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By Michael Tenenbaum

A REVIEW of process metallurgy of iron and steel during 1944 in many ways reflects the political and military developments of the year. Early in 1944 the tremendous wartime emergency expansion program was virtually completed and the industry directed its efforts to maintaining maximum production wherever needed. The vigorous production programs inaugurated to support the Normandy invasions did not persist as Allied armies approached Germany. General public apathy which developed with the prospect of an early ending of the European fighting was reflected in a general relaxation in armament programs. Toward the end of the year, as the prospect of a prolonged war became real, the entire program revived considerably and the need for steel became acute. Between January 1940 and October 1944 more than 12,400,000 tons had been added to the nation's steelmaking capacities, and over 12,700,000 tons added to the blast-furnace facilities. The total cost of this enormous program was more than two billion dollars. By July 1, 1944, total steelmaking capacity had exceeded 94,000,000 tons, with blast-furnace capacity rated at 68,400,000. Annual steel production, which was 88,900,000 tons in 1943, increased slightly during the past year and was estimated at 89,500,000. Production of pig iron also increased somewhat from 61,800,000 tons in 1943 to an estimated output of 62,500,000 in 1944. This review deals with a few of the numerous factors involved in maintaining the wartime iron and steel program at the level necessary to accomplish this enormous output.

Jan 1, 1945

By Erik Vlot

"The mining industry has recognized the advantages of high density backfill or ‘paste’, which is typically pumped with a hydraulically driven piston pump. Due to the discontinuous flow of this type of pump, pressure pulsations can occur in the discharge line. Pressure pulsations are an undesired phenomenon in pumping installations for a number of reasons that include: damage to the pumping system; piping and supports; disturbing noise levels; and even safety risks for operators and maintenance personnel.This paper describes an advanced system on the GEHO® piston pumps, which will prevent virtually no pressure pulsations from occurring, rather than merely reducing the already existing pulsations.INTRODUCTIONThe first GEHO® hydraulically driven piston pump was developed in the mid-1970s. It was an industrial design pump designed to operate in the high-standard industrial environment with regards to operating hours per day, duties, maintenance and lifetime of the pump and spare parts. This type of pump has a proven track record and has been further developed for the type of applications that we are describing today. The special feature of this pump type is its ability to pump extremely viscous slurry with solids content of up to 90% by weight, at high pressures. Typically, in the mining industry, this pump is used for tailings transportation, with a focus on mine backfill and is often referred to as a paste pump.In the 1980’s the hydraulically driven piston pump made its entry into the application of mine backfill, thanks to the high discharge pressure capabilities enabling the mines to pump higher density (i.e. higher solids concentration) slurries and pastes over longer distances.Part of the ongoing development was (and still is) the increase in discharge pressure and flow capacity to comply with the ever growing demands for high power piston pumps. In line with the technological developments and increase in performance duties, the popularity of this pump type increased significantly and many other industrial applications have discovered the benefits of this pump type.Together with the increase in pump discharge pressures and flow capacities the effect of an undesired phenomenon also increased: the phenomenon of pressure pulsations. Before we explore this subject in more detail it is important to first understand the design and the characteristics of a hydraulically driven piston pump."

Jan 1, 2017

By James R. Boyle

The mining methods and practices used at the Young zinc mine, American Zinc Co. of Tennessee, have resulted in a low-cost, high-yield operation. Zinc ore (sphalerite) occurs in limestone-dolomite beds of the Kingsport Formation and is mined by modified room and pillar method. Utilizing trackless mining equipment which incorporates a high degree of flexibility, this operation has had a steady increase in productivity.

