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By Tiejun Chun, Jian Pan, Deqing Zhu, Vinicius Mendes

"Fine manganese fines are characterized by large amount and low price compared to lump manganese ores. However, fine manganese must be agglomerated as EAF (electric arc furnace) feed. In this paper, high quality fired pellets were produced by simulating grate-kiln process to supply the feed for EAF from some imported manganese ore fines containing high combined water. Manganese ore fines assaying 44.47wt%Mn, 5.89wt%Fe, 12.09%LOI and with 72.7wt% ranging between 0.5mm and 8mm, are pretreated up to the particle size of 84.7wt% passing 0.074mm by HPGR (high press grinding roller) twice in open circuit. The finely ground manganese fines were mixed with 1.2wt% bentonite, balled at 15% moisture for 7min in disc pelletizer. The drop numbers, compressive strength and thermal shock temperature of green balls reach 11 times/0.5m, 11 N/pellet and 360oC, respectively. After the green balls drying in the oven, the dry pellets were preheated at 1050oC for 12 min and then fired at 1300oC for 12 min in electric tube furnace. The compressive strength of fired pellets reaches 2621 N/pellet. Therefore, these pellets are high quality burden for blast furnace or EAF due to high mechanical strength and high Mn grade of 49.11wt% and low detrimental elements.IntroductionManganese, mainly using as deoxidizing agent, desulfurization agent and alloying elements, is widely used in the steel company. With the rapid development of iron and steel industry in China, domestic manganese ores cannot meet the requirement, resulting large quantities manganese ores import to China [1-4]. Compared to lump manganese ores, fine manganese ores containing high combined water are characterized by large amount and low price. However, they must be agglomerated as EAF (electric arc furnace) feed. There are three ways to agglomerate the manganese fine ores, sintering, briquetting and pelletizing [5-6]. Compared to the other two methods, pelletizing technology possesses the following superiorities, such as uniform size distribution of product, stabilizing chemical composition of product and lower energy consumption in producing. Therefore, pelletizing is a superior way to treat the fine manganese ores [7]. The systematic research of producing manganese oxide pellets by fine manganese ores containing high combined water was studied in this paper."

Jan 1, 2011

By G. W. Evatt

This paper presents the scientific framework underpinning the Resource Valuation and Optimisation Model (RVOM). The RVOM is a Real Options software package, which helps mine owners optimally plan their operations, understand their project risks, and make defensible valuations. This is achieved in the presence of both financial and physical uncertainty. The three key outputs from the RVOM are: Valuation, Optimal Decision and Probability of Decision, where a decision can include any combination of: normal operation, expanded operation, care and maintenance, and abandonment (and variants thereof). This paper presents a clear example of the RVOMs usage to a case-study gold mine.

Jan 1, 2011

By Mick Lownds, Ruilin Yang

The potential advantages of electronic detonators with accurate timing have been increasingly recognized by the blasting community. However, in comparative blasts the results with pyrotechnic timing are sometimes comparable to those from electronic timing. Statistical variation in blast results is a plausible cause of these observations.

Jan 1, 2011

By E. Steiakakis, A. Athousaki

Nowadays, stakeholders have a strong say to the enforcement of best practices by mining and quarrying companies. In most cases there is a direct relationship between sustainable development principles and best practices. Mining companies try to apply best practices in order to sustain their operation without lost time and effort to litigation, and other obstacles. However, when and where there is a lack of state or regional mineral policy, or when the mineral policy is fragmented and touching on conflicting laws, mining operations may be subject to additional administrative hassles, and, thus, operators feel threatened and tend to apply best practices loosely. This paper argues that the only way that mining and minerals operations can be a source of development is to ensure that they are working within the framework of sustainable development. Furthermore, in order to follow the paradigm of sustainable development they would need to be guided by a regional, national or even transnational (i.e. European) minerals policy.

