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By Baojun Zhao, Zhixiang Cui, Zhi Wang

"Bottom blown oxygen copper smelting process has been developed in Dongying, China by Dongying Fangyuan Nonferrous Metals Co., Ltd. in commercial scale. This is the first modem copper smelting technology developed in China with the advantages of high oxygen enrichment, low temperature and autothermal operation. Production capacity of more than 100,000 tonnes per year of copper has been achieved through a single bottom blown oxygen furnace with instantaneous feed rates reaching up to 90 t/h. The main features of the bottom blowing smelting process are that high grade matte (up to 72 wt% Cu) can be produced at relatively low temperatures with 2-3 wt% Cu remaining in the smelting slag. Analyses of quenched smelting slag show that significant amount of magnetite crystals are present in the slags at operating temperature which indicates that the operating temperature was much lower than the liquidus temperature of the slag. After four years operation this new technology has shown great potential for expanding production capability and energy saving. Process development continues on the first commercial scale bottom blown furnace at Dongying Fangyuan Nonferrous Metals and a larger bottom blown smelting furnace is under construction.IntroductionFlash and bath smelting technologies are the major processes used in modem copper making industry [l]. Ausmelt/Isasmelt using top blown and Noranda/Teniente using side blown are typical and common bath smelting technologies. In 1980s-1990s Hunan Shuikoshan Mineral Bureau, jointly with China Nonferrous Engineering and Research Institute (now China Enfi Engineering Corp.), developed the concepts of the bottom blown oxygen processes for both lead and copper smelting [2]. After the pilot test on 3000 ton copper per year scale in 1991, it was not progressed to industrial scope."

Jan 1, 2013

By Lauri Holappa

Copper converting is mostly performed in Peirce-Smith converters. The process is still very similar to the original one developed in the early 20th century. It is a batch process in a horizontal cylindrical reactor with air blowing via tuyeres along the length of the reactor side. The Peirce-Smith converter has its roots in Bessemer's inventions in the 1850's as he tested both horizontal and vertical vessels for steel converting. However, for steel making a vertical pear-shaped converter with air bottom-blowing was established. In the course of time, there was a distinct necessity for oxygen usage instead of air due to harmful effects of nitrogen to steel properties and its cooling effect. In-bath blowing of oxygen did not succeed, however, and top-blown oxygen converter with oxygen lance (LD or BOF) was first developed in he 1950's and emerged rapidly to a dominating position. Somewhat later oxygen bottom-blowing via special shrouded tuyeres was developed (OBM or Q-BOP) but has attained only fractional share. Bottom-blowing technique had, however, impact on the current combined blown converters which adopted the benefits of both top and bottom blowing. In copper converting Peirce-Smith type converters have kept their position until today although new processes have been introduced and at least few of them seem to be emerging. In one respect copper converting has a clear leading position i.e. in the progress of continuous converting processes (Mitsubishi, Ausmelt). These processes utilise top-blowing lances instead of in-bath blowing tuyeres. A different principle for continuous converting is flash converting by Kennecott Outokumpu, which makes smelting and converting independent of each others. Solid ground matte is used as a feed for flash converting in a reactor shaft similar to Outokumpu matte flash smelting. A comparable process has been presented by Inco too. The paper discusses principal physico-chemical and process technical similarities and differences in copper and steel converting. Although these processes are metallurgically quite different it seems that during the modem history of ferrous and non-ferrous metallurgy, starting from the 1850's, the exchange of knowledge between these disciplines has been quite intensive. In long-term perspective, many similarities in the development can be found but also divergences due to different ambient circumstances.

