Search Documents

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 Yuanbo Zhang, FENG ZHOU, Guanghui Li, Zhengwei Yu, RuijunWang, Tao Jiang

Composite agglomeration process (CAP) of iron ore fines has been proved an effective route for ironmaking burden production, and is characterized by low the fuel consumption and high the productivity compared with the traditional sintering process. Sintering behavior of pelletizing feed in CAP has not been studied fully yet. In this study, individual pellet and simulated CAP cells were roasted under the simulated sintering conditions. The compressive strength, FeO content and microstructures of roasted samples were investigated. The results show that pelletizing feed either from magnetite ore hematite concentrate can be indurated under the conditions of conventional iron ore sintering. Hematite pelletizing feed has better sintering property than magnetite pelletizing feed. Pelletizing feed consolidation in CAP cells is identical to the individual pelletizing feed, but the strength of CAP cells is much higher than the individual pelletizing feed. Higher basicity in both pelletizing feed and matrix feed is beneficial to the strength of CAP cells. Individual strength of pelletizing feed is not the decisive factor in CAP as the pelletizing feed has been embedded into the matrix with high basicity and formed an organic whole. The main chemical compositions and basicity of pelletizing feed and basicity matching with matrix feed is important.

Jan 1, 2015

By Y. N. Zhang

Friction Stir Welding (F SW) is a novel "green" manufacturing technique due to its energy efficiency and environmental friendliness. This solid-state joining process involves a rotating tool consisting of a shoulder and/or a probe. The shoulder applies a downward pressure to the work-piece surface, constrains the plasticized material around the probe, generates heat through the friction and causes plastic deformation in a relatively thin layer under the bottom surface of the shoulder. The rotating probe mainly drags along, plasticizes, and mixes the adjacent material in the stir zone, creating a joint without fusion. Friction Stir Processing (FSP), a variant of FSW, has been developed to manufacture composites, locally eliminate casting defects, refine microstructure and/or improve the associated mechanical and physical properties including strength, ductility, fatigue, creep, formability and corrosion resistance. However, major challenges such as tool design and wear currently limit the use of F SW/P for manufacturing applications, particularly for high melting temperature or high strength alloys. In this review, the FSW/P tools are briefly summarized in terms of the tool types, shapes, dimensions, materials and wear behaviors.

Jan 1, 2011

By M. Bunch

Today?s mine operating managers face an incredible challenge of meeting the forever increasing legal and regulatory requirements for mining projects. Managers know that meeting compliance of these requirements is just a starting point of assuring sustainability for the project. So how do today?s managers meet these requirements while at the same time focus on continuous improvement in Health & Safety, Environmental, Costs & Production, Labor Relations, Social Corporate Responsibility, and Quality? This paper outlines means by which managers can take control of their operation through the implementation of an integrated Business Management System (BMS) and lay the foundation of a continuous improvement culture in their organization.

Jan 1, 2010

By Junwei Han, Kai Xue, Wenqing Qin, Tan Xu, Fen Jiao, Lianbing Cai, Wei Liu

"The research aimed at solving the problem of the stacked spent magnesia-chrome refractories using in non-ferrous metal smelters, which contain various heavy metals and are considered as a hazardous waste. The purpose of the research is to recycle the spent refractories environmentally and economically using gravity separation and flotation to obtain metal concentrates for smelting and using chloridizing volatilization to remove the trace metals from tailings, providing raw material to reprocess magnesia-chrome refractories. In the course of the study, laboratory techniques for the preparation of experimental samples of spent magnesia-chrome refractories were developed including the sequence of operations of material grinding, gravity separation, tails regrinding, flotation, filtration and subsequent unification of concentrates, filtration and chloridizing volatilization of tails, and collection of volatiles. Laboratory tests carried out on several types of samples of spent magnesia-chrome refractories from different smelters showed that gravity separation provided increase in quality of concentrates including about 80% metals (including Ag, Pb, Bi) and flotation separation provided increase in recovery of concentrates under the condition of 200g/t of emulsified kerosene, and 500g/t of combined collector. Based on combined technology of gravity and flotation separation, about 90% metals were recovered from the refractories by a closed-circuit test and the total concentrates contained 40% metals, which can be returned to smelting process as a feeding. Because a small amount of metal in raw materials will seriously affect the performance of refractories, chloridizing volatilization is necessary for removing the remaining 10% metals from tails mixed 8% coke and 13% magnesium chloride at a temperature of 1200°C. Thus, the tailings can be reused as a raw material for new refractories.INTRODUCTION Magnesia-chrome refractory has been used extensively in various industries such as secondary metallurgy, non-ferrous furnaces and cement making due to their high temperature stability, low thermal expansion and outstanding erosion-corrosion performance at high temperatures (Gotod et al., 2005; Vezza et al., 1997; Gregurek et al., 2015). Generally, the magnesia-chrome refractories are produced from a mixture of magnesia and massive variety of chrome ores. However, massive chrome ores are being depleted throughout the world. Even more serious is that the heavy metal chromium (Cr) can transfer into soil and water, which will have an influence on the survival and development of human beings (Zhao et al., 2006; Jiang et al., 2004; Qintie et al., 2013). As a result, regulations treating spent magnesia-chrome refractories as potentially hazardous waste are being enforced, making their disposal difficult and expensive."

