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By S. L. de Moraes

This study aimed to identify a way to reduce the use of bentonite in the pelletization of magnetite. With this goal, different combinations of binders were compared to bentonite by examining the quality of pellets obtained by balling drum agglomeration. Pellets were subjected to routine tests that included simple compression of the wet and dry 105°C pellets, dropping wet pellets to determine their ability to survive handling and submitting pellets to thermal shock to determine how they tolerate drying and preheating. The best results use sodium silicate (1.5%) as a binder and show that it is possible to pelletize iron ore without using bentonite.

Jan 1, 2010

By Helge B. Wurst, Michael P. Cipold, Jan F. Bachmann, Claus C. Bachmann

"In washability, the objective is to establish the set of maximum possible separation performance criteria for a given mineral feed. The method of choice for this has been the conventional sink-float analysis. Time, cost and safety aspects of the sink-float method have prompted the search for a new approach for establishing separation performance criteria, especially as performance levels of separator plants can be maximized if reliable information based on an analysis of washability in conjunction with particle size distribution, elemental constituency becomes readily available. The new method to establish washability and associated performance information utilizes at least two measurement technologies concurrently: single energy x-ray transmission and image processing. For porous or very inhomogeneous materials the results can be refined further by using dual energy x-ray transmission and image processing. The value of the collected data increases considerably if the washability data were additionally available in time to be considered in the control of the process plant. The incorporation of an automated washability monitor gives near real-time data that would impinge positively on the profitability of the plant operation. The method was extensively tested with a range of sample with different densities, varying from 1 g/cm³ (coal) to 5 g/cm³ (iron ore).INTRODUCTIONWashability of minerals like coal and iron ore is expressed by a curve or graph showing the results of a series of float-and-sink tests. Several of these curves are drawn to illustrate different conditions or variables, usually on the same axes, thus presenting the information on one sheet of paper. Washability curves are essential not only for the design but also for the operation of preparation plants.In determining the washability analysis, particle density is the underlying feature of all washability curves. Conventionally, the particles are separated into density fractions by immersing them in fluids of a predetermined density followed by skimming of those particles that stay afloat. The particles remaining afloat thus have a density lower than that of the fluid they were subjected to. The particles that remained at the bottom of the fluid container thus had a higher density higher than that of the fluid. By progressively increasing, for example, the density of the fluid and immersing the remaining particles so as to be able to skim the next density fraction, the particles would be fractionated into density groups. The liquids used range from aqueous solutions to organic liquids to suspensions. Unfortunately the liquids used for this separation process are often toxic and expensive. It stands to reason that a new method of determining washability is sought."

Jan 1, 2016

By G. T. Lineberry

Reduced clearance is one of the most important characteristics of encumbered space in underground coal mining. Another key variable is the maximum velocity at which a piece of mobile mining equipment can operate in this limited space. Typical velocity- clearance curves for different mine transportation systems are developed and characterized. Applications of the relationships are examined, emphasizing their significance in the design and control of mine materials handling systems.

Jan 1, 1983

By Ronald S. Conti

This U.S. Bureau of Mines (USBM) report describes various fire-fighting resources available to the mining industry and examines the fire preparedness of four western coal mines. Information regarding fire-fighting equipment indicates that an inadequate maintenance program may cause component failure of fire extinguishers, damage to waterhoses is usually a result of improper care, and foam may be a convenient means of conveying water to the fire. Performance data relative to water nozzles (throw distance) and specific practices to improve the state of preparedness in many of these areas are discussed. Studies also indicated that a high-expansion foam plug, will travel down an entry, with a 1% rise in elevation, 207 m (680 ft) before a plywood stopping separating the generator and plug failed. The advance rate of the foam plug decreased when the entry is dry, requiring more foam concentrate and as the foam spread further down the entry. An examination of the mines showed state-of-the-art monitoring systems were common at the minesites. Fire safety was also stressed, including early detection and rapid response of the miners to evacuate the mine. However, the mines placed little emphasis on performance of water nozzles, or personal protective clothing for the underground firefighters.

Jan 1, 1994

By Deepak Malhotra

This paper discusses the need for periodic auditing of mineral processing flowsheets and the potential benefits a company can gain from a study of this nature. A carefully designed flowsheet auditing can have a significant impact on the metallurgical performance in the plant. Several case studies illustrating the potential benefits that can be attained from flowsheet auditing of mineral processing plants are discussed.

