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By Vladimir Panjkovic, Ostrovski. Oieg, Campbell Cripps Clark, John Truelove

"Effects of properties of raw materials and blast on the performance of an iron bath reactor have been examined by a mathematical model. The model consists of three modules: 1) chemical reactions in the gas phase and heat transfer from gas to droplets ejected from the bath; 2) heat losses from the vessel and radiative heat transfer from the freeboard to the bath; and 3) heat and mass balances for the bath. The following parameters of the process are calculated: coal, ore, flux and oxygen consumption, post-combustion ratio and heat-transfer efficiency, temperature and composition of the off-gas, and slag and metal chemistry.IntroductionOne of the anticipated advantages of smelting reduction over conventional ironmaking is the use of lower-grade raw materials. In this work, the effect of-properties of raw materials on the performance of an iron-bath reactor is examined with a numerical model. The model is also used to assess the effect of properties of the blast (flowrate, temperature and oxygen enrichment) and ejected droplets (generation rate, size and ratio of total weights of slag and iron droplets) on the key parameters of the process. In the process coal, oxygen, ore (which may be partly prereduced) and fluxes for specified slag composition are charged to the bath. Slag and iron droplets are ejected from the bath into the gas phase, where they are heated before returning to the bath. Iron droplets undergo decarburisation and reoxidation with CO2 and H2O. Dust is also generated from the bath, and oxygen or preheated air for post combustion is injected from the top of the vessel.The model consists of three modules: 1) reactions in the gas phase and heat transfer from gas to droplets ejected from the bath; 2) heat losses from the vessel and radiative heat transfer from the freeboard to the bath; and 3) heat and mass balances for the bath. The structure of the model and the data exchange between the modules are shown in Fig. 1. The following parameters of the process are calculated: coal, ore, flux and oxygen consumption, postcombustion ratio (PCR), heat transfer efficiency (HTE), off-gas temperature and composition, slag and metal chemistry, and rates of decarburisation and reoxidation of the iron droplets."

Jan 1, 1996

By L. R. Smith

BUTANE OPERATED drilling rigs are a recent innovation in the petroleum industry, so extensive data on their operation are not available. However, experience indicates that, within limitations, as much can he accomplished with butane as with steam, at a decided reduction .in expense of installation and cost of operation. Commercial butane is a liquid motor fuel similar to gasoline, but much more volatile, so that it has to be stored under pressure. At 10° F. it is liquid at atmospheric pressure, but at 100° it has a pressure of 70 lb. or more. As soon as the pressure is reduced, it turns to vapor and in that state is far more easily mixed with the air necessary for combustion. Butane occurs as a by-product in the absorption process of natural gasoline extraction from casing-head gas. The product has been used to some extent 10 raise the octane value of gasoline. However, because of its volatile nature, such admixture is stable only to a limited degree. Attempts also have been made to introduce the product in a gaseous form into oil- hearing formations in repressuring work. It has, however, until recently, for the most part been wasted.

Jan 1, 1937

By M. W. BERNEWITZ

IT is 27 years since I last visited Broken Hill, New South Wales, one of the world's greatest lead-silver-zinc districts. Then, the flota¬tion of ores was in its infancy. The Minerals Separation process had its birth as a practicability in the Central Mill, which is still operating and yielding high recoveries. The average Australian knows that Broken Hill is an important mining center in a "corner" of New South Wales, but he does not know what a factor it is in the lead, silver, and zinc production of the world. Nor does he realize that among the ramifications arising from metal production at Broken Hill are the great lead smelter at Port Pirie, South Australia, 254 miles southeast; the electrolytic zinc works at Risdon, and the limestone mine at Davenport, Tasmania; the acid works at Cockle Creek, New