Jan 1, 2018

By H. S. Caldwell

Molten zinc, condensed from zinc vapor, was used by the Federal Bureau of Mines to leach aluminum from an aluminum-silicon alloy made by carbothermic reduction of silicious aluminum ores. Zinc requirements were minimized by re-fluxing condensed zinc in a low-pressure, Soxhlet-type distillation unit. The minimum ratio of zinc used to aluminum in the crude alloy was approximately 2:1. When the system pressure was reduced from atmospheric pressure to 100 microns or less, the rate of aluminum extraction increased by a factor of 20. Leaching rates were much higher when the zinc vapor was condensed directly on the crude alloy than when molten zinc was passed over the alloy in the absence of appreciable zinc vapors. Observations indicated higher extraction efficiencies from crude alloys containing greater amounts of iron. Complete extraction was obtained with negligible loss of zinc. Assuming complete removal of zinc, the aluminum products will contain 1 to 6 percent silicon and about 0.5 percent iron plus titanium. The leached crude-alloy residue is a highly friable spongelike material containing about 80 percent silicon, several percent iron and titanium, with the remainder aluminum. This extraction method has been patented (Patent 2,810,637) and assigned to the Government. Research and development investigations are continuing at the College Park Metallurgy Research Center.

Jan 1, 1961

China's coal energy development, characteristics and relationships with atmospheric pollution are reported. Atmospheric pollution sources from coal combustion are analyzed. Some of the projects for clean coal combustion in the Shanghai area include use of industrial briquettes, investigation of coal combustion additives, and blending combustion of coal with industrial wastes. Coal is China's main energy source, and 80 percent of China's annual coal production is used in combustion devices. Coal-flue gases from the domestic stoves and industrial furnaces are the main atmospheric pollution source. China's atmospheric pollution is, in fact, the pollution of coal-flue gases. To 2000, in view of China's energy needs as a developing nation, the atmospheric pollution from coal combustion must receive our utmost attention.

Jan 1, 1994

Population growth, social inequality, pollution, global warming, poverty, overexploitation of natural resources and biodiversity loss, are a few examples of the many challenges facing the world today. Sustainable development is about meeting these challenges and improving the standard of living for the benefit of the maximum number of people. These issues concern governments, communities, environmental and social action groups and individuals all over the world. Business too, has a fundamental role to play in delivering sustainable development. In particular, sustainable development is becoming increasingly recognised as a critical issue for the oil and gas industry to address and act upon. BP is committed to positively respond to the challenges posed by the objective of sustainable development.

Jan 1, 2002

By M. S. Eygi

This study covers the investigations based on the electrokinetic and rheological properties to explain the interactions between kaolin minerals and commercially available polyelectrolyte in anionic character. Additional adsorption test were also conducted to support the interaction mechanism. Adsorption tests showed that adsorption densities decrease by increasing the solid content. In-creasing the solids contents from 1% to 30% by weight resulted in the decrease on adsorption from 2.14 mg/g to 1.85 mg/g. Because of its difficulty, the solids ratio at 70% was not studied. However, following to trend of the curve plotted adsorption density-solid ratio, an estimation was made and adsorption density at 70% solid content was extracted from the curve as 1.75~1.80 mg/g. The electrokinetic studies pointed out that the presence of polyelectrolyte increase the zeta potential of kaolin from 40 mV to 60 mV which is reasonable conditions to disperse and stabilize the kaolin slurry and lower the viscosity. When these result of the different tests are combined and considered together, 2 mg/g polyelectrolyte concentration was noted as optimal concentration where adsorption density, viscosity and zeta potential of the slurries give maxima and remain constant after this concentration.

