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By Ivan César Lopes Diniz, César Romero Afonso Goulart Júnior

Mandrels are tools applied to manufacturing seamless tubes. In VSB plants (Vallourec Soluções Tubulares do Brasil), it is used in two mills. Mandrel and PQF Mills. This is an expensive tool due its alloy (hot work tool steel – AISI H13) and lengh (between 12 meters and 22,5 meters). An opportunity to apply mandrels from PQF in Mandrel Mill has been identified. However, mechanical properties of PQF mandrels must be improved. This work presents the heat treatment process of Quenching and Tempering developed internally at VSB to improve PQF mandrel properties aiming to achieve Mandrel Mill requirements. Hardness and metallography tests were performed before and after some steps of the heat treatment to characterize and validate the process.

Oct 5, 2019

By R. Jacob Cefalo, Miguel Valenzuela

The modern drill and blast engineer operates in an environment often rich with data from drilling data and blast designs vs. actuals to fragmentation distributions and vibration records. Despite this abundance, much of the information generated remains underutilized, often collected as a matter of routine rather than for a means to an end. This paper explores how artificial intelligence (AI) can bridge that gap, transforming raw operational information into actionable insights that lead to more consistent and optimized blasting outcomes. Through AI-driven analysis of drilling logs, burden and spacing measurements in design vs. actual, fragmentation distributions, and vibration records, we can identify hidden patterns and correlations that traditional analytics overlook or that we may not be aware of. These insights enable engineers to proactively adjust designs and loading strategies, ultimately improving performance aspects such as improving fragmentation, minimizing ground vibration, and lowering overall operational costs. The paper examines the industry's reliance on lagging indicators, such as post-blast fragmentation surveys or actual powder factors, and suggests the need to shift toward leading indicators like real-time drill data monitoring and predictive fragmentation modeling. Utilizing AI to forecast outcomes before a blast is carried out allows engineers to take corrective actions early in the process, thereby creating a feedback loop that continuously improves performance. This integration of AI into drilling and blasting practices marks a pivotal opportunity for the explosives engineering field to evolve from reactive to predictive methodologies unlocking a new level of operational intelligence and value creation.

Jan 26, 2026

By Paul E. Rosten

Introduction This papers describes some of the latest improvements that have been incorporated or planned by the Cleveland-Cliffs Iron Co. to reduce operating costs and improve pellet quality. The Cleveland-Cliffs Iron Co. operates and manages mining, beneficiation, and pelletizing operations in Michigan, Canada, and western Australia. This paper deals with the grate-kiln pelletizing operations at Republic, Humboldt, Tilden, Empire, and Pioneer in Michigan, and the Adams and Sherman in Ontario, Canada. Table I characterizes each operation in regard to location, ore type, pellet capacity and date that pellets were first produced. All of the operations with the exception of Pioneer and Tilden, utilize downdraft-two-pass grate cycles of drying followed by preheating. Pioneer utilizes an all-downdraft, three-pass grate cycle which consists of three drying zones followed by the preheat zone. The Pioneer and Tilden cycles have been described previously (Lindroos and Koski, 1966; Villar and Dawe, 1975; Koski, 1977). Tilden utilizes a three-pass grate cycle with a stage of updraft drying, followed by two downdraft drying stages. Recuperation systems which supply hot gases to a drying zone from second stage cooling were designed and fur¬nished for Tilden I. Tilden II will be identical. Empire IV will also be furnished with a recuperation system. The Adams grate¬kiln system was retrofitted with a recuperation system. This paper will summarize some of the efforts that are in effect or planned for grate-kiln pelletizing systems to: (1) reduce operating and maintenance costs, (2) reduce energy requirements, (3) improve product quality, and (4) meet environmental standards.

