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By M. J. Bunyard, I. Mullany

"The pressures on mine operators are varied and constantly increasing, declining ore grades, more remote locations and increasing environmental concerns. The challenge facing the mining industry is to find new ways to process ores which are more efficient and less costly and to control them better. This requires a fundamental rethink in the way in which projects are developed, it is no longer good enough to just copy what has been done before. The process starts with the surfacing of the primary underlying constraints for the project and the establishment of new design principles to address these. The generation of new design criteria and processing options follows the well-established path of brainstorm, focus, brainstorm, refocus and economic evaluation. The aim is process intensification, doing more with less, as early as possible and better use of plant data. The methodology requires a complete geometallurgical understanding of the orebody to facilitate the evaluation of viable processing options. Examples of early stage processing considered are blast optimization and ore sorting to reject waste and reduce processing costs. Mine to mill integration, which starts with the optimization of blasting for separation, offers another way to significantly reduce operating costs and increase efficiencies.VALUE MODEL The mining industry has, over the past decade, experienced an unprecedented cycle of increased commodity prices and investments in new mining and processing capacity followed by a market collapse and fall in prices and confidence. Whilst there are now some signs of a return to investment in new capacity, the metals and mining industry is still wrestling with eroding margins and investor demand that companies achieve the full value of their assets. Metals and mining companies must work on all available levers to deflate their costs back to more manageable levels and capture the full value for their products. Levers include optimizing external spending, re-thinking make vs buy trade-offs, debottlenecking, improving availability and operating time of key equipment, more accurate and agile planning processes, value-in-use optimization, and tighter performance management. Figure 1 is a diagrammatic representation of a company’s value model. The three goals of a successful mining enterprise are social acceptance, environmental acceptance and sound financial returns to shareholders. Some of the KPI’s used to measure the success or not of achieving these goals are shown in the translation layer."

Jan 1, 2017

By R. A. RAGATZ

THE preparation of specimens for microscopic examination from metal articles of relatively large cross-section offers no particular difficulty. It often happens, however, that articles submitted for examination are so thin that specimens satisfactory for microscopic examination can not be successfully pre- pared by the methods commonly employed when working with larger articles. Ordinarily, the preparation of metallographic specimens involves the following operations : (1) cutting the small specimens to be examined out of the larger mass of metal, (2) cleaning and electroplating, (3) mounting to furnish support during the grinding and polishing operations, (4) grinding and polishing to produce a scratch-free surface, (5) etching and drying. All of these operations must be carried out in such a manner that when the specimen is finally examined under the microscope, the structure seen is a true and well-defined representation of the structure that the larger mass of metal possesses at the place where the small specimen was removed. It is important that the deformation involved in cutting out the specimen be as slight as possible, in order that the subsequent grinding and polishing operations will completely eliminate the cold- working effects in the vicinity of the cuts. It is also important that the specimen never be allowed to attain a temperature high enough to alter its structure; the maximum permissible depends on the metal being handled. With some metals, zinc for example, consider- able care must be taken to avoid heating; with other metals, annealed steel -for example, no particular pre- cautions need be observed because there is no tendency for structural change to occur at relatively low temperatures.

Jan 1, 1929

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 Henry H. Ginsberg

The Federal Bureau of Mines made pilot plant investigations of the process requirements necessary to produce heavy fuel oil by the liquid-phase hydrogenation of bituminous coal. The investigation was carried out in three separate series of experiments. The first series studied the effect of temperature and contact time on product distribution at 3,500 p.s.i.g. and 420° to 480° C. in the presence of 0.1 wt.-pct../ stannous sulfide plus 0.05 wt.-pct. iodoform based on gross coal. As a result of increased contact times and temperatures, the conversion-6/ and yield of hydrocarbon gas increased, the viscosity of product oil decreased, and elimination of oxygen, nitrogen, and sulfur from coal increased. The yield of oil did not indicate any definite trend with changes in temperature and contact time. The yield of oil ranged from 76 to 85 pct. for Pittsburgh coal and from 60 to 85 pct. for Rock Springs coal. Asphaltenes in the product oil ranged from 17 to 38 pct. of the total oil for Pittsburgh coal and from 12 to 22 pct. for Rock Springs coal. Fuel oils meeting Bunker C or American Society for Testing Materials (ASTM) Grade 6 specifications were produced with Rock Springs coal at 0.2- to 1.0-hr. contact time and 440° to 480° C. and with Pittsburgh coal at 0.3- to 1.0-hr. contact time and 420° to 460° C. In the second series of experiments tin, nickel, iron, and zinc were evaluated as catalysts for the hydrogenation of Rock Springs coal to heavy fuel oil at 3,500 p.s.i.g. and 460° C. Using the apparent conversion of coal as criterion of catalyst activity, at a contact time of 0.45 hr. tin was the most effective catalyst; nickel and iron were nearly as effective, but the use of zinc resulted in much lower conversion. When the contact time was increased to 0.80 hr., the apparent conversion of coal was essentially the same for each of the catalysts. When the yield of oil boiling below 3550 C. was used as criterion of catalyst activity, at 0.45 hr. the order of activity was tin, iron, nickel, and zinc; at 0.80 hr. tin was far superior and the others were essentially equal. The product oils contained from 8 to 20 pct. asphaltenes.

