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By John Griffen

DURING the past year, purchases of coal-preparation equipment and the discussions and plant-scale tests conducted indicate that much attention is being given to better recoveries of coal by preparation plants and improved quality of the finer sizes to widen their market. In the anthracite regions the new equipment was predominantly for the cleaning of the steam sizes, much of it for treating No. 4 and No. 5 buckwheat. The units installed were largely coal-washing tables, Hydrotators, and Menzies cone separators.

Jan 1, 1944

By C. J. Newman, K. Molnar, A. G. Storey, G. Macfarlane

"The Kidd Creek copper smelter started operation in June 1981 using the Mitsubishi Continuous Smelting Process. A steady increase in plant production rates has been demonstrated, and the annual tonnage of concentrate smelted is now double the original design rate. This paper summarizes recent modifications made to increase concentrate feed rates, increase on-line time, reduce copper losses and control the impurity level in anode copper. It includes improvements made to furnace design, improvements to reduce downtime f or boiler cleaning, and improvements made to the acid plant to allow handling of increased gas flowrates and higher gas strengths while maintaining low acid plant emission rates. IntroductionThe Kidd Creek Division of Fal conbridge Limited operates a base-metal mining and metallurgical complex, located in Timmins, Ontario, which includes an underground mine, a 13 500 tonne/day concentrator, a 130000 tonne/year zinc plant and a copper smelter and refinery, The copper smelter and refinery were commissioned in 1981, with an installed capacity of 59 000 tonnes/ year of cathode. The smelter, utilizing the continuous smelting technology of the Mitsubishi Process, has subsequently been expanded in production capacity, and in 1991 produced 113 500 tonnes of blister copper The capacity of the refinery, which uses Onahama No. 3 tankhouse technology, has been increased to 96 000 tonnes/year of cathode. The capacity increase at the smelter has been realized through the input of additional oxygen to both the smelting and converting furnaces, without increasing the process off-gas flowrate through the associated waste heat boilers.In this paper, a brief review of smelter operation and modifications in the period 1982 to 1987 is presented, together with a more detailed discussion of operation during 1988 to 1991, and a discussion of future planned improvements."

Jan 1, 1992

By M. E. C. Snyman, N. Naudé

"Coal fines produced during processing are difficult to dewater and result in a lower quality product and consequent lower value. A South African coal mine experiences severe difficulties with belt filter dewatering operations due to the presence of fines reporting from the thickener underflows. Plant 2 currently handles super-fine particles of size -34 µm and has low belt filter efficiency: excessive moisture retention lowers the product quality and strains downstream processing. It was necessary to determine an alternative method for dewatering these fines. Blending of fine material with coarser material was proposed as a solution. The effect of coal particle size and layering during ultrafines belt filter dewatering was evaluated using various blends of the fine Plant 2 material with coarser Plant 1 material. The best layering arrangement of the two materials and its optimum blend required to achieve reduced filter cake moisture content was determined in practise using a vacuum filter to simulate belt filtration. A blend of the two materials gave improved dewatering efficiency for the belt filters compared with that of the Plant 2 material alone. The best layering configuration was with Plant 2 material at the bottom and Plant 1 material on top. The optimum blend for industrial applications comprised 48% fines from Plant 2. IntroductionFines are produced during the processing of coal. It is estimated that 2 to 3% of run-ofmine coal reports to the ultrafine portion (-100 µm) (le Roux, 2005). The particle size of coal is inversely proportional to the amount of water adsorption, so smaller particles adsorb more moisture. Moisture removal requires either mechanical processes or thermal drying: mechanical processes are less expensive, but the fines still have high moisture retention. Discarding of fines leads to economic losses, so it is essential that they be dewatered so that they can then be sold as a product: fines need to be treated for both resource management and conservation reasons (Kenney, 1994). Removal of free surface moisture from ultrafine coal particles using a belt filter therefore remains a process that needs to be continuously improved. Ultrafine coal originating from a thickener underflow is known to be difficult to dewater owing to factors such as filter cloth blockage and moisture retention due to clogging. Mixing of finer and coarser materials has been proposed to deliver better dewatering efficiency and improved the quality of the recycled water (Kenney, 1994)."

