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By Daniel Saramak, Agnieszka Saramak

A big issue in crushing and grinding operations in raw materials handling is high energy consumption and low breakage effectiveness. According to the Legendre [7], only 10% of energy input is directly consumed on the feed material breakage, while the remaining portion is dissipated in the form of heat and noise [8]. In the industry of limestone powder production, the grinding operations constitute integral part of technological circuits, and the energy consumption in operations of industrial comminution consume as high as 2% of world energy [14]. High-pressure grinding is the technology with proved energy benefits both in ore processing circuits and in limestone grinding. The promising results concerned mostly the achieved energy savings and good results of material breakage were achieved and demonstrated in numerous investigations [1,3,12]. However, it appears that a proper selection of operational parameters of the press devise, determination the feed material characteristics and adjustment of process course san be of a key-significance in improving an effectiveness the HPGR operation. Operational parameters of devices and process course should be verified towards the characteristics of the feed material, which mainly applies to the particle size and shape of the feed material and its moisture, and also mineralization in case of ores [2,4,9]. There are various investigations concerning an impact of the operational pressing force on comminution results which mostly refer to the determination of energy consumption and crushing ratio [5,6,10,13]. Investigations on the moisture content are less common, however their results suggest that, in general, the HPGR feed with higher moisture shows the tendency to higher comminution intensity, while the energy consumption increases together with increasing of feed material moisture. Investigations on olivine sand feed [11] showed that crushing ratio decreases for higher moisture, especially when the material is crushed at higher pressing force. HPGR devices, however, shouldn’t be regarded as a unique and perfect solution for comminution of each type of material. But they indeed may bring technological and economic benefits, comparing to conventional crushing and grinding machines, resulting in more favourable breakage of material particles and lower consumption of energy per unit mass of processed feed material.

Feb 1, 2025

By W. Krieglstein

Due to the natural variability of ores, it is necessary to carefully test flotation behavior of flotation cells before designing flotation circuits. For performing quick and versatile tests in the laboratory, Siemens developed a laboratory-size Hybrid Flotation Cell, which has been down-scaled from the 300 m³/h production cell to a 0.6 m³/h flotation cell. This small cell is being used as a test bed for technical and chemical concepts, the improvement of decisive components and the characterization of customer ores. In this study the evaluation results for Andean porphyry copper ores are shown. Total recovery rates of the order of 45 to 50 % have routinely been achieved in a single flotation cycle over a wide range of feed grades. In addition, the Hybrid Flotation Cell has proven to be particularly well suited for the flotation of fine particles below 20 µm down to below 1 µm, at high recovery rates and concentrate grades.

Sep 1, 2012

By L. L. Oden

The Bureau of Mines is conducting research to develop methanation catalysts for converting synthesis gas derived from coal to synthetic natural gas. This report describes a method to prepare supported Raney nickel coatings by dipping screen-covered nickel sheet in molten aluminum-nickel alloy. Coatings were formed at 1,050° C that were comparable in thickness, composition, microstructure, and catalytic properties to flame-sprayed commercially pre-pared Raney nickel. A molten salt comprising cryolite-8 wt-pct LiF was employed over the molten metal bath to clean and preheat the substrates, to protect the metal bath from oxidation, and to heattreat the coated specimens. Immediately following heat treatment, specimens were quenched to 700° C in a molten salt bath containing CaC12-34.5 wt-pct NaCl, which also functioned to remove the insoluble occluded fluoride salt.

Jan 1, 1976

By D. E. Shanks

This U.S. Bureau of Mines (USBM) research simplified an earlier hydrogen chloride (HCI) leach-sparge process developed by the USBM to recover reduction-grade alumina from domestic kaolin clay. Improvements were made by decreasing the initial leaching acid concentration from 25 to 20 pet, decreasing the leaching time from 1 to 2 h to 15 to 30 min, eliminating the solvent extraction step for Fe removal, and eliminating the step to recover the AI content of the bleedstream circuit. A 10-cycle bench-scale experiment of the simplified process showed that the ferric chloride (FeC13) concentration built up to 9.3 g/L in the recycle stream. This did not interfere with any of the unit operations or final alumina product purity because Fe forms stable soluble chloride complexes when sparged with HCI and is easily washed from the large aluminum chloride hexahydrate (ACH) crystals. The reduced leaching time and acid concentration did not decrease Al extraction.

