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By P. R. Hervey, J. W. Foise

Quartz is the second most widely used electronic material, with approximately 3,000 t (3,300 st) of single crystals used each year. Most of the quartz used in electronics is synthetic and is manufactured using a technique called hydrothermal growth. This paper reviews the basics of hydrothermal growth, the feedstocks used for these crystals and the challenges to improving the growth process. This paper also reviews the processing of these crystals, the markets and applications where they are used, and the global outlook for these markets.

Jan 1, 2002

By Fuller P. G, Dugan K. J

Artificial support can be used to improve wall stability in open pit mines. This is examined for a particular case where the factor of safety for a slope is kept constant by using artificial support as the slope angle is increased. It is demonstrated that the savings in excavation generally exceed the cost of support. However, in order to correctly judge the eco- nomic impact of artificial support on the project, all the elements relat- ing to the use of artificial support must be taken in account.

Jan 1, 1989

By Lori Kormos, Jhonny Carrión De la Cruz, Dominic Fragomeni, Elizabeth Whiteman, Jorge Oliveira

"Process diagnosis, flowsheet design and optimisation are most effectively and efficiently achieved through the use of metallurgical testwork combined with more modern quantitative mineralogical techniques. Integration of the mineralogical data in testwork programs provides a resolution that cannot be obtained from assays alone and can direct the flow of work to result in optimized conditions more quickly than would otherwise be possible. At Xstrata Process Support (XPS), QEMSCAN (Quantitative Evaluation of Materials by Scanning Electron Microscope) and EPMA (Electron Probe Micro Analyser) information can be employed to diagnose specific issues in a plant or lab scale test and are routinely combined with other metallurgical data sets to benchmark performance, design and optimise flowsheets. Representative sampling protocols for ore bodies or test products, the use of geometallurgical unit classification and high confidence metallurgical test programs are key components of the strategy. Two case studies from Xstrata Zinc’s Antamina Mine and Concentrator in Perú, and Xstrata Nickel’s Nickel Rim South Mine in Sudbury are described to show how the use of quantitative mineralogy were used to diagnose a plant issue and how the data can be integrated into metallurgical programs to assist mineral processing engineers to design and optimise flowsheets.INTRODUCTIONOver the past decade, there has been a shift away from metallurgical testing that employs only chemical assays to quantify performance; the use of empirical observation in order to optimise a flowsheet; and the extraction of bulk samples for testing or piloting. The integration of geological information into the planning and execution of testwork programs including the use of quantitative mineralogy has improved the overall quality and predictability of metallurgical programs. At the same time, improvements to metallurgical testwork protocols such as rigorous statistical assessment of results, the use of factorially designed experimental strategies (DOE), and replicate flotation with appropriate quality controls, has improved the confidence level in these results.Process diagnosis, which utilizes quantitative mineralogy, can clearly define the root cause of the metallurgical issue. Whether used on its own to diagnose an issue or in combination with other metallurgical testwork, the use of mineralogical data has become the standard in the mining industry."

Jan 1, 2010

By R. J. Robbins

The mechanization of hard rock underground mines offers a large potential for reducing cost, improving efficiency, and increasing profitability. However, in spite of serious efforts by quite a number of equipment developers and mining company initiatives, the industry has achieved little real progress. The task is difficult and the blasting alternative to mechanical excavation is an effective and well-developed method, which continues to improve in spite of its inherent limitations. A large number of machines have been built and tried. Only a few developments have succeeded to make a major impact on underground hard rock mining. It is certain that hard rock mines would be laid out and designed quite differently if the mining engineers knew they had available continuous mechanical excavation machines. In the absence of the machines, mines will be designed for excavation by traditional methods. It is not easy to utilize mechanical excavation in a mine which is designed to operate with normal drill and blast excavation. This is certainly an impediment to machine development. But what if an ore body cannot be mined conventionally, simply because the mining company cannot get permits to satisfy the ever increasing strict EIS requirements of the general public and governmental agencies? This may provide the incentive necessary to develop the equipment that will be needed by a new mining method that will have almost no impact on the environment.