Mar 1, 2019

By F. J. Longworth

FoR a number of years an intensive study has been made to improve the blast-furnace practice at Copperhill not only as to cost% but to provide a good grade of gas for the acid plants. This study took us back to the fundamentals of successful pyrite smelting; namely, a blast furnace working on a clean sulfide ore, free from fines, and the use of quartz high in silica as a flux. In 1919, the quality of the flux was improved and its effect on the metallurgy was very marked. To improve the practice further, it was necessary to work out some method of treatment for the sulfide fines and the siliceous and refractory ores, other than in the blast furnace. A series of milling tests indicated that these products could be successfully treated by differential flotation, and in 1922 plans were made and a flotation plant built. It was estimated that the flotation plant would deliver to the smelter 40 to 50 tons of concentrates per day; the problem was what to do with these concentrates. It was out of the question to attempt to smelt them in a blast furnace because of the dust losses and because our practice demands a charge free from fines for satisfactory operation. There is no custom smelter in the vicinity to which concentrates may be sold, pending the time when the tonnage will be sufficient to warrant roasters and a reverbatory furnace. Sintering and nodulizing were investigated but neither method fitted into our scheme of metallurgy. A close study of the converter practice was then made to see if some method could not be evolved to smelt this tonnage of concentrates in a converter without preliminary treatment. At that time, the converter installation consisted of two 12-ft. Great Falls converters, which were handling 12 to 14 per cent. matte. The heat balance of the converters working with 12 to 14 per cent. matte was more than sufficient to smelt the contemplated tonnage of concentrates but the mechanical difficulties of feeding fines into the Great Falls converter made the use of this type of converter impractical. While there was no opportunity to experiment with the Pierce-Smith converter, equipped with a Garr gun, theoretically it seemed practical

Jan 1, 1925

By K. Norris

"The Campbell mill has undergone numerous changes over the past 43 years. However the rate of change has increased significantly in the last 4 years. A new grinding circuit, carbon-in- pulp circuit, pressure oxidation plant, and column flotation circuit are all new additions. Other changes have occurred in the last 2 years including a large reduction in sodium cyanide consumption, and the introduction of a computer controlled grinding circuit. More improvements are planned in the next 2 years. Some of these improvements include the construction of an effluent treatment plant, and the replacement of filtering and Merrill-Crowe precipitation with carbon-in-leach and electrowinning.Recent changes and improvements to the Campbell mill are a commitment by Campbell mill personnel and Placer Dome Inc. to decrease operating costs, increase gold recovery and gold production, improve industrial hygiene and safety, and meet environmental compliance with current government legislation.INTRODUCTIONThe Campbell Mine has been and continues to be one of Canada's premier gold mines. Campbell Mine is 100% owned and operated by Placer Dome Incorporated. Milling of ore commenced in 1949 at a rate of 300 tons/day producing 58,000 ounces per year of gold. In 1992 Campbell Mine will mill 1340 tons/day of ore at a grade of 0.6 ounces/ton, producing 275,000 ounces of gold at a cash cost of $205.00 Cdn./ounce.This paper discusses some of the changes that have been made to the Campbell mill in the past 4 years. The flowsheet has undergone extensive changes and will continue to change rapidly in the next 2 to 3 years. A simplified flowsheet of the Campbell mill is shown in figure 1."

Jan 1, 1992

By Frank A. Vonesh

In order to reduce the amount of visible, airborne emissions in the Metals Industry, a new Industrial Gas Technology was developed by Air Liquide. This patented technique is called ALECT?, Air Liquide Emission Control Technology. Demonstrations have been conducted for many cutting and lancing operations as well as for hot metal transfer from vessel to vessel. Fume reductions of 90% and greater have been achieved in actual practice. Air Liquide continues to improve the process and the associated control equipment.