Jan 1, 2003

By L. L. Oden

The U.S. Bureau of Mines and the Department of Energy (DOE), through its contractor EG&G Idaho Inc., are collaborating on a multiyear research project to evaluate the applicability of three-phase, electric arc furnace melting technology to vitrify materials simulating low-level radioactive and mixed wastes buried or stored at the Idaho National Engineering Laboratory and other DOE sites. The melter is a sealed, 1-t (1.1-st), three-phase, 800-kV?A electric arc melting furnace with 10.2-cm-(4-in?) diameter graphite electrodes, water-cooled roof and sidewalls, and four water-cooled feed tubes. A water-cooled copper fixture provides for continuous tapping of slag. An instrumented air pollution control system (APCS) with access ports for analysis and a feeder based on screw conveyors and a bucket elevator are dedicated to the facility. Test data are provided by an arc furnace analyzer and by sensors indicating feed rate; slag temperature; and temperature, pressure, and velocity in the APCS. These data are received by a data logger, digitized, and transmitted to a personal computer for storage and display. This unique waste treatment facility is available for public and private use on a cost-sharing basis.

Jan 1, 2010

By J. G. Ross

IN the paper entitled Block Caving at the King Mine (1), which was presented at the Annual General Meeting held in April, 1934, at Quebec, it was pointed out that, owing to certain conditions and financial restrictions, it was advisable to provide a temporary shaft. This was raised from the )00-ft. level to the bottom of the pit, and a 45-degree incline track was constructed up the face of the pit to surface. The temporary shaft and incline were within the ore-body, but were to be used only until such time as the new shaft-the subject of this paper-could be sunk and made ready for operation. After a careful study had been made of all available information pertaining to the ore-body, including examination of diamond-drill core records and geological data, a shaft location was selected well outside the ore-body. Further, since the crusher and dryer buildings are located over part of the ore-body, it was necessary to plan the removal of these buildings and to construct a new crushing and drying plant. This, and the new shaft, must operate in conjunction with the present mill and rock storage bin, which would continue robe used as formerly. No part of this programme, with the exception of drifting toward the shaft site, was started prior to 1937. More than usual detail on technical features is given in this paper in the hope that some parts of it may be of assistance to other members of the Institute who have to undertake somewhat similar work. The engineering and operating staff designed and supervised the work, while at the same time carrying on regular production in four mines at the rate of 12,000 tons of rock mined per day, the output at the King mine being at the rate of 140 tons per hour. No additional engineers were required.

Jan 1, 1939

By E. O. Binyon

"Corundum and andalusite were discovered in August 1944 on what is now known as the Blue Metal group of claims. The property, comprising five unpatented lode claims, is situated 20 Miles northwest of Yerington in the Buckskin Mining District, Douglas County, Nevada, An engineer of the. Bureau of nines examined the property on November 1, 1944, and recommended a small: amount of drifting and crosscutting to determine more definitely the extent and character of the ore deposit. The work that had been done by the owners was for sampling purposes only and was confined to a few small pits on the outcrop, and no effort had been made. to delimit the ore zone. Samples taken from the best surface showings were sent to the experimental station in Salt Lake City for beneficiation tests. The results of the preliminary test work appeared favorable, and upon the strength of them and the recommendations made by the Bureau, 2.5 miles of access road was approved and completed early in 1945. Exploration was started on June 24 and completed September 26, 1945.In its program of exploration of mineral deposits, the Bureau of Mines has as its primary objective the more effective utilization of our mines resources to the end that they make the greatest possible contribution to national security and economy. It is the policy of the Bureau to publish the facts developed by each exploratory project as soon as practicable after its conclusion. The Mining Branch, Lowell B. Moon, chief, conducts preliminary examinations, performs the actual exploratory work, and prepares the final report. The Metallurgical Branch, R. G. Knickerbocker, chief, analyzes samples and performs beneficiation tests. Both these branches are under the supervision of Dr. R. S. Dean, assistant director.This paper is one of many reporting on various aspects of the Bureau of Mines program initiated in August 1939 by passage of the Strategic Minerals act, the scope of which was. greatly expanded by subsequent legislation.Some of these papers were published as war minerals reports, others as bulletins, technical papers, reports of investigations, and information circulars of the Bureau of Mines or• in, technical journals.The Bureau's program at first included separate investigations by the Mining and metallurgical Divisions, but these were consolidated under Assistant Director R. S. Dean beginning July 1, 1942. Mining and metallurgical investigations carried on in three regional organizations more closely integrated thereafter by a staff of specialists, who reviewed findings made in the field and in Bureau Laboratories, considered proposals for additional work, revised reports for publication, and served as advisors to the assistant director."

