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By Heikki Tuovinen

The total utilization of raw materials and energy is the most important criterion when planning. industrial processes. The main goal is clearly to use the raw materials and energy as effectively as possible in order to make the desired products directly in the primary process itself', or to recycle unused materials and energy either as such, or after cleaning back into the process. However, few industrial processes are so straightforward. Most processes generate by-streams of materials and energy, which cannot be recycled directly and it is namely these by-streams which tend to remain as wastes. These by-streams are slags, dusts, vaporized metals, liquids, slurries, sludges, gases etc. Most base metal processes produce all these by-products. Waste water and gas emission controls and regulations are tightening all the time, so new processes must be developed to keep pace with these requirements. These processes generate more solid wastes, which must be utilized or at least processed into a harmless form landfilling. Municipal and hazardous wastes also contain valuable materials and energy, which must be used to minimize landfilling. The development of processes for these purposes places even greater demands on research and development. The same principles and methods developed for mining, ore dressing and metal refining processes can also be adapted for research and development work on processes for waste minimization. However, the problems encountered are much more complicated and less familiar, demanding more versatile and accurate tools and equipment. This paper presents principles, examples and some references of R & D work on processes for waste minimization.

Jan 1, 1992

By J Benn, V Kuznetsov, G Timms, A Spain

Earthen covers are now widely used in the mining industry to control the generation rate and/or release rate of low quality drainage from piles of sulfidic minewastes. Covers are usually designed to reduce the water infiltration rate and in some cases may also reduce the oxygen flux to the underlying sulfides. Engineered covers have only been used since the 1980s, however, and there is very little field data on their performance in the longer term. This lack of information has implications for the degree of confidence that can be placed on the predictions of the environmental impacts of sulfidic minewastes, for the acceptance of close-out criteria by regulatory authorities and for the financial liability of the mining industry. Covers were placed on sulfidic waste rock dumps at the abandoned Rum Jungle uranium mine during 1984 - 1985. These covers were designed to reduce the water infiltration to less than five per cent of incident rainfall by both water shedding and storage-release mechanisms. Regular monitoring by the Australian Nuclear Science and Technology Organisation (ANSTO) demonstrated that the covers performed better than the design criterion for around ten years, but infiltration rates have subsequently increased. There is a 66 per cent probability that the infiltration rate now exceeds five per cent of incident rainfall. The cover on the largest pile, WhiteÆs heap, was sampled in pits dug at eight locations. Sampling was carried out at the end of the monsoonal wet season and again at the end of the ædryÆ season. This, together with laboratory testing, enabled cover performance to be assessed against five criteria: design, construction, cover material characteristics, physico-chemical characteristics and biological characteristics. We are of the opinion that the design of the cover was suitable to achieve the objectives of stability, water shedding, storage-release, and provision of a substrate for vegetation growth. Over most of the surface of the heap, the construction of the covers, drains and erosion prevention structures was in accordance with design specifications. However, several small and localised bare patches on the upper surface of WhiteÆs heap coincide with a reduced cover thickness, which is likely to have been due to poor construction in those patches. The construction of covers on minewastes is dependent on an adequate source of material meeting design specifications. From our limited examination, it appears that there was shortage of material for each of the three zones û a lower impervious clay layer, the moisture storage-release layer and the upper erosion-resistant layer for vegetative growth. An indication of this was that the upper layers in some areas were observed to be thinner than specified. We are of the opinion that this shortage of suitable material has been responsible for some of the changes observed ten years after emplacement. Physical and geotechnical testing indicated that the cover materials no longer meet the original specifications. In particular, the permeability at the 8 locations was found to be greater than specified, by up to several orders of magnitude. The higher permeability may explain the higher observed rainfall infiltration and moisture content of the waste rock. This increased permeability appears to be due to a combination of biological and physical processes û galleries formed by termites and ants and an extensive system of shrinkage/desiccation cracks formed by the development of a polygonal blocky structure involving the entire lower clay layer. The desiccation cracks may fill with coarser illuviated materials and form a conduit through which roots access the underlying waste rock. Measurements were made of oxygen flux into the heap as cover layers were excavated in the pits. They indicated that the full cover currently reduces the oxygen flux to 20 - 23 per cent of that into bare waste and that this reduction seems to be proportional to the cover thickness. It was also found that the oxygen flux into the cover is about four times higher at the end of the dry season than at the end of the wet season and that the difference is due primarily to the difference in moisture content of the cover. Recommendations are made for the design and construction of covers.

