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By George W. Sheary

Situated 45 miles west of Philadelphia and 50 miles southwest of Bethlehem Steel Company's Bethlehem plant, the integrated Grace mine facilities produce 4000 tpd of high-quality iron ore pellets. Startup of the Grace mill was in November 1958, and iron concentrates were shipped until March 1960, when the pellet plant went into operation. The underground mine, when fully developed, will hoist about 9000 tpd, including development rock. The crude ore, which has an iron content of approximately 42%, is magnetically cobbed and crushed in closed circuit with 3/4-in. slotted vibrating screens. The ore is washed and screened in the mill and the plus 1/4 in. screen product is again cobbed prior to feeding to the rod mills. Grinding is done in rod mills, and in ball mills that are in closed circuit with 30 in, cyclones, to 1% on 100 mesh and 65% minus 325 mesh. The ground ore is magnetically concentrated by three-drum permanent type finisher magnets to 67% Fe. The magnetite concentrate is pumped from the mill to a 50 ft thickener in the pellet plant. The thickened magnetite concentrate is relayed to the filters through a two-stage pump arrangement. The filter cake is fed by belt from filter concentrate bins to mixer-muller belts where it is intimately mixed with bentonite and a slight amount of water for moisture control. The fluffed concentrate then drops into balling cones. The green pellets from the balling cones are fed in a prescribed feed pattern to shaft furnaces through the use of shuttle car mechanisms. The green pellets are dried, heated to 2500°F and cooled to 1200°F as they descend through the furnace and into pellet coolers where the pellets are further reduced in temperature to 250°F. Heat is recovered in the cooling process through the use of air-to-air heat exchangers. The cooled pellets discharge on a rubber conveyor belt and are transferred to 6000-ton pellet railroad loading bin. The final pellet product consists of 90% plus 1/4 in. material (after tumble testing1) and contains 66% Fe plus 3% silica.

Jan 5, 1962

"The effective thermal conductivity (ETC) is one of the most important thermo-physical properties of porous media. Due to the lack of higher precision influence of temperature on thermal conductivity, we took 6 groups of experiments on rock samples (including igneous rock, sedimentary rock and metamorphic rock) under different operating temperatures from 20? to 50? by 7 acquisition points. The general equation of thermal conductivity drives the value of it increasing along with the decreases of the temperature. While in our experiments, it is easy to find a singularity among them for each sample. The experimental investigations we attempted to observe and interpret the alteration mechanism. According to the Heat Capacity Theory in solid state physics, this research gives the explanation about the “singularity” from 3 understanding of specific heat, average free path, and thermal conductivity. Our research divided the condition of the rock thermal conductivity into 3 different types. INTRODUCTION The effective thermal conductivity (ETC) is one of the most important thermo-physical properties of porous media(Huang & Han ,1988; Peierles ,1955). This parameter is necessary for analysis of heat transfer(Vaferi et al, 2014;Hans-Dieter & Rudiger,2003). It’s well known that a general equation for ?(T) was set by Sass et al. (1992) which based on the coupled effect of composition and temperature on the thermal conductivity(Jesse et al, 2013; Mongelli et al,1982).The equation was further successfully verified for other rock (Zumrud et al,2010;Abdulagatova et al,2009;Seipold& Huenges,1998).Thermal conductivity is also related to other physical proper ties of porous rock, such as thermal diffusivity, heat capacity(Brettmann et al,2011;Abuel-Naga et al,2008). It is well known that ETC and other thermo physical properties of rock materials are affected by various factors, such as temperature, pressure, mineralogical composition, porosity, stratification, size and shape of the components, and nature of pore fluid, etc. (Tiedje & Guo, 2014; Touloukian et al,1970).The understanding of heat transport processes still requires the knowledge of thermal properties of rocks."