Aug 1, 1946

By A Flatten, F Reusch

Recent advances in the disciplines involved in simulating large mining operations provide increasingly precise and accurate methods for the study of cave mechanics; however, in large regional-scale models, hydrological aspects are often neglected or studied independently from the mechanical problem. There exists a great demand for a unified approach to study and simulate both the mechanical and hydrological phenomena that allows for a more detailed understanding of the effects of groundwater flow, dewatering and the impact on block cave mining operations.This paper presents a numerical framework that combines three-dimensional regional-scale hydrological simulation techniques for groundwater flow, together with non-linear continuum–discontinuum rock mechanics models, provides such a unified modelling approach. The underlying simulation technique is based on a coupled parallel solution formulation adopting single-phase fluid flow formulations into a discontinuous, strain softening and dilatant finite element model. This approach is adopted for the presented case study of a realistic block caving example in a simplified unidirectional coupling formulation, to investigate the effects of the mechanical analysis on the hydrological response. Here, particular emphasis is on the non-linear coupling of the deformable and strain-softening solid skeleton and fluid phase; eg the change of hydraulic properties with evolution of damage in the rock mass and large-to-intermediate scale structures due to ongoing caving operations. The importance of discontinuum structures is discussed, as mining-induced fault reactivation significantly influences the hydrological response.CITATION:Flatten, A, Reusch, F and Beck, D, 2016. The application of hydromechanical mine-scale modelling for large block caving operations, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 341–348 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By D. Shuck

Incorporation of a 2,727 mtpd, $5.7 million flotation circuit into the Mclaughlin flowsheet was completed in November 1991. This capital addition reduced overall operating costs and improved the gold recovery of the low grade refractory reserves over that expected for direct cyanidation. In addition, flotation provided a means to generate a sulfide concentrate which is utilized to supplement feed to the pressure oxidation circuit.

Jan 1, 1994

By A. E. Wraith, J. Protheroe Jones, P. J. Mackey

The world’s first copper electrorefinery started production in 1869 at Burry Port in South Wales. Built within the Pembrey Copper Works which had commenced smelting operations in 1849, the new refinery was based on principles described in the British patents issued to J.B. Elkington in 1865 and 1869. Refining principles and practices pioneered there were key to the foundation of modern electro-refining practice in what is now a dominant international industry producing over 16 Mt of electrical grade copper annually. This paper explores the background to this pioneering application of the new, early 19th century, science of “electro-metallurgy” and examines its links to the contemporary decorative electro-plating industry and to the shortcomings of 19th century fire refining. The beginnings and early years of the Pembrey electrorefinery are briefly discussed in relation to the quality, applications and pyrometallurgy of copper at the time. More than a decade would elapse before the birth of the electrical age: the Pembrey refinery may be seen as one of its vital precursors. Note: This paper was originally published as part of the Copper 2013 proceedings (A.E. Wraith, P.J. Mackey and J. (formerly R.) Protheroe Jones, “Origins of Electrorefining: Birth of the Technology and the World’s First Commercial Electro-Refinery”, paper in Electrorefining, Vol. V, Book 2, (Eds. R. Abel and C. Delgado), Cu 2013 International Conference, pp. 19-33, IIMCh, Santiago, Chile, 2013). It is reproduced here together with a new Appendix and supporting references that lists the year of commencement of the first electrolytic copper refinery by country, 1869 to 1956. It all, the year of the first electrolytic copper refinery established for 15 countries is included. These 15 countries now produce more that 70% of world refined copper (for 2018). INTRODUCTION In the 1840s, the new science of ‘electro-metallurgy’, a term coined by Smee in 1841 (Smee, 1841), was being adapted to the decorative electro-deposition of silver in a thin, bright adherent coating that was evidently equal in appearance to traditional silverware (Williams, 1976). Chief among innovative manufacturers of decorative objects who took up the new art of silver electro-plating was the acclaimed firm of G.R. Elkington and Co. of Birmingham, England. The company, which vigorously developed all aspects of electro-metallurgy for the decorative trade, entered the field of ‘electrotyping’, a technique in which the surface features of a mould are copied on an electro-deposited copper layer which, when stripped off, can be used to reproduce an imprint of the mould. In essence, it is a form of casting by electrodeposition, invented in 1837 independently by Jacobi in Russia (Pavlova, 1968) and Spencer in England (Wyatt, 1851).