Jan 1, 1960

By J. C. Watts

Monitoring and control of conventional industrial wet grinding circuits is conceptually straightforward. However, since production objectives and operating constraints can vary widely from plant to plant, there is probably no single overall grinding circuit control strategy which is "best" in all cases; in-variably some compromise is necessary between performance desired under ideal conditions and performance achievable in practice. The recent advent of relatively low cost, reliable, high speed small computer systems is revolutionizing daily operations in increasing numbers of metallurgical processing plants. Of special power and capability is a hierarchical computer network like that currently in use at the Pinto Valley Operations of the Cities Service Company. Several satellite processors for key plant areas communicate with a master computer operating under a powerful multitasking real-time operating system. Hardware and software structure is such that downtime on one of the processors -including the master -does not have a major impact on overall system operation. Admittedly, the powerful, core efficient table driven satellite software, which handles process/computer communication, calculation of nonmeasured process variables, and basic Direct Digital Control functions, is difficult to modify. However, important high level process monitoring, report preparation, graphic display, and supervisory control functions -including economic optimization -can be implemented by project engineers at the plant site. Thus, for example, new control strategies can be quickly examined and rapidly evaluated. Such computer monitoring capability also permits use of short duration process pulse tests for approximate dynamic modeling and rapid calculation of controller tuning constants for single loop dominant systems. Following a brief back-ground discussion of the Pinto Valley Project, we present some of the more interesting results and conclusions of our work over the past year.

Jan 1, 1978

By C. W. Huggins

The primary objective of this Bureau of Mines research was to measure the size distribution of respirable quartz collected at metal mines, nonmetal mines, and processing plants to select the best reference standard for use in quantifying quartz in mine and plant dust samples. The secondary objective was to size all the nonquartz particles collected at the same sites. Particle size measurements were made on 29 samples using a scanning electron microscope in the backscatter mode of operation, interfaced with an image analysis system. The Mine Safety and Health Administration, Denver, CO, provided the 29 samples, which were collected at mines and processing plants in 19 states. The accumulated particle size measurements indicate that NBS 1878, minus 5-f.lm Hin-U-Sil, and minus 5-f.lm Supersil would be preferred over Silver Bond B as reference standards for most quantitative determinations by X-ray diffraction and infrared spectrometry. The respirable dust samples collected at sand plants, however, would be better served by a new reference standard having a quartz particle size distribution of approximately 2.2 um, as none of the four existing reference standards matched closely with them. Commercially available NBS 1878 and minus 5-um Hin-U-Sil CQuid be used as reference standards for 28 of the 29 samples studied in this investigation.

Jan 1, 1986

By P. R. Taylor

The ability to treat refractory gold concentrates that contain appreciable amounts of sulfur and arsenic, in an economic and environmentally safe manner is important to the gold mining industry. Processing alternatives include: autoclave oxidation, bacterial oxidation and roasting. Roasting may be the cheapest of all the alternatives if inexpensive methods can be found to contain the arsenic and sulfur. The research program, being reported here, has been evaluating the ability to use hydrated lime in the roaster to capture both the arsenic and the sulfur. Lime roasting is not a new idea, it was proposed for copper ores by Bartlett in the early 1970's (Bartlett and Haung 1973) and for cobaltite concentrates by Taylor in the early 1980's (Taylor et al., 1981). In addition, ores have been roasted that contained limestone and it was shown that partial capture of the sulfur was possible. Lime -sulfur containment has been proposed for the coal fired electricity industry, as well.