Jan 1, 2001

By G C. Sen

All mining and quarrying operations that employ blasting to fragment and move broken ground have a price to pay for æby-productsÆ such as vibration and noise. These æby-productsÆ cannot be eliminated but they can be controlled and modern blasting techniques have improved to the point that excessive environmental restrictions can be adhered to whilst maintaining acceptable production rates and quality. Accurate measurement is the key to control, and as the environmental limits are becoming tighter, the proper way to measure vibrations from blasting operations becomes an integral part of the mining or quarrying operations. The basic vibration monitoring system consists of a primary sensor connected to a data logger and computer software for the analysis of the signal received and recorded. Currently, as with all fields of measurement, much improvement has occurred over the past decade, and electronic devices are much more accurate and reliable. Data analysis has also improved considerably with the computing power that is available to field operatives today. Mounting the primary sensor has been often overlooked in supposed æstandardsÆ with procedures such as double sided tape, resting on a flat surface provided the vibration level is less than a given amount. But if it is worth going to the expense of the monitoring equipment and manpower, surely it is worth a little extra effort to ensure the primary sensor is coupled to the ground effectively. The primary sensor must move with the ground and measure this movement; so if the primary sensor is allowed to move without respect to the ground (ie poor coupling to the ground) then a false record of the physical event will be measured. This scenario can easily be a practical reality if the primary sensor coupling method to the ground is not effective. In this study a number of mounting methods were fabricated and connected to similar data monitors and a series of ænormalÆ production blasts were used as the vibration source. These mounting devices were measured against an in-house procedure (the æstandardÆ) and the relative merits compared. A laboratory investigation was also carried out to look at the physical parameters of the æsoil and their effect on vibration attenuation of the in-house standard method.

Jan 1, 1999

By R. Ward Stahl

This publication is a revision of Report of Investigations 5363 updated to reflect the improvement in fire protection at selected coal mines and contains suggestions on what may be considered good fire protective equipment, suggested methods of organizing the attack on fires at various locations underground, and helpful hints on testing and evaluating firefighting facilities.

Jan 1, 1968

By Bernard Schneider

The diversity of methods available to engineers and geologists for studying rock masses is a reflection of the fact that, despite the rapid and encouraging progress made over the last few years, there is still no unified and comprehensive method which can be used to predict the over- all behavior of a foundation. Nevertheless, it is agreed that the fundamental characteristic affecting the engineering properties of rock is fissuration, and this paper de- scribes a few new or improved methods of studying fissuration and its influence on major engineering factors such as permeability, deformability, or internal stresses in the rock volume. TESTS ON SAMPLES Conventional tests on samples using thin slices can be improved by staining the slices before cutting with certain ionic dyes which have an affinity for certain types of surface. This shows up the microdiscontinuities. For example (quoted terms are French trade names) : "Turquoise Motylhne JSA" will show up porous alteration of basic feldspars. "Vert brillant SA" is used for acid feldspars. "Fushine ASA" will show up voids in all rocks. A mixture of "Turquoise" and "Rhodamine BSA" will show up zones of alteration in all types of feldspars. With this technique, it is easy to make an optical classification of the different structural types, e.g.: (1) rocks completely free from voids; (2) rocks with microfissures, which in turn can be subdivided into (a) rocks with microfissures secant to the mineral structure, (b) rocks with microfissures parallel to the mineral structure, and (c) rocks with ran-

Jan 1, 1970

By Donald V. Fites

In the face of an increasing demand for minerals, the resulting technological developments, and rising overburden-to-ore ratios, many open-pit mines now incorporate totally different concepts for the removal of ore and overburden. Moreover, under a growing number of these concepts, wheel tractor scrapers are being assigned a major role in material- handling systems for unconsolidated overburden removal. To say that scrapers move only unconsolidated overburden is incorrect. On the contrary, ripped phosphate rock, copper ore, iron ore, and moderately consolidated overburden are also being moved by scrapers in various areas of the world. According to the Minerals Yearbook, about one half of the material moved in metal and nonmetal mines is never drilled, blasted or broken by other means. Scrapers Find Wider Application The increased use of scrapers in open-pit mining today is due in part to improved design which has endowed these units with added versatility and in- creased their production capability. The modern scraper, which is designed as a loading and hauling vehicle, cannot be compared to the original tractor- drawn scrapers which were limited in capacity, maneuverability, and speed. Improved design of the scraper bowl ejection system has aided production. Gravity ejection has been replaced with positive, forced ejection of material by hydraulic or mechanical action. Bowl and cutting-edge design which allows for maximum load with minimum effort has also increased production. An example of this was the introduction some years ago of the low-silhouette scraper bowl which reduced the work required to lift the material.