Jan 1, 1965

By D. G. Willard

The U.S. Department of Interior, Bureau of Mines has evaluated the potential resource and annual availability of cobalt from 27 deposits or districts in 11 market-economy countries. More than 95 pct of primary cobalt production from market-economy countries, mainly byproduct output from copper and nickel operations, was analyzed. Approximately 1,200,000 mt of cobalt is potentially recoverable at the demonstrated resource level. Very large additional resources exist, especially in laterite deposits, but are at the inferred level. The producing operations evaluated in this study are expected to produce about 19,000 mt of cobalt in 1989, significantly less than the available capacity of about 31,000 mt. More than 14,000 mt per year of cobalt is produced from copper-cobalt deposits in Zaire and Zambia, of which 11,000 mt can be produced at a copper price of $O.60jlb or less with a O-pct discounted cash-flow rate of return (DCFROR). Approximately 4,400 mt of cobalt is produced annually from nickel-cobalt deposits in six countries, of which about 1,800 mt (in Canada and Brazil) could be produced at a nickel price of $1.50jlb or less at a D-pct DCFROR. Approximately 200 mt per year of cobalt is produced from a cobalt mine in Morocco. Most of the evaluated nonproducing operations and prospects that could potentially produce cobalt as a principal product or byproduct would require a total cost (including a 15 pct-DCFROR) significantly exceeding January, 1989 market prices of the principal commodities. Principal-commodity dependence, transportation routes, cobalt toxicity, and other issues that could affect the availability of cobalt are addressed herein.

Jan 1, 1991

By B. Holen, J. R. Baregi, J. A. Organiscak, A. B. Cecala

The National Institute for Occupational Safety and Health (NIOSH) cooperated with 3M Company in the design and testing of a new environmentally controlled primary crusher operator booth at the company’s Wausau granite quarry near Wausau, WI. This quarry had an older crusher booth without a central heating, ventilation and air conditioning (HVAC) system, and without an air filtration and pressurization system. A new replacement operator booth was designed and installed by 3M based on design considerations from past NIOSH research on enclosed cab filtration systems. NIOSH conducted pre-testing of the old booth and post-testing of the new booth to assess the new filtration and pressurization system’s effectiveness in controlling airborne dusts and particulates. The booth’s dust and particulate control effectiveness is described by its protection factor, expressed as a ratio of the outside to inside concentrations measured during testing. Results indicate that the old booth provided negligible airborne respirable dust protection and low particulate protection from the outside environment. The newly installed booth provided average respirable dust protection factors from 2 to 25 over five shifts of dust sampling with occasional worker ingress and egress from the booth, allowing some unfiltered contaminants to enter the enclosure. Shorter-term particle count testing outside and inside the booth under near-steady-state conditions, with no workers entering or exiting the booth, resulted in protection factors from 35 to 127 on 0.3- to 1.0-µm respirable size particulates under various HVAC airflow operating conditions.

