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By G. J. Heferen, A. Pranowo, N. J. Aslin, P. O. Eriksson

Glencore Technology (GT) has over four decades experience supplying stainless steel cathode plates (“cathode plates”) to the electro-refining and electro-winning industry. Cathode plates are typically the single biggest capital investment in a refinery. Refineries may view cathode plates as fixed asset or consumables depending on their operational characteristics. This paper examines the issue of cathode plate life and the strategies and philosophies used by different plants in the management of their cathode plate asset. Some plants operate with their original plates after more than 20 years. Others accept high turnover and regular maintenance as normal operating practice. Reference data are provided on plate life for various operating plants including benchmark plants achieving best-practice plate life and operating cost. The role of the electrode handling equipment on cathode plate longevity is also examined, including latest developments in Cathode Stripping Machine, robotic copper stripping, and full-automation production cranes. The ability to identify and manage the population of plates in service is also critical for maximising plate life and minimising its overall operating cost. This paper discusses a novel and unique RFID system for tracking and managing cathode plate inventory. INTRODUCTION Permanent cathode plates The adoption of permanent stainless steel cathode electrodes in the electro-refining of copper was the most significant process development since the first commercial electro-refineries were built in the late 19th century. It provided significant improvement over the labour intensive and complicated starter sheet system. Copper grows over the permanent cathode blade for a number of days before being stripped, and the permanent cathode can be returned straight back to cells for the next cathode cycle. Glencore Technology (formerly Mount Isa Mines (MIM), then Xstrata Technology) has been manufacturing permanent stainless steel cathode plates from the late 1970s with the birth of ISA PROCESS™, and the Kidd process that came one decade later. Invented and commercialised by Mount Isa Mines, the ISA PROCESS™ was first implemented into Copper Refineries Limited (CRL), Townsville, in 1978. The KIDD PROCESS by Falconbridge evolved in the 1980s and was first implemented into the Kidd Creek Tankhouse, both operations converting from traditional copper starter sheets.

Jan 1, 2019

By Hewitt Wilson

A review is given of the nomenclature, sources, imports, statistics, common methods of preparation, and testing of mineral pigments. A description of the Deer Park-Spokane colored-clay district and the laboratory methods of preparation of these colored clays, others, and siennas follows. The mineral pigments were prepared by washing or grinding the original material as received and by calcination of the yellow ocher and brown sienna with and without manganese dioxide to produce red, brown, and black colors. These prepared powders were tested for fineness, oil absorption, and color as compared with well-known brands of commercial pigments. Similar tests were made with several basalt red clays occurring in the neighborhood of Salem, Oreg., and Kalama, Eatonville, and Clay City, Wash. The color particularly was studied, since this property is the most important commercial characteristic of the minerals. PURPOSE OF INVESTIGATION Since the development of the clay industry in the Pacific Northwest, some curiosity and interest have been aroused by the red and yellow clay or ocherouslike material that has often been found associated with the commercial clay deposits. These include the red and yellow "paint pots" near Deer Park and Spokane in eastern Washington, a red clay at Clay City, another close to Eatonville in western Washington, and red basalt earths near Salem, Oreg., and along the Columbia River near Kalama, Wash. Several companies have been organized to produce pigment colors from two of these deposits but have either discontinued or never started operations.

Jan 1, 1929

By D. W. Alexander

In 1993, CONSOL began investigating new methods of permanently filling coal mine shafts, which after ventilation is stopped, may contain a potentially hazardous atmosphere. Fill materials such as fly ash/cement can be pumped, are non-combustible and non-incendiary but tend to flow into the mine entries. A non-flowable mixture has been developed that minimizes the volume of fill used. The paper presents our recent shaft filling experience including fly ash material properties, mix designs, field problems, placement success, and gas testing techniques.