Jan 1, 2019

By J. Nsasi Bakambu

This paper describes an autonomous platform for exploration and navigation within networks of tunnels, as those typically found in underground mines and caves. In the exploration mode, a remotely located supervisor instructs the platform to move through successive sections of the network, gathering range data that is, then, concatenated into 2D/3D survey maps of the environment. In the navigation mode, the supervisor specifies high-level missions on the previously acquired survey maps. A motion planner, then, translates each mission into a set of consecutive navigation actions, separated by natural landmarks. Mission execution consists of detecting landmarks, self-localizing and performing the planned navigation actions.

May 1, 2003

By T Niitti, J Turunen, P B, A Rinne

In todayÆs marketplace, with high metals prices, many operations are faced with the challenge of improving recovery in the particle size ranges which are normally difficult to recover. This presentation focuses on the various methods used to alter the flow dynamics in a mechanical flotation cell, thereby improving metallurgical results. Modern computational fluid dynamics (CFD) tools have been used in the design phase, with subsequent validation at the plant. Some of the validated variables include mixing profile, power draw and local air hold-up. This presentation underlines how modern CFD analysis can be used to screen and select different approaches before commencing costly trial-and-error experiments at plant scale. Two methods of affecting flow dynamics are discussed û firstly, by altering the geometry of the rotor-stator area and, secondly, by fitting additional features in the tank. The rotor-stator area can be modified to provide more concentrated turbulent kinetic energy or, respectively, to provide more pumping efficiency with less attrition. The tank can be fitted with various additional features, aimed to create different particle suspension profiles. The benefit of both methods is that they can be applied not only to newly installed flotation technology, but also to existing plant cells, thus enabling potential improvement in the mixing profiles, solids suspension, tank sanding and metallurgical performance. Results of several sitesÆ tests are discussed in terms of flow variables measurement as well as metallurgy. This paper demonstrates the effects of different flow dynamics on the mixing profiles and metallurgical results of existing mechanical flotation cells.

Jan 1, 2006

By A. J. Barry

Recent developments in mechanizing longwall it mining in Europe have aroused considerable interest among American coal-mine operators because this method provides an opportunity to improve safety, production, efficiency, and recovery. The success of longwall mining in Europe has depended to a large degree on development of effective roof-control systems. One of the major contributing factors in designing these systems is development off improved supports, which combine high load-bearing capacities with controlled yield characteristics, to use in the face areas. Other factors that relate to successful longwall mining involve knowledge of the structural properties of the strata above end below the coal bed being mined, movements of these strata induced by mining, and effects of the strata movements on the strata itself, as well as on the support system used. Extensive studies of the above factors relating to long-wall mining have been made in coal-mining countries abroad, and corresponding studies (1, 2, 3, 4, 5)3/ of room-and-pillar operations have been made in this country. Although descriptions and results of experiments of mechanized longwall operations in the United States have been published (6, 7, 8), this is the first instrumented study of roof behavior on a longwall operation. In view of the possible widespread application of this method of mining to American coal mines, where underground mining conditions are different from those found in European mines, an investigation was conducted at a mechanized longwall operation inn the Lancashire No. 15 mine, Barnes & Tucker Co., Cambric County, Bakerton, Pa., to study the factors that affect roof control. This report describes this investigation and discusses the results. ACKNOWLEDGMENTS This investigation was made under a cooperative agreement between the Bureau of Mines and the Barnes & Tucker Co., Barnesboro, Pa., end was conducted in the Lancashire No. 15 mine located at Bakerton, Cambria County, Pa. The authors acknowledge the cooperation given by Richard Z. Todhunter, Sr., president, Richard T. Todhunter, Jr., general manager, and other mine officials and employees of the Barnes & Tucker Co. Mr. Edward Thomas, chief, Roof Control Section, Bureau of Mines, Washington, D. C., and Dr. Leonard Obert, chief, Applied Physics Branch. College Park, Md., collaborated in the planning and promulgation of the program investigation.