Jan 1, 1994

By David Forrester

Subsidence beneath the land surface has traditionally been monitored using the most accurate surveying methods of the day. Over the several hundred years of subsidence investigation, these techniques have improved, and thus the accuracy of subsidence measurements has improved. In circumstances where the subsiding surface is masked by water or rock, novel methods must be developed. This method describes the recent successes of subsidence monitoring using advanced bathymeric techniques in the Sydney Coalfield. In order to obtain subsidence profiles above submarine coal extractions, seafloor bathymetry surveys, run before and after mining, have shown that subsidence profiles can be detected, despite the primitive nature of some of the trials. Very recently, there have been considerable advances in this field, associated with the availablity of high-powered personal computers to control data collection and analyse the results. The recent surveys described in this paper have demonstrated the considerable potential for such methods. This paper describes bathymetric subsidence monitoring developed in the Sydney Coalfield, illustrated with some typical results, and summarizes the findings of the research leading to the development of subsidence design criteria specific to the Sydney Coalfield.

Jan 1, 1996

By C. W. Morris

The continuous miner training system provides classroom materials training aids, and a continuous miner simulator to provide a short, intensive instruction and skills development program for training or retraining continuous miner operators. This project included refinement of training objectives, revision of training aids, improvements to the simulator, and evaluation of the entire system. This report describes the revised classroom materials and the validation of the training system.

Jan 1, 1982

By J. A. Herbst, G. A. Grandy, T. S. Mika, D. W. Fuerstenau, G. D. Gumtz

As a basis for interpretation of grinding behavior, the discretized batch grinding model is briefly presented and described, with solutions of the resultant equations for linear systems. Techniques for obtaining relevant experimental data are discussed for first order grinding systems, with methods for estimating other systems1 parameters from these data. Computer methods are described for conducting a sensitivity analysis which can be used to obtain an improved estimate of the system parameters. Examples of the use of the computer in conjunction with the grinding model for the simulation of batch grinding, locked-cycle grinding, and closed-circuit grinding are presented.