Jan 1, 1986

By B. R. Westphal

The Integral Fast Reactor (IFR) concept being developed by Argonne National Laboratory is based on the pyrometallurgical processing of spent nuclear metallic fuel with subsequent fabrication into new reactor fuel by an injection casting process. During fabrication, a dilute scrap stream containing uranium alloy fines and broken quartz (Vycor) molds is produced. Waste characterization of this stream, developed by using present operating data and chemical analysis, was used to evaluate different uranium recovery methods and possible process variations for the return of the recovered metal. Two methods, comminution with size separation and electrostatic separation, have been tested and can successfully recover over 94% of the metal. Recycling the recovered metal to the injection casting process was evaluated for the different economic and process impacts. The physical waste parameters and the important separation process variables are discussed relative to their effects on the viability of recycling the material. A discussion of the criteria that is being used to establish the acceptable operating limits is also presented.

Jan 1, 1992

By V Shrotri L Muhmood, P Gandhre

The current work deals with the measurement of some thermophysical properties of Ca(NO3)2 based ternary nitrate molten salts as HTF (heat transfer fluid) / TES (Thermal Energy Storage) material for CSP (Concentrating solar power) plants. The density and viscosity of different compositions of the ternary salt mixture containing Ca(NO3)2, NaNO3 and KNO3 close to the liquidus has been experimentally measured. An attempt has also been made to measure the melting point of the salt using the cooling curve technique as well as Differential Scanning Calorimetry (DSC). Thermogravimetric analysis has also been performed to estimate the peak operating temperature of the salt. Compatibility of suitable pipe material (SS304) with molten salt has also been discussed. The salt mixture proves to be a viable alternative to the already existing HTFs like Therminol VP-1 (organic oil) or Solar Salt® in regards to its lower melting point, wider operating range, low cost, nontoxicity, sufficiently high density and comparable viscosity.

Jun 19, 2024

By Dr. Kyle Perry, Ryan Sibley

Rock blasting is an inherently difficult field to quantify independent & dependent variables and the specifics of how the energy interacts with the material for a number of reasons. Independent variables such as geology are innumerable and stochastic, thus, on a laboratory and full-scale basis these variables are assumed to be homogenous across the desired rock boundary. Dependent variables are difficult to quantify in the laboratory based on the specific aspect of the fracture mechanisms that caused the fracturing. The same variables are difficult to quantify in the field because of the shear amount of material being blasted. The energy interactions with the material are difficult to quantify due to the rate of the reaction and the lack of quantification of independent variables. The second main issue with laboratory scaled rock blasting is the nature of the small form-factor explosives required for use in a scaled setting. These explosives that are utilized, traditionally PETN detonating cord, have a greater ratio of potential energy converted to shock energy rather than gas energy when compared to traditional field explosives, such as emulsion or ANFO. Research over the past decades has indicated that gas pressure has the greatest contribution to rock blasting performance, such as fragmentation and material throw. The factor of varying ratios of energy production has not been discussed in any of the reviewed publications. Publications discuss dimensionless scaling, dynamic similitude, and length-based scaling, however, none of these scaling methods discuss the ratio of energy production. The main focus will be correlation of energy production ratio of shock versus gas to dependent variables. This paper analyzes previous publications within rock blasting and related field as they pertain to scaling procedures and will highlight the similarities and differences in the various publications and detail the observed omitted variables that possibly lead to skewed data.

Jan 21, 2025

By Raúl Castro, Marco Vera, Alfonso Ovalle

The underground mining evolution for block cave mines in Chile and worldwide has made important strides in the last decades. Nonetheless, reserves determination in the initial stages of these types of projects—mainly for long-term planning—is not studied in as much detail as it should be, especially regarding the impact on the final value of the enterprise. Today, the first estimation of the size of a block cave mine, typically expressed in tons, tends to determine very large footprints and ore bodies. The resulting large-scale mine is obtained by applying the marginal cut-off grade (COG) to determine reserves. Yet, in many cases, it is possible to obtain an equal or higher benefit, extracting fewer reserves in less time, with a smaller active area, which significantly reduces the project’s uncertainty. To explore scenarios obtained by applying a higher marginal COG in the initial phases of the project, the Hill of Value methodology is used to estimate the net present value (NPV) in relation to the production rate and the COG. However, the application of this methodology considers certain simplifications that generate results which are not completely satisfactory in specific cases. This paper suggests an improvement of this method to obtain more reliable results regarding determination of a COG profile that will optimize the NPVof a block-cave project. The methodology was developed and applied in a massive polymetallic deposit with zinc, lead, and silver mineralization, corresponding to a real block caving project. The methodology provides NPV results that differ by approximately 15% in comparison to the real mine plan, while also being considerably simpler and faster to calculate. In summary, the proposed methodology provides a reasonable and fast procedure to estimate higher than marginal COG that increases the NPV of block cave mine projects.