Jan 1, 2015

By G. Plenge, M. Brittan

"Plant design parameters for gold extraction, leach residence time and cyanide consumption are generally determined from standard bench-scale bottle roll or agitation leach tests. The application of laboratory data to process design has essentially evolved from the testing of oxide or low cyanide-consuming ores. Such scale-up factors may not be appropriate for ores that deplete cyanide and oxygen since this interferes with gold extraction kinetics. High cyanide-consuming ores also exacerbate the differences between the conditions applicable to small batch tests and large continuous operations. Testing a reactive high-sulfide South American ore deposit necessitated the re-evaluation of conventional bench-scale cyanidation procedures. Pulp density can be a major factor affecting the results for plant design purposes and should be treated as a test work variable. As with high clay-bearing ore, where pulp viscosity can hinder mass transfer, minimizing the influence of test equipment on gold extraction kinetics may require low pulp densities. This introduces interpretative complexity since cyanide consumption changes as a function of pulp density. Activated carbon also consumes cyanide, so its effect has to be accounted for in the case of carbon-in-leach (CIL) or carbon-in-pulp (CIP) plant flowsheets. Since cyanide is an expensive reagent, often a major component of plant operating costs, it is important that the scale-up of cyanide consumption from laboratory to plant be representative. The traditional method of reporting cyanide consumption in bench-scale testing is questioned since it takes credit for residual free cyanide in leach tails. The projected plant consumption may be better estimated by using the total cyanide addition in a laboratory test. We propose a test work protocol that categorizes the cyanide consumption into its components but requires more extensive testing to generate design data. The ultimate validation of scale-up factors used by project engineers requires rigorous bench-scale versus commercial plant comparative data. Such data are not readily available.IntroductionMajor factors in the design of a gold processing plant are gold recovery, leach residence time and cyanide consumption. These parameters are important determinants of project revenue and costs and, thereby, potentially of project financial viability. Estimates of the associated design criteria for a commercial plant are normally generated from laboratory cyanidation, carbon-in-leach (CIL) or carbon-in-pulp (CIP) tests using standard procedures (Angove, 2005). The key question is whether the standard laboratory test work procedures developed historically for low reagent consuming ores are appropriate for ores that are highcyanide and oxygen consumers.The present paper examines test procedural factors that can influence the test work results and, therefore, their interpretation for design scale-up purposes. The study refers in particular to a high cyanide-consuming sulfide ore. The ore was being tested to develop scoping level engineering design criteria for a proposed project in South America."

Jan 1, 2015

By N. B. Greninger

The U.S. Bureau of Mines conducted explosion tests on various full-scale cementitious bulkheads used in abandoned mine areas to evaluate the ability of the bulkheads to withstand gas explosion over-pressures of 20 psig. Tests were performed on 120-ft2 solid-concrete-block seals of varying thicknesses and designs. Of the seven solid-concrete-block seals tested, only the standard-type seal, having a 16-in thickness, keyed at the floor and ribs, all joints mortared, wedged at the roof, and a center pilaster, maintained its integrity when subjected to a 20-psig pressure wave. After being subjected to repeated explosions, the standard seal only showed a small hairline crack and had an air leakage of 87 ft3/min at a pressure differential of 1 in H2O. Tests were performed on cementitious foam seals of varying thicknesses and compressive strengths. Explosion tests have shown that 200-psi strength, 4-and 8-ft-thick seals can withstand a 20-psig pressure wave. At a pressure differential of 1 in H20, no air leakage was detected through the 200-psi, 8-ft-thick foam seal.

Jan 1, 2010

By Meghan M. Murphy, Derek Penrice

The Downtown Rail Extension (DTX) is principal element of the planned second phase of the Transbay Joint Powers Authority’s (TJPA) Transbay Program. When complete, this regionally critical project will connect Caltrain’s regional rail system and the California High-Speed Rail Authority’s statewide system to the Salesforce Transit Center in downtown San Francisco via a 1.3-mile tunnel. Studied since the 1970s, the DTX has now received environmental clearance, and key stakeholders are aligned on the project’s configuration and its expedited delivery. This paper describes efforts to optimize the DTX configuration and develop an informed project delivery strategy that incorporates construction industry feedback on project phasing, contract packaging, and procurement methods that accomplish the project’s budget goals.

Jun 13, 2021

By Anton Gronningsater

AS we know, Sir Henry Bessemer introduced Bessemer converting in the steel industry about 1855. It was not until twenty years later that the principles were adopted by non-ferrous metallurgists. In 1880, Manés first produced blister copper from matte in a converter, a very important forward step in copper metallurgy. For thirty years, up to about 1910, bessemerizing of copper matte was carried out in the acid-lined converter. It is not necessary here to enumerate all the shortcomings of that operation, one of which was that it strictly limited the grade of matte that could be treated; a 35 per cent matte was low in those days. From the early days of copper converting, many and repeated attempts were made to use a basic converter lining, and the older metallurgists will remember the numerous reports and discussions in connection with such experiments. These make interesting reading. I quote from a book published in 1900: ?'The siliceous lining is as much a part of the process of copper converting as magnesia lining is in the basic bessemer treatment of phosphoric iron, and it is suicidal to attempt any other kind of lining, either water-jacketed or basic.' "Even if the silica could be introduced in this way (through the tuyeres), it would still produce another trouble in the converter. The small particles of silica, being cold, would combine very imperfectly with the iron oxide and produce granulated and pasty slags, which could not be skimmed or poured out of the vessel".

