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By Chee S. Theng

As the 2015 president of the Society for Mining, Metallurgy & Exploration Inc., I am pleased to present the 2015 issue of the Transactions of the Society for Mining, Metallurgy & Exploration Inc., Vol. 338. A significant portion of the contribution that we make as a professional society is the publication of professional and technical papers that accelerate the advancement of scientific knowledge and enable the transfer of technology. Communication within the mining community is the key to a successful society. This technology exchange continues a tradition that dates back to the 1871 meeting of 22 mining engineers in Wilkes-Barre, PA, that resulted in the founding of AIME. Those individuals envisioned that these transaction volumes “would form a most valuable and greatly needed addition to our professional literature.” This volume fulfills that pledge. The 2015 Transactions contains some of the most interesting research and insights from the past year and features an international slate of authors spanning industry, academia and government. Papers include the latest findings from the U.S. National Institute for Occupational Safety and Health (NIOSH) and special-focus articles on gold processing, iron ore processing and coal processing. The 2015 Transactions consists of a total of 67 technical papers, encompassing all 22 papers published in 2015 in the Technical Papers Section of Mining Engineering (Vol. 67) and all 29 papers published in 2015 in Minerals & Metallurgical Processing (Vol. 32). Additionally, this volume contains 15 papers and one discussion that are being published for the first time in this issue. The papers presented in this volume were written by some of the most distinguished professionals in the industry worldwide. All of the technical papers were peer-reviewed. The process of review and publication requires much hard work by authors, reviewers and our publications staff. As the 2015 president of SME and on behalf of all our members, I would like to extend our gratitude to all whose volunteer efforts contributed to the publication of this volume.

Jan 1, 2015

By Roshan B. Bhappu

Although the economic importance of recovering copper by leaching of mine work dumps from open-pit operations has been realized for some time, serious attempts to understand and to improve such operations through scientific research has been made only in recent years. This progress report covers the results of chemical, physical, and biological studies pertaining to the dump leaching process and discusses salient features and parameters that may be helpful in improving such operations.

Jan 1, 1968

By M. Aushouri, S. H. Mansouri, N. Aminizadeh

A thermo-chemical model of the Peirce-Smith copper converter has been developed to predict the molten temperature. The primary assumption of the model was that all matte, slag and gaseous phases in the converter were in thermal and chemical equilibrium. In this model, the matte components were considered only as copper, iron and sulfur elements. In the slag making stage, all the reacted iron was converted to fayalite. The reaction rate of iron and oxygen in this stage was considered to be constant. The converter temperature was calculated by heat balance over time. The model was validated by a detailed comparison with measured industrial data. A good agreement was obtained. The converter temperature depends on process parameters such as oxygen efficiency and molten emissivity.

Jan 1, 2007

By Dagoberto Brandão Santos, Marcus Vinícius Pereira Arruda, Fernando de Souza Costa, Túlio Magno Fuzessy de Melo

The development of advanced high strength steels (AHSS) is motivated by the automotive industry demands for higher strength steels with better formability and stretch-flangeability to avoid fractures during parts forming. In response to this, the new steel grades must have special microstructures in terms of constitution, morphology, distribution and hardness, which are strongly dependent on the chemical composition of the steel sheet and its processing, especially in the continuous annealing stage, in the case of cold rolled sheets. In this study the influence of the annealing heating rate and intercritical temperature (IT) on the microstructural evolution and the final hole expansion ratio of a cold rolled 980 MPa AHSS grade was evaluated. The annealing process was simulated using a Dilatometer and a Gleeble machine, and the microstructures were characterized using scanning electron microscopy, electron backscattered diffraction (EBSD) and nanohardness measurements. The increase of heating rate resulted in an overlap between ferrite recrystallization and austenite formation, changing the austenite morphology from a random to a fibrous distribution, while a higher IT resulted in more homogeneous microstructures and higher hole expansion ratios. This microestructural homogeneity, confirmed by nanohardness measurements, suggested that the difference in hardness between ferrite and the second phase affects the micro-void formation and crack propagation during the hole expansion test.