Jan 1, 2015

By Bennet A. G

As part of the construction of the Melbourne Underground Rail Loop it was necessary to construct two 7 metre diameter tunnels, each 100 metres in length, by shield driven excavation through an alluvial valley at Elizabeth Street. The tunnels had a primary support of bolted precast reinforced concrete liner blocks and were excavated with the aid of compressed air. The work was undertaken by the Tunnelling Group of the Melbourne and Metropolitan Board of Works as nominated sub-contractor to John Holland (Constructions) Pty. Ltd. The paper describes some of the problems associated with the construction of the above tunnels and the methods used to overcome them. In particular

Jan 1, 1981

By P. D. Lindahl

[A cost/benefit analysis was conducted by comparing the industry cost to protective structures on low-coal face equipment with the benefits paid for injuries/fatalities considered preventable by the use of these structures. Th industry costs were based on estimates by OEM's and rebuild shops for install protective structures on new and rebuilt face equipment. The accident benefit was based on evaluations performed by the USBM Accident Cost Indicator Model. Industry wide population data were developed on low-coal face equipment and injuries/ fatalities preventable with protective structures. The results of the analysis are to be used as a tool by USBM in determining the feasibility of continuing development of cab and canopy technology for low-coal equipment.]

Jan 1, 1983

By Krishnendu Mandal

"For a multi-story building project in Kolkata, a pile load testing program was conducted to minimize pile performance uncertainty resulting from variable subsurface conditions and to verify the pile load vs. settlement response. The program consisted of performing five (5) instrumented load tests on augured cast-in-place (ACIP) pre-production test piles. Vibrating-wire strain gages and extensometers were installed in the test piles at strategic locations to enable measurements of the load vs. deformation behavior of the test piles. This paper presents a description of site subsurface conditions, test pile installation, instrumentation setup for a maintained load test (MLT), static compression pile load test results, and pile instrumentation result interpretation. Average mobilized unit shaft resistance values are calculated.2.0 INTRODUCTIONThe project site is located in Kolkata, near river Ganges, and the proposed development plans consist of constructing six (6)25-story (G+25) towers; see Fig. 1 and Fig. 2 below for approximate site location and proposed development layout, respectively. The buildings were designed to be supported on ACIP piles. A field load test program was implemented to verify sub-surface conditions and pile design. The test program consisted of installing Five (5) instrumented test piles numbered LP1A and B through LP6A and B, and performing static compression load tests on these piles. The piles were instrumented with vibrating-wire strain gauges and extensometers, so that the pile shaft resistance distribution along pile length and the pile toe resistance could be interpreted using direct instrumentation measurements."

Jan 1, 2015

By Keith G. Wallace

The effect of face resistance on ventilation air leakage through stoppings was measured in a twin development heading. Face resistance was varied by alternately tightening or loosening the face line brattice to change the line brattice leakage. Results indicated that tight brattice lines are necessary to maintain acceptable airflow at the face but result in higher leakage throughout the entire system, reduced overall ventilation efficiency, and higher operating costs. Conversely, a low face resistance which simulated an auxiliary fan/duct system gave reduced stopping leakage losses, higher quantities of air at the last open cross-cut and greater entire system efficiencies

Jan 1, 1984

By C Chambers

"AustraliaÆs mining sector faces challenges to its competitiveness; operating costs are being adversely affected as a result of volatile commodity prices and growing international market pressures.Diesel fuel-generated power used in typical remote mining projects is generally reliable and quick-to-deploy; however it is ongoing expensive operating cost.Many mines and communities in remote locations source electricity from diesel generation, and often pay over $300/MWh in fuel and carbon only (i.e. excluding CAPEX). These costs are expected to rise over time and are vulnerable to price shock events or supply chain interruptions in international markets.Solar photovoltaic (PV) and other renewables can be integrated with existing diesel units to provide a highly reliable power supply. Such renewables now provide a cheaper source of electricity while maintaining the mining industryÆs stringent reliability requirements; some renewables are now cheaper than diesel power ù supplying electricity at approximately $226/MWh.Also, significant funding and concessional rate financing have recently become available to support the development of remote solar-diesel (or solar-wind-diesel) hybrid systems, including: up to $2.2 billion of as-yet uncommitted grants through the Australian Renewable Energy Agency (ARENA) and is now seeking mining industry partners, up to $10 billion of concessional financing for emerging renewable technologies through the Clean Energy Finance Corporation (CEFC) and this commences July 2013, ongoing revenue support through the Renewable Energy Target scheme, and other regional support programs administered by various governments.This paper explores: the business case for renewables - what applications and when to consider them, the potential operating cost savings if solar was integrated, the technical challenges and common pitfalls, and how to overcome them, and the upfront investment costs and whether the site is eligible for Government subsidy programs.CITATION:Chambers, C, 2013. Off-grid solar in the mining sector - Can renewable energy reduce your operating costs?, in Proceedings MetPlant 2013, pp 71-85 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jul 15, 2013