Jan 1, 1935

By O Joneydi, J Viljoen, R Funnell

Computational Fluid Dynamics (CFD) modelling is a useful tool that can assist engineers in designing effective ventilation systems for the control of airborne dust generated during mining operations. Thistechnology can save time, effort and the costs associated with re-work or the traditional on-site experimental field trials by running desktop 3D simulations of the various proposed scenarios using state-of-the-art CFD analysis tools. Before implementing a dust management system, an understanding of the behaviour of airborne dust particles in the face zone can be achieved, which can improve the confidence in the secondary ventilation and dust management design. Usingadvanced numerical models, suitable dust extraction strategies can be foreseen, and multiple scenarios can be simulated and investigated quickly. As a case study, dry drilling operations in Kimberlite orebodies produce large quantities of fine dust which poses health and safety risks. An effective dust management system is required to achieve acceptable face conditions. A possible practical solution is a ducted exhaust ventilation system with a force fan in the face zone. This paper demonstrates how CFD analysis can be used as a tool to assist the design engineer with validating and optimising the proposed ventilation design by tracking the trajectories of different size dust particles, to determine the best equipment layout and appropriate flow rates which minimises airborne dust.

Oct 12, 2022

By S. P. Marsh, D. Banerjee

"Casting processes involve phenomena that occur on widely disparate length-scales. Simulation of macroscopic effects, such as heat transfer and convection, are generally addressed by solving the appropriate equations in discretized form on a finite-element mesh. Microscopic phenomena are described by micromodels that may be empirical or analytical in form. Coupling of phenomena in these two regimes is a critical issue in predicting microstructure and defect formation resulting from macroscopic process conditions. A formalism has been developed for expressing micromodels in a consistent manner using stereological parameters to quantify the geometric characteristics of the developing microstructure. This approach provides a robust and physically consistent method for coupling local micromodels with the macroscopic fields. The macroscopic state variables at each node serve as global constraints on the micromodels that are applied to a local unit volume. An outline of an equiaxed solidification model based on this approach is presented, along with preliminary simulation results. Coupling of convection and enthalpy effects between the micro and macro regimes is also discussed. IntroductionThe primary goal of casting simulations is to improve the reliability of cast parts while minimizing cost and development time. Effective simulations can speed up the mold design process and reduce the likelihood of defective parts by refining a particular casting process on a computer, reducing the dependence on cost- and time-intensive prototype castings. The challenge in developing effective simulations stems from the need to address physical processes that occur over a wide range of length-scales, from microscopic (atomic) and mesoscopic (microstructural) scales to macroscopic distances comparable to the size of the casting itself. Overviews of the various thermophysical phenomena and computational factors that are important in solidification modeling are provided in the literature by Rappaz [1] and Tseng et al. [2].Macroscopically, the solidification process is largely governed by the rate of heat flow from the alloy through the mold wall. Another important effect that occurs on the scale of the casting size is convective flow of the melt, which is driven by density-variations in the melt. Macroscopic calculations employ finite-element or finite-difference methods to solve the sets of equations that govern these effects, and the spatial resolution is determined by the grid spacings used for the calculations. Typical spatial resolutions are on the order of 10-2 to 10-3"" meters. This represents a compromise between the resolution required to simulate the continuum transport processes accurately, and the computational time required to model the entire solidification and cooling process."

Jan 1, 1994

By Jr. Norman

Thermoelectric properties of depleted uranium selenides and tellurides were investigated from room temperature to 700 C. Several depleted uranium monoselenides and monotellurides were doped with selected cationic and anionic materials to determine the effect of impurity additions on the thermoelectric properties. The undoped uranium selenides and tellurides were semimetallic conductors exhibiting low Seebeck coefficients and electrical resistivities. Partial or complete degeneracy was in evidence, indicating a charge carrier energy distribution similar to that in a metal. Doping increased the Seebeck coefficients of the uranium monoselenides and monotellurides; however, the corresponding change in the power factor in the figure of merit was small because of the increase in electrical resistivity.