Jan 1, 1969

By B. Soundara, A. Suganya, S. Selvakumar

"Expansive soils have a potential for shrinkage or swelling under changing moisture content. Attempts were made to reduce the swelling potential of expansive soils with conventional additives such as lime, cement, etc. and non-conventional additives such as industrial wastes. In this research an attempt is made to study the feasibility of using granulated waste expanded polystyrene (EPS) as an additive to expansive soil to control swelling. To investigate the effect of mixing waste EPS granules with expansive clays, three expansive soils with different plasticity index were manufactured in the laboratory by mixing sand with sodium bentonite of various proportions. A series of standard proctor test, California bearing ratio (CBR) test, one dimensional free swell and swell pressure tests were performed on these soils. Test results show that the inclusion of EPS granules significantly reduces the percent swell and swelling pressure when subjected to one-dimensional free swell conditions. The dry density and CBR values decrease with increase in EPS content and increased plasticity of the soil.INTRODUCTIONExpansive soils cover an area of about 257 Million hectares on the earth’s surface (Dudal et al. 1965). In India, the area covered by expansive soils is nearly 20 percent of the total area (Mohan et al. 1961). Movement is usually in an uneven pattern and of such a magnitude as to cause extensive damage to various structures, especially lightly loaded structures or pavements (Chen 1975). Stabilization is one of the methods of treating the expansive soils to make them fit for civil engineering purposes. The variety of stabilizers may be broadly divided into three groups (Petry et al. 2002): (a) traditional stabilizers (lime, cement etc.), (b) by-product stabilizers (fly ash, quarry dust, phosphor-gypsum, slag etc.) and (c) non-traditional stabilizers (sulfonated oils, potassium compounds, polymer, enzymes, ammonium chlorides etc.). Apart from these, a number of other ground improvement techniques such as sand cushion technique (Satyanarayana 1966); cohesive nonswelling (CNS) layer technique (Katti 1978) were adopted for the stabilization of expansive soils. Expanded polystyrene (EPS) is a polymeric foam normally available in white colour and is a wellknown packaging material. The geotechnical specialists recognize EPS as the most commonly used geofoam material, a type of cellular geosynthetic which has been in consistent use in geotechnical applications since the early 1960s (Horvath 1995). EPS has very low thermal conductivity and nearly 98% of the volume is air (Lye et al. 2002). EPS has many exceptional properties such as being lightweight, thermal insulating, shock-absorbing and having low-water pick-up, etc. EPS find its applications in geotechnical engineering as light weight fills in the form of blocks (Refsdal 1985, Karpurapu et al. 1992, Zou 2001, Ikizler et al. 2008). EPS can be used as compressible inclusion and as a vibration damper (Horvath, 1994&1995). EPS is also used in lightweight concrete owing to its lightweight, excellent heat preservation and sound insulation properties (Ravindrarajah et al. 1994; Miledet al. 2004 and Babu et al. 2005). Waste EPS granules have been used in with horticultural soils to improve a number of soil characteristics like improving drainage, lightening heavy soils and improving water uptake capacity of soils (Scheirs 1998). Furthermore, it was also used as sub-base materials for pavements and railway track beds (Hanna 1978; Duskov1996), construction materials for floating marine structures and fenders in offshore oil platforms (Bagon et al. 1976), sea beds and sea fences; as an energy absorbing material for buried military structures, (Perry et al. 1991)."

Jan 1, 2017

By Wantae Kim

Ultrasonic stimulation of constituent suspension (metakaolinite/NaOH) can improve the rate of synthesizing reaction for zeolite Na-A. Zeolite Na-A can be synthesized from the suspension by sonicating treatment at comparatively shorter exposing time than conventional heating treatment. The main effect of ultrasound for the production of zeolite Na-A in the present heterogeneous solid/liquid reaction is intense stirring the solid and liquid substances to produce relatively narrow-sized zeolite Na-A particles with higher CEC value.

Jan 1, 2006

By R Holmberg, P A. Persson

Recent developments in the methods of measuring rock motion close to the contour at the moment of blasting have given an improved understanding of the extent of rock damage caused by different charge systems. The paper presents the new results and the methods of prediction of damage zones which are used in Sweden for the design of contour blasting rounds. A survey is given of the tools and the techniques for smooth blasting that are now used on a routine basis in Sweden.

Jan 1, 1978

By C. Jardine, D. Freudenreich

The system concept is to minimize costly unscheduled equipment breakdowns by replacing components earlier than their life expectancy. Periodic unit services are scheduled according to preset constraints. Service sheets are generated by matching a job and component master listing based on assigned cyclic component lives. The system can account for all man-hours reported, and history information can be selectively retrieved. By reducing unscheduled equipment shutdowns, this system allows for better manpower utilization and an overall improvement in equipment reliability and availability.

Jan 1, 1982

By Michael Weaver, Dale Ramsey

Description of Project: The National Gateway Clearance Initiative is an improvement program to achieve a minimum of 21 feet of vertical clearance along CSX Transportation Inc’s (CSX) rail corridor so that double-stacked intermodal railcars can be transported between mid-Atlantic states and their ports to midwest markets.