By C OÆKeefe, A Thomas

Boom time in the mining industry has presented mill operators with several unique challenges including the need for increased throughput while being constrained by a shortage of skilled labour and aging capital equipment. New instrumentation technology that provides reduced installation costs; no process down time for installation; and reduced maintenance costs and labour requirements; has been introduced to address the labour situation while maintaining production. This new tech- nology also enabled more accurate and reliable process measurements thus providing the capability for operators to maximise throughput with their existing capital equipment. This passive SONAR based technology can accurately measure the volumetric flow rate of single phase and multiphase fluids as well as the amount of air entrained within slurries. This is accomplished in a non-invasive manner. This paper will describe the principle of operation as well as the application of the technology to critical minerals processing applications. Included will be operational examples comparing the SONAR measurement performance to traditional measurement techniques. These examples will include hydrocylone feed flow, flotation concentrate flow, and slurry streams containing magnetic ores. Actual plant data will be presented as well as a discussion on the operational advantages such a measurement capability.Also described will be the power of the technology platform to provide novel process monitoring and control capabilities such as pipeline sand-out prevention and pipeline acoustic monitoring.

Jan 1, 2009

By D. R. Taylor

Treatment of bentonite clay with mineral acids yields a modified clay product of high surface area and acidity which exhibits enhanced adsorptive and catalytic properties. A highly specialized segment of the clay industry based on this process has evolved into worldwide business with a capacity of about one-half million tons/yr. This paper will present data on the chemistry, mining, manufacturing and applications for acid- activated clays.

Jan 1, 1986

By K. Forsberg, A. Rasmuson, R. Rodriguez Varela, J. Martinez De La Cruz

"This study analyzes the separation of rare earth elements by means of a supported liquid membrane (SLM) with the final objective of recovering REE from an apatite concentrate (Alemrajabi, Forsberg, & Rasmuson, 2015; Mohammadi, Forsberg, Martinez de la Cruz, & Rasmuson, 2015). In this study, the feed phase consists of an aqueous phase containing REE, the membrane phase contains the organic solvent and carrier (D2EHPA and EHEHPA), and the stripping phase is a hydrochloric acid solution. An evaluation of mass fluxes, separation efficiency, and membrane performance is conducted. In order to analyze the suitability of liquid membranes in the extraction of REE, a deeper insight into the mechanisms causing instability is needed. In this study, surface tension is considered as the key factor of Marangoni instabilities and spontaneous emulsification.INTRODUCTIONThe demand of REE and their compounds has increased considerably due to their special physicochemical features that make them crucial elements for numerous high-tech applications, including wind turbines, hybrid cars, mobile phones, and defense technologies. They are also extensively utilized in traditional industries such as nuclear energy, petroleum, metallurgy, agriculture, and textiles (Xie, Zhang, Dreisinger, & Dyole, 2014; Zhang, Wu, Bian, & Zeng, 2014).Solvent extraction is widely used for the separation of REE (Xie et al., 2014; Zhao, Huo, Pan, Li, & Liu, 2014). Di-(2-ethylhexyl)-phosphoric acid (D2EHPA) and 2-ethylhexylphosphonic acid mono-2-ethylhexyl ester (EHEHPA) are two of the most effective extractants for the separation of rare earth elements among organophosphorus extractants (Gupta & Krishnamurthy, 2005). However, the difficulty in stripping loaded D2EHPA extractant, especially for heavy REE, has limited its utilization. Yttrium can be stripped at lower acidities in EHEHPA systems compared to D2EHPA systems (Gupta et al., 2005), but the extraction efficiency is lower. Conventional solvent extraction by mixer-settlers is restricted by its large solvent inventory and loading limits, and suffers from phase disengagement, emulsification, loss of solvent, and flooding problems (Swain, Jeong, Lee, & Lee, 2007). In this context, supported liquid membranes (SLMs) present a potential alternative due to their advantages, being low solvent inventory, process simplicity, low energy and operational costs, great enrichment ratio, and combination of extraction and stripping into one single step. A SLM is a system in which two aqueous phases are separated by an organic liquid membrane suspended in the pores of a porous support by capillary forces. One of the aqueous phases is the feed solution with the solute and the other is the stripping or receiving solution. The solute diffuses through the liquid membrane and then is extracted into the stripping solution (Kislik, 2010)."