Jan 1, 2003

By W. A. Lang

"IntroductionCARBONIZATION, gasification, and chemical utilization of coal are interrelated topics, which makes it difficult to review one without indicating its connection with the others. Hence, in Progress in Coal Technology, Series No. 5: Carbonization, reference was made to gaseous products recovered in the carbonization of coal, and .to a number of chemicals made from the tars, light oils, and ammoniacal liquors which are by-products of coal carbonization.In this, the sixth paper in the review series, prime consideration will be given to the complete gasification of coal to give a fuel for domestic industrial, or power purposes and a synthesis gas suitable for the manufacture of gasoline, Diesel oil, and chemicals. The hydrogenation of coal, an alternative source of liquid fuels and of chemicals, will be reviewed, as will be a number of processes for •the recovery of chemical products from coal by extraction and chemical treatment."

Jan 1, 1952

By R. W. Bruce, K. W. Downes

"IntroductionSULPHUR production in Canada from all sources for the year 1953 amounted to about 375,000 tons. Except for 16,000 tons of elemental sulphur derived from natural gas, this production was in the form of by-product pyrites, liquid sulphur dioxide, and sulphuric acid. In the same year, Canadian industry imported 359,000 tons of elemental sulphur from the United States. The cost, including transportation charges, to Canadian consuming plants ranged from $35.00 to $45.00 per long ton, depending upon location.Although most of the sulphur consumed is used in the oxidized form it is often most convenient to buy sulphur in the elemental form, and convert it to sulphur dioxide or sulphuric acid in situ as required. This is because elemental sulphur is easily shipped and stored, weighs only half as much as an equivalent quantity of sulphur dioxide and one-third as much as the corresponding quantity of sulphuric acid, and is readily converted to these forms in a sulphur burner. A process, therefore, which could economically recover elemental sulphur from sulphide ores would be most attractive.Since the turn of the century, notable improvements have been made in extractive metallurgy, but until recently only limited attention has been paid to the possibilities of elemental sulphur recovery. This has been due to the plentiful supplies of cheaply mined Frasch sulphur which have been available on the world markets."

Jan 1, 1955

The principal activities of the Bureau of Mines Explosives Research Center from July 1, 1963 to June 30, 1964 are described briefly in part 1. Part 2 gives short abstracts of publications that appeared during fiscal year 1964; in general, the research reported in these publications antedates the report period. Part 3 describes a short-term investigation into safety problems associated with shipping of molten sulfur; this investigation is not at present destined for publication elsewhere.

Jan 1, 1965

By Jennifer J. Swenson

El presente texto describe los problemas de deforestación, precios e importaciones de mercurio en la minera artesanal aurífera de Madre de Dios. En ese sentido, a medida que la interconexión de la economia mundial avanza, es más difícil que países en desarrollo aprovechen las fuerzas lucrativas de la demanda global para lograr una sostenibilidad social y ambiental. En consecuencia, los países en desarrollo contienen un peso ambiental desigual en relación con los países desarrollados qie importan materias primas. Como ejemplo de ello, el precio del oro aumentó, así como la minería aurífera informal y no industrial en los países en los países en desarrollo y el mal manejo del mercurio en el uso del oro, repercutió en el medio ambiente y los mismos mineros, al igual que el problema de la deforestación. Por ello, se plantea un programa para enfrentar dchos problemas en la región de Madre de Dios y reducir el aumento de la minería informal.

