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By O'Halloran. Gerard F.

"ECSTALL MINING has installed in their plants the most modern equipment in the mining industry. At the minesite, digital blocked frequency controls are used to monitor all crushers, conveyors, ventilation equipment and pumps from underground. Distant pumping stations are monitored and controlled by radio. Modern friction skip and cage hoisting systems have been installed with static power supply designed for automatic operation. Rotary-type compressors of recent design are in service in place of the conventional reciprocating-type units. At the concentrator, the 800- and 1500-hp synchronous motors driving the grinding mills have static field excitation and pneumatic clutches, still meeting modern-day concepts, having been• installed in 1966. The maintenance work load has increased annually for the past eight years. The modern plant, with all the present-day sophistication, must have a welltrained and well-organized force of skilled workers, and a maintenance system which will supply realistic facts and guidelines. This presentation will review the relative location of plants, utilities, maintenance and services, plant maintenance control and mechanical control. It is the hope that enough information will be presented to weigh the size of the job and how the resources are utilized for controlled maintenance."

Jan 1, 1974

By T. Johnson, D. Kelley, J. Graham

"Hydrometallurgical processes can be exceptionally corrosive. Conditions associated with metal extraction and refining require materials of construction that can withstand process acids and acid chlorides at temperatures up to 90°C (194°F). Process vessels, piping, scrubbers and ducting can be rapidly compromised in these aggressive environments if not designed with care. Design engineers are challenged to find materials that can stand up to hydrometallurgical processes especially for copper, zinc, nickel, cobalt and uranium. This paper will evaluate material solutions to determine which provides attractive economics for initial procurement as well as high durability for reasonable life cycle costs.INTRODUCTIONMining activity in a number of metal ores has been running quite high over the last few years. In particular, those metals that employ acid functional extraction processes such as copper, nickel cobalt and uranium have been particularly active.The world’s largest nickel mine – the massive $4.76 billion Ambatovy nickel mine on the African island nation of Madagascar is nearing completion. When it reaches its full production capacity in 2013, the mine will produce 60,000 MT/yr of nickel and 5600 MT/yr of cobalt. Coming on the heels of the Ambatovy project is the Long Harbour Processing Plant in Newfoundland, Canada which will process the ore from Vale’s Voisey Bay mine in Labrador. Voisey’s Bay is expected to generate more than 50,000 MT/yr of nickel ore when it starts up in 2013. Next up will be the Boleo project in Mexico on the Baja peninsula. When commissioned in 2013, the $858 Million Boleo project is expected to produce 60,000 MT/yr copper, 3100 MT/yr cobalt, 36,000 MT/yr zinc and 100,000 – 250,000 MT/yr manganese carbonate.High nickel alloys and rubber lined steel have been used for decades to design corrosion resistant equipment for mineral processing environments. These materials demonstrate reasonable resistance to corrosion for most environments. Unfortunately, higher nickel alloys are quite expensive. Rubber lined steel is a bit more affordable but requires continuing service over time which ultimately drives up its cost as well. FRP (Fiberglass Reinforced Plastic) has also been used extensively in mineral processing for tanks, piping and ducting employed in aggressive environments. Today, more and more design engineers and material specifiers are calling for FRP composites for both new and replacement equipment used in the refining and processing of a variety of metal ores."

Jan 1, 2012

By Robert E. Wilson

TO show the vital importance of our future oil supplies to our economy, I will merely point out that this country, with something like 15 per cent of the world's land area and something like 7 per cent of the world's population normally uses between 65 and 70 per cent of the motor vehicles of the world, between 65 and 70 per cent of the world's rubber, and produces and refines between 65 and 70 per cent of the world's petroleum. Despite all the arguments as to which is cause and which is effect, all will agree that all three of these important industries are mutually dependent. If we had not been able to produce 65 or 70 per cent of the world's oil in this country we would not have the degree of mechanization, or the efficiency of transportation, or the high industrialization that we enjoy. Furthermore, the fact that oil has been plentiful and cheap has had a tremendous effect on all the things in which we as engineers are interested. For that reason, if for no other, it is well to look ahead to see what the outlook is for the near and far-distant future.

