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By Pekka Hanniala

The Outokumpu Flash Smelting process today is the most feasible method for copper matte smelting. The economic feasibility of the process has always been one of the main decision making criteria in smelter projects. Thus, today about 50 % of the world primary copper production utilizes Outokumpu Flash Smelting Technology. However, in the future, environmental criteria will have stronger and stronger impact on decision making. Flash Smelting technology offers the best pollution control features of any process. today. It is foreseen that, in the near future, the global trend will be that all the smelters must decrease their emissions at an accelerating rate, compelling the smelters to make increasingly larger investments on environmental protection. In most of smelters ?today, Peirce-Smith converting and transfer of the molten material in ladles are the number one pollution source. The key today for copper converting and minimizing emissions is the Kennecott-Outokumpu Flash Converting process, which has proven to be the most effective converting method in terms of pollution control and, production efficiency including capital and operational costs. Outokumpu Flash Smelting technology is applicable also for small to medium scale smelters but the most interesting area is the upper capacity limit for smelting in one line, which has not yet been reached. We predict that by the year 2000 to 2005, there will be at least one smelter which produces 500,000 tonnes of Cu per year based on one Flash Smelting and Flash. Converting unit. The current state-of-the-art of the Outokumpu Flash Smelting - Flash Converting process is presented in this paper as well as some new options for copper production to be utilized in the near future but which are available already today.

Jan 1, 1998

By Bruce McDonald

This report contains the findings of a study to perform a task and skill analysis of roof-bolting operations, with respect to the operational training requirements and to prepare detailed recommendations for the operational training system. The extent of the problem was determined by visiting underground coal mines, interviewing training and safety personnel, observing and interviewing roof-bolter operators, and reviewing present training programs and facilities. In conjunction with the mine visits an extensive literature search was conducted with emphasis on training, mine safety, and accidents involving the roof-bolting operation and roof-bolter operators. A number of training programs and training devices were considered resulting in the development of a recommended training program including training devices to be used and establishing training objectives.

Jan 1, 1977

By F. L. Wideman

This paper lists resources of sulfur in Wyoming, Colorado, Utah, New Mexico, and Arizons, an area comprising approximately 522,600 square miles, Sources of sulfur occuring within the region are sulfur are, pyrite and pyritic ores, and natural gases and petroleum. Data concerning these sources are presented on a statewide basis. Some of the known deposits of sulfur ore are surficial and of fumerole origin; other deposits have resulted from oxidation of pyrite or sulfide ores of copper, lead, and zinc. The deposits are small and the sulfur is distributed erratically in them. There is a small production from some of the deposits, and the material produced is used as soil conditioner.

Jan 1, 1957

By O. A. Bascur

Several new hydrometallurgical plants have been built in the past years, new processes and equipment as well as advanced process control systems are being used to deal with the increasing requirements of safety, quality and production. Plant Information Management Systems are now being recognized as a key infrastructure component of the plant, giving the management, the operators, process engineers, finance, maintenance, and regulatory agencies an integrated view of the operation and providing the links for the (increasingly) multidisciplinary organization. This paper reviews several implementations of Plant Information Systems; real time performance management infrastructure examples are reviewed as a key component of business strategies, such as Mine to Port Planning and Supervision, Metallurgical Mass Balances, Solvent Extraction Composition Statistical Process Control, methods to minimize organic losses, reduce variable costs and to improve metal extraction. Several examples are provided to illustrate how companies are using the real time and historical information from assets and metallurgical processes to enable and empower people to improve the operations quality, safety and throughput, as well as continuous improvement and innovation initiatives.

