Search Documents

By J. Visman

"SummaryThis paper is presented as part of a programme to show the steps taken by industry and others interested in supplying a solid fuel of constant quality to 'satisfy a consuming market. The paper deals with the general principles underlying quality control in coal preparation plants, namely, constant quality and close adherance to acceptance limits. It also describes how control of ash content is ""generally hampered by the problem of coal sampling .and the long duration of the ash analysis and how these difficulties may be overcome.Quality control can be effected in several ways. Thorough blending wll reduce variations appreciably, except those of long trend. The latter can be detected by automatic sampling and quick ash analysis. At present, under favourable conditions, a system of half-hourly ash determinations with an accuracy of 0.5 to 1.0 per cent can be realized, to the effect that trends with a 'wave length' of more than two hours cu be eliminated within the limits of accuracy of the ash figures. The general solution of the problem is a combination of blending, accurate sampling, quick ash determination, and statistical analysis of the pattern of ash distribution.The use of statistical methods of analysis, such as the t test and F test, is •discussed at some length in order to emphasize the importance of the correct evaluation of observational data if there is to be confidence in the validity of test results.General ConsiderationsCOAL, as a fuel, is too cheap for a long haul across the country. The limiting distance depends on the price of the local competitive fuels, and, as the price depends to a great extent on quality, so does quality, to the same extent, command the market."

Jan 1, 1952

By Daniele Tolazzi

In today’s highly competitive market situation, it is of outmost importance for EAF steel makers to optimise their processes in order to reduce operating costs and to improve safety and reliability of the equipment. The laser based off-gas analysis technology, With laser units installed on the fix duct, downstream the combustion gap, uses the “Tuneable Diode Laser Absorption Spectroscopy” (TDLAS). The system performs real-time off-gas emissions measurements of CO, CO2, O2, H2O and temperature. A closed-loop operation is in place for dynamic control of the chemical energy package combustion/post-combustion of CO, H2 and CH4 gases into the EAF furnace shell. A statistical framework which builds on a data analysis engine, based on Danieli Automation Q3Intelligence technology, evaluates the “fingerprint” of the process represented by average and deviation trends of both gases and other process parameters. Process fingerprinting is conceived both for offline profile optimisation and on-line control of the refining process. This paper describes how the technology has been applied and the results achieved at ACCIAIERIE BERTOLI SAFAU (Italy) 100 t AC Electric Arc Furnace.

Aug 16, 2017

By Philip E. J. Green

Two of the cornerstones of total quality management, the use of statistical and problem solving tools, and the involvement of employees, are directly applicable to environmental protection. The reduction in variation decreases the chances of violations and mishaps. Involving employees in minimizing environmental impacts is critical. One mistake, even with the best technology, and your plant can be shut down, customers lost and fines and penalties imposed - your reputation and the environment damaged. Proven strategies for involving employees in environmental protection, and over-coming the frequently strong differences of opinions about what constitutes environmental protection, will be discussed.