Jan 1, 2016

By M. A. Naimanbayev, Zh. A. Baltabekova, N. G. Lokhova

"Integrated utilization of natural resources using energy-saving and waste-free technologies is relevant around the world. This applies to such type of raw material as titanium-magnetite ore. Shortage of ilmenite raw materials in the Republic of Kazakhstan for titanium slag melting challenges the search of alternative titanium-containing raw materials, titanomagnetites in particular. At the same time there are deposits of indigenous titanomagnetite ores of huge reserves, which can become the complex raw material for production of iron, titanium and vanadium. Tymlay field in the South-Eastern part of Chu-Ili watershed is of particular interest, within the Karasay ore unit with iron content of 30,4 and titanium dioxide - 10%, and after beneficiation titano-magnetite concentrate contains Fe-52,4; TiO2-of 16,06%. Technology of titanium-magnetite concentrate ore-thermal melting was developed at Tymlay deposit producing hot metal and low titanium slag that can become the raw material for titanium production using chloride method. Slag produced in course of titanomagnetite ore-smelting consists mainly of alumosilicates and sodium silico titanates, magnesium and calcium titanates, titanium dioxide and lower titanium oxides. Following operations were carried out to improve titanium slag quality: slag sintering with sodium hydroxide; cake leaching with water to remove water-soluble impurities; to reduce the number of operations impurities leaching with hydrochloric acid was combined with pyrohydrolysis of titanic acid; rutile concentrate production (85% TiO2, 7,66% SiO2), silica removal by means of sodium hydroxide solution treatment, finally sellable rutile concentrate was produced with titanium dioxide 91-92% and silica 1,7 to 2,0% content. Based on research results technological scheme of titano-magnetite concentrate processing at Tymlay deposit was proposed producing hot metal and certified rutile concentrate, suitable for chlorination."

Jan 1, 2018

By Ron H. Derammelaere

Coal Slurry Test Pipeline and First Recorded Commercial Pipeline Wallace Andrews founder of New York Steam Company awarded patent for ?Method of Transportation? that involved pumping finely divided coal in slurry form built test facility at Madison Avenue and East 58th Street in New York City died in 1899 in a fire and coal pipeline work was not continued First recorded commercial coal slurry pipeline designed by Gilbert Bell in 1914 to move coal from barges on the Thames River in London to a powerhouse in 8? tubes (660 yards long)

May 1, 2013

By Robin Shepherdson

Security concerns have prompted the Department of Homeland Security to investigate the use of recording systems on all vessels holding materials used for blasting; a new regulation is expected in the near future. By measuring the strain developed in the legs of vessels with bolt-on sensors, it is possible to monitor the weight of vessel contents. Several companies make this type of sensor and recent versions give the required accuracy. This paper describes two generations of sensor, the second generation having a simpler method of installation that uses standard power and hand tools. Three types of indicator are available to monitor the material weight. 1) A simple electronic bar-graph indicator with a digital weight display. 2) A touch-screen display showing bar-graphs of multiple silos with digital weight displays plus their associated trend graphs, recent readings and an alarm log. 3) A data acquisition unit which acquires the weight digitally from up to 32 vessels and stores the raw and filtered date and time stamped data in a local computer database. This local computer then transmits the data via an Internet connection to a secure central database which allows the weights of all the storage vessels for a company to be viewed anytime and anywhere via the Internet. Historical trend graphs can be viewed and the data can be uploaded into an Excel file for further processing; for example to determine filling or discharge amounts. In addition, E-mail and SMS (Short Message Service) text alerts can be sent automatically when selected alarm levels are reached. Current research and development includes connection of vessels to the central database by a cellular wireless modem when a local computer or Internet connection is not available, as well as connection of remotely located vessels to a central point via “Wi-Fi bridge" radio data links. Future versions will include digital I/O (Inputs and Outputs) to record, for example, activation of filling and discharge devices as well as opening and closing of doors.