Jan 1, 1965

By Donald L. Mordell

Introduction A very large part of the world's fuel resources are in solid form, as various grades of ?coal, but an increasing proportion of fuel demands on this Continent and else-where are having to be met by liquid fuels. Convenience and, in many cases, cost weigh heavily in favour of the liquid: fuels, and there are many fuel burning applications where the use of coal would be impractical, such as for automotive or air transport. By extrapolating the present trends one might conclude that, in future years in Canada and the United States, coal will be used only in a few power stations close to coal fields. If such a state of affairs should arise, it will obviously prove embarrassing to those accustomed to make their livelihood from the winning and marketing of coal, but it is perhaps not so obvious that it must also prove an embarrassment to the nation. The major reasons for this are two in number. Firstly, if present coal production is to be replaced by oil production, a large capital expenditure is necessary, which must inevitably be paid by the consumer; and secondly, in times of emergency, large amounts of oil fuels are required for military purposes which cannot be achieved with solid fuels. It is obviously unwise, therefore, to discontinue the use of coal for those non-military jobs that it can do. If we examine the major fuel markets we find that there are three: Domestic heating Steam generation Transport by air, sea, and land For domestic heating, the extreme convenience of oil, in spite of its greater cost, has captured much of the coal market.

Jan 1, 1952

By Guy N. Bjorge

HOMESTAKE'S mining methods today are of necessity controlled to a considerable extent by that which has been done in the past. This may be shown by the fact that our two main operating shafts now, the B. & M. and Ellison, were begun in 1878 and 1896 respectively, so that-the loca-tions of shafts, locations of all the drifts on the upper levels, and a great deal of sloping was done before any of us now connected with the mine had anything to do- with it. Anything that I may say is not to be construed as criticism of those who have gone before for it would be a sad commentary indeed on us if we had not learned something from their experience. The levels down to the 1100 in the Homestake mine are spaced at 100-ft. intervals, and below that at 150-ft. intervals. The general plan of develop-

Jan 1, 1934

By J A. Rowland

When executing a ventilation change the mine ventilation circuit is in a state of flux throughout the entire change period with discrete mine areas both under ventilated and/or over ventilated during the change process. Whilst routine risk reduction strategies such as removing electrical power and people from the mine are commonly deployed it is wise to complete the change in the shortest practical time frame. This not only minimises the chance of unacceptable concentrations of contaminants accumulating around the mine but reduces the impedance on production activities which are routinely suspended during these change periods. This paper firstly highlights the importance of the maintenance of an accurate ventilation model and discusses issues which should be considered to assist to maintain in it a suitable state of health. Further it provides some tips on how to monitor that your model is in an acceptable state of tune so that it can be confidently deployed in the change process. Finally, it details the sequential process how a finely tuned and accurate ventilation model can be utilised to carry out major ventilation changes according to appliance pressure adjustments only and without the need to constantly measure and check resultant branch flows throughout the whole change process. Also discussed are some simple practical tips which will help ensure that the ventilation change process will go according to the devised plan on the day and in the most appropriate order including checking the efficiency and accuracy of the change, after it is completed.

Oct 12, 2022

By Nabil A. Bibawy

An improved method for preparing gravimetric standard gas mixtures of helium-4 in nitrogen has been developed by the U.S. Bureau of Mines. A single-pan 12-kg analytical balance that has a sensitivity of 3 mg is used to prepare the mixture. The balance will accommodate a cylinder having a volume of approximately 4 L that weighs approximately 5 kg. The method has been improved to a precision of ±O.04 pct by performing four successive dilutions, by improved handling of gases in the manifold, and by using an improved analytical method to select high-purity gases.

Jan 1, 1990

By D. W. Collins

The uptake of gold from halide solutions by activated carbon has been investigated using various techniques. Halide systems typically exhibit combined adsorption-reduction type behavior. In an attempt to gain more information about the nature of these processes, samples of synthetic highly-oriented pyrolytic graphite (HOPG) were contacted with aqueous solutions of gold-iodide. HOPG represents a model structure for activated carbon comprising of basal- plane sites, edge sites, and various defect sites. Two basic instrumental methods were used to examine the uptake of gold by HOPG. The first was standard X-ray photoelectron spectroscopy (XPS). The other involved several scanning probe techniques. XPS clearly indicated a preferred uptake of gold at edge sites. However, iodine appeared to be distributed on both basal-plane and edge sites. At low iodine additions, tapping mode AFM showed that clusters were concentrated along steps and surface defects. At high iodine concentrations, the HOPG surface was uniformly covered by iodine.