Jan 1, 2011

By V. C. Kelessidis

The interaction between rock and drill bit during drilling has been modeled for many years, but a complete understanding of the phenomena occurring has yet to materialize. Successful models will allow the prediction of rate of penetration in a given environment and optimal selection of drill bit and drilling parameters, thus minimizing exploration costs. In most rock-drilling models the value of the unconfined compressive strength of the rock (UCS) is used in the predictive equations, within the concept of specific energy, and the value of UCS is the percentage of the value of the stress applied on the drilling bit in order for the bit to advance. While the exact percentage depends on the model used and it is not known with certainty, good knowledge of UCS is nevertheless required before any decent prediction can be made on rate of penetration. Determination of UCS, normally done via destructive testing, requires not only the availability of sound rock core samples but also expensive testing and significant time for the test, which frequently are not available for routine drillability predictions. Hence, a multitude of methods and techniques has been proposed for estimating UCS from various indirect and/or non-destructive measurements, or combination of measurements with neural networks, such as point load index, block punch index, unit weight, and apparent porosity, water absorption by weight, sonic velocity, and Schmidt hardness. The many proposed approaches are critically reviewed and the results are compared, and what becomes apparent is that after many years, not only in mining but also in oil-well drilling, accurate indirect determination of UCS is still an elusive goal. An equation to predict UCS from sonic velocity data is suggested based on several data sets reported in the literature. Use of the specific energy equation with UCS or sonic data and utilization of drilling data allows an estimation of the efficiency of energy transfer from the bit to the rock and of the friction coefficient. Analysis of data reported in the literature, both from laboratory and field studies, has shown that this approach is sound and enables the determination of energy transfer efficiencies and friction coefficients, which for the cases studied range between 15 and 30% and 0.15 and 0.30 respectively. Thus, the suggested data analysis approach allows drillers to focus on inefficiencies and optimize drilling practices in future campaigns. Keywords Rock drillability, unconfined compressive strength, prediction.

Jan 1, 2011

By Andre Thess, Jurij Kolesnikov, Christian Karcher

"During the motion of molten metal under external non-homogeneous magnetic field the induced electric currents produce Lorentz body forces in the opposite direction to the flow, causing deformation of velocity profile, vortical structures, and adding a pressure drop across the magnetic field. The same Lorentz force acts on the magnet system. We analyse these phenomena in metallurgy, namely, at molten metal pumping, stirring, continuous casting, and in contactless Lorentz force flowmeter (LFF). Experiments with liquid metal alloy, including direct measurements of Lorentz forces, velocities, and flow structure visualization were conducted. Based on this study the industrial prototypes of LFF systems were designed, built, and tested in a secondary aluminium production. A molten metal flow at high temperature (700°C-850°C) can be effectively measured. The LFF technique method allows measuring precisely the volumetric and mass flow rates linked with Lorentz force, and the mass accumulated within production process.IntroductionThe present work demonstrates the development of a non-contact electromagnetic system for measurement of a liquid metal flow. Our approach embodies the Lorentz force velocimetry [1-6] technique which is physically based on a measurement of the force acting on an external magnet system the field of which interacts with the flow. This force is exactly equal to the braking Lorentz force induced in a flowing conducting fluid. In what follows a measurement system based on the Lorentz force velocimetry principle. For monitoring and controlling the production process it is desirable to measure continuously the mean velocity of the liquid metal in order to deduce the mass-flux and volume-flux from it. The form and dimensions of the magnet system are in agreement with geometry of the operating channel. We consider here a version of magnet systems in a composition of permanent magnets.The LFF possesses a number of advantages which make it attractive for the measurement of flows in hot and aggressive melts. The relation between the measured force and the desired volumetric flow rate is often linear (for closed channel or at a constant liquid metal level in open channel). For the converting of the measured force into volumetric and mass flow rate we should know the calibration factor. The calibration factor is independent of the viscosity and density of the liquid metal and depends only on the magnetic field magnitude, the electrical conductivity of the liquid metal and the geometry of the channel in which the liquid metal flows. In aluminium production, for instance, there exists a number of standard alloy compositions having welldefined conductivities for which the calibration factors can thus be tabulated. We consider below consistently effects in liquid metals arising under influencing magnetic field, construction principle of LFF and measurements of metal flows at industrial conditions."