Jan 1, 2010

By A. K. Martin

Adaptive management can be described as a structured, iterative process of robust decision making in the face of uncertainty, with a goal of reducing uncertainty over time through system monitoring. Adaptive management is a tool which can be applied to not only change a system, but learn about the system (Holling, 1978). Adaptive management has been used in ecosystem management for years and guidance is provided in a variety of handbooks and publications. Adaptive management can be applied to industrial facilities and mines through the use of an adaptive environmental management plan (AEMP) and associated practices. The goal of this paper is to provide an explanation of how the plans and practices support regulatory agency approvals and permitting, span the life-cycle of mines, manage uncertainty, and assist in addressing mining impact and legacy issues. AEMPs and associated practices are useful tools to address the uncertainties in identifying, evaluating, and managing impacts of proposed new and modified mining facilities undergoing environmental review. Once a proposed project is approved, the AEMP continues as a living document, being informed, revised, and adapted by the operations. The AEMP can serve as an ongoing management tool for describing and evaluating environmental impacts, continuing in operations into post reclamation. If initiated during planning and environmental review of a project (and in some locations such as the United States [U.S.], the preparation of an Environmental Impact Statement (EIS)), the AEMP becomes a basis to identify, monitor, and manage potential project environmental impacts. Development of an AEMP for an operating mine is also beneficial since there are generally developing and ongoing environmental issues at those facilities as well. Over time, the AEMP is adapted to changing requirements and conditions including those anticipated and unanticipated. Ever increasing scrutiny of mining projects and the complexities of the EIS process highlight the uncertainties inherent in impact predictions. In making the momentous decision of initial project approval, these uncertainties can discourage the regulatory agencies? actions and create stakeholder anxiety and controversy about a project. A well-designed AEMP can support the decision to approve an EIS and enable a project to move forward. Additionally, an AEMP can inform financial assurance estimates and revisions over the life of a mine providing all parties including the citizens of the surrounding communities with greater confidence that potential environmental impacts and risks will be well managed.

Feb 23, 2014

By Peter L. Siems

Humid tropical environments pose many problems for mineral exploration. The problems result from thick lateritic soils, dense vegetation, seasonally heavy rains, deep chemical weathering, few outcrops and thick saprolites. Although geochemical exploration should be potentially a useful technique in these environments, it appears from the scarcity of reports in the literature that insufficient attention has been paid to developing procedures that are specific to the needs of humid tropical areas. For this reason, the authors believe that this account of a geochemical study in a tropical coastal area on the edge of the Brazilian shield is of general interest and importance for potential geochemical exploration surveys in similar areas within the tropics. The objective of the geochemical study was to develop a practical technique of reconnaissance geochemical prospecting for copper deposits in Brazilian tropical coastal lowland areas. In order to achieve this objective, information concerning the secondary dispersion of copper in these areas was required. Consequently, an orientation survey was designed to provide this information. The present account contains details of the geochemical study and the information about the secondary dispersion of copper that was acquired during the course of the orientation survey. Location and Climate The field area is on the Atlantic coastal lowland of Brazil at latitude 13°S. It lies approximately 10 kilometers south of Maragojipe, a city of 15,000 inhabitants; this city is on the western side of the Bay de Todos os Santos about 45 airline kilo¬meters northwest of Salvador. (See Fig. 1) A good gravel road from Sao Felipe to Sao Roque do Paraguay crosses the southern part of the field area. The climate of the area is hot and moist, and is without prolonged dry periods. The mean annual rainfall is about 1600 mm (63 in.) and the greatest precipitation occurs during the winter months of May and June and the summer months of December

Jan 1, 1972

By R. A. Allwes

In-plane bending and torsion tests were conducted on full-scale masonry walls to evaluate three post-reinforcement designs. The designs were developed to minimize longwall mine subsidence damage to existing residential masonry foundations. The bending tests show that vertical and horizontal post tensioned tendons significantly increase the resistance of a masonry wall' to in-plane bending. The torsion tests reveal that post tensioned tendons increase a masonry wall's limit of deformation but do not increase its torsional stiffness. The torsion tests also show that the masonry units minimally contribute to the torsional stiffness of a masonry wall.