Jan 1, 2014

By M. E. Rossi

This paper discusses the use of Conditional Simulation (CS) models to provide mill feed grade profiles for different time periods. The conventional approach of classifying block estimates as ore or waste generally does not adequately represent dilution, lost ore and the anticipated grade control data, including variability of mill feed from the pit and possible stockpiles. The detailed simulation of grade control practices can be done, but at the Pre- or Feasibility stage of the project may be impractical, since drawing dig limits on multiple benches is tedious and time consuming. Using the Feasibility Grade Control (FGC) method as developed by the Centre for Computational Geostatistics (CCG, University of Alberta-Edmonton), the CS models can be processed quickly to establish dilution and lost ore, and predict daily or short-term feed to the mill. The simulated nodes can be aggregated into selective mining units with adequate representation of likely geometries to be recovered from the pit, to mimic anticipated selectivity. An example from a large copper deposit is shown. The study provides an estimated stream of tonnages and grades fed to the plant by mining periods of interest and based on a specific mine design and schedule. The resulting cash flows support the economic and financial analyses of the Feasibility Study; also leads to improving mine schedules; and aids in developing blending schemes if necessary. INTRODUCTION The conventional approach of separating mineralized material into ore or waste categories does not always include a realistic amount of dilution and ore loss. Also, often it does not provide a good estimate of the grade that will be fed to the mill. If the grade control estimates are unbiased, they will over the long run represent the long-term average of grades fed to the mill; but the anticipated variability of mill feed from the pit and stockpile sources may be misrepresented. Some references on traditional grade control implementations can be found in Chunnett (1982); Davis et al. (1989); Srivastava et al. (1992); and Nowak (1992). Alternative methods based on economic variables improved significantly on the purely grade-based control methods, see Douglas et al. (1994). Further developments involved the use of geostatistical conditional simulations (CS) and profit models, which in several cases have been successfully implemented (Aguilar and Rossi, 1996; Rossi, 1997; Deutsch et al., 2000; Norrena and Deutsch, 2002; Neufeld, 2005; Jewbali and Dimitrakopoulos, 2009). But they can be impractical, mostly due to the lack of understanding of the methodology involved; even if semi-automatic dig limit drawing is implemented, there is always a need for is tedious and time consuming checking and corrections, even if using a single profit model derived from the simulated grades.

Jan 1, 2019

By Anahita Modiriasari, Benjamin S. Rivers

Measurement while drilling (MWD) is a subsurface exploration technique associated with real-time and continuous monitoring and recording of drilling data during the drilling process. This technique can be used for underground investigations to differentiate ground strata, detect the presence of fractures and voids, and evaluate geological features and mechanical properties of geomaterial. When MWD is used for geotechnical investigations, it can improve site characterization, identify variable conditions, improve design and construction, lead to shorter project delivery times, reduce the cost and risks associated with limited subsurface data and geotechnical uncertainties, and maximum return-on-investment. Given these benefits, MWD is gaining attention among transportation agencies and the geotechnical industry. Federal Highway Administration’s (FHWA’s) innovation deployment program “Every Day Counts (EDC-5)” includes the implementation of Advanced Geotechnical Methods in Exploration (A-GaME), which aims to implement effective, underutilized subsurface exploration methods, including MWD, in U.S. practice. This paper provides an overview of the MWD technology for geotechnical site investigations and presents a case history where MWD was employed to design deep foundation for the construction of a building in Massachusetts. The advantages of this technology for risk reduction and project cost and time saving are also discussed.