Jan 1, 1945

By Cory Dippold, Michael Mett, Jérôme Steinkühler, Kristi Latimer

For decades, tunnels of all types have been a significant part of our infrastructure. In particular, water tunnels carry millions of gallons of fresh water every day to major metropolitan areas and surrounding communities. As a critical piece of public health infrastructure, it is important to inspect the condition of these tunnels regularly to ensure reliable and continuous operation. A specific challenge with water infrastructure is that it’s often difficult or impossible to shut down the system for long periods of time to perform the needed inspections. The latest method of tunnel condition assessment is the use of hybrid reality 3-D scan data. Photogrammetric and LiDAR based 3-D data ensure a reliable and objective view of tunnel conditions. The data can be used to support a detailed digital inspection including the compilation of databases that consist of a wide variety of deficiencies such as cracks and spalls within the structure. Mott MacDonald, a design engineer company worked closely with Dibit, used a 360-degree scanning system to collect high-resolution photogrammetric and LiDAR data on a recent project involving a water tunnel. The allows for full 360-degree coverage of the tunnel surface including a water covered invert. It operates at walking speed and ensures a fast and reliable data acquisition which can reduce the time of tunnel shutdowns. Several allocated inspection weeks can reduce to few days, with the final work product being a higher quality and more complete deliverable than traditional inspection methods would have provided. The true-color 3D-model has a photo resolution of 1 × 1 mm (0.039 × 0.039 inches) which makes cracks visible with a width of down to 0.3 mm (0.011 inches). The assessment of water tunnels, its technical challenges and the results of the 3D-tunnel inspection case study are illustrated and described in this publication.

Dec 1, 2022

By Carl R. Christiansen

The primary objectives of this project are (1) the determination of manpower demand in primary lead and zinc production for the years 1985 and 2000, and (2) the estimation of the availability of the required manpower for these years. In order to meet the first of these objectives relationships between employee requirements and metal production in the various states were established, The total primary lead and zinc production from United states mines in 1985 and 2000 has been predicted by the U.S. Bureau of Mines. These forecasts and the 1974 figures are as follows: [1974 1985 2000 Lead metal, tons 669,000 700,000 900,000 Zinc metal, tons 494,000 585,000 995,000] Mining By analysis of ore reserve data and industry characteristics, the authors estimated the portion of the primary production which each state would yield in the future years. As manpower requirements are determined by the tons of ore produced and by worker productivity, these figures were determined for each mining state and district by developing relationships between lead and zinc metal production, ore production, ore to recoverable metal ratios, employee productivity, and number of employees required. The number of new employees required annually to compensate for attrition and production growth is provided, also.

Jan 1, 1975

By "Andreas Steinwandter

The demand for increasing energy efficiency and CO2 reduction is one of the global megatrends of our time. Although the steel industry suffers from a volatile economic environment, the steel plants are interested to find opportunities for sustainable cost reduction and put efforts into healthy solutions for the environmental. Integrated steel plants are trying to cut electrical power and energy costs as these are among the biggest cost factors that can be influenced and taking all the advantages they can. For the integrated iron and steel making route the interaction of waste energy utilization along with process energy demand, natural and metallurgical gases, steam and heating systems as well as power generation has to be considered. Potential energy sources, such as sinter plant, basic oxygen furnace (BOF) cooling stack or reheating furnaces are considered in order to elaborate an integrated energy concept. Especially electric power generation is an attractive option for steel plant operators since it can easily be connected to the existing power grid of the steel plant. When direct local use of waste heat is limited, the best option is to convert it to mechanical/electrical power with a Rankine Cycle. A stand-alone system, compact design with minimum operational costs in order to fit into the existing steel plant layout, are the main requirements of such units. The objective of this paper is to demonstrate economic feasible opportunities for energy recovery for sinter cooler and basic oxygen furnace with focus on electric power generation via ORC modules taking at the same time advantages of CO2 reduction by utilizing waste heat from the process. Furthermore typical arrangements and layouts of such solutions as well as basic economic calculations will be presented in the paper.