Jan 1, 1996

By E. C. Yeager, E. O. Wagner, A. W. Koth, V. F. Parry, J. B. Goodman, D. G. Gernes, W. L. Patty

"In July 1943, the Bureau of Nines received an appropriation to investigate the beneficiation of Minnesota iron ores through the use of lignite. The broad objective was to find a way to link the large deposits of lignite in North Dakota with the low-grade iron ores of Minnesota. It was proposed that sponge iron might be made through new methods of processing, and one of the objectives was to determine the possibilities of gaseous reduction of fine ore. The problem of obtaining high-hydrogen reducing gases from lignite was assigned to the Subbituminous Coal and Lignite Section of the Bureau of Mines in August 1943.Through the advice of technical consultants and men familiar with the mineral resources of Minnesota and North Dakota, a tentative program of development was outlined. The first proposal was to study the gasification of lignite briquets in a standard water-gas machine. Previous experience with gasification of lignite indicated that the raw fuel would not be suitable for use in the conventional water-gas process on account of degradation, but gasification of lignite briquets appeared possible. Through the cooperation of the Northern State Power Co„ a series of tests was made at the company's plant in Grand Forks, N. Dak., on lignite-char briquets made by the Lehigh Briquetting Co. at Dickinson, Dak. These briquets are made by the Lurgi process, and they have been used satisfactorily as a domestic fuel. The object of the tests was to compare gasification properties of lignite-char briquets with those of gas. coke made from Kentucky coal, normally used in the Grand Forks plant. The tests revealed that the lignite-char briquets were not suitable for gasification, in the standard water-gas process because of disinte-gration and low efficiency caused by loss of fine carbon.While these investigations were underway, a joint Minnesota-North Dakota Development Commission was formed to aid in planning investigations on development of mineral resources of the two States. Some members of this commission were technical men, who with consulting engineers on the Bureau's staff made up an unofficial technical committee, and assisted in solving certain problems connected with gasification of lignite and beneficiation of iron ores. This committee has been of 'real assistance in guiding the investigation.A technical meeting was held in Minneapolis on November 10 and 11, 1943, for further discussion of objectives and certain technical problems. Results of tests on lignite briquets were presented, and several reports analyzing other methods of gasification were discussed. The Reyerson-Gernes process for the continuous gasification of lignite in an externally heated retort was considered from several angles. This process differs from others in that the natural moisture in the coal is utilized to help gasify the coal, and the volatile matter is largely decomposed. Although this process had been carried out successfully in a small steel retort, no definite design for a commercial-scale retort had .been developed. It was first proposed that the process might be carried out in a Glover-West retort. However, it was brought out that a Glover-West retort would require modification to simulate the process correctly, and that good results might not be obtained even then owing to the leakage of gas through the refractory walls and to an anticipated low rate of heat transfer at the gasification temperature suitable for lignite. Further, the probable leakage of inert furnace gas into the water-gas would be adverse to the Objective to obtain a gas that could be purified to 96 percent hydrogen."

Jun 1, 1946

By M John

The Kwinana Industrial Area (KIA) is by far the largest and most diverse industrial processing region (with supporting industries) in Western Australia. As with elsewhere in Australia (and globally), the KIA is facing sustainability challenges on various fronts, such as increasing water and energy scarcity, climate change, an aging workforce, and growing community expectations. Through the Kwinana Industries Council (KIC) the industries within Kwinana are working closely on common issues in the KIA, including the sustainable development of the region. Over the past decade, significant progress has been made by the industries towards the improvement of the sustainability performance at the company and regional level. Given the ever increasing sustainability pressures, there is strong desire to address sustainability challenges in the KIA, through a pro-active and collaborative industry approach. A sustainability roadmap is being developed to assist the KIC and its industry members with strategic decision making on the long-term sustainability of there. At the heart of the roadmap is a set of key performance indicators for each of seven priority themes or focus areas (water use, by-products produced, greenhouse gas emissions and energy use, economic performance, environment, community impacts and sustainable workforce). Aspirational targets and subsequent strategies are being developed for those activities where the KIC has an influence and can make a positive impact. The indicators and their targets enable constructive stakeholder discussions (eg with government and community) on emerging local issues and possible future directions for the KIA. The paper will report on the development process and the preliminary results of the sustainability roadmap for the KIA, including a historical perspective on milestones achieved so far and future aspirations.