Oct 1, 2022

By R. Kalra

The current paper looks at evaluating the merits of large geared mills versus gearless driven mills by evaluating the following factors: The capability of currently available systems in terms of power and mill diameter Efficiency in terms of overall electrical power consumed vs mechanical output power Capital cost Running costs Cooling requirements in terms of air versus water cooling Installation and delivery time World?s largest geared drive ? 2x8500kW ? Wushan, China (operating) Among the many reasons that geared drives on large SAG mills are not favoured, is due to not having an efficient variable speed drive option (60 to 80% critical speed), which is required for process reasons. As technological advances have occurred quite rapidly in recent years, this paper uses the latest data in applying these comparisons and attempts to dispel some of the myths regarding Slip Energy Recovery (SER) and variable frequency drive technology on twin pinion drive systems. Early attempts to provide load sharing on twin pinion drives used primitive electronics which have since been developed to eliminate the problems encountered in earlier attempts. In particular, torque pulsations between the twin motors have been overcome using a higher number of devices (pulses) and better electronics. With successful operation of 2 x 6.5MW (Phu Kham, Laos) and three 2 x 7MW units under manufacture (Pascu Lama) and a further 40 projects worldwide, energy efficient Hyper Synchronous SER drives are now mature and ready for use on 2 X 10MW dual drive mills. Speed variation required is in the range of +/- 15% of synchronous motor speeds. VVVF drive packages from ABB and Siemens are also available for 2 x 10MW in low and high speed options. Dual hydraulic inching drives provide a much safer and convenient operation with the added advantage of locked charge detection.

Feb 27, 2013

"TREVIICOS CorporationINTRODUCTIONThe Walter F. George lock and dam was constructed on the Chattahoochee River between 1955 and 1963 with the double function of improving navigation and generating power. Its 82 ft. by 450 ft. (25m x 137m) lock can accommodate large barge traffic and its four generating units with a plant capacity of 150 MW have an average energy output of 453,000 MWH. The dam consists of a 1,496 ft. (456m) long concrete structure housing the spillway, a non overflow portion, the power units and two earthen wing dams extending to the Georgia and Alabama sides, respectively 5,810 feet and 6,130 feet long (1770m and 1868m). As soon as the reservoir was impounded it became apparent that excessive seepage was occurring. From 1962 to 1985 a series of remedial works was performed using several techniques, but the problems continued under the dam, jeopardizing its generating potential and possibly undermining its stability.Finally, the decision was made to construct a deep cutoff primarily under the concrete portion of the dam to remedy the problem. PROCUREMENTOn July 5th, 2001 best and final offers were solicited by the Corps of Engineers (COE) for the construction of a deep cut-off to be built in front of the concrete portion of the dam from the bottom of the lake and tied into it. The cut-off had to cross an existing lock structure and an underwater retaining wall, as well as the remnants of a steel coffer cell left in place from the initial construction.The specifications required that the wall be built with a minimum thickness of 24” (600mm) and that it extended from the bottom of the lake to elevation -5 (1.52m) into the Providence formation, an impervious layer.While the land portions of the wall were on average 208 feet (63.4m) deep, the marine portion started from up to 90 feet (27m) of water and continued through different rock formations for another 100 feet (30m).Contractors were invited to propose their own method of constructing the cut-off and offers would be evaluated using several criteria, including technical, economical, organizational and experience.Three proposals were received and on August 14, 2001 an award was made to the Joint Venture (JV) of Treviicos and Rodio."

Jan 1, 2014

By J. M. Hird

By blending phosphogypsum with thickened mill clays, Texasgulf has successfully resolved the problems of gypsum disposal and reclamation of mined-over areas. In the process, clays are thickened to 10% solids through high rate thickeners, mixed with gypsum from a drained gypsum pile (75%) and a direct discharge from belt filters (25%), then pumped to mined-over areas. The blending of clays and the low pH gypsum yield a mixture with a pH of about 7. Dewatering is rapid to 40-45% solids within 3 months. The material spreads with very shallow slopes and within a year desiccation by high flotation ditching equipment is possible. The artificial soil is classified as a silty loam in texture, lacking only in nitrogenous nutrients. The soil material has proven to support many field crops including small grain, corn, alfalfa, and grasses. Sycamore, green ash, sweetgum and bald cypress have done well in 3 years of growth. The nitrogen source for tree growth will be made up through an alfalfa cover.

Jan 1, 1993

By Terry J. Close

At the request of the Idaho Congressional Delegation, the U.S. Bureau of Mines Western Field Operations Center investigated the mineral resources of the 140,000-acre Red Mountain roadless area, located northeast of Lowman, in central Idaho. The area includes U.S. Forest Service Red Mountain RARE II area (4-063). The highly mineralized road less area is underlain mainly by granitic rocks which are transected by a northeast-trending fault system. Associated with the granitic rocks and fault system are gold and black sand mineral resources. At least 1,395 ounces of gold and 858 ounces of silver have been recovered from six lode and placer mines within the roadless area. A total of 525 tons of columbium-tantalum, 2,049 tons of euxenite, 83.5 tons of columbite, and 54,862 tons of ilmenite concentrates have been produced from a nearby black sand mineral placer. Mine workings and facilities in the roadless area consist of two dismantled mills, 15 open and caved underground excavations totaling about 2,900 ft of workings, seven large pits and quarries, over 166 smaller dozer-and hand-dug prospect pits and trenches, and in excess of 66 drill holes. The mineralized sites in the roadless area are covered by about 690 current (1992) mining claims. About 130 individuals are holding the claims. Also within the roadless area are four patented lode mining claims. Twenty-five of the 54 mineralized sites identified during the study of the roadless area have, or likely have, mineral resources. One has gold and three have black sand mineral resources that are marginal or subeconomic. There also are two hot springs with thermal water resources, some veins that could be sources of decorative quartz, and dimension stone which was quarried in the past and could be again.