Oct 30, 2017

Despite modest improvements in the performance of domestic interest rates and gross national product,1 fixed investment in domestic producers' durable equipment continued to weaken during the second quarter of 1982 and declined at a 12.8 percent annual rate compared with the first quarter.2 Large declines occurred during the second quarter in expenditures on many of the major mineral-consuming industries such as aircraft, computers, agricultural and construction machinery and mining and oil field equipment. These data appear to be consistent with the low level of business investment plans for 1982 reported in the DOC's Bureau of Economic Analysis survey of expenditures on new plant and equipment.3 Domestic and foreign industrial production and mineral industry production activities continued to decline in the most recent period because of weak demand conditions (Tables 1 and 2). The U.S. mining production index declined 7.7 percent between April and June as compared with 1.2 percent for total U.S. industrial production (Table 1).

Jan 1, 1982

By E. H. Denny

The presence in the Cripple Creek district, Colo., of irrespirable gas or gases, generally known to consist mainly of nitrogen and carbon dioxide, has been recognized by members of the mining industry in that region almost since underground mining was begun there; the occurrence, origin, and possible control of these gases have been discussed in several articles cited at various places in this report. Similar gases have also been studied in other metal-mining districts, as later discussed. In March, 1925, there were two fatalities from rock-strata gases in the shaft of the Index mine, near Cripple Creek. Two men repairing the bell or signal line preparatory to reopening the shaft were lowered into irrespirable gases and died. Their bodies were recovered by rescue crews from the United States Bureau of Mines and .the Portland mine, Victor, Colo. These crews found it necessary to use oxygen breathing apparatus. In October of the same year a miner was trapped on the 6 level of the Midget mine by an influx of gases that filled the shaft to a point above that where he was working. Oxygen breathing apparatus was again used by Bureau of Mines employees, who were in the vicinity, and the man was brought out in time to save his life. These two fatalities and one near fatality seemed to show that additional investigation of the gases and methods of control might be warranted. Accordingly, field and laboratory studies were begun by the authors of this report after a visit to the district by M. van Siclen, then engineer in charge, mining research division, Bureau of Mines, and after conferences with the Mine Owners' Association of Cripple Creek and with J. T. Joyce, metal-mine commissioner of the State of Colorado. The mine operators of the Cripple Creek district and the State mine commissioner's office gave whole-hearted cooperation in this work.

Jan 1, 1930

By R. W. Raymond

THIS meeting was held in the new home of the Institute, the United Engineering Society Building, 29 West 39th Street, New York City, directly following the Dedication ceremonies. The first session was held in the large Auditorium, Thursday, April 18. The meeting was called to order by Mr. John Hays Hammond, President of the Council, who said Before taking up the reading and discussion of papers, I will call upon Dr. Rossiter W. Raymond, the oldest living past-President of the Institute, who has been in harness almost continuously for thirty-six years, and who has contributed more than any one else to bring this society to its present great success and to establish the reputation of the American mining engineer the world over, for a few words supplementary to those which were uttered to engineers generally, during the sessions of yesterday and the day before. ADDRESS BY R. W. RAYMOND. The generally accepted Darwinian doctrine of the survival of the fittest is sometimes illustrated by persons who are supposed to be the fittest because they have simply survived. I fear that I come under that category. Almost all of my contemporaries in the early history of this Institute have passed away. Only one or two of the original founders remain, and I may fairly say that scarcely any remain who were active at that : time in shaping the organization and the future career of the Institute. In May, 1871, I was thirty-one years old. Next week I shall be sixty-seven years old. All the intervening years have been devoted to the service of this Institute almost continuously, either as President or Vice-President or Secretary. You may easily imagine, therefore, with what pleasure I greet you on this occasion. I am not here to extend to you the welcome of the City - of

