenditure on mining equipment fleets; more effective planning and budgeting parameters and procedures; increased control over ore-extraction and processing; increased employee accountability and organisational performance; and improved co-ordination between planning, operations, maintenance and processing. These improvements can be delivered in different forms depending on the status of the mine and commodity markets. In times of market oversupply and low commodity prices, the benefits can be delivered to the bottom line in terms of reduced cash costs, reduced capital and operating resources to maintain constant production. In times of market expansion, existing capital resources will be more productive delivering increased production and revenue. Mine management systems have the potential to transform a traditional mine operation into a learning organisation with an improved understanding of the critical performance issues and enable development of relevant strategies to continually identify and eliminate operational inefficiencies. The effectiveness of each strategy and operational change can be accurately monitored and its success (or otherwise) will be quantified. The latest downturn in the world metal prices has forced many mining companies to focus on cost reduction and productivity improvements as a means of remaining competitive. Maintenance represents a significant proportion of the overall operating costs in the mining industry. A structured proactive maintenance approach such as Reliability Centered Maintenance (RCM) can achieve significant cost reductions and productivity improvements. Remote condition monitoring systems are becoming increasingly commonplace and have the potential to identify problems prior to failure. Detection of equipment degradation prior to failure will enable repairs to be scheduled, thereby reducing costs and interruptions to production.

Jan 1, 2000

By Thomas Germershausen

Worldwide BOF-based steel plants are faced with demanding environmental requests and rising energy costs. For cleaning of primary gases from the BOF the scrubbing technology is worldwide adapted. For wet-scrubbers there is a direct relation between pressure loss and achievable clean gas dust content. Subsequently main energy consumers within Gas Cleaning Plants are the driving fans. To evaluate actual performance and to identify optimization measures extensive field measurements at existing Gas Cleaning Plants were performed. The operational results from various BOF plants worldwide will be presented and benchmarked. As a conclusion, advanced control strategies for reduced energy consumption and lower environmental impact were developed and implemented.

Jul 30, 2018