Jan 1, 1992

By M Haest, O Dominguez, D Mittrup

With the current focus in the mining industry on reducing costs, while simultaneously improving ore quality, infrared spectroscopy is a tool that can potentially assist companies to meet both challenges. Changes in the nature of infrared spectra are strongly influenced by changes in mineralogy, which is a key input variable for exploration (geology and orebody modelling and ore characterisation) and mining (pit design, mine scheduling and processing plant design/management).Infrared spectroscopic logging of drill holes has been embedded as a standard tool in BHP Billiton Iron Ore exploration, with a process set up to automatically deliver mineralogy and associated imagery to the end users (typically exploration geologists). The availability of consistent and automated mineralogy drill hole logs across a project is improving the output quality and reducing re-work.BHP Billiton Iron Ore is now looking into using the same infrared spectroscopic data for other applications, including improving predictions of geometallurgical and geotechnical parameters. Trials show that addition of infrared spectroscopic data to conventional data sets (element analysis and depth information) is significantly improving the accuracy of regression models to predict the lump-fine ratio.Further initiatives around infrared spectroscopic data in BHP Billiton Iron Ore include the installation of infrared spectroscopic sensors over conveyor belts, infrared spectroscopic mine face scanning and infrared spectroscopic blasthole logging. The ultimate vision is to have consistent, seamless mineralogical data from infrared spectroscopic sensing available throughout the mineral value chain (exploration/mining/processing). This seamless infrared spectroscopic data ‘bridge’ will allow the transfer of knowledge between the different sections of the value chain (exploration, mining and processing). For example, ore handle-ability could be predicted on exploration samples using regression models built from processing plant observations. In the opposite direction, information gathered about the buried stratigraphy by infrared spectroscopy utilised during exploration, could be used to predict the stratigraphy encountered during mining. This collaboration across BHP Billiton Iron Ore is expected to deliver significant savings, while improving the quality of the final product, thus helping to drive efficiency over the next decade.CITATION:Haest, M, Mittrup, D and Dominguez, O, 2015. Reaping the first fruits – infrared spectroscopy: the new standard tool in BHP Billiton Iron Ore Exploration, in Proceedings Iron Ore 2015, pp 277–284 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By Sara J. Davenport

The human race has been exposed to copper for thousands of years, as copper and gold were the metals first used by man (1). if According to Ramazzini (2), "of all the metals that man's ingenuity has contrived to dig out of the bowels of the earth, iron and copper are the most useful, far more so than silver and gold." Workings of copper in the oldest known copper mine associated with the smelting of this metal have been traced back to 4300 B. C. Facts revealed by archeological research in India, Austria, Hungary, France, Italy, and Spain indicate that the use of copper probably began about 5000 B.C. (3), and that about 4000 B.C. a copper age came intermediate between the stone and bronze ages (4). Copper ores are rather widely distributed and are found in nearly every country. Many of the copper minas of Europe have been worked since before the Roman Empire. The must important mines in Europe occur in the district around Huelva, extending into Spain and Portugal. The German deposits are located mainly about Mansfeld (Rhenish Prussia); they have been worked continuously for 1,000 years. Some of the mines in Africa have been worked by the natives for centuries, and China has produced copper from shallow pits for thousands of years. India also has many ancient mines worked in the early centuries (2).

Jan 1, 1953

By R Goater, P Kirsch, S Goater, I Goater

With staff productivity and retention a crucial factor in the longevity of AustraliaÆs mining industry, some mining companies are increasing their focus on the health and well-being of their people, to minimise the risks of deteriorating health in an ageing workforce. Many of AustraliaÆs mining operations rely heavily on long distance commuter (LDC) rosters, which are argued to have a significant impact upon worker health, wellbeing and lifestyle choices. The potential impact of workforce health on mine safety performance, efficiency and operating practice is an interesting additional line of enquiry. Food choice, exercise and recreation initiatives offer living and working conditions that æempower healthy choicesÆ in the shift worker community, but do not guarantee improved worker wellbeing. This paper explores first-hand the experiences of one individual over two and a half years of employment at different mine sites, under different shift conditions and across different operating crews. Novel insights and recommendations concerning the LDC lifestyle are offered through integrating reflections on one individualÆs fly-in, fly-out (FIFO) experiences in open pit mining operations from personal, family, professional and academic perspectives.CITATION:Goater, S, Goater, R, Goater, I and Kirsch, P, 2012. This life of mine - Personal reflections on the well-being of the contracted fly-in, fly-out workforce, in Proceedings Eighth Open Pit OperatorsÆ Conference , pp 31-40 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 18, 2012

By H. Cho

There is an indication that high-pressure roller milling promotes selective liberation due to preferential breakage along the mineral boundaries. A study was undertaken to compare the degree of liberation obtained by high-pressure roller milling with that of conventional ball milling. Coals with different HGI's were ground in a high-pressure roller mill and a ball mill to produce products with similar size distributions. The products were then subjected to float-sink separations to determine the degree of liberation. Also, the relative cleanabilities were compared by separating the ground products by froth flotation. The results from this study are presented in the paper.