May 1, 1907

By I. L. Jennings

In most industrialized countries, the largest element of the mining industry in physical volume is that devoted to the extraction and processing of materials for use as construction aggregates. Required for all developments in industry and commerce, power and transportation, and housing and public services, their use is so widespread that possible sources are exploited throughout all geographic regions, as close as possible to the point of use. Thus, it is also the most frequently encountered form of mining throughout the world. These materials come from four main sources:- (a) Excavation of unconsolidated deposits of sand and gravel (b) Stone quarrying. (c) Processing of slags and other mineral wastes. (d) Manufacturing from clays and shales by heat fusion. The major uses are in: (a) Portland cement concrete, that most versatile of construction materials, including the many concrete products in current use. (b) Asphalt cement concrete; widely employed for paving roads, parking lots, airfields, etc. (c) Foundation materials, such as road base, granular backfills, railway ballast, etc.

Jan 1, 1968

By Alan Stanley

The MacIntyre Development of the National Lead Co. is located at Tahawus, N. Y. The operations involve the mining and concentrating of a titaniferous iron ore to produce an ilmenite concentrate and a magnetite concentrate. Construction of the MacIntyre plant was commenced during the summer of 1941, when world conditions threatened to cut off the supply of Indian ilmenite. An open pit mining operation was developed and the crushing and milling equipment put in operation in July 1942. A general description of the operation was given in the Adirondack Issue of Mining and Metallurgy for November 1943. The metallurgy of the mill operation was described by Mr. Frank R. Milliken,* Plant Manager, National Lead Company, MacIntyre Development, and presented at the AIME New York Meeting, February 1948.

Jan 1, 1949

By Donald R. Clark

"Drilled shafts are being used as foundation support for parabolic solar troughs at the Genesis Solar Project being constructed near Blythe, California. Three types of drilled shaft foundations are required for the project. At project build-out, there will be a total of 23,008 drilled shafts installed at the site. Preliminary designs for the axial and lateral capacity of the drilled piers were based on conventional geotechnical engineering methodologies and soil-structure interaction. The drilled shafts and subsurface conditions were modeled through the use of the computer program LPILE v6.0.Conducting lateral load testing of drilled shafts was considered appropriate to confirm or modify the geotechnical parameters used in the preliminary design. The lateral load testing program was conducted to provide site-specific test data that would allow the design engineers (both geotechnical and structural) to predict the actual performance and adequacy of the proposed drilled shaft foundations and improve the efficiency and hopefully reduce project costs.The lateral load testing was conducted within two solar fields at the site. Three pairs of drilled shaft foundations were installed in each field, instrumented, and laterally loaded to determine load-deflection response. A value-engineered option, proposed by one of the drilled shaft contractors, was also load tested. The results of the load-deflection data obtained in the field was used to modify the soil modeling used in the original L-PILE analyses and adjust the production drilled shaft lengths.Based on the results of the lateral load testing, the in-situ moduli of the subsurface soils were significantly increased over that assumed in the preliminary analyses. Based on the final soil-structure interaction analyses, the preliminary drilled shaft lengths were reduced by 2 to 2-1/2 feet. This resulted in an overall reduction of 55,654 feet of drilled shaft construction on the entire project, a savings of approximately 16.5% over the preliminary"