By Afshin Sadri

One of the main reasons for blast furnace reline is the loss of refractory lining, particularly in the hearth and taphole regions. Intense operation of the blast furnace can result in extensive refractory wear and deterioration. This can then affect the continuity of the operation and the furnace campaign life. Novo-Lipetsk (NLMK) and Hatch developed a systematic approach to monitor the condition of blast furnace hearth linings using Acousto Ultrasonic-Echo (AU-E), a non-destructive testing system developed by Hatch. Continuous and periodic inspections of blast furnaces revealed areas with accelerated refractory deterioration, formation of elephant foot, extent and speed of refractory wear, as well as cracks and other anomalies. Improvement in coke quality, stave washing, the addition of titania, and other changes were recommended and implemented to prolong furnace life while maintaining the intensity of furnace operation. This paper demonstrates how the coordinated efforts between NLMK and Hatch resulted in prolonging the blast furnace campaign life.

Aug 17, 2017

By Hyun Kyu Shin, Byeong Deok Lee, Young Eun Lee

The reduction of Mn oxides at pre-smelting steps is an integral part of smelting processes for Mn alloys, and an understanding of its reaction mechanism is expected to contribute to the improvement of processing efficiency for Mn alloys smelting. The phase diagram shows that five Mn carbides are operative in the Mn-C system. Although they are expected to participate in the reduction of Mn oxides, no specific information is available yet to clarify their roles in presmelting carbothermic reaction of Mn oxides. Experiments with composite pellets prepared with Mn oxides and graphite powders show that Mn3O4 is reduced initially to MnO at about 1130oC and, subsequently, to Mn7C3 carbide as temperature increases further. At 1331oC, Mn7C3 carbide dissociates to Mn alloy and carbon. The degree of reducing reaction increases with increasing carbon balance in composite pellets and increasing temperatures.

Jan 1, 2014

By Jason Ganley, Yingjia Liu, Adam Dekich, William Tilson, Jeffrey Fergus, Dileep Kumar CJ

"Manganese cobalt spinel oxide coatings have been shown to be effective for preventing chromium volatilization from interconnect alloys, and the associated cathode poisoning, in solid oxide fuel cells. During high temperature exposure a reaction layer consisting of chromium containing spine! forms due to reaction with the chromia scale formed on the alloy. The electrical conductivity of this reaction layer is much lower than that of the coating material and thus can increase the overall area specific resistance (ASR) of the system. The approaches to reducing the ASR are to reduce the thickness and/or increase the electrical conductivity of the reaction layer, which includes both the high-chromium spinel phase and the chromia scale. In this paper the effects of transition metal dopants on the amount and properties of reaction products formed during the reaction of spine! oxide coating materials with chromia are presented.IntroductionThe high cost and difficulties involved with the processing of chromia based ceramic interconnect materials for SOFCs are driving the search for metallic interconnects [1, 2]. The reduction in the operating temperature of SOFC has allowed for the use of high chromium alloy steels for this application [3]. However, the volatilization of chromium from the chromia scale, and the associated poisoning of the cathode, remains a problem which needs to be addressed [ 4]. Though the application of manganese cobalt oxide spine! coatings on the alloy surface substantially reduces chromium poisoning of the cathode [5], the low electrical conductivity of the reaction layer formed between the chromia scale and coating affects the performance of interconnect. Incorporating transition metal ions in the reaction layer could alter the electrical characteristics and improve the performance. Copper and nickel doped manganese oxide spinels are widely used as thermistors due to their high electrical conductivity and negative temperature co-efficient of resistance characteristics [ 6, 7]. Hence doping of copper and nickel in manganese-cobalt spine! oxide composition may improve the electrical characteristics of interaction layer as well and is attempted here."