Jan 1, 1954

New Mexico?s active coal mines have reclamation challenges that are being successfully resolved through the application of geomorphic grading methods. Soils and overburden material are often of poor quality, and annual precipitation is low. Revegetation on south and west aspect slopes often failed to persist. The New Mexico Mining and Minerals Division had therefore been encouraging topographic diversity on reclamation to improve water harvesting and reduce the percentage of south aspect slopes. Steeply dipping, multiple coal seams may be mined by open pit methods. Structurally-controlled trellis drainage patterns that exist premine have to be replaced with dendritic drainage patterns on reclamation where the overburden had been pulverized. Sodic spoil material is prone to differential settling and the creation of piping features in areas where runoff ponds, which may lead to downslope instability. In each of these scenarios, the approximation of natural drainage patterns on the reclamation has reduced erosion and sedimentation by creating shorter slopes with correct profiles, and by improving conditions for revegetation establishment.

Jan 1, 2010

By S. A., Taylor

IT is very difficult to arrive at exact figures for the cost of maintaining excess capacity of coal mines, but we can approximate the various items. To do this, I will take the Pittsburgh district of Pennsylvania and the other districts can be compared to this one. I believe we can take the depreciation item of plant ac- count as a whole and discount it over a period of 20 years; while this is high for some items it is low for others and I believe it is not far from a safe basis. This equals 5 per cent per year, and this depreciation will take place about as rapidly when not in use as when in operation. A fair value in the Pittsburgh district to- day for plant and houses is close to $4 per ton per annum. At 5 per cent this will equal 20 cents per ton per year. The item of keeping the mine in condition, free from water, etc., will be close to an average of 2y2 cents per ton per annum.

Jan 1, 1928

By S. S. Teal, W. W. Weber

"AS THE TITLE implies, this paper will deal with the unusual rather than the standard practices as employed . at the property of North Rankin Nickel Mines, Limited. Fortunately •the mining, with the exception of permafrost conditions, and the milling practices, are the normal approaches dictated by the size, type, and character of the orebody. The unusual aspects are linked directly or indirectly to the isolated location and are •principally ancillary requirements or services covering a broad range from climate to supplies and from finance to entertainment. It is our intent to cover the more salient points of interest together with a brief description of the general operation.To understand the primary motivation of the mine, it must be made clear that North Rankin was conceived as a foothold in the Canadian North, that region embracing 40 per cent of the Dominion which ex-tends north of the commercial tree-line and which includes nearly 50 per cent of the Precambrian Shield, our mainstay of Canadian mining. Secondly, this project was born in an atmosphere of premium sales in the nickel markets, assuring a rapid pay-back of the heavy •capital expenditures. And finally, it has •been coddled through the stark reality of a competitive metal market with the hope and trust that the experiences and achievements will lead over the bill to a bigger and better mine in this virgin territory. This is the briefest story of the mine's history, but it pays tribute to the many people who, in thirty years since .discovery, have championed this project."

Jan 1, 1959

By Lifeng Li, Jhon Silva-Castro

In a previous work, the authors analyzed the overlapping probability of two adjacent charges in a single hole for pyrotechnic and electronic detonators. This document extends such work to a complete mine blast where more than two holes are detonated. In a mine blast, all the blast holes are connected as a network by detonators to follow a given initiation sequence. Such initiation sequence’s performance is based on the adequate timing between charges in the mine blast. The analysis of the reliability of a mine blast based on the timing between charges and the initiation type is presented in this document. For a long-run time and under proposed operating conditions, the reliability of the mine blast can be analyzed based on the network which is treated as a system. The failure of the system is defined as no success between any two delays charges either in a single hole or in between two holes.