May 1, 2012

"Metallurgical process development in greenfield projects must define the comminution flowsheet and establish the equipment sizes that are required to deliver the project design criteria. These are critical steps that heavily influence the financial performance of the project, requiring a detailed understanding of the ore properties of the project resources and the best practice methods to size comminution machines. This paper reviews current practices for determining the ore characteristics relevant to comminution circuit design. Particular attention is given to the design of sampling and testing programs, and the methods commonly applied to size crushers and mills for conventional size reduction applications in mineral processing. IntroductionMetallurgical process development in greenfield projects requires the selection of a comminution flow sheet and must establish the equipment sizes required to deliver the project design criteria. This necessitates a detailed understanding of the ore properties that define the project resource. For brownfield projects the same objectives may apply for plant expansions, or the project objective may be simply to define the capacity and operating cost of an existing facility for a new ore source. The process development phase in either instance will typically comprise the following key activities:• Geometallurgical classification and sampling of the ore deposit or deposits.• Determination of comminution energy requirements.• Benchmarking similar projects.• Identification of flow sheet options.• Equipment selection and sizing.This paper is concerned specifically with process development testing and will as such focus on the first two activities on the list: sampling and testing of the deposit. The discussion will focus on testwork programs to support the design of comminution circuits commonly in use in mineral processing today, specifically crusher, tumbling mill and stirred mill technologies.It is important that any testwork program is designed giving consideration to the types of flow sheets that are viable for the project, and the data that will need to be generated to support the final equipment sizing. Designing a testwork program to only provide information about one particular type of flow sheet will not allow sufficient information to be generated for a rigorous trade-off analysis of options, and may therefore preclude financial optimization of the project. Testing programs should be designed to collect sufficient data to ensure that any backtracking at a later stage to fill in missing information is minimal."

Jan 1, 2016

By Christiaan Zeilstra, Jan van der Stel, Koen Meijer, Gerard Louwerse, Tim Peeters

The steel industry is producing about 5% of the world wide CO2 emission. Therefore the European steel industry has defined a research program to reduce the CO2 emission by 50% per ton: ULCOS. Since its start in 2004 ULCOS has identified four technologies for further development. Two of these technologies which produce liquid hot metal are discussed. The ULCOS blast furnace is based on recycling of decarbonated topgas and the capture and storage of CO2. The concept has been demonstrated during three campaigns at LKAB EBF in Luleå, Sweden. The smelting reduction process HIsarna is a combination of the cyclone-technology and Hismelt. The process has been demonstrated successfully in four campaigns at a pilot installation on the IJmuiden steelmaking site.

Jan 1, 2015

By W. P. Diamond, J. R. Levine

The explosion hazard of methane-air mixtures has become an increasingly serious mine planning problem, and an advance assessment of methane gas potential can therefore be essential for a safe and economic mine development pro- gram. As part of its coal mine health and safety program, the Bureau of Mines has developed a simple, inexpensive test to measure the methane content of coal samples obtained from exploration cores. The gas content of coal per unit weight as determined by the direct method test can be used as a basis for a preliminary estimate of mine ventilation requirements, and to determine if degasification of the coalbed in advance of mining should be considered. Since the Bureau began measuring the gas content of coal samples in 1972, experience has led to equipment and procedural changes, the most significant of which has been the development of a ball mill for crushing the coal sample to release the residual gas at the end of the desorption test period. This revised procedure replaces the crushing box and graphical methods described in earlier Bureau publications. The results of 583 direct method tests are summarized in tabular form. These results include data on the gas content of 125 coalbeds in 15 States.

Jan 1, 1980

By Betty J. Laswell, Gerald W. Laswell

Rotary drilling in modern open-pit mining is usually considered the lead phase which not only establishes the production rates but frequently limits them. From this viewpoint alone, the drilling phase must be maximized. The drill phase is the step that permits all the other operational phases to function within their design limits. This means that, in most cases, the drill is literally run to destruction to ensure that the shovel will be able to smoothly and consistently load a manageably size muck, the haul trucks can carry a balanced load without having a boulder dropped through the bed, and the crusher can devour constant rock size.