Jan 1, 2009

By A. E. Sands

This report deals with a portion of the research and development work in the field of synthesis gas purification, carried out by the Bureau of Mines at its Morgantown, W, Va., Station in cooperation with West Virginia University. The Bureau's work in connection with gas purification has been performed with the objective of finding effective, low-cost, processes for removing impurities from synthesis gas to protect the catalyst used in the Fischer-Tropsch process for production of liquid fuels. Synthesis gas used for the production of other chemicals, such as ammonia, alcohols, and methane, requires equally rigorous purification. Although present-day practice in the manufactured-gas industry does not require such a high degree of purification, there is increasing interest in the complete removal of sulfur compounds from city gas. Although the gas-purification work at Morgantown deals with several impurities, major effort has been devoted to organic sulfur compounds in gas; this paper represents a progress report on some of the more important studies in connection with those compounds. Because this is a progress report on the Bureau's experimental work, no attempt has been made to cover the work of others on the subject; references to the literature have been restricted to those bearing directly on the work described.

Jan 1, 1950

By E. Watkins, M. B. Daza

Although there have been great advances regarding the understanding of mine fires in underground mines in the last century, fires remain high risk incidents. During fire scenarios, many crucial decisions and actions can be made that greatly influence the outcomes of these scenarios. Underground worker decisions are mainly based on training and experience, which in some cases can be complemented with previous analysis of fire effects. In order to review the guidelines that should be taken into account for this kind of examination, a numerical analysis of effects produced by a shuttle car fire under five different ventilation conditions was carried out. The analysis provides some insightful recommendations for firefighting personnel such as time for direct attack and best attack position for first responders and fire brigade groups. Also, the most critical parameters for each scenario were determined. Finally, all results were systematically organized and a first approximation of a fire classification based on the tenability limits was provided for first responder and fire brigade groups. The methodology used in this study for the fire classification could allow for the most appropriate decisions by firefighting personnel increasing the probability to put fires out without compromising their health and safety. INTRODUCTION While there have been great advances regarding the causes of mine fires in underground mines in the last century “small fires have occurred and always will occur in underground mines” (Conti, Chasko, Wiehagen, & Lazzara, 2005). The response time and decisions made during an underground mine fire are critical elements that have direct influence on the event outcome. Mine fires can grow in size quickly causing catastrophic consequences, thus rapid and suitable response actions can result in the difference between an minor emergency situation and a disaster. Upon the confirmation of a fire, a decision must be made regarding whether to fight the fire or evacuate the mine. Even though all underground coal mines possess emergency response plans and firefighting personnel are highly trained, decisions can be complemented with previous numerical analyses. Such analyses could contribute with the knowledge of potential fire effects and consequently with fire preparedness in the mine. Preparedness in underground mines is an important element to reduce the probability of the negative consequences of a mine fire. The time elapsed between the detection of the fire and response in the early stage is a serious component since small fires can produce larger and more serious consequences. If a mine fire cannot be put out within the short time after discovery, the chance of getting the system back in balanced or the success of safely controlling and extinguishing a mine fire is reduced (Conti et al., 2005, Conti, Chasko, Wiehagen, & Lazzara, 2000, Trevits, Yuan, Teacoach, Valoski, & Urosek, 2009, Brake, 2013). As confirmed by Conti and others, if a mine fire cannot be controlled by direct firefighting methods the probability of extinguishing the fire, without sealing is greatly reduced (Conti et al., 2005). However, response actions such as direct extinguishment must be carried out without compromising the health and safety of the firefighting personnel (Kim, Lönnermark, & Ingason, 2010).

Jan 1, 2019

By John E. Lambert

Automatic control of drum head continuous mining machines was investigated as a means of reducing respirable dust generated and operator variabitity. Literature survey, manufacturer interviews and mine visits were the major information sources. Technically feasible automation concepts were Identified to control sump and shear rates, cutter head elevation limits and sumping distance. These are the elements of a programmed cutting cycle which maintains peak penetrating force on the cutter, to maximize depth of cut and therefore reduce dust generation. Based on the industry surveys, successful underground hardware demonstrations must be completed in order to stimulate the market demand for these advanced control features.