Jan 1, 1981

By B. Elevli

Production scheduling of an open-pit mine is one of the most important steps in open-pit mining. The production schedule of a mine defines the distribution of cash flows and as a result directly influences the net present value (NPV) and overall economic feasibility of a project. Although the need to plan and operate a mine with an optimum production schedule has been obvious for some time, the methods used to obtain such a schedule have not been. The current practice for doing is to do it by hand on the basis of trial and error analysis. In an attempt to improve the way production scheduling is currently done, a new computer based production scheduling algorithm is developed. This paper describes the fundamentals of this newly developed heuristic scheduling algorithm and its application on a gold deposit. The results coming from a case study show that the schedules based on the new method provides improved cash flows compare to a manually done production schedules.

Jan 1, 1989

Most mining dredges are adapted from canal/harbour dredges. Their automation and control systems are generally not designed for integrated mining operations. Consequently they have a number of limitations. This paper describes a new dredge control concept which paves the way for improved efficiency and increased production.

Jan 1, 2001

By Ingham PD

Selection of equipment for a mining operation, such as Mount Isa Mines, requires certain parameters to be correctly defined. Management control is essential for monitoring, improving and future purchase of equipment. Some research is being done independent of supply manufacturers. Observations about future outlook are made.

Jan 1, 1982

By Jose Bengoa

Low metal prices and environmental restrictions are always a challenge for copper smelters operation and its productivity. Thus, in order to reduce production costs and control gas emissions, improvements of the Teniente Converter (CT) operation were made at 110 Smelter Plant of Southern Peru Copper Co" 110, Peru, and the main objective was to increase its capacity for smelting copper concentrates without affecting normal operation, The present work eorresponds to a recent study conducted during the normal industrial operation of the Teniente Converter in this plant and, it shows the effect of increasing air oxygen enrichment from 28 to 34% on its productivity. The results show an increasing of concentrate smelting rate from 800 to 1370 tpd and hence a notorious improving in copper production, and practically no effect on the refractory consumption. The increment of the concentrate throughput, increases also the SO2 concentration and the sulfuric acid production, showing the effort done by this operation in order to accomplish the environmental Peruvian regulation,

Jan 1, 2003

By Jose Bengoa

Low metal prices and environmental restrictions are always a challenge for copper smelters operation and its productivity. Thus, in order to reduce production costs and control gas emissions, improvements of the Teniente Converter (CT) operation were made at 110 Smelter Plant of Southern Peru Copper Co., 110, Peru, and the main objective was to increase its capacity for smelting copper concentrates without affecting normal operation. The present work corresponds to a recent study conducted during the normal industrial operation of the Teniente Converter in this plant and, it shows the effect of increasing air oxygen enrichment from 28 to 34% on its productivity. The results show an increasing of concentrate smelting rate from 800 to 1370 tpd and hence a notorious improving in copper production, and practically no effect on the refractory consumption. The increment of the concentrate throughput, increases also the SO2 concentration and the sulfuric acid production, showing the effort done by this operation in order to accomplish the environmental Peruvian regulation.

Jan 1, 2003

By M. Schwarze

SMS Meer GmbH with its COPPER PLANTS DIVISION produces a full line of systems and machines for the processing of copper. The product range includes: shaft melting furnaces, anode casting lines, horizontal and vertical casting lines, casting and rolling lines for copper wire rod and strip, cold pilger mills, planetary rolling mills as well as tube drawing equipment. The new designed shaft furnaces are the most economic way of copper melting. The CONTILANOD® system with hydraulic shear represents a breakthrough into higher production capacities and improved geometrical accuracy of anodes. The new generation of CONTIROD® lines with individual drives of rolling stands guarantee cost effective production of highest rod quality. A new horizontal continuous casting technology for the production of tube shells as feed stock for the copper tube manufacturing process ? directube® was developed and introduced into production. A first line for continuous vertical strip casting - called VERTICAST® - for higher production rates and improval quality of cold-rollable strips is in the final stage of commissioning. These innovative technologies increase product quality, reduce process costs and help for a wide use of copper in all sectors of life.