Jan 1, 2011

Large quantities of combustible materials are often found in underground metal and nonmetal mines, with support timber most often the predominant combustible material. Oils, lubricants, paper, cartons, and rags are additional combustible materials and are commonly found in maintenance shop areas. Welding and cuting, shorted or overloaded electrical cables, spontaneous combustion, and careless smoking are some of the common fire ignition sources. Inexpensive, reliable fire detection and suppression systems are available to provide early warning of such fires and to isolate and extinguish fires that originate in underground maintenance shop areas. Technology developed and demonstrated under Bureau of Mines Contract H024216, Mine Shaft Fire and Smoke Protection System, may be applied to protect underground maintenance shop areas. The mine area described in this report is a representative ex-ample only; the fire protection system described considers costs, benefits, equipment performance and includes the concepts of: ? Early warning and alarm ? Isolation ? Extinguishment ? Control. Each fire protection system application requires analysis of numerous variables including total mine profile (depth, personnel, escape routes, hazards, etc.).

Jan 1, 2011

By Ahmet Haxhiaj, Jaroslaw Drelich

"Both composition and porosity of pellets are the main parameters influencing the reductive melting process in water-jacket furnace during the roasting of sulfide lead concentrate. Roasting in a smelter located in Trepçë is done at about 9000C, for pellets which are composed of PbS, CaCO3, Fe2O3, and SiO2. In order to faciltiate the formation of slag in the reductive melting, the pellets must have the proper content of CaO, SiO2, and FeO, and porosity. The plant’s practice indicates that pellets with porosity of 18% do not melt adequately in the water-jacket furnace. The optimum porosity for the proper melting of pellets needs to be 32-40% and can be achieved when pellets are loaded with more than 10 wt.% CaO. Pellets with less than 10% CaO have a limited network of pores, such that reactive gases cannot reach the entire ore structure. Also, the composition of the pellets must satisfy the ratio of CaO : SiO2 : FeO = 1 : 1.2 : 1.8 to facilitate the formation of slag in the reductive melting process.IntroductionAgglomeration roasting of sulfide lead concentrate is an important phase in the production of lead by reductive melting [1-6]. The reductive melting process is a complex process with contradictory effects of several technological indexes which many times are hard to measure and determine. In this process, loading the water-jacket furnace with pellets of optimized composition and structure can reduce the consumption of coke, and achieve high level of lead recovery. Pellets (agglomerates) should be porous, but at the same time they should have necessary mechanical strength. ‘Self-melting’ ability of pellets is controlled by the types and quantities of fluxes blended into the pellet composition. Three major additives and their role are:"

Jan 1, 2011

In early March 2011, a 6.2 m (20.3 ft) diameter Rob-bins Double Shield tunnel boring machine (TBM) crossed the finish line in Sochi, Russia. The machine completed a 4.5-km- (2.8-mile-) long section of tunnel that will ultimately become part of the transportation infrastructure for the 2014 Winter Olympic Games. The TBM advanced through difficult ground at aver-age rates of 100 to 120 m/week (330 to 390 ftpw) for contractor OJSC Bamtonnelstroy, a division of the SK Most Company. The section of tunnel will ultimately become a service tunnel for Complex #3 - a section of Sochi?s transportation infrastructure under construction, which includes road and rail tunnels. A second, 10 m (32.8 ft) diameter Robbins Double Shield TBM is currently excavating the parallel 4.6-km- (2.9-mile-) long main railway tunnel using a continuous conveyor system for efficient muck removal. A 13.2 m (43.3 ft) diameter highway tunnel is also under construction. The 6.2 m (20.3 ft) Robbins TBM achieved high rates despite difficult conditions. The tunnels run through mixed ground including massive to completely fractured limestone with clay seams. Some sedimentary rock including sandstone and siltstone is present, along with fault zones consisting of breccias and conglomerates. In May 2010, the machine was stopped after encountering a significant fault zone consisting of broken rock and running soft ground. Field service personnel and crew successfully freed the machine by excavating a bypass tunnel around the TBM, freeing the cutterhead. Following the restart, a combination of continuous probe drilling and ground treatment with cement silicate and foam kept the machine moving forward.