Jan 1, 1942

By Norman A. Parlee

Introduction The principal primary iron and steel producing capacity of the Dominion Steel and Coal Corporation is at the Dominion Iron and Steel, Limited, plant at Sydney, Cape Breton Island, Nova Scotia. The main raw materials are Cape Breton coal, Wabana (Newfoundland) iron ore, and Port-au-Port (Newfoundland) limestone. This plant, which was established at the turn of the century has gradually expanded its production facilities so that today its ingot producing capacity is over 720,000 tons annually. Principal operating units of the plant at present are three batteries of 173 Koppers by-product coke ovens with conventional by-product recovery equipment, three blast furnaces .of 15 ft. 6 in., 18 ft. 3 in., and 19 ft. 3 in. hearth diameter (inside the brick), one 700-ton hot metal mixer, ten open hearth furnaces (two of 175-ton capacity, three 12 5-ton, five 60-ton), one 10-ton electric furnace, a 40-inch blooming mill, a billet mill, a rail mill, a tie plate mill, rod and bar mills, and a wire and nail mill. Extensive machine shops and an iron and brass foundry are also available for plant maintenance and repairs. This paper will describe developments during the past five years and those now in process. It will also briefly discuss research being done and indicate the direction of future development.

Jan 1, 1951

By Thomas K. Matson

The coal reserve base in the Western United States is presented for coalbeds amenable to extraction by underground mining methods. The Federal Bureau of Mines has abstracted data on the quality and quantity of coal resources/reserves from numerous State and Federal publications and modified such data as necessary to allow computer storage and retrieval. Tonnages are compiled by State, county, coalbed, and rank, and allotted to sulfur categories by statistical apportionment. The coal reserve base in those States west of the Mississippi River, amenable to underground mining, is estimated to be approximately 131 billion tons. Of this total, about 30.8 billion tons are bituminous coal, 100.2 billion tons are subbituminous coal, and 126.4 million tons are anthracite. Lignite is not considered for underground mining in this report. Included in this report is a glossary of terms applicable to a classification system for coal resources and reserves as jointly defined by the Bureau of Mines and U.S. Geological Survey. The purpose of this system is to provide for direct comparison or compilation of various resource/reserve data.

Jan 1, 1975

Choosing the right valve for corrosive, abrasive slurry applications requires exacting analysis and a comprehensive understanding of the complete slurry process. Within the realm of flow control in abrasive and corrosive slurry applications, there is no room for a one-size-fits-all approach. To ensure minimal maintenance, maximum uptime and the lowest overall cost of ownership, the slurry processing toolbox must contain countless alloy and elastomeric pairings ? each carefully targeted to the particular process medium and conditions. This materials selection process is best tackled by turning to expert slurry application engineers and valve product managers who work closely with customers to specify the optimal valve for the given parameters. ?When plant operators and design engineers apply conventional valves in abrasive applications or use metal seated valves or simply apply the wrong valve for a particular flow control situation, it typically leads to rapid valve failure, the potential for hazardous leakage, unexpected shutdowns and costly downtime,? said Cal Cobb, valve products manager for Weir Minerals North America, manufacturer of Isogate slurry valves for service in mining, minerals processing and metallurgical environments.

Jan 1, 2011

By A. S. Tawadrous

This paper is an evaluation of Artificial Neural Networks (ANN) as a tool in the design of the geometry of surface blast patterns. The built model uses eight different parameters, which affect the design of the pattern. Those parameters are rock type, stratification, blasthole diameter, bench height, type of explosive, priming position, powder factor and fragmentation size required. The network was trained to predict burden and spacing of the blast pattern. The model was built and trained (back-propagation technique) using 43 case histories collected from the literature. The model has then been validated using 16 cases from operational quarries.