Oct 1, 2019

By D. T. McMurray

INTRODUCTION Shabanie mine, situated some 180 km east of Bula¬wayo, has been a producer of chrysotile asbestos for more than 50 years. The ore bodies occur in serpentinized dunite, which overlies talc-carbonate schist. A zone of relatively competent rock of varying thickness occurs between the schist and the ore bodies, which are gen¬erally less competent. The hanging wall of the ore bodies is economic, and the hanging-wall serpentine carries a variable subeconomic amount of fiber. It is important to note that, in general, the ore body competence is less than that of the foot and hanging-wall formations. Historical After surface operations ceased, cut-and-fill stoping was used to win ore from underground; this was success¬ful until the increasingly stoped-out area caused insta¬bility in the stope pillars and back. Consequently, dur¬ing the early 1950s, a gradual change to cave-mining methods was made, the ore being won by hand lashing in drawpoints, situated in the basement of the stope blocks, and passed through orepasses under gravity to the haulage level some 13 m below. About this time, interest was focused on the sub¬level caving method in use in Swedish iron ore mines: it was felt that it might be applied economically to the Shabanie ore bodies. Accordingly, in 1958, an experi¬mental stope block was laid out in which sublevel inter¬vals and extraction tunnel spacing were 9 m. The tun¬nels (ring drilling drives) were oriented on strike-in contrast to the Swedish system, in which crosscuts that retreat from hanging to footwall are used. The advantages of the method were quickly appre¬ciated by the operating personnel and, despite the in¬evitable teething troubles pertaining to the introduction of any new mining method, it was not long before sub¬level caving was providing a high proportion of the mill feed. The disadvantages also became apparent at an early stage, however, and, from that time to the present, continuing modifications have been made to mining lay¬outs in an effort to improve ore recovery. GENERAL DESCRIPTION OF METHOD The mine is served by a vertical hoisting shaft, in which two skips, a man cage and a service cage, provide adequate capacity for production requirements. The rock hoist is a Ward Leonard control hoist, in which two electric motors drive a common gearbox. The man winder is driven by an a-c motor. Several auxiliary shafts provide secondary egress and intake and return ventilation. Main haulage levels are above (Fig. I a and b). Blasthole fan patterns are drilled by drifters of 100 mm bore, drilling 41-mm holes; when a sufficient strike length has been drilled, a slot is cut in the upper¬most sublevel and the rings are broken into the slot. Initially, a limited tonnage is drawn, since it is essential to ensure that the hanging wall caves behind the retreat¬ing stope face. Once this has been established, maxi¬mum tonnage can be drawn, as described later in this chapter, under the heading "Draw Control." The broken rock is loaded by 0.14 and 0.20-m3 load¬ers into cocopans (rocker-dumping type of tipping truck), which are hand trammed to orepasses, discharg¬ing on the haulage where 11-t electric trolley locomo¬tives haul 3.95-m3 Granby cars to the main shaft bins. As is evident from Fig. 1, the layout is simple, the block is brought rapidly into production, there is a high degree of selectivity and flexibility, and the result is a low-cost high-productivity mining method. DEVELOPMENT Main haulages are developed at 3.2 x 3.2 m, and once the service winze connections have been completed the development of the sublevels is undertaken. The footwall drives are cut first, to obtain access to the block. These ends are of the standard section, 2.4 x 2.8 m, and from them crosscuts at intervals of 70 m are driven through the ore body to the hanging wall. These crosscuts are used to supplement the geo¬logical information previously obtained from diamond core drilling, and they provide additional and more de¬tailed data on fiber percentages and lengths, structural features, and other relevant criteria which are used to build up the geological assessment of the area and to classify it in terms of the geomechanics rock classification (Laubscher and Taylor, 1977). The crosscuts also allow the necessary orepasses to be sited conveniently so that tramming distances from the loading points are not excessive. Development Drilling Once the skeleton development has been completed, the extraction headings are developed at 2.4 x 2.4 m as shown in Fig. 1. Standard development practice is to use crews of a machine operator and his helper, equipped with air-leg mounted jackhammers, to drill rounds of 1.8 m with integral tungsten carbide tipped drill steel. The round drilled is a normal drag round, as shown in Fig. 2, but considerable attention is paid to the drilling of the perimeter holes to use effectively the