Jan 1, 1992

By Caio Trindade Almeida, Tharcysio Oliveira Rocha Paiva

Tharcysio de Oliveira Rocha de Paiva2

Oct 3, 2019

Australia as a leading producer of mineral sands has also occupied a leading position in many areas of research'in the processing and applications of these minerals. Research in upgrading ilmenite to produce synthetic rutile has resulted in the develop- ment of many processes, e.g,., Becher, Murso, Chlorine Technology, and ICI processes. Studies on the reducibility of ilmenites, aqueous leaching of reduced ilmenites, Fe-Ti-O system, leachability of natural and treated ilmenites in hydrochloric acid and selective chlorination of iron from ilmenites have been carried out in order to develop and improve the efficiency of the above processes. While research on the processing of zircon sand to produce high purity (99.99% ZrO2 zirconia powder and zirconium chemicals started only recently, research by CSIRO in the early 1970s led to the discovery of the phenomenon of transformation toughening in partially stabilized zirconia (PSZ) ceramics. Australia, with very significant resources of lanthanide-containing ores, pro- duces substantial quantities of monazite each year but research in processing and appli- cations of rare earths was neglected in recent years in this country. However, research to improve processes for the recovery of rare earths is now under way and studies on the production and testing of Nd-B-Fe magnets which are 1.5-2 times stronger than the strongest magnets (Sm-Co) currently available, have also commenced.' An overview of the research in the pro- cessing and applications of mineral sands during the last two decades in Australia and its implications for the industry are pre- sented in the paper.

Jan 1, 1986

By D. F. Hambley

This report documents the work carried out by Engineers International, Inc. and its subcontructor, W. G. Pariseau, in order to develop a design manual for ore passes for open pit mines. The work included an extensive information search, novel analyses in rock flow theory, cost and time estimation for shaft and raise construction methods, and development of design criteria for the are pass proper, dump point, and draw point.

Jan 1, 1983

By AIME AIME

THE outstanding event of the past month has been the conference in Washington of the representatives of about seventy-five of the leading national, regional and local engineering and allied technical organizations." Editorial-July Journal-The American Society of Mechanical Engineers. ?Prominent engineers from all parts of the country, representing more than 75 engineering societies, with an aggregate membership of more than 125,000, participated in the organization.? Editorial-July Journal-American Institute of Mining and Metallurgical Engineers. ?Civil, mechanical, electrical, mining, heating, sanitary, chemical, agricultural, marine, refrigerating, radio, fire protection, automotive, industrial and military engineers, as well as some architects and geologists assembled at Washington, D. C. to consider the advisability of organizing a national federation capable of bringing the united efforts of the entire membership to a focus on any problem of mutual interest." American Architect, June 23, 1920. ?"the object sought places it above any engineering gathering ever held." Editorial-American Machinist, June 17, 1920. "The youngest. profession has voluntarily accepted its responsibility in human affairs and is now reaching forward to a career of essential service." "This is .unmistakably the meaning of the Organizing Conference " Editorial-Industrial Management, July; 1920.

Jan 1, 1920

By Alfred Weiss

Over the past 25 years hard-rock mining companies have developed a number of profitable computer applications which appear applicable to operations in the coal industry. The evolution of these applications are described and the most profitable discussed. The basic nature of these systems is that they must cut across organizational boundaries. While technological advances contributed significantly to the successful implementation of computers within mining, the human aspects related to organization, management and control of systems projects remain as key to future success in coal as they were and still are in hard-rock mining.

Jan 1, 1983

By Staff

Introduction As the Sherritt Gordon property is still in the development stage, . it is rather difficult to write a proper account of the mining methods and milling practice that will be used. While the general scheme of operation will remain the same, there will undoubtedly be many minor changes to meet special conditions which we cannot forsee at the present time. Most of the work accomplished to date has followed the usual routine of preliminary development in the Canadian North. However, we have learned a few things which might be of use to others operating under similar conditions. The most important of these is the saving in power cost made possible by the use of Diesels as against steam power when using wood fuel, and the movement of freight by tractors when rail transportation is not available. Location The property i6 located about 90 miles north of The Pas, or 40 miles northeast of the Flin Flon mine. A branch line from Cranberry Portage, on the?C. N. railway, between Flin Flon and The Pas, connects the property with the outside.

Jan 1, 1930

By Daniel S. Gwinner

The tolling, or processing for a fixed fee, of aluminum drosses to recover the metal units is a common practice in the Aluminum Industry. The Dross Toller is acting for the owner, and since most dross processes result in material going to landfill, it is important for the owner of the dross to insure that the toiler is processing the material and handling waste disposal in an environmentally responsible manner. The paper discusses the Dross Toiler Audit Program, first from the Reynolds Metals Company perspective. Included are the reasons the company deems it necessary to audit and a description of the items covered during the audit. Finally, there will be a discussion of the audit from the Tollers perspective - what the Toiler can expect when the auditor arrives.