Jan 5, 1969

Economic Significance of High-grade Concentrates BY PAUL M TYLER AND CARLE R HAYWARD (Min & Met, Dec, 563 4000 words) Generally pyro¬mctallurgical methods yield a higher recovery but cost more per ton of ore treated Milling methods are inherently cheaper for the reason that they do not involve dissipa¬tion of heat energy in slag formation, ctc It is vaguely realized that the smelter man could do a better job if he were supplied with purer raw materials but hard¬headed mill men have been offered little inducement to do a really good job of cleaning concentrates To do this may involve some sacrifice in percentage yield and in mill capacity and unless there is a compensating saving in freight and smelter charges, it simply is not good business to go beyond a certain point in the way of making clean concentrate Opportunities exist for eliminating one or more steps in the expensive series of processes for recovering various metals, or at least reducing the volume of materials that has to be handled at the most costly steps The beneficiation of nonmetallic minerals likewise affords numerous examples of over-all economies obtainable through more refined methods of mechanical improvement All this leads to the conclusion that perfecting selective processes for isolating pure minerals (e g, galena) virtually free from other sulfides as well as gangue may be productive of industrial economies Conversely, cheapening smelting methods may invade the field of mechanical improvement of ores but, as Kiphng said, that is another story

Jan 1, 1937

By Richard F. Lynch, Frank E. Goodwin

"The development of Galfan, a new generation 95% zinc-5% aluminum-mischmetal alloy coating for steel, offers opportunities for greater fabrication flexibility and upgraded corrosion performance in automotive applications. The formability of Galfan is equivalent to that of electrogalvanized steel, based on laboratory tests and automotive component fabrication. Corrosion resistance of Galfan exceeds that of hot dip and electrogalvanized, including performance in automotive industry tests. Automotive production applications for deep drawn and stamped components in France and Germany are based on the ability to meet dual performance requirements for upgraded formability and corrosion resistance. The first U.S. Galfan application was on 1985 model Ford cars and light trucks for transmission oil cooler lines which has now expanded into a number of power steering tubing uses. IntroductionContinuing requirements for improved vehicle performance coupled with the ever present need for reduced cost have spawned the development of a number of new coated steel products. Among this new generation of coated steels is Gaifan™, a 95070 zinc-Solo aluminum-mischmetal hot dip alloy coating. Galfan exhibits particular promise for automotive use based on broad fabrication advantages and upgraded product performance(I ),The unique characteristic of Galfan is the key combination of greatly improved formability with much longer corrosion life. Galfan provides significantly better formability than any other hot dip coating. Testing shows that formability is limited primarily by the steel substrate to which the Galfan coating is applied. Galfan exhibits excellent resistance to flaking and microcracking during commercial forming operations. The result is the elimination of unnoticed damage to the coating which would show up later as premature rusting on the finished product."

Jan 1, 1987

By J. Iannicelli

Kaolin, normally an inert filler when compounded with polymers, is converted into a strongly reinforcing pigment by prereaction with certain functional silanes. Modification of kaolin with amino and mercapto silanes allows it to form crosslinks and confers significant improvements in modulus, abrasion resistance, compression set and other physical properties of a broad range of polymers.

Jan 1, 1990

By Dave Deglon

"The Western Cape Mineral Processing Facility (WCMPF) is a collaborative educational initiative between the Departments of Chemical Engineering of the University of Cape Town, the University of Stellenbosch and the Cape Technikon. The primary objective of the WCMPF is to facilitate the education, development and graduation of suitably qualified engineering graduates and diplomates for the mining industry. The WCMPF consists of academics and Technical Officers in the Departments of Chemical Engineering of the three tertiary institutions. The Technical Officers are usually metallurgists, with several years of industrial experience. The main objective of the Technical Officers is to improve the practical education of mineral processing students. In addition, the Technical Officers are responsible for organising an annual mineral processing student field trip for students from all three tertiary educational institutions. In recent years the WCMPF has embarked on a number of additional initiatives aimed at improving the quality of mineral processing education. These include the development of several new pilot plant practicals, an initiative in pyrometallurgy, the introduction of novel ‘end to end’ or ‘integrated’ practicals and the use of mineral processing simulation packages to complement the practical training.The WCMPF has been functioning for well over a decade and, by virtue of this, might be considered a successful collaborative educational initiative. The WCMPF has played a key role in the education of over five hundred mineral processing graduates and diplomates. During this time period, the WCMPF has gained a body of internal knowledge which might be of benefit to other educational institutions, viz."