Jan 1, 1982

By I Gipps

Each of us has a vision of what the future mine will be and, generally, these visions have many similarities and some differences. One of the major discrepancies in visions of the future mine is not the ultimate goal but the path to achieve it. Many of the future concepts require a radical re-thinking of how things are and will be done yet. So how do we reach this visionary future mine? We need a path that satisfies both our future aspirations of a high tech gee-whiz operated from our iPads and the unfortunately mundane approach that says ‘we must know the method works, ie nothing new’.This paper explores how, within a research based organisation, we firstly set our ultimate goal and then divide the path into realistic technology development chunks that would appeal to mining companies to progress within their organisational constraints. Through examples, such as, automated LHDs, communications systems, surveying and localisation, rock cutting and geological sensing, we illustrate how this path will get us from the here and now to the out there future.This paper also demonstrates CSIRO’s short, medium and long-term research in many of the areas needed to create the Future Mine: mining methods, automation and remote control, mine communications, mapping and mission planning, geological sensing and, importantly, human-system integration, which examines how to effectively present data as information to operators and supervisors in an intelligent and useful manner.

Nov 22, 2011

By Thomas A. Wheeler

The reagents commercially used in coal flotation and their roles are reviewed and discussed According to their function the reagents are divided into often overlapping groups: 1. Collectors 2. Frothers 3. Conditioning Reagents Frothers have by far the largest effect on the amount of coal recovered They act not only in their traditionally accepted function of “bubble makers”, but in coal flotation they serve in a seldom acknowledged role of collectors. A lab flotation study on four samples of different coal ranks shows how these react to various frother families and proves that no froher is the optimum reagent for all types of coal. The advent of new technology in flotation equipment in the past decade has resulted in various novel designs of column cells, Jameson and Centrifloat™ cells, air-sped hydrocylones, etc. All should require special frothers or blends of frothers to meet their specific needs.

Jan 1, 1994

By Robert M. Busche

[Recent developments in the gasification of coal, both by the Bureau of Mines and American industry, have intensified interest in the thermodynamic and kinetic principles necessary for understanding the reaction mechanism and rates and the physical changes that take place. In the course of a Bureau of Mines study of the kinetics of coal gasification at the Synthetic Liquid Fuels Demonstration Plant, Louisiana, Mo., a bibliography of approximately two references was compiled. They are listed n this publication and refer both to American and foreign sources.]

Jan 1, 1952

By T. Güyagüler, U. Y. Önder

"This study investigated the psychrometric properties of ventilating air in GAL coal mines. Related measurements were done in underground openings and have been arranged as input data for computer programs prepared for ventilation network and psychrometric analysis.Results obtained from network analysis have been used for psychrometric analysis of ventilating air. Changes in heat and moisture content of air in two major path s between entry and discharge of ventilating air have been investigated. Psychrometric processes occurring in the mine were determined and are shown graphically in Figures 1 and 2. Special attention has been given to determine the changes in psychrometric properties and processes involved in the faces. Results are outlined in this paper.IntroductionThe psychrometric properties of mine air are important factors to mine productivity and efficiency. Therefore, psychrometric analysis should be made for all underground mines; any undesired situation observe d could be corrected by taking the necessary precautions.The analyses were done as a case study for GAL mines, the only mechanized lignite coal mine in Turkey. In this mine, workable reserve is about 300 million tons of coal and yearly planned production is 2.2 million tons. Production is continuing from a coal measure-bed having two coal seams with average thicknesses of 1.52 m and 1.72 m respectively. A 0.85 m shale band exists between these two seams.Two full y-mechanized faces, approximately 220 m long, usually work simultaneously. All measurements, including mine gases and air velocity, are done by sensors connected to a control room by a monitoring system.In the analysis, a line diagram is utilized to described the mine on which every junction and branch is numbered."