Jan 1, 1994

By Paul Pugsley

The EMSpec sensor employs the principle of measuring the complex impedance of the target steel over a range of frequencies these impedance values in turn varies with transformation fraction of the steel. A full scale implementation of the Real Time Transformation Monitoring has been installed at a quality large European steel producer to show the benefits of such a system. A total of three EMSpec sensor heads have been installed between the exit Finishing Mill and the Down Coiler on a HSM. For the successful production of Dual Phase, TRIP and TWIP steels increased control of the cooling regime is demanded; the use of surface temperature measurements alone cannot guarantee to achieve the desired mechanical properties. The EMSpec sensor, which is engineered to withstand this harsh environment, in real time directly measures the percentage transformation of the steel in the cooling area, typically in the accelerated water cooling zone. Using the information from the sensors integrated into the mill model enhances the models ability to predict the transformation profile.

Aug 17, 2017

By E. E. Harton

Bureau of Mines Information Circular 16, Bibliography of Investment and Operating Costs for Chemical and Petroleum Plants, was published in October 1949 as an aid in making estimates of investment and operating costs of processes for manufacturing synthetic liquid fuels. Development of such processes by the Bureau of Mines was authorized by Public Law 290, 78th Congress. This bibliography included refer¬ences to and abstracts of publications appearing from 1930 to September 1948 on all processes in general use in the petroleum refining and chemical industries. Publications in this field have been numerous since compilation of the above bibliography, and the present report was prepared to cover the field from September 1948 through June 1952.3/

Jan 1, 1955

By P. V. Amosov, V. A. Masloboev, D. V. Makarov, S. G. Seleznev, A. A. Baklanov

"The development of industry and intensive use of natural resources leads to a significant decrease in the share of reserves of rich ores, deposits of which have nearly all been exploited. Large amounts of displaced rock mass are accumulated, significant emissions of gas and dust from mining, dust from dumps and tailing pits, ingress of chemicals and toxic elements in surface and groundwater all can have negative effects on existing ecosystems and human health. Especially dangerous is the impact in Arctic regions with extreme climate conditions. The maintenance of overburden dumps and tailings dams requires significant capital and material costs. In this paper, some mining enterprises of the Murmansk region, in the Russian Federation, consider the environmental problems of the industry and propose some solutions.INTRODUCTIONThe safety of environment during the extraction and processing of minerals is a very acute problem throughout the whole world. The problem acquires a specific character in the Russian Federation. There, rather poor minerals, often existing in unconventional forms and including several mineral components are processed. The Russian mineral base has a specific geographical location; most of the deposits under operation are located in the Subarctic or Arctic regions, as well as in Siberia and in the Far East. Vast amounts of rock waste and tailings pose serious economic and ecological problems in mining regions. The operation of overburden heaps and tailings requires considerable capital and material costs. The dumps withdraw vast lands from potential commercial use. Large amounts of mined rock disturb the existing geological balance; emissions of gas and dust which accompany the mining operations, dusting of waste heaps and tailings, emissions of reagents and heavy metals into natural surface and ground waters all can produce negative effects on existing ecosystems and human health."

Jan 1, 2016

By R. J. Gunderman

Explosionproof electrical enclosures for coal mine face equipment have been of the same basic design for many years without significant change. Characteristics for potential improvement were investigated through interviews, visits to mines and studies. Improved safety, health and productivity were the goals. Areas identified for improvement included rapid venting of pressure build-up due to an internal explosion, quick and easy entry or removal of cable entrances, and a quick and easy cover removal for rapid component access. Concepts were identified and evaluated, and the more promising devices were fabricated and tested. Encouraging results from initial tests led to further design refinement and establishment of design guidelines. These design guidelines for a pressure vent and for an elastomeric grommet type cable entry are described along with the testing used. An application for an experimental permit was requested from MSHA. After test and evaluation experimental permit #396 for evaluation in an underground coal mine was granted.