Jan 1, 2011

By Thomas L. Ochs

The stripping of iron-laden solvent with hydrochloric acid in the iron-removal step of the clay-hydrochloric acid process for the extraction of alumina from calcined kaolinitic clay results in a loaded ferric chloride stripping liquor. Treatment of this stripping liquor at boiling with calcined kaolin to form insoluble Fe203(s) and a dilute A1C13 solution was undertaken by the Bureau of Mines to characterize process problems and to aid in sizing of solids-liquid separation equipment. Variables identified as important in the chemical reaction were calcined kaolin particle size, ratio of calcined kaolin to FeC13, and reaction time. These parameters were tested for significance and their interactions investigated. Fine calcined kaolin (-65 mesh) at a greater than 1:1 mole ratio of contained acid-soluble A1203 to Fe203 equivalent of the FeC13 in the stripping liquor required less reaction time than coarser (-16 mesh) material. Solids-liquid separation of the reacted slurries by both settling and filtration requires flocculation.

Jan 1, 2011

By K. M. Kim, J. B. Kemeny

A case study was conducted with 5 shots with varying pre-blast block sizes and explosive energies. From this case study a site-specific predictive fragmentation model was developed. There are two main innovations in this study. One is using an image analysis program (Split-Desktop 3.0) on the bench face to obtain the pre-blast block size (F80) quickly and consistently. Another innovation is to utilize the Schmidt Hammer Hardness (SHH) to estimate intact rock strength.

Jan 1, 2011

By Michael Twomey, Alastair Torrance, Alan Twomey

Low density explosives have been available in various forms for nearly 20 years. These initially consisted of various diluted forms of ANFO formulated to slow the rate of reaction. One such product that was developed was a blend of ammonium nitrate and rubber. This product uses a coarse fuel provided by granulated rubber to slow the reaction rate of the explosive rather than being a diluted form of ANFO. There has always been a technical difficulty in blending two dissimilar materials without subsequent segregation.

Jan 1, 2011

By P D. Katsabanis, S Kim

A number of small scale fragmentation tests have been conducted to analyze the effects of blasting effort on the grindability of granite, granodiorite, limestone and iron ore. Powder factors were modified, post-blast fragments were screened and drop weight tests were conducted on fragments of different sizes to deliver a variety of specific impact energies. The fragmentation from the drop weight tests has been analyzed to examine the effect of impact energy and powder factor on size reduction. A consistent effect of blasting on the various fractions of the fragmentation distribution has been obtained for all rocks used. The effect of powder factor on the impact fracturing of the rocks has been expressed in a convenient relationship between progeny size, impact energy and powder factor used in obtaining the primary fragmentation. It is clear that explosives consumption affects downstream size reduction; depending on the rock, the effect can be substantial at coarser final sizes but very small in the case of grinding to small final sizes. Differences from the expected trend can be attributed to changes in blast design. As an example, the effect of in-hole collision of detonation waves is analyzed.

Jan 1, 2011

By Jesús E. Gómez

In the Summer of 2011, emergency repairs to the Jefferson Memorial North Plaza and Seawall were completed. These repairs were necessitated by settlement and lateral movement of the seawall and North Plaza which prompted the National Park Service (NPS) to initiate an investigation as to the possible causes of the movement, and commission a design for its mitigation. Information gathered from extensive instrumentation on site led to the design of a movement mitigation scheme that included demolition of the Ashlar Seawall and reconstruction of a new seawall. The new seawall foundation is an A-Wall consisting of vertical caissons and battered pipe piles connected to the seawall itself. The scheme provides resistance to future vertical and lateral movement of the North Plaza and the new seawall. Repair to the seawall and plaza began in December 2009, and was completed in August 2011. This paper discusses the mechanisms believed to be responsible for settlement and lateral movement, summarizes the procedure followed for design of the mitigation, and describes the construction methods and some challenges faced during the repair.