Jan 1, 1995

By Q Qu

Reliable prediction of longwall gas emission sources and rate plays a critical role in mine ventilation and methane drainage capacity planning. Over the years, Australian longwall mines have been using the historic Winter method and the Flugge method in modelling specific gas emissions (SGE). The predicted results often experience high discrepancies from the operational reality. To improve gas emission prediction, post-mining gas contents were measured in several mines in Qld and NSW by safely drilling core holes into the longwall goaf. The results revealed many new insights into gas emission characteristics from different coal seams and the drawbacks of the European methods in their use in high-production gassy Australian longwall mines. Based on measurement data, a new, time-dependent gas emission prediction model has been developed. Considering several factors such as caving, desorption and production rate, the new model can predict more accurate and meaningful gas emissions to meet today’s needs in mine gas emission management. A case study is provided to demonstrate the application of the new SGE model.

Oct 12, 2022

Roasting of molybdenite concentrate is an important stage in the production of commercial molybdenum trioxide. The oxidation kinetic and mechanism of molybdenum sulfide concentrates from two plants were investigated at temperatures from 444 °C to 640°C. The rate of reaction was determined for thin layer samples in a muffle furnace at controlled temperatures, oxygen excess and removal of sulfur dioxide. For both concentrates the rate of reaction is fairly slow at temperatures below 500°C and remains fairly constant from 540 to 600 °C. It was observed that the concentrate from the first plant presents a tendency for sintering or glazing at temperatures above 620°C, whereas the same phenomena was observed at 20 or 30 °C higher temperature for the second concentrate. A kinetic model of two reactions, involving the formation of Mo02 as intermediate oxide for the production of Mo03 is proposed and activation energies of 23.0 and 20.8 kJ/mol for the first and second reaction were calculated for temperatures between 520 °C to 600 °C. These low values of activation energies indicate that the overall rate of oxidation is controlled by mass transfer, particularly in a porous layer of oxides. Therefore, the renewal of the surface by mixing and motion of the concentrate layer is of great importance. Sublimation of Mo03 becomes significant for temperatures above 650 °C.

Jan 1, 2007

By E. Siami-Irdemoosa, S. R. Dindarloo

"Pareto analysis was used to investigate the failures database of a Hitachi EX1900 hydraulic shovel over one year of continuous operation. The hydraulic system and hydraulic links, hoses and piping were identified as the most critical system and subsystem, respectively. A three-parameter gamma distribution function was identified as the best fit for a probabilistic modeling of the time between failures (TBFs). This distribution was used in a Monte Carlo reliability analysis of the hydraulic system. Autoregressive integrated moving average (ARIMA), within the context of a time series analysis of the TBFs, was proposed as a viable alternative to the traditional technique of distribution fitting. The mean absolute percentage error (MAPE) metric was used to compare the two models. The MAPE value that resulted from the ARIMA was 66 percent smaller than that from the traditional technique in predicting the TBFs.Resumen ¦ Se usó análisis Pareto para investigar la base de datos de fallas de una pala hidráulica Hitachi EX1900 durante un periodo de un año de operación continua. Se identificó al sistema hidráulico y a los enlaces hidráulicos, mangueras y tuberías como el sistema y subsistema más importantes, respectivamente. Se identificó una función de distribución de tres parámetros gamma como el más apto para un modelado de probabilidades del tiempo transcurrido entre las fallas (Tabes por sus siglas en inglés). Esta distribución fue usada en un análisis de confiabilidad Monte Carlo para un sistema hidráulico. El promedio de movimiento integrado auto-regresivo (ARIMA por sus siglas en inglés), dentro del contexto de análisis de serie temporal de los TBFs, fue propuesto como una alternativa viable a la tradicional técnica de ajuste de distribución. Se usó el porcentaje de la media absoluta de error (MAPE) para comparar los dos modelos. El valor MAPE que resultó de la ARIMA fue 66 por ciento menor que el resultado obtenido con la técnica tradicional de predicción de TBFs."