Jan 8, 1978

By C. L. Pillar

In many cases, substantial time may elapse between the exploration stage and a serious detailed planning stage which has the objective of putting a mineral property into production. This is always true where properties change ownership and new partners are brought in for joint venture situations. Such conditions make it imperative that the recording of complete and accurate geological data for the property is done during the active part of the exploration phase and accomplished by competent geologists and engineers. This work should not be left to helpers and technicians. Furthermore, it should not have to be redone years after the actual drilling was accomplished, when either those involved have parted company or those present have lost the touch and feel of their part of the exploration program and must rely on a memory sketchy in detail, at the best. All of this emphasizes the importance of thorough geological evaluation and reporting during the exploration program. To evaluate and comment on the application of geological data by a mine planning department, we must assume (1) that sufficient diamond drill holes have outlined the existence of a potentially economic ore deposit, and (2) that the next step is to obtain the required information to allow a detailed feasibility study. This paper will comment on: 1. what types of geological information are required, 2. how it can be obtained, and 3. comments on the application of this information by the mine planners.

Jan 1, 1973

By Mark Spence, Tom Lardner, Matthew Janes

"IntroductionThe design-build method streamlines project delivery through a single contract between the Contract manager and the design-build team. The design-build method places emphasis on collaborative project management between design and construction disciplines to minimize project schedule, reduce costs, encourage balance risk amongst the design-build team. Since 1985, the percentage of nonresidential design and construction projects has increased from 5% to 45%.1A project carried out in Edmonton, Alberta, Canada will be used as an example to illustrate the challenges of the design-build project delivery method and the merits of establishing a GBR. The project involved a complex slope stabilization as part of an extensive freeway widening. At the project location the roadway was being widened within the base of a historic stream valley into a steep slope with a history of a previous slope failure. The slope was to be steepened through the installation of a series of 14 interlocking arc structures constructed half way up the slope. Access and schedule proved critical to the successful completion of the project.Geotechnique and Site HistoryThe geotechnical investigation undertaken for the site included six boreholes drilled at the crest of the slope to depths ranging from 14.5 m to 30.2 m. Laboratory testing of the soil samples included direct shear tests, Atterberg limits and grain size analysis. The geotechnical report also referenced a previous geotechnical investigation that was carried out in response to a failure of the slope in 1971."

Jan 1, 2015

By C. G. Carlström

The total iron ore production in Sweden in 1969 was 33.3 million metric tons. 31.7 million tons were exported mainly to Western European countries. 27.8 million tons (87 per cent) originated from the mines at Kiruna, Svappavaara and Malmberget, located just north of the Arctic Circle in Sweden. Planned production for 1970 is 25 million tons during 10 months, due to a strike at the beginning of the year. Present production plans for the next five years expect an annual export capacity around 33 million tons in 1975, including 5.7 million tons of pellets. The mining and shipping at the loading terminals of Narvik on the Atlantic coast and Luleå at the Gulf of Bothnia are managed by LKAB - a 96 per cent state-owned company. 4 per cent of the share capital is owned by the private Grängesberg Company. The railway - 106 miles from Kiruna to Narvik and 130 miles from Malmberget to Luleå - is operated by the State Railways in Sweden and Norway. Comprehensive expansion of the Narvik ore port will be carried through during the next five years to increase the annual shipping capacity to at least 35 million tons and meet the development of rapidly growing ship sizes.

Jan 1, 1970

By Robert Louis Adams

A general discussion of the structure of the junk automobile recycling system shows that the generation of stripped automobile hulks and scrapped automobiles is price inelastic. As a result, it is extremely difficult for the price mechanism to automatically achieve an equilibrium that will prevent the accumulation of excessive automobile wrecker inventories and vehicle abandonment by the last owners of scrapped cars. The new shredder processing technology and the new portable flattener technology have altered the structure of the junk automobile recycling system. The shredder technology has increased the demand for processed automobile scrap. This increased demand is reflected in higher prices paid for hulks by scrap processors. The portable flattener has reduced the transportation cost of shipping hulks to processors. The two new technologies have eliminated, at least potentially, the net cost of shipping stripped hulks so frequently incurred by wreckers in the past. The elimination of this cost eliminates the economic incentive for excessive wrecker inventories. Unfortunately, the incentive for last owners to abandon their cars does not appear to have been eliminated by the new technologies. The last owner of an automobile with no spare parts value is still likely to incur a cost by delivering his automobile to the recycling system. Although a subsidy payment is probably unnecessary to reduce excessive wrecker inventories, such a payment might be one solution to the problem of automobile abandonment. However, there are a wide variety of subsidy programs that could be introduced. Before any Federal subsidy program is introduced to reduce automobile abandonment, it is recommended that the program be tested on a limited basis in many different parts of the country.