Jan 1, 1979

By Nathan P. Schmidt

Climate and hydrology data are required during all phases of mining projects, including impact assessment, mine planning and design, operational water management and mine closure and reclamation design. In the Canadian north, data sources are spatially sparse and often short-term in nature, and design parameters are often estimated based on data collected at sites far distant. Confidence in such data can be increased by verification or modification using data collected during properly implemented baseline and operational monitoring programs. A data set that accurately reflects conditions at the project is more readily accepted by regulatory agencies during the permitting process, and allows development of more effective and economic water management, mitigation measures and compensation. Data requirements and collection methods for developing an adequate data set for mine development are reviewed. These are illustrated using examples from oil sands, diamond and metal mines in the Canadian north.

May 1, 2004

By Northcutt Ely

This chapter deals with the systems of laws by which governments regulate the exploration for and production of the minerals within their jurisdictions. It is a summary, restricted by necessary space limitations, of material assembled by the author for a publication of the United States Bureau of Mines, "Summary of Mining and Petroleum Laws of the World," (Information Circular 80 1 7, 196 1. ) The present study is organized in three parts, dealing with (1) the historical background of these legal systems, (2) laws of the United States, and (3) laws of other countries of the world. The reader's attention is invited to the acknowledgments at the end of the chapter, which inadequately express the appreciation due those who have assisted in the collection of this material. Part I. Historical Development of Major Western Systems of Land Tenancy with Respect to the Ownership and Control of Minerals The use of metals in primitive societies was largely confined to the manufacture of weapons for self-preservation. The ruler's control over copper, then bronze, then iron, was essential to maintenance of his own ascendancy at home and his group's position against neighbors who had access to similar metals. Ancient societies were thus characterized by the ruling group's ownership of minerals and metals. The Egyptian civilization, which emerged in the fourth millenium B.C. upon the agricultural subjugation of the lower valley of the Nile, was responsible for extensive development of the upper valley as a source of mineral wealth. The production of gold during the height of that civilization has been estimated at $30,000,000 per year, thus equaling the early placers of California and Australia. The mines of Egypt were the property of the Pharaohs and were controlled at their direction. Greek mining developed a different scheme of land tenancy which more closely resembled modem concepts. Development of mineral resources was

Jan 1, 1964

By C. Peter Hayes

The world continues to change and with it the supply of minerals and metals, the location of centres of production of primary metal and the increasing levels of metals and materials recycling. New technologies are being developed to meet the ongoing search by industry for lower costs, cleaner production and new markets. To keep abreast with these changes, and to utilise fully, the potential benefits of these technical advances, the industry will need a professional workforce having different knowledge, skills and professional attributes than in the previous millennium. What are these skills and attributes? How to best attract and develop the metallurgists of the future, and provide for the ongoing educational and research needs of the industry?

By R. S. Dean

[During t!~c past f isc.~l y~:-.r the Xetzllvz-gicd 3ivi oion has made im- portant contribution-, don,- tlie lines rlictnteil by the Bureau policy of con- servation of domestic rnker~l rcsoul-ces throui;h use. During t!~c past f isc.~l y~:-.r the Xetzllvz-gicd 3ivi oion has made im- portant contribution-, don,- tlie lines rlictnteil by the Bureau policy of con- servation of domestic rnker~l rcsoul-ces throui;h use.]

Jan 1, 1940

By W. T. Reid

A shortage of anthracite for home heating indicates the necessity of using other fuels for this purpose; low-volatile bituminous, or "soft" coal is the most feasible supplementary fuel, either burned alone or when mixed with anthracite. Comparison of Bituminous Coal and Anthracite Whereas anthracite is clean, burns without smoke, and requires little attention, bituminous coal is dusty, tends to burn with a smoky flame, and forms coke in the fire pot that must be broken up to maintain a continuous high output of heat. When properly fired, however, bituminous coal responds more quickly than anthracite to changes in damper settings and consequently can supply more heat in a short time. It is generally less expensive and usually contains less ash than anthracite.