Jan 1, 1993

By C. -S. Jiang

In most copper refineries, addition agents are added at predetermined rates with no further monitoring of their activity or concentration in the electrolyte. Increasingly stringent cathode quality requirements, and a desire for better process control in tankhouse operations, have recently directed a number of refineries to search for a better addition agent control strategy. Extensive development work has been carried out at the Noranda Technology Centre for the monitor in of glue and thiourea in copper refinery electrolyte using cyclic voltammetry (cv~. Data from both synthetrc and commercial electrolytes are presented, showing the ability of CV to produce reliable and easily identifiable fingerprints of addition agent concentrations in copper refinery electrolyte.

Jan 1, 1991

By T. Kretschmer, F. Villwock

Conveyor systems are an essential part of many material movements in all conceivable areas of application. They are used to transport goods in raw materials extraction, agriculture, and even articles for daily use. In the process, not only distances of several kilometers but also differences in altitude of several hundred meters are bridged. The layout of the conveyor usually follows the topography at the respective installation site. Particularly in the case of large height differences, safety devices must be provided to prevent uncontrolled movement. Backstops can take over this task in predominantly ascending overland conveyors and are used either as a primary or as a secondary safety system in conjunction with a service brake. They are always used when the system comes to an unplanned standstill, whether due to a power failure, an emergency stop or a defect. When designing backstops, it must be ensured in any case that all conceivable circumstances are taken into account so that failure is ruled out without the product being unnecessarily large in size. Various safety factors are applied, some of which are even prescribed by authorities. One example is the Australian standard on machine safety for bulk material belt conveyors (AS/NZS 4024). This stipulates a redundant acceleration safety device that can absorb at least 150% of the maximum load. ALTRA Industrial Motion with its sister companies Marland and Stieber manufacture backstops for a wide range of applications. With more than 85 years of business activity in freewheeling and backstop applications, they are among the most known and experienced companies and provide a great know-how.

Mar 2, 2022

By P. S. Arthur, G. R. F. Alvear

Development of a new smelting process is risky. Many novel processes in the metals industry failed to fulfil the initial expectations of their inventors. Large sums of capital have been invested in technologies that either didn't provide a satisfactory return on investment, or didn't perform at all, and had to be replaced. One of the keys to success in process development is incremental scale up of the technology, with potential problems being identified and rectified as early as possible. In this way the cost of any rectification that is required can be minimized. The ISASMELTTM process was developed to maturity by Mount Isa Mines through the 1980's and 1990's using incremental scale up. Commercialization only occurred once the process had been proven on laboratory, pilot and demonstration scale over many years. As a result ISASMELTTM technology now operates successfully at numerous plants around the world. The methodical approach to development of the technology has allowed owners to modernise their existing operations or create new businesses with significantly reduced technical risk.

Jan 1, 2011

By D. D. Hamilton

The ISMS program provided for the development and demonstration of equipment modifications for improved safety in both conventional and continuous coal mining systems. This report documents the success of the program in identifying accident hazards in underground coal mines with 4-to 8-foot seam heights, in designing modifications to reduce the hazards, and in demonstrating improved safety through extended underground use of the ISMS equipment.

Jan 1, 1977

What has been billed as the underground drilling technology of the 1980's got a dramatic head start when Boliden engineers at Stekenjokk decided to go with all hydraulic drilling for primary ore production and mine development. This application represents a major first in meeting the needs of high productivity, better energy utilization, and an improved drilling environment. At Stekenjokk, engineers chose three Atlas Copco Boomer H132 two-boom electro-hydraulic drill rigs with the COP 1038 rock drills. An additional single-boom Boomer H131 was also selected with the COP 1038 HD for roof bolting functions.

Jan 12, 1977