Jan 1, 2003

By Mark Holdsworth

In 2002, Kennecott Utah Copper Copperton Concentrator installed an Expert Control system for optimization of their SAG and Ball milling circuits. The advanced process control has been well received and is utilized well over 95% of the time. In the years since, many lessons have been learned and many advances have been made. Improvements have produced millions of dollars of benefits and have included directly controlling feedrate with complex logic as opposed to using a bearing pressure controller, modifications to how sound is used for control, modifying logic for maximizing asset utilization and using advanced control for automating equipment restart.

Jan 1, 2012

By Thomas Schanz

Current steel market conditions require small investments only to lower operational cost. SMS Concast has developed new products which optimize continuous casting process cost for long product steel production. This paper describes a selection of three products. All three systems are patented (patent pending for CONDRIVE). CONSAFE, a non-radioactive mould level measurement system for reliable mould level measuring on open stream casting CCM’s; CONSTIR-MWS, an improved control software for electromagnetic stirrers which lowers energy cost by 35%; CONDRIVE, a brand new oscillation drive system which provides the features of a hydraulic oscillator, however with a cost efficient electric drive.

Aug 17, 2017

By D Brett

The Paper presents the authors thoughts on how the mining industry should be improving the education of site personnel so they can provide a greater level of effective control of tailings dam safety including empowerment to develop their own documentation, monitoring and surveillance systems and to better liaise with specialist external technical staff or consultants.

Jul 1, 2021

By Noel Jarrett

Energy consumption and distribution in aluminum production, conservation accomplishments, and future goals are presented. Electrolysis and electrode manufacture show the greatest promise for major improvements. Means are proposed for reducing waste heat generation in smelting and for conserving energy in anode manufacture by furnace design and substitution of other materials for petroleum coke. Hall-Heroult Process modifications, alternative designs, and the Alcoa Smelting Process are discussed as energy savers. Scrap recycling, more use of aluminum in transportation, and the installation of offshore smelters in less developed countries are shown to be additional means of coping with possible energy dislocations.

Jan 1, 1981

By G. H. Blackwell

Open pit mine management must ensure that sufficient trucks are available and are being used effectively for production, and that operating costs are under continued control and review for improvements. This paper describes methods for estimating truck fleet requirements which have been used effectively at large- and medium-sized open pit mining operations. Applied to commonly available data, multiple regression analyses can indicate when mine plans should be revised toward optimizing the number of trucks required. Prediction of major cost items for budgetary purposes is addressed, along with an example of how readily available production data can be used to reduce costs systematically.

Jan 1, 1999

By Hossein Kazemi

This article is a review of fluid flow and mass transport in fractured rocks. The topics include: single-phase and multiple- phase flow theory, formation productivity or injectivity improvement by artificial fracturing, and mass transport associated with fracture acidizing. Possible extension and application of such ideas to in situ mining in fractured rocks are presented.

Jan 1, 1974

By Zoltan F. Oszter

Feeding bulk solids from bins or bunkers sometimes poses a problem to the materials handling engineer. The paper describes, by practical examples, how material flow can be improved on existing installations, and how difficult-to-handle materials can be successfully drawn from storage and fed to fully automated process systems. The examples illustrated are based on actual experience with projects designed for the mining and metallurgical industry. Maintenance costs, where available, are also indicated.

Jan 1, 1966

By J. P. Thomson

Magnesium alloys are steadily improving their market share as structural components especially in the transportation sector. Therefore, there is a great deal of interest from the automotive and the metal casting industry to develop viable economic casting processes for magnesium-base alloys. This paper summarizes the preliminary results on the continuing projects within CANMET-MTL on casting processes such as gravity and low-pressure casting in sand molds, permanent molds and lost foam.

Jan 1, 2004