Jan 1, 1992

By R. G. Henley

Mount Isa copper concentrate was combusted in a laminar-flow furnace. The conditions simulated those likely to be encountered in flames in flash smelters of the Outokumpu (air as oxidant) and INCO (oxygen as oxidant) types. The range of conditions studied was as follows: T 400-1400°C, 02 0-100%, SO2 0-95% for residence times up to 0.23 s. The distribution of sulfur, arsenic and lead between the particles and the gas phase was studied. Combustion was very rapid provided the concentrate was adequately dispersed, i.e., no agglomerates. The importance of the latter is discussed. It was possible to oxidize 80% of the sulfur present in the con¬centrate after only 0.1 s reaction time at 1000°C in an atmosphere contain¬ing 8.5% 02 and 12.5% SO2. Best volatilizations (90% of the As, 52% of the Pb) were obtained under localized conditions attained in an air-type flame. Average volatilizations were: air-type flame, As 50%, Pb 32%; oxygen-type flame, As 40%, Pb 30%. The substitution of oxygen for air reduced the arsenic volatilization. The products of combustion were mainly cuprospinel and cuprite; small inclusions of elemental copper were found in some of the particles. At high temperatures, there was a loss of copper due to vaporization of CU( g) CuO kg) (g)

Jan 1, 1983

By D. Harrington, W. J. Fene, H. B. Humphrey

In the fiscal years 1946 and 1947 the number of mine explosions decreased compared with the preceding years. However, the loss of life was so serious during the fiscal year 1947 the period when the Government administered bi- tuminous-coal and lignite mines that from April to June 1947 extraordinary measures were taken in mines then under Government possession to obtain com- pliance with provisions concerning rock dusting, ventilation, and blasting that had not been followed. The great loss of life in explosions during the fiscal year 1947 as compared with 1944, 1945, and 1946 is not easy to explain, but the necessity for maintaining adequate protection has been definitely demonstrated. Management, workers, and inspection agencies alike must keep the mines reasonably safe against explosions or allow them to lapse into a condition where chance is the principal protection against disaster. The at- tention given to protecting coal mines and the men employed in them against mine fires, following the disastrous fires in 1944 and 1945, has at least tem- porarily controlled this hazard loss of life from coal-mine fires was re- duced to 1 fatality in 1947. The number of fires was also less, and progress has been made in reducing the heavy losses in both life and property from un- derground coal-mine fires that occurred in the two years mentioned. Fatalities from mine explosions during the past 6 fiscal years, July 1942 to June 1947, totaled 674, and there were 149 explosions; during the preceding 6 years there were 655 fatalities in 132 explosions. The 6 fiscal years 1942- 47 cover the active period of Federal coal-mine inspection. During the fiscal year 1947, there were 154 fatalities from explosions compared with 58 during the fiscal year 1946, 64 in 1945, 94 in 1944, 152 in 1943, and 152 in 1942.

May 1, 1948

By W Assibey-Bonsu

The paper provides a brief review of the multivariate uniform conditioning and the localised multivariate uniform conditioning techniques and presents a case study based on a porphyry copper gold deposit in Peru. Two other important scenarios have been investigated and will be particularly emphasised: The recovered selective mining unit (SMU)s depend on a combination of copper and gold content, which can be expressed by means of ænet smelter returnsÆ (NSR). Two approaches are compared. Firstly, the application of a composite cut-off on NSR on the joint distribution of each grade and the application of uniform conditioning to three variables is investigated, ie for the first approach NSR is used as the main variable. The second approach considers copper as the main variable. In the case of multiple domains the procedure used to apply the technique to process mixed panels is clarified and recommendations are made.

Sep 26, 2011

By R. W. Hiteshue, R. W. Fridy, W. Kawa

A study of the production of coronene , a high - melting ( 440 ° C ) , highboiling ( 525 ° C) , polynuclear hydrocarbon , was made by the Bureau of Mines to determine the maximum yield obtainable by the hydrogenation of coal and coalderived materials . Experiments were made with anthracite and bituminous coals and with asphaltenes and centrifuged residue obtained from heavy oil produced in a pilot plant by the hydrogenation of a bituminous coal at 2,000 psi and 480 ° C. With anthracite , yields of coronene of 0.5 to 0.7 wt pct of moistureand ash - free coal were obtained at 6,000 to 8,000 psi , 700 ° to 750 ° C , and a residence time of 30 minutes . With bituminous coal , yields averaging 0.4 wt pct of maf coal were obtained at 6,000 psi , 800 ° C , and 30 minutes ' residence time . With asphaltene and centrifuged residue , yields of less than 0.02 wt pct of maf coal were obtained at 6,000 psi , 700 ° C , and 60 minutes ' residence time .