Jan 1, 1980

By Yi Yang, Xiuzhu Su, Wei Sung Ng, Shuiping Zhong, Miao Chen

With over 260 tons of gold reserves, the Shuiyindong gold mine is one of the largest Carlin-type gold deposits in China. A particular challenge in the processing of the ore is the presence of carbonaceous compounds, which can cause substantial losses in recoveries via the preg-robbing and adsorption of gold. To investigate the structural properties of the native carbon and to compare between different characterization techniques for such compounds, pre- and post-flotation mineral samples containing 0.9–4.8% non-carbonate carbon from the Shuiyindong mine have been examined via mineralogical and thermogravimetric approaches, as well as spectroscopic techniques, including X-ray photoelectron spectroscopy (XPS), near-edge X-ray absorption fine edge structure spectroscopy (NEXAFS), solid-state 13C nuclear magnetic resonance (NMR) spectroscopy, diffuse reflectance infrared Fourier transform (DRIFT) spectroscopy, Raman spectroscopy and preg-robbing measurements. NEXAFS and DRIFT yielded the most reliable results, indicating that 60–75% of the organic carbon in all samples consist of aliphatic alkenes with substantial unsaturated content, highly similar to activated carbon, with the remainder being graphitic and humic. Speciation by XPS was sub-optimal due to spectral overlaps between graphitic and aliphatic carbon, and between carboxylic and carbonate functionalities, while NMR spectroscopy could not provide reliable speciation of the carbon groups. The preg-robbing strength was strongly correlated to the aliphatic content and structural disorder in the carbon, while no such relationship was found with the graphitic and humic content.

Nov 29, 2021

By M. Mai Manga, M. Renaud, A. Faucher, C. Bazin

ABSTRACT Grinding circuits are operated in the presence of disturbances resulting from ore changes and equipment malfunctions, such as hydrocyclone overloading, worn or partly plugged apexes, surging, and internal liner detachment that may cause a loss of classification performance. Metal recovery losses in downstream leaching or flotation circuits justify the development of methods for rapid detection of hydrocyclone malfunction. Two methods are presented in this paper. The first method uses measurements from sensors available in a grinding circuit and the second uses vibration sensors installed on the individual hydrocyclones of a nest.

Jan 1, 2011

By Ralph H. Whaite

To assist the anthracite industry obtain technical data on pneumatic packing, the Federal Bureau of Mines imported a pneumatic packing machine from Germany and installed it in a mine of a cooperating company in the Northern anthracite field of Pennsylvania. This report covers the second in a series of experiments in applying pneumatic packing for controlling strata movement (subsidence) above mine workings in the Pennsylvania anthracite region. The first experiment2/ was begun in January 1950, in a section of the mine where about 50 percent of the original coal remained in the form of pillars; since the company did not plan to mine the pillars in this particular area, pneumatic packing of the chamber voids was done for test purposes only. During this initial test the machine was operated on 204 shifts, and 652,400 cubic feet of breaker refuse material (22,834 tons) was packed into the voids of 16 chambers. The work was completed in December 1951.

Jan 1, 1956

By T. Hofbauer, M. J. Dry, G. B. Harris, C. W. White

"Urban Mining is a term that is increasingly being used, and represents an appreciable source of secondary materials for the metals extraction industry, a source that does not incur mining costs, but does, at present, incur considerable disposal costs. Electric Arc Furnace Dust (EAFD) is probably the most common of these materials, with an estimated global production of 8 million tonnes annually, of which 1 million tonnes is generated in North America. The contained annual metal value in EAFD at current prices is of the order of $6 billion, yet, apart from the zinc, virtually none of this is recovered.Despite many attempts over the years, with pyrometallurgical, hydrometallurgical or hybrid processes, currently the only commercially viable method of treating these materials is smelting in a Waelz Kiln (or a Rotary Hearth Furnace), which essentially recovers only the zinc, in an impure oxide form, and generates a secondary slag waste, which is still toxic and requires disposal. This paper describes the development of a chloride-based treatment process to recover all components of the EAFD in a marketable form, which centres around the novel hydrochloric acid recovery and recycle operation. Laboratory, miniplant and pilot plant data are presented, leading to the definition of a viable process flowsheet enabling the recovery of pure iron and zinc products (the principal components of EAFD), together with secondary products such as copper, silver, lead, cadmium, magnesium and manganese. A rigorous mass-energy balance is used to examine the preliminary economics involved."