Jan 1, 2015

By R. E. Coleman

The molecular species occurring at the mineral-reagent interface of the galena-aqueous potassium ethyl xanthate system was studied by developing a technique for using an attenuated reflection method in conjunction with standard infrared spectroscopy procedures. Lead ethyl xanthate was detected from the infrared spectra of all galena surfaces treated in the pH range of 7 to 11. At pH 8.5, lead ethyl xanthate formed as a film chemically bonded to the galena surface. A solvent extraction sampling method was employed with infrared spectroscopy to obtain quantitative data on the lead ethyl xanthate removed from the galena surface. The data showed that between pH 7 and 11 thy quantity of lead ethyl xanthate physically adsorbed decreased as the pH was decreased; in the same pH range, the quantity of free lad ethyl xanthate in the aqueous medium remained constant, and the amount of unreacted xanthate varied.

Jan 1, 1966

The National Mine Health and Safety Academy near Beckley, W. Va., is dedicated to reducing accidents and improving health conditions in the mining industry through education and training. Though this basic mission remains unchanged, the Academy now serves a much broader mining community than it did when established in the late 1960s. From its original emphasis on training federal coal, metal, and nonmetal mine safety inspectors, the Academy has expanded its programs to reach mining industry and labor representatives, state agency employees, and university students taking mining-related courses. The Academy's resident programs, short courses, seminars, and continuing education courses cover a wide range of subjects and various experience levels, but all have been developed with one idea in mind - to reduce accidents and health hazards through education and training of the widest possible audience.

Jan 11, 1979

By M. P. Sinha, Rashmi, Tata Steel Ltd., S. Jaiswal, A. Bhatnagar, P. Garg

Reagents form a crucial part of flotation process as they have the power to control the surface properties of minerals. In case of coal flotation, collectors and frothers are two the important and commonly used reagents. But other types of reagents such as promoters, modifiers and depressants are also finding wide applications because of their availability to improve selectivity and increase recovery. Because of these chemicals the scenario has changed from flotation being used mostly for high rank hydrophobic coals to low rank, oxidised or inferior coals. In the present work a case is presented in which two non-ionic surfactants (abbreviated as A & B) known to act as emulsifier have been studied to get a better flotation performance for a preparation plant with varying feed characteristics. Laboratory flotation tests were conducted with both the surfactants using three feed samples of the plant by varying the dosage at three different levels. The highest combustible matter recovery (more than 80%) was obtained for surfactant B at a dosage of 75 ppm (parts per million) for feed 1. But at the same dosage the recovery decreased by 21% and 10.2 % respectively for feed 2 and 3. On the other hand surfactant A showed a consistent result for all the three feed samples giving the highest value at a dosage of 50 ppm followed by a decrease beyond this point. The tests were complemented by contact angle measurements that demonstrated the same trend. In addition to this the reproducibility of data for Surfactant A was checked and found that the standard deviations for both separation efficiency and combustible matter recovery were within the permissible range (less than 5%). Finally an in-plant process optimization study to evaluate the performance and applicability of surfactant A at industrial level was done and has been discussed.

Jan 1, 2016

By J. G. Mieczaniec

"A key element for a successful mining operation is the grinding circuit. It must be reliable, maintainable and must perform to or above design capacities for 95% of the time. Once chosen and installed major modifications are either prohibitive or very expensive. The selection of mills and drive system is probably the single most important decision made within the concentrator complex.Economic studies revealed that the optimum expansion for Lornex was a 68070 increase in plant throughput. This indicated that the new mill would have to be larger than the existing 32-foot mills.The Lornex ore has a wide range of hardness which has a great influence on mill throughput (Table 1). To smooth out the fluctuations, a blending program ha s always been in effect at the mine, coupled with ball charge control for the primary mills. As can be appreciated, an optimum balance is difficult to achieve. A sudden change to so ft ore with a high ball charge puts the mill into jeopardy with a constant speed drive.The blending philosophy would continue after the expansion, but with the addition o f a second primary crusher, it was envisaged to have the new mill process harder ore to maintain production targets. In theory, the new mill would have a proportionally larger ball charge than the existing mills.This scheme makes the new mill vulnerable for processing so ft ore for a fixed speed mill. Thus, variable speed seemed an attractive option.In early 1979 prominent mill manufacturers were invited to submit proposals for the new mill. Fixed and variable speed mills were to be considered with mill size ranging from 32-foot to 36-foot diameter. The proposals were to include the drive, ball charge, % critical speed, couplings, gears, etc. - the complete package. The recommendations were variable with most manufacturers submitting several alternatives. Recommended mill speed varied from 68% to 78% critical. The concept of variable speed was becoming more attractive, Lornex ultimately decided on a twin DC motor drive system for a 34-foot diameter mill.After start-up it was discovered that best throughput occurred at 78% mill critical speed or top speed of the drive motors. The motor speed range was adjusted upward from 186 to 200 rpm. Today the mills operate at 79% critical or a motor speed o f 193.5 rpm.Clearly the selection of the variable speed mill allowed the flexibility to optimize throughput."