Jan 1, 2007

By Ajit Kumar Jaiswal

"Electric Arc Furnace (EAF) being a power-intensive equipment, EAF based industries are highly dependent on scarce electric energy. This is the reason Government of India is highly concerned about this and laid emphasis on the conservation of electric energy.This paper highlights factors contributing to reduction in specific electric energy consumption in EAF and suggests measures not only for power saving, but also for productivity improvement. To name a few, these are proper sealing of furnace, introduction of oxy-fuel burners, foamy slag practice, increased usage of hot metal/DRI, post-combustion of CO gas for preheating of scrap, improved selection & design criteria of electrics, power demand management, and process automation. Few cases also have been cited, where the above measures have helped in reaping significant benefits.IntroductionFor a long time, Government of India had focused on increase in energy supply, in particular, through electricity generation. Now the emphasis of Government of India has shifted from electricity generation to its conservation for following two reasons:??Power plants have become very cost-intensive??By saving energy, more of it can be delivered at lower cost to the consumersPower generating units, transmission & distribution agencies as well as consumers all have roles to play in the area of energy conservation. By energy conservation, we mean curtailing energy requirement by reducing energy wastages and taking up measures to improve energy efficiency of electric equipment/appliances. In almost all cases, this would be economically beneficial.India’s cost-effective energy conservation potential has been estimated by the Planning Commission at 23 per cent of total commercial energy generated ?1?. A national movement for energy conservation can significantly reduce the need for fresh investment in energy supply systems in coming years. It is imperative that we make all-out effort to realize this potential. Whether a household or a factory, a small shop or a large commercial building, a farmer or an office worker, every user can and must make this effort for his own benefit and for the nation’s benefit as well."

Jan 1, 2009

By A. Collings, A. Farmer

Power ultrasound may be used in the processing of mineral suspensions to clean the particle surfaces of oxidation products and fine coatings, mainly through the large, but very localised forces, produced by cavitation. This effect may be utilised in lowering the level of iron contamination in silica sand used for glass making, in improving the sharpness of electrostatic separation of heavy mineral concentrates, in shortening the time of leaching of minerals and in improving the selectivity and recovery of flotation processes. Parameters affecting the efficiency of these processes, such as input power and levels of reagent addition, are discussed. In particular, we present data showing the relationship between power input and the particle size of surface coatings removed, which can be explained by the Derjaguin approximation for the energy of interaction between a sphere and a flat surface. Pilot scale studies, using commercially available components, are currently being used to assess process viability and will be compared with laboratory scale results.

Jan 1, 2003

By Qin Hua, Xiangru Chen, Qijie Zhai, Yongsheng Yan, Liang Chang

"In this paper, pure bainite ductile iron and their alloying form of 0.2wt% niobium were prepared by a controlled cooling heat-treatment. The effect of niobium alloying on the microstructure, hardness and impact toughness of bainite ductile iron was studied. The results show that adding niobium effectively improves the hardness and toughness of bainite ductile iron. The hardness and the impact toughness of niobium-alloyed bainite ductile iron were investigated by varying the temperature at which samples were fed to the incubator.IntroductionThere are two essential methods to prepare the bainite ductile iron: isothermal quenching [I-31, and alloying [4• 51• Isothermal quenching process is very time and energy consumable, concerned as a high cost technique for mass production. Besides, there are certain limitations on the size and shape of castings in this process. In addition, it potentially harms the environment. As for the alloying, Ni, Mo, and Cu have to be utilized to obtain bainite. However, the large demand and high cost of Ni makes it not feasible in practice.It is well known that niobium can promote the formation of carbon compound, and improves the stability ofundercooled austenite, which is preferred to the increase of the hardenability. Previous studies showed that niobium could refine the grain and improve the mechanical properties of gray cast iron [6-81 • Therefore, in the present work, the effects of niobium and the temperature at which samples were fed to the incubator on the microstructures and properties of niobium alloyed bainite ductile iron were investigated."