Jan 1, 2011

By Yuanbo Zhang, Qian Li, Helei Zhang, Heng Yu, Guanghui Li, Tao Jiang

"Large reserves of specularite iron ores have been found all over the world, which is characterized by high total iron grade, low gangues content, as well as low commercial price. However, it has not been widely used in sinter or pellet production due to its inferior sintering and roasting behaviors. It has shown that the proportion of specularite ores was increased as high as 40%~50% and good results was achieveed by using Composite Agglomeration Process (CAP), an innovative agglomeration process invented by Central South University. But the mineralization of specularite is still unknown during composite agglomeration processing. In this paper, the induration characteristic of specularite ore is studied by simulating CAP in laboratory, as well as microstructure analysis of CAP product. The results show that specularite pellet is mainly indurated through recrystallization of Fe2O3, calcium ferrite within high basicity sinters matrix interweaves with the recrystallized Fe2O3 on the surface of the pellet, which forms an integral microstructure, and ensures high strength of CAP product for ironmaking.IntroductionLarge reserves of specularite iron ores have been found all over the world, especially in Minas Gerais of Brazil, Xuanhua city and Anshan city of China, Elba island of Italy, St.Gotthard of Switzerland, Cumberland of Britannic, and so on. The specularite ores have a smooth surface, as well as a good crystallization and dense texture. When specularite is used to produce pellets, the specularite ore grains are difficult to adhere onto green ball due to its poor ballability. Moreover, specularite pellet requires high roasting temperature over 1300°C [1]. When specularite ore is used in sintering, the permeability of sintering bed gets bad and the quality of sinter is diminished. The practice in a few sintering plants finds that the output and strength of sinter decrease with the increase of specularite proportion, and the consumption of coke increases [2-4]. Therefore, the utilization of specularite has been limited. Composite Agglomeration Process (CAP) is an innovative technology invented by Central South University [5-7]. The process has the following merits: making reasonable utilization of different iron ore resources; improving the quality and output of sinters; manufacturing sinters with low basicity; significantly reducing energy consumption, etc[8-9]. It has been shown that large proportion specularite ores, as high as 40%~50% can be used well by CAP [10], but the mineralization of specularite pellet is still unknown during composite agglomeration processing. In this investigation, the induration characteristics of specularite ore pellets is studied by simulating CAP in laboratory, and the phase composition and microstructure of CAP product are also characterized by using microscope and Leica image analyzer (Germany, Leica DM RXp)."

Jan 1, 2011

By W. L. Saunders

RBH Note: In the early days of drill & blast tunneling the jobs utilized large crews of drillers and muckers. Advance per round was limited (typically around four feet) but two rounds per 8-hour shift were expected, around the clock. The scene after a shot must have been chaos, with the muckers expected to quickly make space for the drill setup. Makes one wonder how much time was allowed for the smoke and fumes to clear. Note the headgear of the tunnelers.

Jan 1, 2011

By Wanderson Silva Rodrigues, Paulo Adão Marinho dos Santos, José Antonio Silva Souza, Luis Alves Venancio, Emanuel Negrão Macedo

"1 AbstractThe production of alumina from bauxite using the Bayer process generates 0.7 to 2.0 ton of the residue known as red mud per ton of alumina. This material has no large scale current use and is usually stored. This paper shows that it can be used in a suspension with water as a gas effluent cleaner with high efficiency to remove SO2. It can substitute other materials currently used reducing the overall environmental impact and potentially reducing the cost of gas treatment.2 IntroductionThe production of millions of tons per year of alumina around the world generates from 0.7 to 2.0 ton of the residue known as red mud per ton of alumina. The vast majority of the red mud is stored in large sealed lakes. Due to the high reactivity this material is considered dangerous and currently there is no operating process capable of reuse all the material produced at any refinery. These lakes after filled of solid material eventually have the surface revegetated. In any cases they will remain as an environmental passive and need monitoring for decades. The search of industrial processes that combine the cleaning of gas effluents emission and reuse of these residues can contribute to the reduction of the overall impact of the alumina production process.The main objective of this work is to study the efficiency of the red mud as alternative raw material for the control of emissions of SO2 in combustion gases. Usually this is made through alkaline solutions of CaCO3 or NaOH in absorbing equipments like spray towers or packed column. This project main objective is to study the reaction of the SO2 with a suspension of red mud and water in order to obtain the basic parameters to design equipment capable of process this reaction on a pilot scale. With that goal compositions of red mud on spray were processed with flow of gas containing SO2 with concentration similar to the exhaust gases of the combustion process of the refineries."