Jan 1, 2006

By Crystal Poon, Paul Matlashewski, John Morkeh, Kathryn Dorfschmidt, Jose Carvalho, Chad Williams

Rockfall hazards are ubiquitous in mining environments making their control critical for safe mining operations. The complex processes involved in rockfall events necessitate a probabilistic modeling approach with well-calibrated material properties. The controls designed to mitigate rockfall hazards need to be reliable, efficient, and safe to deploy to meet the constraints present at an active mine. This paper presents an innovative solution to rockfall at Rio Tinto’s Bingham Canyon Mine. The solution incorporates the site-specific calibration and creation of a predictive rockfall model with the design, field testing, implementation, and monitoring of the rockfall controls.

By Crystal Poon, Paul Matlashewski, John Morkeh, Kathryn Dorfschmidt, Jose Carvalho, Chad Williams

Rockfall hazards are ubiquitous in mining environments making their control critical for safe mining operations. The complex processes involved in rockfall events necessitate a probabilistic modeling approach with well-calibrated material properties. The controls designed to mitigate rockfall hazards need to be reliable, efficient, and safe to deploy to meet the constraints present at an active mine. This paper presents an innovative solution to rockfall at Rio Tinto’s Bingham Canyon Mine. The solution incorporates the site-specific calibration and creation of a predictive rockfall model with the design, field testing, implementation, and monitoring of the rockfall controls.

By H. Yin, T. Emi

"Advantages of gas/flux injection technology as materialized in the main stay unit processes for steelmaking are depicted covering hot metal pretreatment through secondary refining. Current status of micro-kinetic issues involved in the injection technology are reviewed including gas-in- metal, gas-in-slag, flux-in-metal, metal-in-flux and three-phase dispersion systems with reference to macro-kinetics. Key problems are briefly addressed to further develop injection technology for steelmaking processes.1. FROM PAST TO PRESENTApplication of gas injection to steel industry started in early 1950's when inert gas bubbling via stopper rod, lance, or porous refractory plug was practiced to make the temperature of steel melt in ladle uniform The gas bubbling in ladle was then extended to slightly removing hydrogen ti'om the steel melt tapped from Electric Arc Furnace (EAF) and Basic Open Hearth Furnace (BOH) when vacuum processing facilities were not popular. Later, oxygen gas injection via calorized steel pipe into molten steel bath in BOH Furnace was also put into operation to promote the decarburization to increase the productivity of the process. This line of development has been made in parallel with more profound processes, i.e, top blowing Basic Oxygen Furnace (BOF) for primary steelmaking and side blowing Argon Oxygen Oecarburization (AOD) vessel for decarburizing stainless steels.On the other hand, injection of fluxes into steel bath was first industrialized in Germany in 1960's, Primary objective was to desulfurize steel melt in ladle by injecting CaC2 or CaCrCaO mixture via lance under neutral slag cover with good success. Difficulties in injecting fluxes without clogging and rippling at a desired flux/gas ratio, and durability of injection lance were resolved in due time to bring forth many injection facilities to flourish for versatile refining operation. Top injection of fluxes from main oxygen lance to BOF was also industrialized as LDAC to promote early slag formation. A new process then emerged which injects oxygen gas and fluxes together through concentric annular tuyere, installed at the bottom of the BOE into steel melt. This process, developed in Germany [Oxygen Bottom Maxhutte (OBM)] and brought into maturity in USA (Q-BOP) and Japan in a large scale operation, became the predecessor of the combined blowing (top and bottom blown) BOF which dominates modern steelmaking."