Jan 1, 2014

By V. F. STANLEY

THERE is not the slightest doubt that the present recoveries of valuable minerals by the Broken Hill mills could be improved, and that further machinery would be installed for the purpose if it could be assured that a high price of metals would be maintained; but concentration, like all other com¬mercial propositions, is a question of profit and loss, and no sensible metallurgist would carry out his work in such a manner as to obtain high recoveries at a financial loss to his company. There is a point in all concentration at which the added money obtained from the higher recovery of minerals is balanced by the extra cost of obtaining the last part of the recovery; a wise metallurgist will be content with his work before his working-expenditure reaches this point. To a casual observer, the work being done by the various Broken Hill mills is identically the same. A closer investigation will show that this is far from being the case, for it is a remarkable fact that, although the larger mines extend over a length of approximately only 2 miles, such a difference in the physical and chemical properties of the ores exists that, from the first reduction downwards, special treatment is necessary in each case, and hardly any two mills are identical in operation. The details of this paper refer directly- to the work of one . particular mill in Broken Hill, for the reason that the ore from each mine presents special difficulties and requires its own special treatment. I have selected the mill referred to because it has been constructed and modified under my supervision.

Sep 1, 1909

By Sunny Murmu, Gnananandh Budi

One of the most significant concerns in longwall ground control is the instability and failure mechanism of the coal wall. The current research uses FLAC3D to simulate panel 1 of the Adriyala Longwall Project, India, in order to evaluate the distribution of vertical stress and material failure mode, in and around the longwall face. Additionally, three distinct criteria are used to evaluate coal wall spalling: vertical stress distribution, maximum shear strain, and residual cohesion. A novel algorithm is also proposed to appropriately capture roof bed caving, shield installation and advancement, and coal extraction from the face. The findings of the modelling show that progressive longwall extraction creates an elliptical stress relief zone around the excavation void. During the peak stress phase, the height of the stress relief zone is greatest, whereas the width is highest during the main fall phase. As mining advances, the coal wall at the face line appears to lose its stress-bearing capability. Shear failure was the most common coal wall failure mode. Maximum spalling depth (MSD) and longwall face spalling index (LFSpI) were used to measure the extent and volume of coal wall spalling in FLAC3D. For panel 1 of the ALP mine, the MSD, and LFSpI were determined to be 3 m and 90.5 %, respectively. The mode of coal wall spalling was expected to be total or fragmented failure. The field observations and the numerical modelling findings were in good agreement. The compressive strength and deformation modulus of the immediate roof appear to have a substantial role in coal wall spalling. The results of the proposed numerical simulation exercise can help strata control engineers better detect the risks of coal wall spalling and enhance face control for safe and productive working environment at the longwall face.

Aug 8, 2023

By Ryan T. Smith, Anthony Sahj, Alexander T. Darnell

Every second can count when trying to board a departing flight or catch a ride-share to your final destination. Hartsfield-Jackson Atlanta International Airport is in the midst of a project that aims to cut about 13 seconds between automated people mover trains (Plane Train) that move passengers between the terminals and concourses. The project involves extending the Plane Train tunnel west from its existing terminus under the domestic terminal. Working from inside non-public areas of the terminal, Keller North America, Inc. (Keller) incorporated systems of micropile-supported steel beams and grillage to both underpin existing columns prior to tunneling and support open-cut excavation at the tie-in of the new to the existing tunnel. Dewatering aided in mining a challenging section at the start of the drive of the mixedface, sequentially excavated tunnel and an automated instrumentation system monitored the performance of the construction and its impact to the terminal. Cut and cover egress and ventilation tunnels required braced support of excavation.