Jan 1, 2011

By A. Allaire, J. Torrealba-Vargas, R. Welyhorsky

Early testwork was carried out to select the plant process design criteria and flowsheet selection. Additional testwork was carried out during the feasibility study to support the optimization of the plant design criteria. The test results showed that the recovery of gold was not very sensitive to grind size in the range of 75 to 105 microns. An additional result was that the presence of lead nitrate did not improve the kinetics of gold leaching. This conclusion was supported by the low content of sulphides in the ore. It was also found that the presence of lead nitrate increased copper dissolution, producing the potential for an increase of copper reporting to electrowinning, which is detrimental to the overall gold recovery process. The use of oxygen in leaching was investigated to increase leach kinetics. The results of leaching tests to compare using oxygen instead of air indicated that, due to the improved leach time, it was possible to reduce the number of leaching tanks from twenty four (24) to twenty (20).

Jan 1, 2011

By R. Moss

Gold and silver are important byproducts of mining volcanogenic massive sulfide (VMS) deposits. Both metals occur in VMS deposits ranging in age from the Archean to the currently forming massive sulfides found on the ocean floor. The gold- and silver-rich deposits on the modern seafloor are geographically diverse and occur in several different tectonic settings (Figure 1a,b) including seamounts (e.g. Franklin Seamount, Papua New Guinea), unsedimented mid ocean ridges (e.g. TAG and Snakepit, Mid Atlantic Ridge), sedimented mid ocean ridges (e.g. Escanaba Trough) and back-arc basins (e.g. Manus Basin, Papua New Guinea). Interestingly, the most gold- and silver-rich deposits are found in the back-arc basins of the western Pacific, commonly associated with differentiated volcanic rocks such as the dacite-rhyodacite suite at PACMANUS in the eastern Manus Basin. This suggests that different, or more efficient, mechanisms are concentrating precious metals in such back-arc settings. Such mechanisms may include leaching of volcanics enriched in gold (e.g. rifted arc crust) or silver (e.g. continental crust) and/or the introduction of gold into a hydrothermal system by a magmatic fluid. The gold content of modern seafloor precipitates varies from a few ppb up to a high of 54 ppm reported from eastern Manus Basin (1). The Jade Deposit in the Okinawa Trough has the highest silver contents with values up to 1.1% (2). Both gold and silver are preferentially concentrated in late-stage, low temperature precipitates with zinc-rich assemblages being favoured in most cases. Gold is found as relatively pure native gold and sub-microscopic inclusions in gold-rich deposits, but occurs predominantly as sub-microscopic inclusions and possibly as solid solution in the gold-poor deposits (3). Silver occurs as rare silver minerals such as acanthite and native silver in the silver rich Jade deposit (2), but more commonly in the silver-containing minerals tetrahedrite and tennantite, as is the case in the PACMANUS deposit. Tetrahedrite is also known to be an important host of silver in ancient VMS deposits (4). More abundant sulfides can contribute significantly to the silver balance. In the silver-poor deposits at 21 N East Pacific Rise, silver is contained entirely within chalcopyrite, isocubanite, pyrite, marcasite, sphalerite/wurtzite and galena. In this case silver may be present as sub-microscopic inclusions of silver minerals or in solid solution.

Jan 1, 2011

By H. Edinger

China?s engagement with the African continent has increased impressively in the past decade. Even though China is not the African continent?s largest stakeholder, the rapidly increasing engagement is evident in the huge number of Chinese migrants that have come to Africa in the wake of unprecedented trade and investment levels, as well as in increasing diplomatic and political interactions, which has taken most other commercial partners by surprise. All but four countries in Africa have adopted the ?One China?1 policy stance; and in so doing opened the door for new or strengthened commercial dealings with China, including increasing investments into Africa?s extractive industries. This has been particularly evident since the turn of the century, with a clear shift in China?s policy towards Africa elevating the continent in China?s foreign policy objectives. As such, Africa has become a strategic focus2 for Chinese outward bound and internationalizing companies, especially in the extractive industries. This planned shift in focus is based largely on geo-strategic and commercial needs and interests, rather than previous ideological ones.3

Jan 1, 2011