Jan 1, 2014

By Yang Guangqing, Shao Jiugang, Zhang Jianliang, Wan Dan, Fu Yuandi, Guo Hongwei

"Resource of metallurgical coke is becoming scarce, and although coke can be partially replaced by pulverized coal injection, there are many restrictions for further increase in coal ratio. Mixed charge of ore and lump coal from top to replace more coke was studied in this paper. Softening-melting property of the burden was affected by charge of lump coal. Softening-melting properties of mixed charge of ore and coke, mixed charge of ore and lump coal were tested respectively. Results show: the property of the burden mixed with coke is superior to the burden mixed with lump coal; lump coal would not deteriorate softening-melting property of the burden and some of them can even improve softening-melting property of the burden. Top charge of lump coal would not deteriorate softening-melting process, and this should be a new way to increase coal consumption to decrease coke rate.IntroductionThe blast furnace is still the predominant process for the reduction of iron ore and will probably remain so for the next decades. Metallurgical coke is becoming scarce and expensive, so the cost of hot metal can be decreased by reducing the consumption of metallurgical coke[l]. Coke can be partially replaced by pulverized coal injection, currently the highest rate of pulverized coal reached 266kg/tHM, most of blast furnace PCR is about 150kg/tHM, and it is very difficult to further increase of PCR. Nut coke is charged into blast furnace mixed with iron ore, not only for improving utilization of metallurgical coke, but also for lowering the coke rate. Presently the majority of blast furnaces in the world use nut coke although its amount is very different: from 10-20 to 70--100 kg/tHM and more[2-4].The effect ofnut coke in blast furnace is extensively researched, and the main conclusions recommend: to improve gas permeability of cohesive layer in blast furnace, to promote reduction of iron burden, protect metallurgical coke from the solution in the shaft due to higher reactivity of nut coke. There is no special requirement for the strength of nut coke[5-8]. Nut coke is also used for sintering fuel, which may lead to the shortage of the nut coke charging into blast furnace. So lump coal mixed with iron ore is considered to be charged into the blast furnace, not only to reduce the cost of grinding coal, but also to increase the use amount of coal."

Jan 1, 2013

By M. A. Meyer

Underground mining accidents in the USA in recent times have prompted the Mine Safety and Health Administration (MSHA) to review emergency and tracking systems for underground mines. Several communication and tracking systems are available on the market and various systems have been installed in mines around the world. In addition, MSHA?s standard on Diesel Particulate Matter (DPM) requires mines to comply with the final PEL of 160µg/m3 by May 20, 2008. Barrick Goldstrike Mines Inc., Underground Division, has been in operation since 1995 and an extensive control and monitoring network, and a leaky feeder voice network is in place. Enhancements to the communication and control system are currently being implemented to include a PED emergency notification system, wireless LAN with tracking of personnel and equipment in the mine, and a ventilation control system that will use the tracking information and ventilation data to automate much of the mine ventilation system. Expected benefits from such a system would be enhanced communication with miners, emergency notification, location of miners and equipment, energy savings, improved ventilation control, and improved atmospheric conditions in the mine including reduction of diesel particulate matter (DPM).