Jan 1, 2007

By AIME AIME

THE United Electric Coal Companies, operating large strip mines at various points in Illinois, pioneered in developing and perfecting the strip method of mining coal by use of large shovels and drag-lines. Coal stripping was first started on the properties owned by this company near Danville, Ill., in 1885. The first mechanical' excavating machine used for the purpose was really a dredge minus the hull, which had been purchased from the Marion Steam Shovel Co. It was erected on a wood frame supported by wheels and was referred to as a dry-land dredge or stripping machine. Wood was used throughout in the construction of this primitive excavator, even for the boom which was 50 ft. long. A single-cylinder vertical steam engine furnished power to hoist the %-yd. dipper arid swing the boom. 400 cu. yd. of overburden moved in a day was a great record.

Jan 1, 1936

By Arthur L. Crawford, R. E. Head, Glen Burgener, F. E. Thackwell

"INTRODUCTION This report embodies the results of a detailed statistical microscopic examination of the ore and the mill products of the Silver King Coalition Mines Co., Park City, Utah.The study was conducted under the joint auspices of the United States Bureau of mines is cooperation with the University of Utah at Salt Lake City, Utah. The work was done in the cooperative Microscopic Service Laboratory, which was equipped by contributions from the following companies: Utah Copper Co., International Smelting & Refining Co., American Smelting & Refining Co., United States Smelting, Refining & Mining Co., Tintic Standard Mining Co., Silver King Coalition Mines Co., and Park Utah Consolidated Mines Co. The salaries and the other costs involved in operation of the laboratory were met by contributions from certain supporting companies. In addition to the regular personnel of the laboratory the Bureau of Mines contributed the part-time services of a microscopist-consultant to direct and assist with the technical work.ACKNOWLEDGEMENTSThe authors acknowledge the courtesies extended by the Silver King Coalition Mines Co., through its general manager, M. J. Dailey, in furnishing the various ores and products on which the study was made, together with general information concerning the problems encountered or recognized in connection with the milling of the Silver King ore."

Jun 1, 1934

By Harry R. Nicholls

As part of the pre- and post - shot mine examination at Project GNOME , acceleration data were recorded underground from a series of chemical explosive shots . The cube root of the charge weight was used to scale acceleration and distance because charge weight was not constant . Regression analysis of particle acceleration - distance data gave the following propagation equation : A W1 /3 = 5.10 x 105 ( R / W¹ / 3 ) −2 .43 The quantity A W1 /3 is scaled particle acceleration expressed in g's - lbs¹ / 3 , and R/W1 /3 is scaled distance expressed in ft / lbs¹ /3 Data obtained from the nuclear explosion were scaled and fall within one standard deviation of the calculated propagation law for the smaller shots . Cube root scaling laws were adequate to group acceleration data from explosive charges varying by a factor of more than 1 x 10 in charge weight and over shot - to - gage distances varying from 100 to 46,000 feet . Data obtained from a series of small tests provided sufficient data from which reliable predictions of acceleration could be made for the large nuclear explosion .

Jan 1, 1964

By Piyush K. Dutta

This report describes the design, development and manufacture of a prototype quiet hard rock stoper drill and results of its field tests. It is shown that the stoper drill noise level can be reduced from 118 dBA to below 100 dBA by using this design. The design concept of this drill is based on a valveless independent rotation system, use of an integral muffler and pivot mount. The drill was manufactured in a standard commercial drill manufacturing setup and organization. The design and production technology proved that commercially viable quiet drills can be made available for mine use.