Oct 1, 2022

By Nathaniel Arbiter

The development of flotation machines since the first industrial use of the process can be divided into three stages. The first, up to about 1930, was marked by diversity in the means for contacting floatable mineral with the air/ water interface and for generating the interface, as well as in cell design. By 1927 Taggart (1) could list 170 patents covering flotation cells, and he mentioned dozens which were or had been in operation. He divided cells into eight categories according to design, type of separating interface, and where in the cell and how separation took place. These were: (1) Film or skin flotation with wet or dry oiling of surfaces; (2) pulp body process with bubbles generated chemically by pressure reduction, by vacuum or by boiling; (3) agitation-froth processes involving local supersaturation with air; (4) bubble column; (5) pneumatic; (6) cascade; (7) subaeration; and (8) combination and miscellaneous types and processes. Most widely used then were the agitation-froth, sub- aeration, pneumatic types. By 1943 a significant reduction in categories had occurred to the two main divisions of mechanical and pneumatic cells according to whether agitation and aeration were (a) by an impeller with or without compressed air, or (b) by compressed air alone. Cells at that time were still relatively small; the Morenci Concentrator completed in 1942 used 432 1.7m3 (60 cu ft) Fagergrens for roughing 45,000 and later up to 55,000 t/d.

Jan 1, 1979

By M C. Ackland

The Grande Côte Mineral Sands Deposit (GCMSP) is located on a coastal mobile dune system in Senegal on the west coast of Africa. Senegal is a stable, democratic republic, having gained its independence from France in 1960. It has a population of about 12.5 million people. The dunes begin about 25 km north-east of Dakar, the capital city of Senegal, and extend northwards for more than 140 km. The mineralised dune system averages about 2 km wide with some areas extending to up to 4.5 km wide.Mineral Deposits limited (MDL), a Melbourne-based company with over 60 years operational experience in mineral sand mining in Australia, holds, through its Senegalese subsidiary MDL Senegal SARL (MDLS), a 25-year Mining Concession covering the deposits. The main heavy mineral (HM) areas identified to date are, from south to north, Mboro, Fass Boye, Diogo and Lompoul. Within the Mining Concession there is potential to identify additional resources beyond the limits of present drilling. The dunes are mobile or semi fixed, pale yellow in colour and overlie older white marine sands. The dunes range between 5 m and 30 m in height and the mineralised zones, which are essentially flat-lying, average around 15 m in thickness. The mineralisation consists, principally of ilmenite with accessory zircon, rutile and leucoxene. Zircon and ilmenite are the main commodities of interest.Independent consultants AMC estimated mineral resources for the four main deposits in 2006 of 1330 Mt of sand averaging 2.0 per cent HM at a cut-off grade of 1.5 per cent HM. At a cut-off grade of one per cent the resources were 3200 Mt averaging 1.5 per cent HM. All of the estimate was classified as Inferred Resources under the 2004 Australasian Code for Reporting of Exploration Results, Mineral Resources and Ore Reserves (JORC, 2004).Subsequent completion of infill drilling, sampling and assaying of the initial mining area, centred at Diogo, was completed in 2008, enabling a final dredge path to be designed and ore reserves estimated, based on a JORC compliant Measured and Indicated Mineral Resource. Infill drilling is continuing in the Lompoul and the results of this campaign will be included in the JORC compliant data base by AMC in April 2010 to enable the 15 per cent year dredge path and mine plan to be finalised.Development studies have shown that the project can be optimised as a dredging operation, with mineralised sand being treated in a conventional floating spiral preconcentrator, wet concentrator and dry mineral separation plant. Engineering work now substantially completed by Ausenco Limited (Ausenco) has developed the combination of some existing plant from MDL’s past operations, and new plant for the complete process from dredging to final product separation and grading. Testwork on a series of bulk samples has determined that the project can yield a high quality zircon product and an ilmenite product along with minor rutile and leucoxene.Work to date indicates a likely output of around 80 000 t of zircon in various quality streams (Primary, Secondary, Standard and Foundry Grades), around 550 000 t of ilmenite plus around 15000 t of rutile and around 12 000 t of leucoxene/secondary ilmenite. Planned zircon output would represent around 7per cent of the total world production, which would make the GCZ&IP a significant producer on a world scale.The studies have indicated capital costs to be in the range of US$400 M total operating cost (after completion of ramp-up) of around US$50 M - $55 M/a. Revenue is expected to be in the range $127 M - $157 M/a.

Oct 5, 2011