Jan 1, 1943

By H. R. Babitzke

The purpose of this investigation was to evaluate the potential of columbium-hafnium alloys as structural materials for use at elevated temperatures. The work described in this report was conducted to determine the properties of columbium-hafnium alloys and to select the more promising ones for further improvement. Properties determined in this report were machinability, hardness, workability, tensile strength, and oxidation resistance. Ten ingots, ranging from 100 percent columbium to 70 atomic-percent hafnium, were prepared and subjected to tests. The test results showed that the alloys with 33 and 50 atomic-percent hafnium were superior in workability, strength, and oxidation resistance. For the alloy series tested, the strength and hardness values increased with the increasing hafnium content. Maximum values were reached with 50 atomic-percent hafnium. The oxidation resistance was poorest at the 1 atomic-percent hafnium level but improved with increasing hafnium content through 70 atomic-percent. Eight of the ten ingots were fabricable at room temperature. The two remaining ingots, those with 5 and 10 atomic-percent hafnium, required hot-working.

Jan 1, 1962

By A. J. Kauffman

The alluvial deposits of the Pacific Northwest have been investigated and worked with varying degrees of intensity since about the middle of the 19th century. Earlier efforts, of course, were centered about the placer-gold content of the deposits; later, the Oregon beach sands were exploited for their chrome content, and, still more recently, deposits in Idaho were worked for their content of monazite, a rare-earth mineral which also contains significant quantities of thorium. The composition of alluvial deposits seems to depend mainly upon the nature of the source rock from which the detrital material was derived and upon the resistance of the individual mineral grains to the agencies of weathering and transportation. The processes of crushing and concentration used in ore dressing are applied in a leisurely but nonetheless effective manner when exposed rock masses are eroded by natural forces. Weathering effects a continuous disintegration and chemical decomposition, wherein resistant minerals are set free as individual grains and new minerals are formed. Erosion carries these detrital products down the slopes into natural waterways, where a mechanical separation of heavy particles from light is accomplished by the running water. The accumulation of such resistant, heavy particles through the ages has resulted in formation of the black-sand deposits. In addition to the associated gangue minerals, heavy sand deposits in the Pacific Northwest may contain the following constituents of possible economic value: Gold, platinum, chromite, ilmenite, magnetite, garnet, zircon, monazite, columbite-tantalite, and radioactive blacks.

Jan 1, 1956

By T. C. Campbell

This Bureau of Mines publication presents an analysis of information related to the transportation of bituminous coal by unit trains and slurry pipelines. Even for short hauls from mines to markets, transport costs frequently account for between one-third and one-half of the delivered price of coal. Minimizing these costs has become an even more critical objective for hauls from the western mines than for hauls from farther east. Factors related to minimizing costs and transporting the western coal receive special attention. Although no general rule of preference is likely to be developed that can be applied to all shipments, both rail and pipeline service will be needed on an increasing scale. The study should provide useful background information and analysis for government and industry in approaching investment decisions in the mining and transportation industries.

Jan 1, 1975

By H. B. Humphrey

WHEN THE BUREAU OF MINES was created in 1910, the organic act had as one of its main provisions the following: That it shall be the province of said bureau and its director, under the direction of the Secretary of the Interior, to make diligent investigation of the methods of mining, especially in relation to the safely of miners and the appliances best adapted to prevent accidents, the possible improvement of renditions under which mining operations are carried on, the treatment of ores and other mineral substances, the use of explosives and electricity, the prevention of accidents, and other inquiries and technologic investigations pertinent to said industries, and from tinge to time make such public reports of the work, investigations, and information obtained as the Secretary of said department may direct, with the recommendations of such bureau. The nationwide nature of the health and safety work of the Bureau of Mines has given its representatives an opportunity to study and report on matters pertaining to health and safety in mines and related operations from the time the Bureau was established to the present. Regular annual reports and numerous additional papers and reports have been published each year to place on record and to make available the information gathered. While the basic purpose of this bulletin is to describe health and safety reports for the period January 1947 through June 1955, a selected number of earlier publica¬tions that are believed pertinent for reference purposes are included.