Jan 1, 1985

Just as geophysics, in the form of 3D seismic and wireline logging, plays a key role in petroleum reservoir management, so too will geophysics play an important role in mining of coal, metals, and minerals in the 21 st century. The commercial and social imperatives driving greater use of geophysics are reduced costs, increased revenues, and enhanced safety. In short, superior utilisation of capital and management of risks. In relatively undeformed sedimentary environments it is possible to adapt petroleum-style 3D reflection seismic to image mines. This has been demonstrated most impressively in the Witwatersrand. Anglo-American, for example, completed a $1 million 3D seismic survey at Western Deeps in order to site a new $300 million shaft with confidence. Likewise, 3D seismic has gained rapid acceptance at Australian coal mines in recent years. Encouraged by these successes, metalliferous mining companies are supporting research in Canada and Australia, as well as South Africa, to adapt 3D seismic for more highly structured, metamorphic terranes. Because the mining industry is far more diverse than the petroleum industry in terms of commodities and geological environments, 3D seismic is not always cost-effective. A plethora of other geophysical techniques can be applied, many of which are employed in mineral exploration. Mine applications of geophysics differ from traditional exploration applications in two main ways: time scales and length scales are shorter, and boreholes are more plentiful. Borehole geophysical techniques therefore play a more significant role, both for logging and imaging. Logging systems detail the variations of in situ physical properties down the borehole at scales measured in centimetres, while geophysical imaging techniques can map features located tens or even hundreds of metres from the sensors. While geologists tend to think of boreholes in terms of chips and core, geophysicists perceive them first and foremost as access paths for instruments. Borehole logging has been employed at iron and coal mines for decades, mainly to accurately define ore boundaries in delineation holes. In base metal mines, Outokumpu implemented logging widely for orebody delineation in percussion holes in the 1980s. The benefit was a direct cost-saving, arising from substitution of core drilling with percussion drilling plus borehole logging. The practice has since spread to other companies. INCO, for example, defines nickel boundaries in blast holes at Sudbury using conductivity logs. The benefits are in the form of reduced dilution and enhanced ore recovery, flowing from a more accurate mine model. Density, natural gamma radiation, magnetic susceptibility, and conductivity are the principal metalliferous mine logging parameters because they can be recorded in both dry and water-filled holes. Sonic velocity is the premier geotechnical logging parameter, given its sensitivity to rock strength, stress, porosity, and degree of fracturing. Sonic is recorded routinely in exploration and geotechnical holes at coal mines. With the advent of slimline dipmeter, full waveform sonic, and optical and acoustic scanner tools, the role of borehole logging in geotechnical evaluations is expanding. Monitoring of strain and micro-seismic activity enhances safety during mine production. While qualitative interpretation of logs is adequate for stratigraphic identification or definition of boundaries, a wealth of quantitative information, eg density, can be derived from properly calibrated, repeatable geophysical logs. Moreover, geophysical logs can sometimes serve as surrogates for geochemical assays, and not only for magnetite and uranium. At OutokumpuÆs Kemi chromite mine, for example, gamma-gamma logging provides the basis for grade control. By reducing reliance on assaying, three benefits can be realised: reduced reliance on core drilling; lower core handling and assaying costs; and shorter turn-around times. Conventional downhole EM and borehole magnetics are used for near-mine exploration, and for ground sterilisation. Inco has enjoyed considerable success with borehole UTEM in the Sudbury Basin, for example, and Geopeko has applied three-component borehole magnetics successfully in the Tennant Creek area. Electrical techniques such as applied potential and magnetometric resistivity (MMR) are also finding application at mines. For higher resolution, borehole seismic, radio imaging, and radar have been invoked, with varying degrees of success, to delineate orebodies and map structures, or to geotechnically characterise the rock mass and identify hazards. Success mapping nickel sulphide shoots with borehole radar has been reported by WMC at Kambalda. There are no universal geophysical panaceas, and each mine imposes different geological, logistical, and economic constraints. Geophysics will not always be cost-effective. However, the greatest single impediment to expanded use of geophysics at mines has been the low level of awareness of geophysics on the part of most mine geologists, engineers, and managers and, equally, the limited understanding of mine geology and engineering exhibited by the majority of geophysicists. This myopia will be remembered as a 20th century affliction! Blue Sky areas for mine geophysics in the next ten years include integration of geophysical data acquisition with drilling, enhanced grade estimation and rock mass characterisation, and the incorporation of geophysical information into mine models using geostatistical techniques. All these advances will be predicated on an expansion of petrophysical knowledge.