Jan 1, 1995

By Faruk Oksuz, Cary Hirner, Ray Brainard

"Key project participants, including owners, engineers, and contractors continually seek for sound and structured decision analysis on how to select the best contracting method for successful project delivery. In addition to being burdened with technical challenges, lack of resources, budget shortcomings, regulatory requirements, and bureaucratic and politically mandated obstacles, the project participants need a reliable decision analysis model on the best project delivery method. The pendulum of choice for contracting continually swings back and forth between traditional design-bid-build and alternative delivery options such as design-build, progressive design-build, construction manager at risk, and public-private-partnership. For large tunnel projects, the decision process is further complicated due to contract packaging options as well as risks in underground construction. Contracting strategies for large tunnels require thorough consideration of performance, risk, quality, operability, cost and schedule. This paper compiles an array of decision making criteria and tools for an unbiased and balanced evaluation and ranking system in the procurement of large tunneling projects. INTRODUCTION Successful project delivery hinges upon meeting the owners’ expectations and key performance indicators. Large tunneling programs benefit from a thorough understanding and successful implementation of project delivery options by key project participants including the owners, engineers and contractors. The key to success is a collaborative advancement of project as the key project participants knowledgably address the applicable management, performance, risk, quality, cost, operability and schedule considerations throughout a project realization cycle. PROJECT REALIZATION CYCLE All projects have customary planning, design, construction, commissioning and operation phases that may seem to be sequential but in reality that are well integrated and dependent on one another. A glitch in any phase of a project realization cycle could hinder a successful outcome and none of the project partners are immune to consequences whenever and wherever they may surface."

Jan 1, 2016

By J Gotte, C Morley, J Froud

Newcrest Mining LimitedÆs Telfer Mine is a world-class gold and copper producer, situated in the Great Sandy Desert, in the north west of Western Australia. The mine has a number of distinctive characteristics such as being one of AustraliaÆs most remote mine sites, being within 270 km of the hottest town in the southern hemisphere (Marble Bar) and having been shut down and reopened after a two-year feasibility study. The construction of a new plant and reopening of the mine gave Newcrest the opportunity to review their mining practices and systems including the opportunity to incorporate reconciliation as a core process. Telfer is now well on the way to being one of the largest gold and copper concentrate producers in Australia. When the mine reopened in June 2003, Telfer implemented SnowdenÆs Reconcilor software system to facilitate reconciliation of geological models, production data and plant measurements. The system was implemented on site in June 2004, as a web-based information management system, integrating other existing mining and plant software packages. It continues to provide an auditable process and consistency of data, providing ease of analysis with standard and customised reporting. This paper provides a case study of the reconciliation system implementation at Telfer. It outlines the consolidation of a number of management systems into one centralised system that can be used to compare and reconcile the tonnes and grades from the mine through to the mill. The authors outline the key estimates and measures that are used for reconciliation at Telfer, detailing the characteristics of the system used to capture the information and the benefits that have been gained through the use of a rigorous reconciliation process on a complex orebody.

Jan 1, 2007

By C. G. McLaughlan

The Noranda concentrator was placed in operation in October, 1928, and the object of this paper is to outline operations during the twelve months which have elapsed since that time. The ores milled are massive sulphides carrying copper and gold, and, in certain cases, zinc. These ores have a specific gravity of about 3.8. The average assay of the copper-gold ore so far treated has been 2.0 - 3.5 percent Cu; 0.10 - 0.20 oz. Au; 40 - 51 percent Fe; and 6 - 15 percent SiO2. In this ore the copper occurs almost entirely as chalcopyrite, and the iron which is not combined with the copper is present mainly as pyrite and pyrrhotite. ?some iron is also combined with the silica, the ratio being about 1 to 4, and a small percentage is present as magnetite. The occurrence of the gold has been shown by microscopic work carried out by Prof. L. C. Graton, of Harvard University, to be very variable. Some of it is free, and is included within the base-metal sulphides or occurs at their boundaries. A similar distribution also holds for a portion of the gold which is combined as a telluride. Little is so far known of the occurrence of the silver other than that some of it may be combined with the gold in the telluride, petzite. The copper-zinc ore contains up to 6 percent copper, and has a very variable zinc content. The copper in such ore is present as chalcopyrite, and the zinc as sphalerite. In starting the mill we had three conditions to face; the first of these was climatic, the second was the lack of skilled flotation operators, and the third was the ore itself." The last of these three proved much more difficult to contend with than the other two combined.