Jan 1, 2012

By A. Suarez, M. Menendez, M. R. Gent, P. Riesgo

"Recent requirements to reduce thermal coal plant emissions, and ultrafine coal's tendency to produce these emissions due to its typically high ash and moisture contents have limited the use of ultrafine coal. Ultrafine coal in beneficiation plants are usually either disposed of in tailing ponds at a loss in combustible material or disposed of by blending with coarser higher-grade products, resulting in a reduction in marketed product quality. A study of the options for processing ultrafine coal, consisting of < 200 µm hydrocyclone overflow, with 38.8 percent ash content is presented here. Ultrafine coal was processed based on 200-µm sieve bend and 10-µm hydrocyclone classifications, enhanced gravity separation (EGS) and froth flotation concentration as well as combinations of these. Yield, combustible material recovery (CMR) and product humidity were evaluated as test results.Depending on the processing applied, product ash content could be reduced up to 49.7 percent, and up to 95.8 percent CMR of the actual run of mill feed could be attained. All of the processing options analyzed could reduce produced thermal electric plant emissions due to ash and moisture from 22 to 38 percent of the actual unprocessed ultrafine coal product.Froth flotation was found to be the optimal process, yielding a product with the lowest ash content attained of 19.5 percent and CMR of 92.3 percent. Being the most versatile of the processes evaluated, it is capable of producing coal with varied ash contents but is subject to potential variations in coal flotability. The most complicated of the processing options, a combined sieve bend recovery of the > 200 µm fraction and EGS processing of the 10 to 200 µm fraction was found to be the next best option, attaining a combined 90.1 percent CMR and 25.0 percent ash content. IntroductionMunicipal, regional and national objectives to reduce fossil fuel combustion emissions and their effects on air quality and global weather changes are affecting thermal electric plant operations. Plans and regulations such as President Obama's Clean Power Plan (U.S. Environmental Protection Agency, 2015), the European Directive 2010/75/EU (European Commission, 2010) and China’s proposed Enhanced Actions on Climate Change (Wei, 2015) are of major significance to thermal electric plant operations. Although thermal plant efficiencies depend in large part on the losses of heat by plant components, the ash and humidity contents of thermal coal invariably reduce plant efficiencies and increase emissions of carbon dioxide (CO2), nitrogen oxides (NOx) and dust.Any noncombustible material present in thermal coal will result in higher CO2 emissions per unit of energy produced. Since no particle emission control can be totally effective, it is to be anticipated that any reduction in coal ash content will also result in reduced particle emissions. Kurose, Ikeda and Makino (2001) reported that NOx emissions also increase with coal ash content. The effect of coal moisture content during combustion is complex. Kurose, Ikeda and Makino (2001) showed that an increase in coal moisture content significantly reduces thermal NOx to total NOx production, and Bosoaga et al. (2006) showed that it tends to reduce NOx emissions. Since the humidity, pyrite and ash content of thermal coals directly affect thermal electric plant efficiencies and emissions, minimizing these factors should facilitate, at least in part, compliance with thermal electric plant emission limits. This, in turn, would affect the specifications and prices of the coal preparation plant products."

Jan 1, 2016

By J. W. Shield

Refractory sulfide flotation or gravity gold concentrates are coated onto a sized support matrix and placed in a heap configuration for biooxidation. The surface coating is typically less than 0.05 in. thick and the support matrix is preferably composed of 0.375 to 0.75 in. diameter material. The exposed thin coating of sulfides reduces biooxidation rate limitations due to oxygen mass transfer. The large spaces between matrix particles reduce resistance to fluid percolation and aeration in the heap. The capital and operating costs for this biooxidation configuration are significantly less than for concentrate biooxidation in stirred tanks. After 30 to 90 days of biooxidation, sub- sequent gold recoveries exceed those seen in whole ore heap biooxidation and are comparable to recoveries obtained from stirred tank biooxidation processes. Results from laboratory and pilot testing indicate that this technology is a viable alternative for pretreating sulfide refractory gold ores.

Jan 1, 1997

In both surface and underground coal mines, the detection of geological structures ahead of workings is recognised as being fundamental to the efficient operation of the mine. Mining into zones of unexpected structures has a drastic effect on a mine&apos;s productivity. For the prediction of structures, geophysical methods can be applied from the air, from the ground surface, from boreholes and from underground workings. There are several improvements to report in the geophysical methods being developed for these purposes. These include developments in three-dimensional seismic reflection surveying, cross-hole seismic reflection methods and radar systems. The recent development of the radio imaging method for use in underground mine workings will complement existing in-seam seismic methods. Geophysical techniques for use in horizontal boreholes are also under development.