Jan 1, 2017

By Donald R. Clark

Drilled shafts are being used as foundation support for parabolic solar troughs at the Genesis Solar Project being constructed near Blythe, California. Three types of drilled shaft foundations are required for the project. At project build-out, there will be a total of 23,008 drilled shafts installed at the site. Preliminary designs for the axial and lateral capacity of the drilled piers were based on conventional geotechnical engineering methodologies and soil-structure interaction. The drilled shafts and subsurface conditions were modeled through the use of the computer program LPILE v6.0. Conducting lateral load testing of drilled shafts was considered appropriate to confirm or modify the geotechnical parameters used in the preliminary design. The lateral load testing program was conducted to provide site-specific test data that would allow the design engineers (both geotechnical and structural) to predict the actual performance and adequacy of the proposed drilled shaft foundations and improve the efficiency and hopefully reduce project costs. The lateral load testing was conducted within two solar fields at the site. Three pairs of drilled shaft foundations were installed in each field, instrumented, and laterally loaded to determine load-deflection response. A value-engineered option, proposed by one of the drilled shaft contractors, was also load tested. The results of the load-deflection data obtained in the field was used to modify the soil modeling used in the original L-PILE analyses and adjust the production drilled shaft lengths. Based on the results of the lateral load testing, the in-situ moduli of the subsurface soils were significantly increased over that assumed in the preliminary analyses. Based on the final soil-structure interaction analyses, the preliminary drilled shaft lengths were reduced by 2 to 2-1/2 feet. This resulted in an overall reduction of 55,654 feet of drilled shaft construction on the entire project, a savings of approximately 16.5% over the preliminary design.

By J Ross

The foundation of effective leadership is communication. You can have all the leadership theories, models and training you want, but in the end it is all about leaders talking to, listening to and understanding the point of view of those below and above them.The foundation of effective safety is peoples’ behaviours. Every incident, every near miss and every safe act comes down to what one person does and how that affects themselves and others. We tend to focus these behavioural considerations on the people at the ‘coal face’, those most in harm’s way. But it is the individual behaviours of everyone in the organisation, particularly those at the top, which are just as (if not more) important. The foundation of effective safety leadership in the mining industry is that it starts at the top, with the individual behaviours of leaders. The behaviours of each and every leader will be reflected in their teams. And where their teams are made up of leaders, these leaders will pass these behaviours on to their teams and so on. It’s the sum total of what people see their leaders do and what they do as a result, that creates the ‘culture’ of the business – and it’s this culture that makes or breaks how safely people work.

Mar 21, 2011

Although Australia is the world's second biggest producer of iron ore, the last few years have not been easy for companies in Western Australia's Pilbara region (see map) where more than 90% of the nation's iron ore is produced. For at least two years, the industry has been plagued by dwindling markets abroad, production-crippling strikes at home, skyrocketing costs (well above the official 13% annual inflation rate), an acute shortage of investment capital, increasingly ferocious competition from foreign iron ore producers-and, as if all this weren't enough, by an over-valued currency that has caused incalculable damage not only to iron ore producers but to the entire mining industry of Australia. (This last problem was mitigated less than two months ago, on November 28, 1976, when the Australian dollar was devalued by a whopping 17 1/2%.)

Jan 1, 1977

By J. K. Gowans

The Research and Design group of the Project Development Division (PDD) of Placer Dome Inc. includes metallurgical, electrical, civil and mechanical engineers. They provide metallurgical research and conceptual flowsheet development, feasibility concepts for the processing and ancillary facilities, and manage the detailed design of the facilities once approval has been given to a mining project. This paper describes how this group works, within the Project Development Division, to help develop feasibility studies with the Evaluations Group, manage detailed design, and provide support for the Construction Group. The paper briefly reviews the history and growth of the group and describes how it is evolving. The role of outside engineering firms and how they are incorporated into the division’s objectives are also discussed. The paper highlights the differences between Placer Dome’s Project Development Division and other mining groups, and why this approach fits the way Placer Dome does business.

Jan 1, 1998

By J M TORLACH

Learning is an iterative process, and we might reasonably expect that after more than a century of mining during an era of sustained technological development, (following a millenium or two of unrelieved hard physical graft), that the more obvious physical hazards could by now be competently managed. It is perhaps a reflection on the perversity of human nature that we have not fully learned our lessons in this exacting environment, and that worse, we have still too often failed to profit by the experience of those lessons. The more obvious underlying factors which impact on this situation are examined briefly, as a prelude to consideration of some outstanding examples of recurrent problems experienced in recent years. Reasons for the continued existence of sub-standard practices are outlined, with a focus on the human element, and finally proposals for appropriate remedial strategies are summarised. This paper therefore seeks to examine and discuss some of our deficiences and to suggest some directions for the way ahead.