Jan 1, 1964

By Donald F. Reed

In the Coastal Plain sedimentaries of northeastern Mississippi, high-alumina clays and kaolins, which are bauxitized locally to varying degrees, are found in many places along the contact between the Midway (Paleocene) and the Wilcox (Eocene) series. The trace of the contact extends from Tippah County, on the Tennessee border, south to Winston County, thence southeast to Lauderdale County, and into Alabama. Its length within Mississippi, disregarding sinuosities, is 185 miles (fig. 1). Commercial production of bauxite from the region has amounted to about 400 tons, shipped from one outcrop in Komper County. In December 1941 and January 1942, the Bureau of Mines and the Federal Geological Survey made a reconnaissance survey of the contact zone and selected the most promising areas for further study. In 1942, four areas in Benton, Union, and Pontotoc Counties were investigated by auger and rotary core drilling, and in 194, core drilling was done on five areas in Kemper, Noxubee, and Winston Counties. The present report records the work done by the. Bureau of Mines and the factual data obtained from the investigations of the nine areas in the two projects.

Jan 1, 1952

By Lakshman D. Jayaweera

Today's rapidly developing and changing technologies and industrial products and practices frequently carry with them the increased generation of materials that, if improperly dealt with, can threaten both public health and the environment. Mercury is an element that poses great problems in the many forms in which it is to be found in the mineral processing industry. These forms are often contained in hazardous wastes and residues which may be unstable, and in which the contained mercury has value. This paper presents some of the stabilisation and recovery methods which are based on hydrometallurgical techniques and thermodynamic stability considerations.

Jan 1, 1994

By N. Waters

"Nickel saprolite ores are normally mined as feed to Fe-Ni smelters or Ni matte smelting operations. The smelting processes typically require high Ni cut-off grades of approximately 1.5 to 2.2% Ni, depending on the operation. These very high cut-off grades result in a significant portion of the saprolite profile being regarded as “waste” and hence having little to no value. The Starved Acid Leach Technology (SALT) was developed to recover nickel and cobalt from nickel saprolites and Caron plant residues. Relatively small amounts of acid are applied to ground saprolites or Caron residues in order to selectively leach nickel and cobalt. The leaching is performed atmospherically under low free acid conditions. Nickel and cobalt may be recovered from the leachate as a mixed hydroxide. The mixed hydroxide may be added directly to a saprolite smelting operation or refined separately. InCoR Technologies is advancing the application of SALT at a number of sites. Bench scale testing has provided a relationship between acid addition and nickel extraction in leaching. Conceptual engineering studies have been completed by SNC Lavalin. The simplicity of the SALT technology provides the benefits of low capital and operating cost and an expected rapid ramp up to full production.INTRODUCTION The recent history of hydrometallurgical nickel laterite treatment plants has demonstrated mixed financial and operational performance. Table 1 summarizes the next generation plants built after the financial and/or technical failure of the Bulong, Cawse and Murrin-Murrin plants in Australia. The Coral Bay plants (Line 1 and 2) stand out (and now Taganito) as relatively low capital cost, simple (no acid plant, production of mixed sulfide product), and modest in scale (10, 12 and 36 kt Ni/a). However, the other plants in the list (Ravensthorpe, Ramu, Goro and Ambatovy) are all characterized by financial and technical challenges. All plants have a very high capital cost ($67,000 to $120,000 USD/annual t of Ni production). Ravensthorpe was sold by BHP Billiton after a poor startup. Ramu has had a steady ramp up but only produces mixed hydroxide for refining by others. Goro has had an extended construction period (since 2001), is high cost and has been very slow to ramp up to design production rates. Ambatovy has had a steady ramp up."

Jan 1, 2017

A. Scott Reid, London, Eng. (communication to the Secretary*) :—As a constructor of several glass mine-models, .I have read with much interest the description of the model of the Montana-Toriopah mine-workings by Edmund D. North.