Jan 1, 1973

By Elmer W. Pehrson

NINETEEN FORTY-SIX was an eventful year for the mineral industries. Perhaps the most significant development was the socialization of industry in Great Britain, initiated in 1945 but carried to fruition in the coal industry in 1946. On Jan. 1, 1947, management of the coal industry will be vested in a National Coal Board, responsible to the Ministry of Fuel and Power. A sum of £164,660,000 has been provided to compensate private owners for assets transferred to the Board. The British coal industry has been a problem for many years. Production has declined to a point where serious shortages of fuel for domestic needs have developed. Exports have dwindled to a small fraction of the previous trade. Costs have increased greatly, and quality has deteriorated. The industry's physical plant has not kept pace with the rapidly mounting wage scales in recent years. Some claim that the best and most accessible coal reserves of Britain are heavily depleted. The industry has been harassed by difficult labor problems, including bad morale among the workers and a shrinking labor force.

Jan 1, 1947

By R. Gray

"Experience from Australia has identified what is referred to as non-conventional surface subsidence behaviour. This occurs under irregular surface topography, resulting in valley closure, valley floor uplift or “upsidence”, and far-field horizontal movements – even occurring beyond conventional “angle of draw” limits. This paper discusses such behaviour recently observed in Pennsylvania and focuses on the 2005 case of Duke Lake Dam in Ryerson Station State Park. In July 2005, there was a significant increase in water leakage through a number of growing cracks in the dam leading to the dam being breached to avoid an uncontrolled failure. An underground longwall mine was located approximately 900ft to the north, mining at depths of 330 – 720ft. Investigations (including a subsequent ground movement monitoring program) found a range of evidence in the vicinity suggesting that valley closure and far-field horizontal movements may have occurred resulting from the adjacent mining. The paper discusses the phenomenon of non-conventional subsidence behaviour and the Ryerson State Park case study, including an assessment of mining, geology and subsidence impacts and suggested ground behavioural mechanisms. INTRODUCTION Non-Conventional Subsidence The conventional understanding of coal mine subsidence on which most current subsidence understanding and prediction techniques are based, includes the concept of angle of draw which effectively limits the lateral extent of subsidence effects and impacts. Within this zone – above and marginally beyond the boundary of mining – downward vertical subsidence is the dominant component, together with localised horizontal movements towards the mined region, with related tilts and strains. However, more recent experience from Australia over the last two or three decades has identified what is referred to as non-conventional surface subsidence behaviour. This is found to occur in areas of irregular surface topography or variable terrain, and is characterised by phenomena such as valley closure, valley floor uplift or upsidence, and far-field horizontal movements, all of which can occur beyond the conventional angle of draw limits. NSW Department of Planning (2008) defined the conditions for both conventional and non-conventional subsidence behaviour as follows: “The conventional or general model of surface subsidence, which finds worldwide acceptance, is based on assuming the following site conditions:"

Jan 1, 2015

By L. W. Laage

MFIRE is a mine ventilation and fire interaction computer simulation program. It allows transient state ventilation simulation and features mass based flow rates, natural ventilation, air recirculation, fan curve fitting, airflow reversal and product of combustion tracking. MFIRE was designed to accommodate the needs of the mining industry for routine ventilation calculations and mine emergency planning. This paper describes recent work by the Bureau and MTU to improve MFIRE by incorporating humidity in the mass flow and heat exchange calculations, a data file preparation program and variable reference density in the network calculations. Recent bug fixes are also discussed.