Jan 1, 1998

By Oliver Bowles

The wire saw, introduced by the Bureau of Mines about two years ago, has revolutionized slate quarrying in Pennsylvania. The success of the saw since its early accomplishments has become greater and greater as the equipment has been perfected and skill acquired .in its use. In the first test made, a cutting rate of 9.7 square feet per hour was attained; in the next four cuts, made early in 1927, the average rate of cutting was increased to 12.8 square feet per hour; in 1928 a maximum of 34 square feet per hour had been attained, with a general average of about 20 to 25 square feet, The wire saw is now regarded as essential equipment in practically all of the quarries in the Bangor, Pen Argyl, and Windgap districts. The wire saw consists of a three-strand steel cable of 3/16 or 1/4 inch diameter running as an endless belt. The driving pulley is a 40-inch double-groove cast-iron sheave. A tension pulley supported by a frame mounted on wheels may travel back and forth on a short track. A weight of 800 to 2,000 pounds gives the desired tension on the wire. The driving units consist of electric motors with direct-drive compactly enclosed gear reduction, or double-belt speed-reduction units; the former is preferred. Silent chain and. pinion gear reductions are used to a limited extent. The travelling speed of the wire is about 15 feet per second. The driving and tension equipment are shown in Figure 1, A.

Jan 1, 1929

By K. Sun

The exothermic behavior of the intermetallic reactions inside an Al-Mn metallic powder compact and its assimilation fundamentals in molten aluminum were examined. In this study cylindrical compacts were manufactured and tested. The experimental work involved simultaneous temperature measurements of three thermocouples as well as detection of the apparent weight of the cylindrical specimen during its assimilation in liquid aluminum. The details of the intermetallic reactions prior to the compact complete disintegration were investigated by microscopically studying the morphology and local composition in a partially reacted compact. The variation of manganese concentration in the melt was determined by chemically analyzing the samples taken from the molten aluminum at specific time intervals. The exothermic reaction increases the compact's temperature above that of the liquid aluminum. In tandem with this exothermic reaction, the compact is suffering a swelling action. This swelling action disintegrates the cylindrical specimen, which is assimilated into the liquid aluminum. The intermetallic reactions proceed in a stepwise manner. Both the bath temperature and the compact composition impact on the exothermicity of the intermetallic reactions. However, when the amount of Mn in the compact is greater than 75-wt%, the maximum centerline temperature rise is slightly reduced as Mn amount increases.

Jan 1, 2004

By S S Solomons

In 1991 the uranium spot market price dropped to approximately US$7/Ib U308, a historical low in real terms and the short-term outlook for the industry in the next five years was grim. At this time the Ranger operation was producing uranium concentrate at its design capacity of approximately 3 000 tonnes/year. The loss of two major long-term contracts owing to price and reduced power utility demand due to excess inventories meant that the company could not match production to sales. Continuance at this production level would have resulted in a rapid buildup of product inventory and the tie-up of significant cash reserves. After analysing various options, an innovative operating strategy was devised such that production and sales were approximately balanced without a significant impact on the unit production cost or a long term effect on the plant or operation. A campaign mining/milling operation commenced and approximately 40 per cent of the workforce were retrenched. Multi-skilling of all employees was a critical aspect of ensuring a successful outcome. This paper examines the strategy and reports on the success of the operation two years after the restructuring exercise was effected in November 1991.