Jan 1, 2000

By K. van Warmerdam, M. Pearson, C. Kember, D. McMullen, M. Thayer, C. Ugarenko

In July 2012, Hatch Ltd. and Air Products & Chemicals Inc. completed construction and commissioning of a 4000 tpd O2 cryogenic air separation unit (ASU) for Barrick Gold’s Pueblo Viejo Project located in central Dominican Republic. The ASU produces high pressure gaseous oxygen, which is used for the oxidation of refractory sulphide ore within the pressure oxidation (POX) circuit. As a result of the project’s remote location and tropical climate, many challenges were faced over the course of construction, commissioning and start-up of the ASU. These challenges included adequate preservation of equipment due to dusty and humid site conditions, final assembly and erection of the cryogenic distillation columns on site, limited spare parts inventory/availability, and an unfinished power source for plant commissioning. This paper discusses the steps taken by Hatch and Air Products to successfully design, construct, commission and start up the largest stand-alone ASU plant for a POX application in the metallurgical industry.

Jan 1, 2014

By V. A. Ettel

Current practices in electrolytic winning and refining of copper , nickel and zinc are reviewed from the point of view of their respective energy requirements. The electrical energy requirements of these processes are broken down in to the individual components, which belong to two basic categories: (a) thermodynamic energy requirements (G of the desired reaction) : (b) energy losses (anode and cathode polarizations, ohmic drops in the electrolyte and in the cell hardware, energy losses due to unwanted side reactions and electrical shorts). The individual energy components are separately examined for each electrolytic process and the potential for energy saving in these processes is discussed. It is shown that many potential energy-saving measures are uneconomical at the present time, as they increase over-all operating costs. The discussion is focused on those approaches which hold most promise for the future.

Jan 1, 1977

By J. E. Lamar

THAT Illinois is an important mineral producing state is well known. A value of over $237,000,000 for the mineral products in 1926 indicates the magnitude of the industries. Coal mining is the largest mineral industry, and the value of its product was about 63 per cent of the total mineral production of the state. Oil and gas constituted about 8 per cent and the non-metallic minerals about 29 per cent. This 29 per cent represents the production of a varied group of mineral industries of wide geographic distribution through the state.

Jan 1, 1929

By Y. Xi

In this paper we present an availability approach for determining the capacity of a major bucket wheel excavator (BWE) system to be used in Yuabaoshan surface coal mine in China. Based on previous time studies on other BWE systems for delay times due to internal and external causes, and a four-level maintenance and repair schedule, we develop a model taking into account all random failures and present a fast and simple solution to this highly complex problem. A procedure employing the Markov renewal theory for determination of the distribution of random failure times and failure rate of the whole system, as well as some other factors useful for calculation of the overall system capacity are discussed in the paper.

Jan 1, 1993

By R. Drozd

"The Bui/moose Mine is in the northeast coal area of British Columbia, and less than $300 million was spent to bring this 2.3 million-tonnes-per-year metallurgical and thermal coal mine into production by November 1, 1983, one month ahead of schedule. The project is an unincorporated joint venture undertaking, with Teck-Bullmoose Coal Inc., a wholly-owned subsidiary of Teck Corporation, holding 51%, Lornex Mining Corporation holding 39%, and Nissho-lwai (Canada) Ltd. holding 10%. Bullmoose Operating Corporation will be the manager and operator of the project. This paper will broadly cover the history and exploration work on the property, the geology, open-pit mining plans and equipment, the preparation plant flowsheet from breaker station to clean coal silo, the 35 km highway truck haul, the railroad loadout system, manpower requirements, approvals and permits, and general financial arrangements. Introduction The Bullmoose Mine Project is located about 87 km by road south of Chetwynd, B.C. and consists of an open-pit coal mine, a plant facility in the Bullmoose Creek valley below the mine, and a separate rail loadout facility on the British Columbia Railway Branchline near the new town of Tumbler Ridge some 35 km by road to the east. The plant will be capable of producing a total of 2.3 million tonnes per year (mty) of washed metallurgical and thermal coal. Long-term metallurgical coal contracts for high-quality, medium-volatile, bituminous coal have been signed with nine Japanese buyers for 1.7 mty, and the balance of0.6 mty will be for thermal coal production. Plant construction began in the spring of 1982, and in May 1983, preproduction waste and overburden removal in the mine was started. The plant began tuning up in October and was fully operational by December 1983. Metallurgical coal began moving to the coast in unit trains during November, and first vessel loading at the Ridley Island port began in late December 1983."