Jan 1, 1992

By Oliver Bowles

WAR necessities have spurred inventive genius in many fields. A grinding mill without any moving grinding parts stirs the imagination. Among the new and striking accomplishments in the heterogeneous group of nonmetallic industrial minerals is the use of an electric arc to speed up manyfold the difficult and delicate task of drilling a microscopic hole in a diamond, the hardest of all known substances. Outstanding in the field of optical research is the ability that man has developed to improve upon nature by making in the laboratory optical crystals many times larger than those usually found in rocky crevices. These are merely samples of numerous events and circumstances of noteworthy import, many of which are recorded in this review. Termination of the second World War in 1945 permits an appraisal of the effects of the conflict and the probable effects of the coming restoration of a peacetime economy on the nonmetallic mineral industries. Some industries were stimulated greatly by the war, notably mica, quartz crystal, graphite, spinning asbestos, potash, fluorspar, barite, and refractories. The large-tonnage industries connected with the building trades, however, were forced to curtail their activities, except where their products were needed for wartime construction. Their reconversion to peacetime production will not be difficult.

Jan 1, 1946

By Charles J. Haas

The objective of this research was to investigate the interaction phenomena of rock and types of rock bolts to develop design principals for using grouted roof bolts. The investigation was to determine the effectiveness of grouted bolts in resisting lateral displacement and axial separation along fracture planes, and also to determine if grouted bolts eliminate the axial tensile stress near the anchor and the resulting rock fracture. The first year's effort involved defining the post-tensioning response of grouted bars and determining the amount of shear resistance generated by conventional and resin-grouted bolts. A finite-element analysis showed that if the rock and resin grout behave in an elastic manner, the post tensioning of a grouted bar will affect mine roof stability only if movement occurs near the collar. An experimental shear test program revealed that both conventional bolts and resin-grouted reinforcing bars significantly increase shear resistance along fracture or bedding plane when the average normal compressive stress on that plane is low (in the order of 25 psi) and when the bolt is oriented so that the shear displacement tends to lengthen the bolt. An increase in shear resistance is also noted at the higher normal pressure of 250 psi; however, the increase is small compared to the corresponding shear resistance without a bolt. Conventional bolts oriented so that they tended to loosen with shear displacement added no significant shear resistance.

Jan 1, 1974

By John Marsden

Despite the recent pullback in metal and mineral prices, and the associated market adjustments, the mining industry is still facing a serious issue with the declining availability of graduate expertise. This is due to a combination of an aging workforce, retirements and retrenchments, coupled with a lack of suitably qualified graduates entering the workforce. The issue has certainly improved since 2004 when the industry picked up the rates of hiring graduate engineers and mining/mineral school enrollments picked up in response. This hiring effort has helped to cover the ?gap? years from about 1985-2000, when industry demand for graduates was particularly poor. However, the recent market pullback is likely to set back this progress, as recruitment and hiring wavers as a result of cost cutting measures and economic uncertainty. A key issue for the mining industry is how to ensure the survival and growth of relevant ?core? degree programs. Such programs include mining, metallurgical, mineral processing and geological engineering. The mining industry needs a healthy, high-level education program to ensure an adequate supply of appropriately qualified graduates for the mining industry. Two-thirds of the professionals entering the minerals industry who graduated within the past 40 years graduated prior to 1985. Since 1985, we have been living off the legacy of graduation classes from the mid-1970s and early 1980s. It is estimated that we have been producing graduates at approximately 40 to 50 percent of the sustaining rate since about 1985. Further growth in the domestic industry would increase graduate requirements significantly, and the export of U.S.-graduates to other parts of the world (as is currently occurring) also impacts the total graduate requirements.