Jan 1, 1994

By Onuralp Yücel, Mehmet Bugdayc, Murat Alkan

"In this study, iron based alloys (Fe-Mo, Fe-Cr-Ni, etc.) were produced by using aluminothermic methods starting from Mill Scales obtained continuous casting processes. Mill scales are an oxidised layer of steel alloys containing iron oxide, which includes + 2, + 3 values, on the surface of slabs and billets occurring during annealing in heating furnace at integrated iron and steel milling plant, and continuous casting unit. In the metallothermic experiments, different ratios of starting mixtures and addition of the oxide powders (Alz03, Si02, CaO, MgO) were examined, and their effects on the metal recovery and alloy compositions were carried out. The samples were characterized by using chemical analysis (AAS), XRD, XRF and SEM/EDS techniques.IntroductionSelf Propagating High Temperature Synthesis process (SHS) has many favour compared to the furnace applications, such as low energy requirement, low cost, very short processing time and simple operation, [l, 2]. In a SHS process, the ignition starts the combustion and propagates throughout the reactant mixture yielding the desired product. However, the disadvantages of the process such as inhomogeneous or unreacted products due to undesirable reaction rates needs to be overcome by changing some parameters such as ignition temperature, particle size, additive, atmosphere etc. [3, 4]. Mill scale is a layer of iron oxide which forms on ferrous materials cooling after being processed in hot rolling or continuous casting plants. Mill scale contains iron (II) and iron (III) oxides, which result in a 70% total iron content in oxide form. Not being able to reuse this material will prevent the raw material entering the production plant from being fully utilized [5]. This study aimed to produce Fe-based alloys via SHS (Self Propagating High Temperature Synthesis) metallurgy which is attractive process technique regarding fast and low-cost production ability of cast alloys by using high metallic iron content by reducing continuous casting mill scale."

Jan 1, 2013

By Jeffrey A. Yonkey, Timothy J. Lutz, Jacob L. Carr, Christopher C. Jobes

"Since 1984, there have been 39 fatalities involving striking and pinning of the operator and other workers by the continuous mining machine (CMM). In January 2015, the U.S. Mine Safety and Health Administration (MSHA) finalized a regulation to require proximity detection systems on all continuous mining machines except full-face machines (MSHA, 2015). Proximity detection systems are designed to stop machine motion to protect miners from striking/pinning hazards. Several MSHAapproved proximity detection systems are commercially available.NIOSH researchers have been involved in the development and testing of proximity detection technology since creating the HASARD system (Schiffbauer, 2002) and have recently conducted research intended to develop more advanced proximity detection technology for CMMs (DuCarme et al. 2013; Jobes et al. 2012; Carr, DuCarme et al. 2013 and Carr, Li et al. 2013). In addition, NIOSH has also conducted research investigating how the signals of a proximity detection system propagate (Li, Carr et al. 2013 and Li, Jobes et al. 2012) and have developed a novel method for determining the location of a personal wearable device (PWD) relative to the magnetic field generators (Carr et al. 2010 and Jobes, et al. 2012).To evaluate the performance of proximity detection systems implemented in industry, NIOSH researchers conducted tests in 2013 on three systems installed on CMMs at three underground mines in Illinois and West Virginia. The results of these tests indicated that, while generally consistent performance was observed, there were opportunities for improving performance. These results were presented at the 2014 SME Annual Meeting (Carr, Lutz, et al. 2014). Since that time, second-generation systems have become available to the industry and are becoming more commonly used.Beginning in early 2014, NIOSH researchers conducted underground testing of these secondgeneration proximity detection systems installed on CMMs. Five tests were conducted on four installations of second-generation proximity detection systems, with one installation being tested twice. The tests were conducted at mines located in Illinois, Virginia and Kentucky with seam heights ranging from 137 cm (54 in.) to 213 cm (84 in.). These tests were conducted using the same test protocol used during first-generation testing, which is summarized in the following section."

Jan 1, 2014

For handling rough rock, the shovel-train system is unexcelled. The ideal application is a physically large, but not excessively deep, open-pit mine from which the coarsely blasted ore and waste must be transported distances in excess of three miles. If, in addition, a high production rate is to be maintained, railroad haulage will probably afford a lower cost per ton transportation than will any other haulage method. Relatively gentle grades must be employed- usually 3% for uphill hauls and 4% for downhill hauls. The greater the differences in elevation the greater are the railroad track grade space requirements. By way of illustration, a 3% ramp out of a pit only 300 ft deep must be almost two miles long. Mainline track locations should be selected carefully so that the frequency of movements during the life of the mining operation is minimized. This applies both to ore and to waste haulageways. Such moves are not only expensive but difficult to execute without adversely affecting production rates. The large mine affords greater opportunities for judicious location of semi-permanent trackage.