Jan 1, 1985

By D Beck

Open access to forecasts of mine geotechnical performance in the form of open databases of model results has been considered risky in the past, with a concern that the results will not be understood or will be misused. However, some modelling techniques allow very high similitude modelling of mine deformation and the results can be presented as deformation, damage and other parameters which are unambiguous and which all engineers can be more easily trained to understand. With some effort, sufficient reliability and quantifications of error are possible to overcome many of the issues.Allowing more members of the planning team to have direct access to forecasts of mine deformation will promote awareness of geotechnical issues and will act as a mechanism for improving mine designs. The models will also be more easily integrated into quality assurance programs, by providing a framework for understanding measurement results.The sufficiency requirements for undertaking simulation aided mining engineering will be presented, included some conclusions about requirements for training, quality standards and software development.

Mar 21, 2011

By Robert C. Weisner

Current production costs and market conditions in the potash industry of the Carlsbad area were studied to determine the potential values of the potash mineral resource that would be lost or foregone if the Waste Isolation Pilot Plant (WIPP) facility is constructed on the proposed site in that area. The purpose of the WIPP project is to investigate the possibility of developing a nuclear waste disposal plant in the salt formations at the site. Analyses were made of all potash deposits determined to be in the site. Mining and processing under the most favorable recovery systems were considered. Value determinations were based upon estimated operating and capital costs of current mine-mill operations in the Carlsbad area. This study was made for the Energy Research and Development Administration (ERDA) by members of the Federal Bureau of Mines Minerals Availability System staff.

Jan 1, 1979

By Mildred Nadler, Alvin Kaufman

To aid industry and Government in planning water developments the Bureau of Mines in 1963 canvassed mineral producers to determine water use in 1962. Water use by the mineral industry comprises only 2 percent of the water withdrawn by industry as a whole. The major water-using mineral industries are natural gas processing, phosphate rock, sand and gravel, and iron ore. Analysis indicated the following conclusions: 1. Total water use and new water intake is dependent on the quantity of material processed and the process water requirements of the particular indus- try or commodity. 2. Recirculation is dependent on the processing requirements of a par- ticular commodity, the manner in which the water is used, cooling and condens- ing requirements in certain large industries, the quality of new water intake, and the need to treat new and discharged water. 3. Consumed water is dependent on the quantity of water recirculated, the temperature and humidity in the area, and the proportion of water used for cooling and condensing. 4. A threefold increase in water use by the mineral industry by 1985 is forecast.

May 1, 1965

By G. St. J. Perrott, G. W. Jones

"In cooperation with The Edison Electric Illuminating Co. of Boston, Mass., a survey was conducted in 1929 and 1930 by the United States Bureau of Mines to determine the general hazards of combustible gases and vapors in manholes and other underground openings owned by this company. The territory served approximates 650 square miles and includes 46 cities and towns. The transmission and distribution systems are on overhead construction and underground wires and cables run in underground conduits and manholes. There are 17,000 manholes on the system, and also an area in Boston proper served by the Edison tube system. These conduits and manholes are laid in various types of streets from the most modern type of cement roadbed to the older type of loose macadam. The conditions as found could be considered as typical of any public utility in the electric-light and power field. The survey extended over a period of about a year beginning in June, 1929, and ending in July, 1930, and during this time 1,765 different manholes were tested and a total of 4,068 tests were made.Previous to starting the actual survey, one of the writers, G. W. Jones, spent considerable time in Boston determining the best methods of practical· test procedure. In this work cooperation was given by John Campbell, superintendent, special service department, who for a number of years has been making a study of explosions in underground street areas and preventive measures in Boston and various cities.After this preliminary investigation the tests were continued by employees of the Edisun Company. Copies of all records of tests were forwarded to the United States Bureau of Mines Pittsburgh Experiment Station so that the writers were in close touch with the progress of the survey, and changes could be made in the test procedure whenever deemed necessary."