Jan 1, 2015

By Luiz A. Teixeira

A process is described whereby worn, deffective or crystallized photoconductive Se-As layers can be stripped off from aluminium photocopier drums, using hydrogen peroxide solutions in conditions such that the aluminium substrate is preserved from chemical attack. The process allows the stripped drum to be recoated with a new photoconductive layer, and to be put again in use.

Jan 1, 1990

By Ari Glazer

"Every year the tunneling business is expanding and collaboration with the International Society of City and Regional Planners (ISOCARP) for the future design of cities and urban communities is in the making. During the last half of this century, billions of people migrated to cities, and it is estimated that by 2030 almost five billion people worldwide will reside in urban communities. Hence, “Underground development will be an important tool in reshaping our urban areas to meet the challenges of the future without destroying their heritage or worsening their surface environment” (Esaki, 2005). In 2013, the Organization for Economic Co-operation and Development (OECD) estimated life expectancy to be around 80 years, meaning that in less than a decade we will need to bury billions of people in cities and urban communities, while trying to retain the deceased’s beliefs and customs. Religion plays a major role in our lives, and many people worldwide still decline to cremate their body after their death; therefore, cemeteries are essential for city inhabitants. Rites and traditions usually call for burials to be near the place of residence, which allows the remaining family members and friends to visit the grave frequently, at least in the first years. This is a challenge that urban designers and architects must confront while trying to solve the problems of future urbanization. In recent years, population growth, the rising cost of land and the extensive preservation of green areas have made cemeteries a burden and a nuisance, particularly for large cities and communities. Many graveyards that were once on the city's outskirts have become lifeless islands in populated areas (Fig. 1), rarely visited by the second and later generations. Cities worldwide face the challenge of allocating less land to maintain current burial practices. In response, some cities have begun to bury their dead at a great distance from the community; others have started to stacked burials, one on top of the other, while still others are constructing buildings and even skyscrapers for the practice of burial (Fig. 2)."

Jan 1, 2016

By M. Hitch, M. B. Lytle

Resource development conflicts arise largely due to differences in worldview between those who support and those who oppose development. This paper illustrates how societies and civilizations with different worldviews produce different levels of creative and economic energy. A questionnaire was created to build a database of responses to test whether worldview and resource development are correlated. Factor and multivariate regression analysis determined correlations for respondent groupings. Results showed a positive correlation between the respondents\u2019 worldviews and their attitudes toward resource development. Correlations became stronger as the homogeneity of the sample subgroups increased.

Jan 1, 2017

By Donald I. Kurth

The Bureau of Mines conducted experimental work on comminuting coal. The size distributions of coarse fragments and fine particles were obtained under different modes of energy application--drop, impact crushing, wedge impact, compression, and shear tests. Four levels of energy application were used in the impact crushing and wedge impact tests. Airborne dust and respirable air-borne dust distributions were obtained for the impact crushing and wedge impact tests. Analyses of nonairborne dust and coarse fragment-fine particle distributions were carried out on impact, wedge, compression, and shear tests. The experimental size data on nonairborne dust were fitted to normal, log-normal, power law, Weibull, log-Weibull, and exponential distribution functions. Both the nonairborne dust and the coarse fragment-fine particle size distributions are best described by Weibull distributions. For the impact crushing tests, mean product size was found to be inversely related to specific crushing energy. The particle counts in a given size range of airborne and nonairborne dust were found to increase with increased input energy and specific crushing energy. However, in another sense the particle distributions were independent of energy level; that is, the percent-ages in a given size range were approximately constant regardless of energy level. Respirable airborne dust was related to respirable-size nonairborne dust by a power law.