Jan 10, 1967

By James Douglas

THOUGH liberality is not supposed to be a prominent trait of the Scottish character, Canada owes to a Scotchman, Sir Wm. Macdonald, more than to any other of its people, not only wise ideas, but pecuniary help towards extending education: and another Scotchman, in New York, has sumptuously housed under one roof three branches of the engineering fraternity, of which we are one. Having thus created us members of the same family-for the metaphorical meaning of house and kinship is identical-Mr. Carnegie expresses more emphatically than even he could in words, that, by affording facilities for closest intercourse, he in¬vites the mechanical, electrical and mining engineers to par¬ticipate in the freest interchange of idea and experience, and to correlate and combine the results of their studies and activi¬ties; and, being members of the same household, to banish re¬serve and secrecy. And now we, the members of the - American Institute of Mining Engineers, meet as though we were at home in a neighboring country. For whether we meet in Canada, in England, or elsewhere, the Institute is always received as though no political or geographical divisions separated its members from those of congenial associations in the land of its host. In truth, the title which we have assumed claims for the sphere of our activities the whole American continent, regardless of such trifling details as boundary-lines. The fact that we meet to communicate each other's experience, to discuss our difficulties, and to seek each other's aid in solving the intricate problems that so often present themselves in the course of our profes¬sional life, is an acknowledgment of our individual helpless¬ness; and therefore an argument for united effort. But no effort can be of any value if there is an underlying suspicion

Jan 9, 1907

By I. Nolet

Matte tapping is one of the most critical operations of a matte smelter. Every smelter has developed particular matte tapping practices and tap-hole repair strategies that are often based on the experience of the smelter personnel. As a result, very little information has been published on these critical topics. This paper aims at providing the information gathered from a survey conducted in the PGM and Ni industries on matte tapping practices and tap-hole maintenance strategies for different PGM-Ni matte smelting operations.

Jan 1, 2014

By D. R. Willmer, E. J. Haas

"DISCLAIMER The findings and conclusions in this paper are those of the authors and do not necessarily represent the views of the National Institute for Occupational Safety and Health. Reference to specific brand names does not imply endorsement by the National Institute for Occupational Safety and Health. ABSTRACT This study analyzed the publicly available health and safety policies of 26 mining companies to determine the quantity of health and safety (H&S) practices that mining companies encourage in relation to the Plan-Do-Check-Act cycle. A thematic content analysis of the policies identified elements and practices within the text. On average, companies communicated information on about 7 elements (range 1–14, standard deviation = 3.49) and discussed 15 practices (range 2–34, standard deviation = 9.13). The elements in which companies highlighted the most practices were risk management, emergency management, leadership development, and occupational health. A discussion of the policy trends shows areas that mine sites can improve upon within their Plan-Do-Check-Act cycle, in addition to encouraging the use of both leading and lagging indicators to manage health and safety performance. INTRODUCTION Mining companies and their employees are expected to identify and manage risks at their worksites to ensure the health and safety (H&S) of everyone at the site. The primary mechanism in place to control these risks is a company’s health and safety management system (HSMS) (Boyle, 2012). Broadly, an HSMS is a set of standard, interrelated, and interacting elements used to promote and achieve occupational H&S goals (ANSI/AIHA Z-10, 2012; BS OHSAS 18001, 2007). The practices conveyed within an HSMS are expected to minimize incidents, injuries, illnesses, and even save worker lives (Alsop and LeCouteur, 1999; Arocena and Núñez, 2010). In the United States, both the Occupational Safety and Health Administration (OSHA) and Mine Safety and Health Administration (MSHA) regulate and encourage aspects of an HSMS (US Federal Register, 2011, 2010). Many HSMS documents (i.e., Chemical Industries Association, 1995; Health and Safety Executive [HSE], 1995; International Labour Office [ILO], 2001) attribute the source of their basic management system to Deming’s Plan-Do-Check-Act (PDCA) model of continuous quality improvement and organize their practices within this cycle (Johnson, 2002). The PDCA cycle is a well-adopted approach in health and safety management and promotes continuous learning and adaptability (Robson et al., 2007)."

Jan 1, 2018