Jan 1, 2014

By Rob Thomas

Pre-driven recovery roads are used to speed up the longwall recovery process by reducing bolt-up requirements and by improving ground conditions on the face during the removal of the powered supports. To lower the geotechnical risks associated with the use of pre-driven recovery roads, and so improve its overall acceptance in the industry as a viable alternative to more conventional, potentially difficult and costly longwall recoveries, this paper outlines (i) a geomechanical model for the use and design of pre-driven recovery roads, (ii) an updated version of the worldwide database on pre-driven recovery roads, (iii) a summary of the various methods of holing a longwall into a pre-driven recovery road and (iv) a series of relevant ground support and strata management guidelines.

Jan 1, 2008

By Rollien R. Wells

The Bureau of Mines was created in 1910 by an act of Congress and subsequently directed to: "...conduct inquiries and scientific and technologic investigations concerning mining, and the preparation, treatment, and utilization of mineral substances with a view to improving health conditions, and increasing safety, efficiency, economic development, and conserving resources through the prevention of waste ..." Under this broad charter, the Bureau's responsibilities have changed and grown from an almost exclusive concern with coal and coal mine safety to the present emphasis on a full spectrum of mineral producing and consuming problems. In the past 30 years, the domestic consumption of coal, oil, gas, metals, and industrial minerals has more than quadrupled, in parallel with the rapid and enormous growth in industrial production. Of the scores of metals and nonmetals essential to the Nation's progress and security, many are scarce and difficult to wrest from domestic sources. Reserves of some ores are dwindling. Available ore resources are becoming leaner and more difficult to treat. In recognition of this many faceted problem, the Bureau has engaged in a continuing quest for new and improved technology to enable economic exploitation of marginal minerals and fuels, to find substitutes for minerals in short supply, and to create better materials to meet the expanding and diverse requirements of the growing economy. The current central concern of the Bureau is focused on meeting projected fuel, metal, and mineral demands at the lowest real cost by recovery from available resources by new and improved technology that minimizes waste, hazards, and social and environmental problems.

Jan 1, 1970

By Paul Clifford

The Florida Institute of Phosphate Research (FIPR) is an independent, state of Florida research agency. It was created in 1978 to conduct research to enhance the competitiveness of the Florida phosphate industry. The institute also conducts research to prevent, minimize or rectify environmental impacts caused by the industry. And it helps educate the public concerning phosphate-related technology and issues. FIPR is funded by a severance tax on the industry and is governed by a five-member board of directors appointed by the governor. FIPR's research is playing a role in enhancing the competitiveness of the Florida phosphate industry. Its technology research program seeks to improve surface mining and pipeline transportation while reducing the energy cost for pumping phosphate matrix. It is developing new and improved methods of beneficiation and fertilizer production. This includes new process flowsheets and on-line analyzers and process control methods. FIPR is also developing uses for the phosphogypsum byproduct of phosphoric acid production and evaluating the risks associated with its uses.

Jan 1, 1998

By Mark Leggett, Kevin Roberts

The need to modernise and increase the safety provision of older road tunnels raises challenges in maintaining the operation of the tunnel during such improvement works. The Mersey Kingsway twin road tunnels located in Liverpool UK, constructed in the late 1960s, have had three new cross passages constructed to allow emergency evacuation from one tunnel to the other tunnel and provide safer access for emergency services. The 3200m long road tunnels are lined with an unusual reinforced concrete steel-faced segmental lining with a paint finish. Construction of the cross passages occurred during night possessions with the tunnels returned to normal operation during the daytime. Constructed through water bearing sandstone and lined with precast concrete segments, the passages required advance ground treatment and support works. This paper presents the historical background to the Mersey Tunnels and describes the procurement strategy, design and construction approach adopted for these important safety improvements.