Jan 1, 1975

By J. Finch, Wei Zhang

In this paper we describe the synthesis of a new homologous series of linear Polyglycol-based frothers that consist of Ethylene Oxide (EO) and hydroxyl as hydrophilic groups and Propylene Oxide (PO) and alkyl chains as hydrophobic groups. The synthesized frothers were of two types: Alkyl-Ethoxy-Propoxylate (abbrev. CnEOlPOm) and Alkyl-Propoxy-Ethoxylate (CnPOmEOl) giving: (a) different number of groups and chain length, and (b) different locations of the groups. The identities were confirmed by proton nuclear magnetic resonance (NMR) spectroscopy and total organic carbon (TOC) analysis. The characterization of the products was carried out in a bubble column. At steady state, bubble size, gas holdup and water overflow rate were measured as a function of frother concentration. The results indicate that increasing number of PO groups led to significant decrease in bubble size, and increase in gas holdup and water overflow rate. Increasing the alkyl chain length, gave similar but less pronounced trends. There was no impact of increasing the number of EO groups on bubble size but there was an in increase in gas holdup and water overflow rate. Changing the location of the PO and EO group had a significant effect on all three parameters.

Jan 1, 2015

By William P. Blake

The salt-beds at Salton, on the line of the Southern Pacific railway, in San Diego county, California, have been successfully worked for many years by the corporation known as the East Liverpool Salt Co., and the salt has been largely used upon the Pacific coast generally and in the interior. But the industry has lately been destroyed by the overflow from the Colorado river. The salt is dissolved, and the waves of the Salton sea now roll 50 ft. above the site of this once thriving and growing business. The salt-bed was evidently the residual accumulation from the waters of an ancient lake, which I have named Cahuilla, from the name by which a large part of the valley—the home of the Cahuilla tribe of Indians—is known. The deposit covered a comparatively small area in the lowest part of the valley, 280 R. or more below the sea-level. This depressed area is now generally known as the Colorado desert, but has a soil of wonderful fertility wherever water can be had on its surface. The deserted beaches, and the water-lines, only a few feet above tide-level, upon the rocks of the bordering mountains, as well as a great abundance of shells in the soil, all bear decisive testimony to the former occupation of the valley by water. The depression is topographically the northern end of the Gulf of California, from which it is now separated by the delta of the Colorado river, extending practically from the mouth of the Gila river across the valley to the coast mountains on the

Jan 1, 1908

By J. W. Cunningham, M. J. Stultzman

THE demand for improved materials for high-temperature service has increased during the last few years. Iron,- nickel,- and cobalt-base alloys have been investigated extensively and many alloys with outs'tanding high-temperature strength have been developed. Considerable research has been directed toward improved methods of processing these alloys. The vacuum furnace as a tool for the purification and improved control of high-temperature alloys has been studied extensively and production units are in operation. The research covered by this paper studied the effects of casting in air, vacuum, or argon upon the elevated-temperature properties of two nickel- and two cobalt-base alloys. The alloys investigated were Stellite 31, He 1049, Udimet 500, and Guy Alloy. MELTING AND CASTING PROCEDURES Two heats of each of the four alloys under investigation were melted and investment cast under the following conditions: 1) Stellite 31 was melted and investment cast in air and in vacuum, with an argon atmosphere for pouring. 2) He 1049 was melted and investment cast in air and in vacuum, with an argon atmosphere for pouring. 3) Udimet 500 was melted and investment cast in vacuum with and without additions of zirconium and boron. 4) Guy Alloy was melted and investment cast in vacuum and in argon. The heats were all melted in induction furnaces equipped with preformed magnesia crucibles of 50-lb capacity. The air-melting furnace was powered by a spark-gap converter of 40 kw capacity. The vacuum-melting furnace was powered by a motor-generator set of 100 kw capacity. The argon heat of Guy alloy was melted in the vacuum melting furnace under an argon atmosphere. Virgin materials were used for preparing all heats except the air heats of Stellite 31 and He 1049. The charge for the air heat of Stellite 31 was a commercial blend of shot. The charge for the air heat of He 1049 was Stellite 6 shot plus those virgin materials necessary to give the desired composition. All of the materials used were of the same grade used com-

Jan 1, 1960

By David Kress

Grinding mills, both autogenous and ball can be powered by several basic means. The three methods used today are girth gear drives, gearless drives and trunnion coupled reducers. This paper will focus on the first of these methods -girth gear drives. The girth gear drive has been used on thousands of mills which continue to operate successfully. These drives are noted for their simplicity and low cost. In the past, the horsepower capacity of girth gears has been slow to keep up with the horsepower increase required by the mill builders, particularly since the advent of the SAG mill. Gear manufacturers had capacity for 2000 HP mills in the 1950's, 5000 HP in the 1960's and 6500 horsepower in the 1970's. The 70's and 80's brought dual pinion girth gear drives which allowed mill sizes beyond 10,000 horsepower. Gear manufactures who could not keep up with the pace of the horsepower demands and the quality and reliability demanded by the mill builders and users have fallen by the wayside.