Jan 1, 2016

By E. J. Murphy

"INTRODUCTION This investigation is a continuation of previous work 3/4/5/ on the gaseous products of permissible explosives with and without sheaths. The range of oxygen balance of the explosives has been considerably increased. As has been shown previously, certain approximate relations exist between the volumes of gaseous products and the oxygen balance. Further systematization of the data is not feasible, since the method of theoretioal calculatln of the gaseous product is not yet satisfactorily developed. In a previously described method, 6/ it has been assumed that the explosion occurs at constant volume and that thermodynamic equilibrium is established. Apart from the presumably less important uncertainty of some of the thermodynamic data, it is not known how the confinement of the shots in the Bichel gage or the Crawshaw-Jones gage should be treated, or whether thermodynamic equilibrium is fully attained; nor can the extent to which the equilibrium composition changes during the subsequent period of expansion and cooling be judged with any reliability. Therefore, no calculations have been attempted. However, in anticipation of possible future theoretical interest and as an aid in answering practical problems, the new data are presented in the same minute detail as was done previously."

Mar 1, 1948

By Owen Matthews

Introduction For the past year and a half, the mill of Cochenour Willans Gold Mines, Limited, McKenzie Island, Ontario has been roasting arsenopyrite-gold concentrates, prior to cyanidation, by means of a roaster employing techniques that are new and novel. The roaster is known as the Dorrco 'fluo-solids reactor', and the technique as 'fluidization'. The reactor has demonstrated its ability to roast a flotation concentrate containing arsenopyrite, pyrite, stibnite, small quantities of other sulphides, and some lime silicates and carbonates, yielding a calcine consisting mainly of porous iron oxide, plus the gold values. This calcine is readily amenable to cyanidation. Bulk shipments of concentrates to a distant custom smelter, as practised prior to this installation, has thus been eliminated, with appreciable savings in smelting charges, freight costs, and interest losses during shipment and smelting. This is the pioneer installation of fluo-solids roasting at a Canadian mill and up to the present performance results have not been published. It is the purpose of this paper to present the information now available for the benefit of other millmen who may be confronted with identical or similar problems to those encountered and solved at Cochenour Willans.

Jan 1, 1949

By R. D. Merer

The production of low- and medium-Btu gas from coal provides a more economic source of energy for most industrial users than pipeline-quality coal gas (SNG), although the latter has received more publicity. The paper reviews existing and advanced methods of coal gasification, with particular emphasis on the production of low- and medium Btu gas for industrial and utility use. Some of the ways in which coal gasification can be integrated into power cycles and industrial plant energy balances are discussed.

Jan 1, 1978

By R. A. Jankowski

Although the number of operating longwall mining systems has remained relatively consistent over the past five years, longwall production levels have increased significantly during this period. Longwall production currently accounts for approximately 50% of U.S. underground coal production. While longwalls are highly productive and offer other advantages, operations employing this method of mining continue to experience dust compliance problems. This increased longwall productivity has meant that far more dust is being produced. An improved understanding of the longwall face ventilation system and advancement of face ventilation technologies are necessary to ensure all face personnel are allowed to work in an environment that is free of excessive levels of airborne respirable coal mine dust. The Dust and Toxic Substances Control Branch of the National Institute for Occupational Safety and Health's Pittsburgh Research Laboratory has examined several basic principles of the longwall face ventilation system, and has evaluated the effectiveness of numerous improved face ventilation techniques for longwall mining systems. These include identifying improved techniques for measuring face ventilation parameters on longwall mining sections and investigating the fundamental relationship between face air flow and the entrainment and dilution of respirable coal mine dust. Studies have been completed to determine the impact on face dust levels from using belt entry air to ventilate the longwall. Novel methods have been identified to increase the amount of face air flow and to manage face air flow to most effectively minimize face workers' dust exposure. Unique systems of auxiliary face ventilation have been developed and evaluated at full-scale, simulated longwall test facilities. The theoretical and applied aspects of each of these principles and technologies are discussed. Application of these results, throughout the longwall mining industry, as documented from surveys conducted in the early 1980's and 1990's, have reduced the health hazard associated with excessive exposure to respirable coal mine dust.

Jan 1, 1998

By J. Larsson

In the pursuit of increased safety the mining industry has worked to develop systems for remote control and autonomous operation of both stationary and mobile equipment. This paper reports on a newly developed system for teleoperation and autonomous tramming of LHD (Load-Haul-Dump) mining vehicles that not only increases the safety of the operators, but also has the potential to increase productivity.

Jan 1, 2010