Jan 1, 1956

By E. C. Tarpley, H. M. Cooper, R. F. Abernethy

The standard method of employing preliminary air-drying to determine the moisture in coal has been criticized with respect to the loss of heating value from excessive air-drying. By this method, the coal is air-dried at approximately 10-15° above room temperature with the loss in weight being less than 0.1 percent per hour, and then the residual moisture at 105°C is determined. The total moisture is calculated from these two values.

Feb 1, 1948

By T. Watanabe, T. Fujiwara, S-Wan Song, Y. Nakagawa, R. Teranishi, M. Yoshimura

"We have tried a new method to fabricate cobalt oxide films onto porous films directly by an electrodeposition method at low temperature. The porous substrate films (membrane-filters and paper) were placed between a LiOH solution and a CoSO4 solution and treated under electricalcurrents of ~1 mA/cm2 using carbon cathode and anode. Effects of temperatures, flow rates and electrical currents have been investigated. As a result, we found that the LiCoO2 films and Co3O4 films were successfully fabricated on paper and/or porous PTFE filters at 120 °C, while CoOOH films were deposited at 80 °C. Furthermore, LiCoO2 films did not cover whole the substrates, but was fabricated just over the anode. The chemical reactions of electrodeposition were also considered from these results.IntroductionRecent agreements on global environment require rapid progress of low energy and low waste processings for the fabrication of thin films that succeed to the mass production with the high consumption of the fossil fuels (such as physical vapor deposition°, chemical vapor deposition2), dip coating with firing3) etc.). The total energy consumption in aqueous systems should be the lowest among all these processing routes, because a much lager excess of energy is necessary to create melts, vapor, gas, or plasma than to form an aqueous solution at the same temperature4)The ""Soft Solution-Process"" (SSP) was one of the best concepts to realize the low energy and low waste fabrication of inorganic materials. 5) Generally speaking, SSP gives similar results to any other processing using fluids (such as vapor, gas plasma) and/or beam/vacuum processing. However, the total energy consumption of all these possessing routes should be the lowest in aqueous systems, because a much larger excess of energy is necessary to create melts, vapor, gas or plasma than to form an aqueous solution at the same temperature (Fig. 1). This idea can be easily demonstrated, using the simple example of BaTiO3. The energy diagram for the formation of BaTiO3 from various precursors is shown in reference 4. The driving forces (AG) for representative synthesis reaction of (1), (2), (3), (4) and(5) are 38, 727, 3685, 17 and —14kcal/mol, respectively at room temperature. 6' 7"

Jan 1, 2000

By Catherine C. Kilgore

The Bureau of Mines investigated the availability of fluorspar (CaF2) from 36 U.S. and 50 foreign mires and deposits in 13 countries. Only 6 U.S. properties are considered to be economic, as 29 domestic deposits were found to have an average total cost of production that was uneconomical at a breakeven (0-pct) discounted-cash-flow rate of return (DCFROR). The 50 foreign properties evaluated represent at least 55 pot of demonstrated fluorspar resources located in market economy countries and China. Al I evaluated foreign operations were found to be economic to marginally economic in January 1984 dollars when compared against published prices for each country. Reserves for 56 properties totaled 97 million metric tons (mt) (recoverable Ca F,) from demonstrated ore resources of 344 million mt that contained 123 million mt CaF2. The average total cost needed to cover all costs over the life of each operation was determined for all recoverable fluorspar products. Comparisons of ruining, beneficiation, and transportation costs per metric ton of fluorspar concentrate illustrate advantages between countries. Of the three countries with the greatest fluorspar production, China, with its high-grade, low-cost operations had the lowest weighted-average total cost of production ($38/mt concentrate), Mexico was next, at $54/mt concentrate, and benefited in U. S. dollar terms from the devaluation of the peso. The Republic of South Africa needed an average of $90/mt of concentrate to cover all costs of production at its large low-grade deposits.

Jan 1, 1985