Jan 1, 1985

By J. D. Marchant

In the spring of 1953 a series of heats were made using a 3-phase, size ST, Pittsburgh Lectromelt arc furnace to develop a method suitable for melting, refining, and granulating cobalt powder produced by the Calera Mining Co., at Garfield, Utah. According to specifications stipulated by General Service Administration, the granules had to pass a 2-inch screen and be retained on a 6-mesh screen, be low in phosphorus and sulfur, and contain a minimum of 98.7 percent cobalt plus nickel. Various combinations of water temperature, water jets, and rate of pouring were tried early in the campaign to produce desirable granules. It soon became evident that a properly refined and deoxidized molten bath was the major requirement for a satisfactory product. The physical characteristics of the granules were improved also if, just before pouring, the surface of the molten metal bath was pre-pared by a method involving the use of silica flux. The Bureau processed 107,750 pounds of cobalt powder. A total of 104,810 pounds of cobalt granules meeting General Service Administration specifications was returned to the producer. The refining slag, which was also returned to the company, contained 1,781 pounds of metal.

Jan 1, 1955

By Y. Mercadier, M. Ait-Ali, M. Dostie

"This paper presents the results of an analytical study to assist in the design of blast furnace tuyeres, including a prediction of the heat transfer process.IntroductionA blast furnace tuyere must be made of a material which must con serve its geometric and structural integrity in the environment of the fire-ball of the furnace. It must be cooled by a fluid forced through its internal cavities in such way as to keep its maximum temperature below the allowable limit. The prediction of the convective heat transfer coefficient inside the tuyere is of great importance in the design of new tuyeres with increased service life. We have developed a computer program which can predict the convective heat transfer coefficient for two-phase flow. This paper shows how the program work s and how it can be used for the numerical simulation of tuyeres.To simulate the h eat transfer conditions in water-cooled tuyeres, one has to predict:a) The heat flux (radiation and convection) generated by the combustion gases. This was evaluated using the single-zone gas-furnace model. This model yields results which are of the right order of magnitude. A more fundamental study of radiation heat transfer based on combustion and gas concentration s will be reported in a future publication.b) The local convective heat transfer coefficient at all points with in the tuyere.Prediction of the Convective Heat Transfer CoefficientTo calculate the convective heat transfer coefficient for refrigerant stream, semi-empirical correlations developed by the nuclear industry were adopted. These correlations permit us to analyze the entire range of the convective boiling range, as shown in Table 1. Our first attempt, with a single-phase flow correlation, has shown the need to take nucleate boiling into account."

Jan 1, 1982

By W. B. Tarpley

This program was conducted to demonstrate the unique advantages of suppressing methane ignition in underground mines by use of Energy & Minerals Research Company's thixogel fire extinguishing system, which stably suspends dry powder extinguishing agent in thixotropically gelled liquefied gas extinguishant. As anticipated, the project demonstrated thixogel system advantages of: 1) capability to disperse state-of-the-art powders in thixogelled Halons; 2) non-agglomerating stability for dependable expulsion; 3) stability in storage for long shelf life; 4) virtually in¬stantaneous dispersion; 5) expansive cloud formation; 6) reach and re-forming around obstacles; 7) at least twice the extinguishant effectiveness; and 8) compatibility of use with Fenwal bottles and MSHA canisters. Thus, it should prove a superior explosion/fire suppressant for coal face cutters and triggered barriers, as well as for motorized equipment, electrical equipment and the like.

Jan 1, 1981