Jan 1, 2009

By R Sinclair, D Landwehr, I Hunter

"The Syama Gold Mine, located in southern Mali, was established in 1990 by Broken Hill Propriety Limited (BHP). The operation began treating oxide, and in 1994 it transitioned to processing hard and refractory ore based on ‘whole-of-ore’ roasting. In 1996, BHP was succeeded by Randgold Resources and the operation ran until 2001, when it was placed into care and maintenance.The Syama ore is classified as a double refractory ore with pyrite occluding the fine grained gold present in the ore and high levels of organic carbon presenting a challenge in terms of preg-robbing behaviour. The ore is extremely competent and this combination of metallurgical features was the main source of metallurgical problems encountered by the previous owners.Resolute Mining Limited (RML) acquired the Syama project in 2004. Following a feasibility study and the development of a revised processing flow sheet the plant was recommissioned in 2008 using a combination of old and new equipment. The revised flow sheet enabled primary sulfide ore to be treated by flotation and roasting of the concentrate to produce a calcine suitable for conventional carbon-in-leach (CIL) processing.Commissioning and ramp up of the plant was a troubled process, with monthly gold production being as low as 3000 oz in 2010. Poor availability of equipment and lower-than-forecast recoveries were the primary contributors.During the last five years, RML has utilised a systematic approach to improve production, focusing on mechanical reliability, metallurgical recovery and process bottlenecks. Modifications to the circuit have been as a result of both innovation and the application of technological improvements. Improvements have been made to the flotation, roasting and CIL circuits and RML has introduced a deslime circuit to treat flotation concentrate, in addition to the very successful commissioning of a new 1 Mt/a oxide circuit in December 2014. These changes have resulted in gold production increasing to more than 20 000 oz per month in 2015.This paper presents the processes, change implementation and outcomes of the modifications made to the sulfide circuit to address the availability and recovery problems.Apart from the expansion of an existing, world-class deposit and discovery of new resources, future improvements on the path to a class-leading gold mine include the continued reduction of the unit cash cost, increase in overall sulfide circuit gold recovery, increased throughput through continued innovation and consistency in the plant’s operation.Citation:Sinclair, R, Hunter, I and Landwehr, D, 2016. Syama Gold Mine - the Journey towards a Class-leading Gold Mine, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 213–224 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By César Ugaz Castañeda, Paulo Fernández Alvarado, Richard Sotomayor Oblitas, Rocke Enríquez

Mina El toro has been making substantial changes in its operation to improve its social impact and productivity. Because of the use of gasified emulsions and electronic initiation system, it was possible to mitigate vibrations and carry out massive blasting, increasing its production by 4.2% and minimizing complaints from communities.

Feb 1, 2020

By John Kazakoff, Andrew Mortimore

"Production at the remote Kumtor Gold Mine in Kyrgyzstan commenced on schedule in December 1996.The ore mined during the first few months of 1997 from the upper benches of the pit did not produce the results predicted by the feasibility study. Low metallurgical recoveries experienced at the time were cause for great concern.It soon became clear the recovery difficulties centred around the preg robbing nature of the ore.Procedures were developed to selectively stockpile highly carbonaceous low recovery ore types. Testing methods were developed in the mill to quante the preg robbing activity of the ore. Preg robbing masking agents were added to the process to reduce the preg robbing activity of the ore.The importance of coconut carbon activity relative to the preg robbing activity of the ore was realized. Every aspect of the performance of coconut carbon in circuit was evaluated and optimized to improve carbon activity.Mineralogical analyses were completed defining the deportment of gold in ore and process tailingsBy year end the recovery difficulties had been overcome and plant design production had been achieved. Process improvements continue through 1998."

Jan 1, 1999

By S. Afrouz, C. Keles, W. R. Reed, E. Sarver, T. Akinseye, A. Greth, L. Pan, F. Animah

The resurgence of severe lung disease among U.S. coal miners has not only highlighted the need for improved dust controls, but also the need for an improved understanding of dust characteristics and monitoring strategies [1]. Following up on prior work by the National Institute of Occupational Safety and Health (NIOSH) to demonstrate a novel wet dust collection system on a roof bolter [2], the current study explores the effect of that system on dust characteristics and uses interlaboratory comparisons to comment on analytical methods. Results indicate the wet system did not appreciably affect the composition or size of respirable dust in the vicinity of the operating roof bolter. However, the system does appear to have substantial benefits for the operator. NIOSH has already shown it can reduce the respirable dust mass concentration to which the operator is exposed during dustbox cleanout [2,3], which is a frequent maintenance activity that can re-aerosolize dust, and new results here indicate the silica and silicates content in this dust may also be reduced, thereby reducing the overall hazard. Moreover, regarding analytical methods, excellent correlation was demonstrated between measurements of quartz mass, taken first by NIOSH and then by a university laboratory, using direct-on-filter Fourier transform infrared (FTIR) analysis. This method is the basis for envisioned “end of shift” silica monitoring (quartz is the predominant form of crystalline silica in coal mines) [4]. For particle-level analysis by scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDX), there was more variability in results generated by two independent university laboratories.

Mar 1, 2024