Jan 1, 1988

By P. van der Veen

There are two key reasons for this presentation: - Sustainability - Improving the economic, environmental and social impact of mining. As I will discuss in my presentation we see sustainability throughout the mine life cycle as critical for successful mine development - that is the mine makes a successful contribution to economic development and poverty alleviation for the host community and host country and at the same time the mine is a successful investment for the investor. - Knowledge Sharing ? The World Bank is not only a development bank, but also a ?knowledge bank?. One of our key functions is the dissemination of usable information and knowledge. We are here not only to share our experience but to learn from your experience as well ? two reasons that fit clearly with the mandate of the World Bank Group.

Jan 1, 2003

By J. A. Hudson, X. D. Pan

A rock mass responds to excavation according to the properties of the intact rock, the network of contained discontinuities and the susceptibility of the rock mass to weathering. Large deformation often occurs when one of these components causes the rock mass to have a low strength relative to the stress conditions. Analysis of such large deformations forms a significant feature of current numerical modelling in rock mechanics. A practical large deformation problem of roadways in a coal mine is described, demonstrating the requirements for improving numerical techniques. The development of a numerical model is then summarised with particular attention to several concepts pertinent to large deformation analysis in geomechanics. A numerical case study is presented in which the developed finite-element model is used and the results are compared with the in-situ measurements. Conclusions are drawn for rock engineering that are also relevant to both civil engineering and mining engineering projects

Sep 1, 1991

Laboratory tests were conducted by the U.S. Bureau of Mines to determine respirable dust reduction effectiveness of and interaction between face airflow and water sprays for a continuous miner. Increases in exhausting face ventilation from 3,000 to 9,000 cfm, in waterflow from 15 to 35 gpm, and in water nozzle operating pressure from 80 to 200 psi were evaluated. Results indicated that airflow had the greatest individual impact on reducing dust levels, with concentrations at return and operator sampling locations reduced by as much as 57% and 99%, respectively. Regression modeling was utilized to predict dust concentrations over the range of values tested for the control parameters. Interactions between the control parameters were significant and often defined an optimum level where further increases in that parameter failed to produce additional dust reductions. Increasing airflow to 8,400 cfm, waterflow to 25 gpm, and water pressure to 140 psi typically reduced dust concentrations at operator and return locations. Application of a control parameter above these levels can provide additional dust reductions if used in conjunction with appropriate levels of the other two control parameters. Otherwise, higher operator dust levels may result and can be attributed to increased rollback and/or airflow turbulence.

Jan 1, 2010

By S. Aram

Product Lifecycle Management (PLM) solutions have been serving as the basis for collaborative product definition, manufacturing, and service management in many industries. They capture and provide access to product and process information and preserve integrity of information throughout the lifecycle of a product. Efficient growth in the role of Building Information Modeling (BIM) can benefit vastly from unifying solutions to acquire, manage and make use of information and processes from various project and enterprise level systems, selectively adapting functionality from PLM systems. However, there are important differences between PLM?s target industries and the Architecture, Engineering, and Construction (AEC) industry characteristics that require modification and tailoring of some aspects of current PLM technology. In this study we examine the fundamental PLM functionalities that create synergy with the BIM-enabled AEC industry. We propose a conceptual model for the information flow and integration between BIM and PLM systems. Finally, we explore the differences between the AEC industry and traditional scope of service for PLM solutions.

Aug 1, 2013

By D E. Tennant

In the fields of geotechnical engineering and slope management, various software packages are used to assess the behaviour or propensity for a slope to fail. Traditional kinematic analysis calculates the probability of failure of design sectors with respect to dominant structural set orientations. A novel methodology is provided here to view potential hazardous slope behaviour in 3D, allowing engineers to make informed decisions regarding various pit slope geometries. Apparent dips are calculated for every point in space with respect to every slope orientation of the entire pit surface/design, specifically in reference to bench and inter-ramp planar failure mechanisms. Implementing a proactive approach to slope design will not only lead to early mitigation of risk but can also add direct value by enhancing or improving upon slope angles for earlier access to ore. From a safety perspective, identification of unfavourably oriented slope geometries can be dealt with before failure occurs. This methodology relies on a strong understanding of the existing rock mass anisotropy, particularly behind the face, thereby removing some of the uncertainty surrounding pit design as well as presenting engineers with an additional means to manage risk.

Nov 29, 2022