Jan 1, 1910

By M I. Pownceby, N A. S Webster, A J. Studer, I C. Madsen, J A. Kimpton, M J. Fisher-White, L Lu

In situ synchrotron X-ray and in situ neutron diffraction-based experimentation have been implemented to characterise the formation of the complex calcium ferrite iron ore sinter bonding phases silico-ferrite of calcium and aluminium (SFCA) and SFCA-I. Experiments were carried out using fine-grained (<20 ¦m) sinter mixtures containing ~77 wt per cent Fe2O3, 14 wt per cent CaO, 3.5 wt per cent SiO2 and 5 wt per cent Al2O3, with diffraction data collected during heating until 1300 - 1350¦C, which was enough to ensure complete melting of the SFCA phases. In the case of the in situ synchrotron experimentation, results showed that altering the nature of the starting sinter mixture (ie substitution of goethite for hematite; substitution of an amorphous Al2O3-based mineral for gibbsite) did not have a significant effect on the thermal stability range of the SFCA phases. It did, however, have a profound effect on the formation and rate of consumption of the calcium-rich ferrite phases C2F and CF, and on the formation mechanisms of SFCA and SFCA-I. The in situ neutron diffraction experimentation is the first described in the context of iron ore sintering, and the observation of both SFCA-I and SFCA formation in the in situ diffraction data represents the first step in achieving the goal of charactering iron ore sinter phase formation in large volumes of industrial sinter starting materials with a wide range of particle sizes (up to 6.3 mm).CITATION:Webster, N A S, Pownceby, M I, Madsen, I C, Studer, A J, Lu, L, Manuel, J R, Kimpton, J A and Fisher-White, M J, 2013. In situ x-ray and neutron diffraction studies of silico-ferrite of calcium and aluminium iron ore sinter phase formation, in Proceedings Iron Ore 2013 , pp 487-494 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

By J. Faitli

The Lake Balaton is the biggest and for many reasons the most important lake in Hungary. To preserve its healthy nature it is necessary to remove the accumulated mud time to time, similarly to the many living waters, lakes and rivers everywhere. Typical existing technologies (mechanical, hydraulic) require large depositional areas, where the removed slurry and mud is dewatered through very long time. One problem is the non existence of an economical mud thickening technology. Another major problem is that current methods remove the sand fraction with the mud as well. Many times sand has to be complemented from outer sources to endanger the natural balance of the living water. By the financial support of the NKFP 3A/068/2004 Hungarian Research Project our consortium has been looking for the solution to the above mentioned problems. The original ideas of the project were: 1. Sand should be separated and returned to the water by hydrocyclon; 2. New mud thickener should be developed based on the principle that vibrating rods can force settling and packing of mud particles. The work was started by fundamental research with different samples from Lake Balaton and River Bodrog. An automated settling column (45L) has been built for the investigation of the effect of vibrating rods on the settling behavior of suspensions. An optical sensor has been developed by with the settling curve (height of settling slurry as function of time) can be automatically measured. Different vibrating methods and parameters have been tested by the application of a linear motor and mechanical eccentric drive. On the basis of the fundamental research a new thickener, called the rod ? lamella thickener has been developed and an industrial size (50m3/h) mud removing technology has been built. Main parts of the technology are the traditional dredging barge and the thickening technology. The thickening and sand separation technology is tugged by the dredging ship. Its main elements are the homogenization tank, slurry pump, hydrocyclon and the rod ? lamella thickener. In this unit lamellas carry out pre-thickening, then vibrating rods further increase the concentration. The thickened mud is transported out by a screw - of which revolution number is precisely controlled - against a spring supported valve. Paper reports about the design, building, water probe and on-site tests of this mud removing technology. Two new patents had been presented, one is about the rod ? lamella thickener and the other is about the mud removing technology with sand separation.

Jan 1, 2014

By Burrows. A.

Temperature profiles in the lead smelter sinter bed at Xstrata Zinc Mount Isa sinter plant have been measured using a wireless temperature probe. Corresponding sinter samples have been collected for characterization. The sinter peak bed temperatures were found to be in the range of 1000 - 1200 °C. Microstructures and softening temperatures of these sinters have been characterised. Strong correlations have been observed between peak bed temperature and peak hood temperature, and between mean sinter softening temperature and peak bed temperature. It was found that higher peak bed temperature results in higher sinter softening temperature. For the feed material used in the trials, to obtain sinters with mean softening temperatures above 1050 °C, peak bed temperatures above 1130 °C are required. There appears to be a direct correlation between granule size distribution in the feed and peak bed temperature attained. High peak bed temperatures are observed in sinters with narrow granule size distribution.

Jan 1, 2008