Jan 1, 1991

By Georgios Kalamaras, Sebastiano Pelizza, Carlo Alessio

"This article describes, through the presentation of five cases-history, technological advances that the Authors together with Tunneling Contractors devised for coping with adverse geotechnical conditions. It is believed that by introducing these new elements in a method that has proven its value in Italy and abroad for the last 40 years, the umbrella arch method, due to its versatility and simplicity, can become a universal method for conventional tunneling in very poor ground conditions. After a description of common faults and mistakes in applying the method, 5 projects are presented which demonstrate that self-drilling pipes give excellent results in terms of performance a zero volume loss, while, function of the ground conditions the various grouting mixtures used, such as expansive jet-injected cement-base grouts and bi-component resins, extend the use of the umbrella-arch in variety of grounds even in presence of water-bearing lenses. The case-histories provide successful applications in different conditions.BASIC FEATURES OF UMBRELLA ARCH METHODThe umbrella arch method provides a short support of the tunnel vault just ahead of the excavation face. The method foresees the drilling and installation of peripheral, sub-horizontal steel pipes in the ground, followed by their grouting. The umbrella arch method is also known as forepoling, steel pipe umbrella, reinforced protective umbrella or simply “umbrella”. The umbrella arch method does not have a static function because the immediate stabilization of tunnel section is entrusted to the internal shell of steel ribs and shotcrete. The “umbrella” provides a pre-support of the excavation which has to be stable for an adequate length and duration permitting the installation of the next steel rib and shotcrete under conditions of safety (Figure 1).The umbrella-arch provides pre-reinforcement of poor ground around the tunnel perimeter in a simple and flexible manner that is adaptable to different ground conditions. In fact, it is possible to vary the number and length of pipes, the distance between them, their diameter and thickness as well as the overlapping length of two succeeding umbrella arches. The versatility of the umbrella arch technique allows its application to: clay deposits, granular alluvial deposits, moraine and debris materials even when containing large blocks, heavily jointed, foliated and tectonically disturbed rock masses."

Jan 1, 2016

By B. Q. Li, S. P. Song

"Numerical models are developed to represent complex electromagnetic, free surface deformation and fluid flow phenomena in floating zone refining processes with radio frequency inductive heating. The computational methodology is based on the coupled finite/boundary element method for the electromagnetic field distribution and the Galerkin finite element method for magnetically driven fluid flow and free surface profiles of the molten zone. With the models, the complex transport and free surface phenomena in a floating zone system can be studied as a function of various operating conditions including applied current, frequency, inductor position and shape, surface tension, floating zone diameter and height. Results show that the equilibrium shape is sensitive to the height of the molten zone and that the free surface shapes can have a significant effect on the melt flow in the molten zone. Our extensive simulations also suggest that to ensure accurate results, the same mesh should be used, whenever possible, for both the electromagnetic forces and fluid flow calculations.1. IntroductionThe floating zone processes have been widely used in the materials industry to grow ultra-pure rare earth metal or semiconductor single crystals for sensor or electronic applications that have a tough demand on purity. Developed based on the principle of magnetic melting/levitation, the processes possess a main advantage that the molten zone is supported in air by the electromagnetic forces generated by the coil (see Figure 1), and therefore is free from contamination from a container. Consequently, the final products made from the floating zone processes have higher inherent purity than those by other techniques [1-4].Complex physical phenomena occur in the floating zone processing of materials. These include free surface deformation, magnetically-driven melt flow, which may be turbulent or mildly turbulent [5] depending on the applied conditions, and solidification. Thermal stresses also develop in the single crystals, which are affected by the flow and temperature field and which can have direct implications to qualities of single crystals [6]. An understanding of the fundamentals governing these physical phenomena can be of critical value in elucidating the physics that controls the properties of the metal or semiconductor crystals being produced, thereby providing a rational basis for process improvement and quality control."

Jan 1, 1997