May 1, 1931

By C. J. Sullivan

"The outlook for supplying the world's metal needs in the next twenty-five years is good, although in several cases basic costs are likely to increase with rising demand. Metal prices calculated at a constant dollar from 1900 to the present show that for nickel, copper, silver, lead, zinc and tin, prices -and presumably production costs -fell from 1900 to the early 1930s. Since then, they have generally risen, apparently reflecting some depletion in relation to demand. This tendency has been accentuated since the post-World War II adoption of managed, full-employment, growth economics, which have resulted in a sharp escalation in world demand for metals. (Abandonment of such policies, apparently now under consideration in North America, would, of course, affect the pre-dictions of this paper.) Nevertheless, metal prices generally are still below those prevailing in 1900. Exploration potential exists for disseminated ores of many metals still thought of as characteristic of lode and vein deposits. These include uranium, silver, gold, tin and nickel and, to a lesser extent, lead and zinc. Considering the discovery potential for some principal metals in relation to expected demand and prices, I would tend to rate them as follows: molybdenum, zinc, lead, uranium, silver, gold, tin, nickel and copper."

Jan 1, 1970

By John Barber

The Deep Ore Zone (DOZ) Mine is PT Freeport Indonesia's (PTFI) newest operation. Production at the mine began in September 2000. The DOZ Mine produces 25 kt/d (27,500 stpd) using mechanized block cave mining methods. The DOZ Mine has several major improvements when compared with previous block cave mines in the district. It has an independent and improved ventilation system, a flexible and efficient truck haulage system, and a more reliable crushing and conveying system. PTFI's copper and gold mining complex is located in the Ertsberg mining district in Irian Jaya, Indonesia (Fig. 1). The Ertsberg district is located in the Sudirman Mountains at elevations from 3,000 to 4,500 m (9,800 to 14,700 ft) above sea level. The topography is extremely rugged and rainfall in the mine area averages 3,000 mm/a (118 in./year). Freeport began production in the district in 1972 when the mill began processing ore from the Ertsberg openpit. Underground mining began in 1980 when the Gunung Bijih Timur-Ertsberg East (GBT) Mine was brought online using block caving methods. In 1991, the GBT Mine reached a maximum production rate of 28 kt/d (31,000 stpd). Ore from the mine was exhausted in 1994. The Intermediate Ore Zone (IOZ) was brought into production in 1994. It, too, used block caving methods and had a design rate of 10 kt/d (11,000 stpd). The IOZ is currently producing at a rate of 21 kt/ d (23,000 stpd). The DOZ was discovered in the mid-1980s by deep drilling from the GBT. The GBT, IOZ and DOZ deposits are all situated in the Ertsberg East Skarn System (EESS). In 1993, the first of several studies was completed that indicated that portions of the DOZ Mine could be economically mined using block caving methods. Limited development was started in 1995. Full-scale development and construction began in late 1997. The crusher and conveying system began operating during the first quarter 2000. The first of two main exhaust shafts has been com¬missioned, along with three of the four new main fans. The second exhaust shaft and fourth main fan will be in service by the end of 2001. Undercutting and production began in September 2000. The DOZ Mine will reach its design production rate of 25 kt/d (27,500 stpd) in 2003. A study is under way to determine if an ultimate production rate of 35 kt/d (38,500 stpd) is feasible.

Jan 1, 2001