Jan 1, 1930

By J. Aravena, S. Gajardo, M. Ayala, P. Salinas

Both, Teck Carmen de Andacollo (Teck CDA) and Orica, work hard in the implementation of new technologies available in the explosives industry and drilling and blasting techniques, with the objective of sustainable development of their operations, regeneration, and protection of the environment, also considering the welfare and relationship with the surrounding communities. The open-pit Carmen de Andacollo mine is located adjacent to the town of Andacollo. Therefore, both companies together have developed the implementation of different techniques and technologies to mitigate the impacts of mining operations in the community, considering an important part of this challenge to minimize the impact of their perception of blasting by reducing the level of vibrations and sound pressure (airblast), in addition to the control of dust and smoke, strengthening sustainable production in harmony with communities. The technologies and techniques that have been implemented are the installation of airblast and vibration monitoring stations stands out, whose database has records since 2011. Using the vibration database, different models were developed to predict the vibration level of blasting in its design phase, achieving a difference of 4.1% between the estimated and measured values in the last year. Two techniques stand out to minimize the ejection of material, "Hydraulic Dome" and "Dual layer blasting", the first consists of water irrigation on the surface to be blasted and the second is an unconventional blasting technique, which was awarded in 2015 for its results in the environment. Also pre-splitting engineering has been modified in a positive evolution, where through different configurations, the airblast has been reduced by 15% compared with records from 2011 to 2022. Finally, due to the impact of operational restrictions, such as days available to blast, number of holes, and powder factors, the wireless initiation technology was implemented, which allowed reducing the limitations in the loading, generating an improvement in terms of blasted materials over conventional systems. Understanding the restrictions and challenges in terms of impact on communities, the correct implementation of all these techniques is important, and in conjunction with collaborative work, it has been shown and validated that producing in a sustainable and sustainable manner is possible.

Jan 1, 2024

This paper describes the technical development of the Newman beneficiation plant over its 23 years of operation and how this development relates to the mine ore reserves of high-grade and low-grade ore. It also discusses the importance of the beneficiation product grades in the overall blending of shippable products from a range of mines to optimise overall ore resource utilisation. Also discussed is the importance of the ore reserve reconciliations in resource utilisation. Data is provided on the capacity and quality improvement results of the plant upgrade, carried out in 1999. This shows how the original capacity upgrade targets have been exceeded and the additional quality benefits that have been obtained from this capacity.

Jan 1, 2002

By S Gezgin, F Beckstein, M Müller, D Rapp, D Sergeev, J Qi, A Lichtinger

Salts and their mixtures play an important role for industrial and energy sectors, eg metallurgy, biomass gasification and combustion, nuclear and solar powerplants and electrochemical processes. Depending on the composition of salts (eg Li+, Na+, K+, Mg2+, Ca2+ // NO3-, F-, Cl-, CO32-, SO42-, etc), the temperature range for different applications can vary starting from room temperature and going up to 1500°C. For the proper design and modelling of heat exchangers and other equipment, it is necessary to have reliable and validated data sets of thermophysical properties. The 50 mol per cent NaNO3 – 50 mol per cent KNO3 salt mixture as a well-studied composition was selected for validation of relevant thermophysical properties (heat capacity, enthalpy of phase transitions, thermal expansion, viscosity and thermal conductivity). To study these properties of the liquid phase, special crucibles and approaches should be implemented. Verification of these crucibles for different methods (differential scanning calorimetry (DSC), thermomechanical analysis (TMA), laser flash analysis (LFA) and rheometers) has been performed. The low thermal conductivity of salts is one of the main problems in implementing latent heat storage. In this project, the authors intend to develop a fundamental solution to this problem using chemically bonded metals with salts. These are known as metal-salt solutions. To fit the main parameters of new phase change materials to the requirements of thermal energy storage, a wide variety of possible combinations should be considered. CALPHAD modelling is used together with thermal analysis for the development of a consistent thermodynamic database including chloride salts (Li, Na, K, Mg, Ca // Cl) and corresponding metals (Li, Na, K, Mg, Ca). The results of the study of quasibinary and multicomponent metal-salt (eg Mg-KCl and Ca-KCl) systems as well as the selection of suitable crucible materials and challenges by studying of these systems will be discussed.

Aug 21, 2024