Jan 1, 1993

By W. Newcomen, G. Dick

"Effective management and mitigation of pit slope instability in open pit mines begins with a comprehensive slope monitoring programme. The ability to differentiate between non-critical pit wall movements due to rebound or relaxation of the excavated slopes and movements that may be indicative of slope failure is important for maintaining a safe working environment and maximizing production. Slope failure prediction methods using velocity, acceleration, and strain criteria have been introduced and put into practice over the past few decades. Forty-eight slope failures with surface monitoring data are presented and assessed using the strain-based failure prediction approach, with consideration of the quality of the rock mass and the potential failure mechanism. The results indicate that the strain-based approach can be used to provide general guidance regarding strain thresholds for pit walls for a variety of failure modes in diverse geological environments. The advantages and potential drawbacks of the strain-based and other slope failure prediction methods are discussed. The importance of implementing a pit slope monitoring and performance evaluation system early in mine development is also emphasized. IntroductionThe successful prediction of the Manefay Slide pit slope failure at Bingham Canyon at 9:30 am on 10 April 2013 (Engineering and Mining Journal, 2014) highlighted the importance of having a comprehensive slope monitoring system that provides an accurate prediction of the time of failure of an open pit slope. Using most of the geotechnical monitoring tools available, the time of the failure was predicted within hours and equipment and personnel were evacuated from the pit well in advance of the failure. From a time to slope failure perspective, the monitoring system in place was a success.There are two general groups interested in monitoring pit walls, with slightly different objectives in mind when the monitoring system is being set up. There are those at the mine site that have to implement the pit slope design, monitoring protocols, and the action response plans, and there are those designing the slopes (often consultants) who regularly visit the mine but may not be responsible for the day-to-day activities. was a success.There are two general groups interested in monitoring pit walls, with slightly different objectives in mind when the monitoring system is being set up. There are those at the mine site that have to implement the pit slope design, monitoring protocols, and the action response plans, and there are those designing the slopes (often consultants) who regularly visit the mine but may not be responsible for the day-to-day activities."

Jan 1, 2016

By M Spagnolo, M Ashley, D, L Reemeyer

PasmincoÆs Century Concentrator in North West Queensland commenced operations in November 1999. The nameplate production capacity of 500 000 tpa of zinc metal production in concentrate was achieved in August 2002. Completion of the production ramp up was successful due to the culmination of a number of initiatives throughout 2001 and 2002. Mine to mill interaction to understand and eliminate head grade related bottlenecks affecting Concentrator production and reduce feed variation. Grinding circuit process development û operating and process control strategies to improve stability and reduce grind size to support zinc recovery. Pumping upgrades to control spillage in ultrafine zinc flotation Low density zinc flotation strategy û to improve silica-sphalerite separation to improve zinc recovery while maintaining acceptable silica in final concentrate. Flotation circuit process development û froth crowders, froth cameras and reagent control strategies to improve primary zinc flotation performance. Review and implementation of longer campaigns between planned shutdowns to improve availability. Team reorganisation û to improve setting and implementation of metallurgical strategies. This paper describes these initiatives and their contribution in achieving the production target. It also notes the ball mill motor failures that delayed the successful achievement of the ramp up, and CenturyÆs response to minimise the production impact. The paper also outlines the capital improvement program that was implemented to improve zinc recovery to design 82.5 per cent recovery once the production rate had been achieved.

Jan 1, 2003

By T. V. Falkie

REMARKS OF DR. THOMAS V. FALKIE, DIRECTOR, BUREAU OF MINES, U.S. DEPARTMENT OF THE INTERIOR, BEFORE THE FALL MEETING OF THE SOCIETY OF MINING ENGINEERS, AIME, ACAPULCO, MEXICO, SEPTEMBER 23, 1974 This is a time of uncertainty on the world mineral scene. For some of the world's so-called "developed" countries, reserves and production of key minerals are running low. And, we have learned that the energy so essential in recovering and processing minerals can suddenly be in short supply. The prospects for a "no growth" situation in energy or mineral consumption are practically nil. Moreover, the world's economy is in flux, casting doubt on whether traditional mineral customers will continue to be able to buy, or for that matter, whether traditional suppliers of minerals will continue to sell. It is clear that the mineral situation is contributing to world inflationary pressures, which incidentally are most damaging to developing countries. So it is appropriate that SME members devote this session to the world mineral situation, and consider some of the opportunities and responsibilities that we will inevitably encounter as the future becomes the present. The opportunities, to me at least, are especially intriguing, I have the good fortune to be part of an organization that has an enormous capability and responsibility for dealing with mineral problems. The Interior Department's Bureaus, including the Bureau of Mines, have been around for a long time. They are. a prolific and reliable source of both mineral information and mineral technology.

Jan 1, 1974