Jan 1, 1996

By Zsuzsanna Zborovszky

A circuit is considered intrinsically safe when any spark or thermal effect produced normally (that is, by operating the equipment in its correct operational manner to fulfill its purpose) or accidentally (caused by short circuit, earth fault, defective components, breaking the wiring, etc.) is incapable under prescribed test conditions of causing ignition of a prescribed gas mixture. The test conditions and gas mixture should be at least as hazardous as the true parameters of the environment where the circuit will be operated. According to present practices, the question of whether or not a circuit is intrinsically safe is decided upon experimentally. The circuit is inspected first for mechanical soundness and a survey is made to determine what faults should be considered as probable. Then the individual branches are connected, in sequence, to a test apparatus called 'breakflash" which acts as an opening, closing contact and thus draws sparks from the circuit. This test is repeated a given number of times in the presence of the prescribed gas mixture under specified conditions (electrode configurations, gas parameters, etc.). The equipment will be regarded as intrinsically safe if during testing no ignition has occurred.

Jan 1, 1972

By Charles Will Wright

This paper is one of a series dealing with mining problems and summarizing the data contained in the Information Circulars on individual mines that have been prepared by the managers or superintendents and published by the Bureau of Mines. The purpose of this paper is to present the problems encountered in the development of an efficient mine organization and to show the means used by certain mining companies in promoting efficiency. There is also a discussion of the advantages and disadvantages of the various systems of paying and handling labor and a description of their application at the individual mines.

Jan 1, 1932

By K. Mansfield

Spent Pot Lining (SPL) is an unavoidable waste product of the electrolytic process in the smelting of aluminium. SPL is considered to be a hazardous waste in various countries because it contains significant quantities of absorbed fluorides along with traces of cyanide. In 1995, Portland Aluminium undertook the investment of AUD$26,400,000 to construct a Research and Development processing facility at Portland, Victoria, Australia, to treat SPL. Extensive research, development and design were carried out over 5 years prior to the investment decision. This study led Portland Aluminium to install an Ausmelt pyrometallurgical furnace to combust and melt the SPL producing a hydrogen fluoride (HF) laden gas, which was cooled and then converted to aluminium fluoride (AlF3). Both the cooling and AIF3 manufacture were processes developed by Portland Aluminium. Many commissioning, equipment reliability and process problems have been encountered that had not been experienced in the trials at Ausmelt or in the developmental process for the treatment of the furnace offgases to form AlF3. Designs based on anticipated process expectations have had to be re-engineered by the SPL team to ensure plant and operational success. In June 2001, the installation of the final major component - a slag granulation process - was completed. This has produced a vitrified (glassy) slag that is expected to have leachability qualities acceptable to the Victorian Environment Protection Authority (EPA) to allow commercial end uses of the slag material to be developed. Today (September 2001), the smelter has successfully used the fluoride product, namely 65- 70% AIF3, in aluminium production and the SPL plant has significantly increased throughput with expectations to be at annual design rates of 12,000 tonne of SPL in early 2002. "The Alcoa Portland SPL Process" has been technically developed and is a proven process for the treatment and recovery of valuable components from SPL materials.

Jan 1, 2002

By C. Díaz

Roast-reduction smelting (RRS) of nickel concentrate, combined with flash smelting of copper concentrate, was one of the process options that Inco considered as a means of meeting its 1994 sulfur dioxide abatement target at its Copper Cliff operations. RRS involves deep roasting the nickel concentrate in fluid bed roasters. The roaster off-gas is heated in a sulfuric acid plant, and the low sulfur calcine is reduction smelted with coke in an electric furnace to yield a sulfur-deficient matte. The latter material is converted to Bessemer matte in Peirce-Smith converters, with minimal evolution of sulfur dioxide, and the converter slag is reverted to the electric furnace. Excellent nickel and cobalt recoveries are obtained. This paper discusses the development of RRS, including extensive commercial scale testing at Inco's Thompson Smelter, and its key operating parameters.

Jan 1, 1993