Jan 1, 2003

By Frank E. Cash, Max S. Petersen

"INTRODUCTION Explosives have been used in ever—increasing amounts since gunpowder was invented. For hundreds of years only low explosives of the deflagrating type were used, and they were fired by means of a flame or hot object. Ben¬jamin Franklin first ignited gunpowder from a distance in 1751 by means of an electrostatic spark. Further efforts to develop a satisfactory electrical method to ignite explosives from greater distances were overshadowed by the invention of safety fuse in 1831, as this offered a relatively simple and inexpensive means of firing explosives.The discovery and introduction of high explosives of the detonating type and the invention of the fulmitate of mercury blasting cap about the middle of the nineteenth century provided the needed impetus for inventors to develop means of firing the cap by electricity. The original high-tension igniter, following Benjamin Franklin's experiment in which the detonating compound was ignited by a spark, was discarded in favor of a low-tension igniter, in which the detonating compound was ignited by a heated wire. The past 2 decades have seen considerable improvement in the design and construction of electric detonators to make them safer and more efficient, yet in spite of the improvement it is estimated that less than 50 percent of the explosives used in industry today are ignited or detonated electrically. The trend, however, is toward the use of electric methods. In recent years numerous-mining companies have introduced electric blasting exclusively at their mines as a means of improving safety and efficiency."

Sep 1, 1946

The mining industry is one of the three pillars of the Namibian economic development, besides tourism and the fishing industry. Generating 20 % of the GDP and more than 50 % of the export income, half of this amount derives from the diamond mining industry. In 2008, the annual production of 2.2 mio carat achieved an income higher than 1.44 billion Namibian Dollars (more than 750 mio Euro). After the global recession in early 2009, which also caused a significant downcrease in production to only 0.93 mio Carat, the diamond mining industry easily restored itself and the production figures for 2010 are expected to be even higher than those achieved in 2008. Compared to other diamond producing countries, Namibia is mainly producing diamonds of highest quality (jewellery quality), with less than 10 % of the mined diamonds not falling into this category. This high quality stands also for the worldwide highest prize achieved per carat. With 370 $US per carat it is more than four times higher than that of the average South African stone. In 1908 the finding of the first diamonds in the Namib desert close to the coastal town of Lüderitz was reported by a Mr Stauch, railway inspector for the then German colonial railway company. This event immediately triggered a Diamond Rush and subsequently the set-up of the restricted diamond mining area ?Sperrgebiet? through the German colonial administration. In 1913, only five years after the first mining operations had started, the steadily increasing production allowed for more than 20 % of the diamond production worldwide. After the First World War, the new South African government concentrated all mining activities in one organization, CDM (Consolidated Diamond Mines of South West Africa) which in following decades conducted an extensive and detailed exploration of the whole Sperrgebiet and started numerous new diamond mining operations.

Jan 1, 2011

By Kevin Whipkey

How is Improvement Being Achieved ? Section Equipment ?Mine Layout/Projections ? Work Schedule ? Maintenance ? Management

Jan 1, 2005

Productivity of mines can be improved by taking fewer, but larger blasts. The initial blasts taken in starting a mining block are restricted by the low amount of void or space to fire into. Block cave mines are using a blasting technique to blast areas that have less than the normally accepted minimum void to establish drawbells for their orebody development. This technique used in block caving mines can be used to improve productivity in mining operations that utilise other mining methods. Some larger blasts have been done in mines, using open stoping methods, which have had void ratios as low as 13 per cent. This has been possible with the use of the explosive gases to transport the broken rock out of the area normally considered to be available to blasts. This trapping of the explosive gases in the broken rock has allowed rock to be moved over 30 m, horizontally, to allow for more void to be available in the blast area. This gives the necessary void ratio allowable to fire larger blasts. This paper will discuss the blasts where this technique has been used in mines to increase the tonnes fired in low void situations. It will also discuss where this type of blasting may improve the productivity of underground mines. Figure 1 shows the how explosive gases have enabled the broken rock to flow out of a draw point without the typical air blast and fly rock that would normally cause a rope suspended sign to be damaged beyond use.

Jan 1, 2008