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By Ottmar Burghardt

Sintering of iron ore has undergone a dramatic development world-wide. Today, the annual world production amounts to approximately 600 million tons. At present, the sintering process in competition with pelletizing, seems to offer certain advantages inasmuch as it allows the use of solid fuels. Also, its charging behaviour in the blast furnace is, in general, considered as being better than that of pellets. This is true, in particular, for the charging behaviour and the gas permeability in relation to the grain size. Moreover, instead of charging limestone into the blast furnace, for instance, the basic components which are necessary for the burden materials can generally be supplied in a simpler and more cost-effective way by using basic sinter instead of basic pellets. While in sintering, with basicity rising to the range of 1.6 to 1.8 CaO : SiO2, the capacity increases and the sinter quality shows improvements in most of its characteristics, the pro¬duction of basic pellets generally requires a higher fuel rate, when compared to acid pellets, while production capacity decreases and some of the quality characteristics deteriorate.

Jan 1, 1982

By G. Robert Frey

INTRODUCTION This chapter on underground rotary drills briefly describes the equipment features, selection or applica¬tion criteria, safety features, and relative costs of both face and roof drills. After a brief description of the basic components, the application, safety, and cost con¬siderations will be explored. ROTARY DRILL COMPONENTS As illustrated in Fig. 1, an underground rotary drill consists of five basic components. These components are the energy system, chassis, boom, feed assembly, and operator's station. Energy System The energy system of a typical underground drill con¬sists of an electric motor, driving a hydraulic pump or pumps. Usually, the drill is equipped with a cable reel to store the trailing power cable from the portable power center in the mine. A simple control box is supplied to house electrical switchgear and protective devices. In addition to the pump, the hydraulic portion of the energy system includes the hydraulic cylinders, hydraulic tram motors, relief valves, control valves, etc., necessary to actuate the various machine functions. Chassis The chassis provides the frame or support structure for the other four basic components of the drill. Fre¬quently, it incorporates an oil reservoir for the hydraulic system. The chasis provides the support for the trans¬mission, which drives rubber tires or, in the case of some foreign machines, the crawler tracks. The steering link¬age and steering tires also may be considered as parts of the chassis. Boom The boom is the structure that supports the feed assembly; it is either hinged or pivoted on the front of the chassis. Hydraulic cylinders on the boom are used to lift or swing the boom relative to the chassis and to swivel or "roll" the feed assembly. Feed Assembly The feed assembly is made up of the support struc¬ture with an integral thrust mechanism, a rotation unit, centralizers to stabilize the auger, and a hose handling arrangement. In addition, most drills have an extension frame with a tilt device to aid in positioning the feed. Operator's Station The operator's station is the area from which the miner operates the drill. UNDERGROUND ROTARY DRILL APPLICATIONS Underground Face Drills Underground face drills are used in mining opera¬tions that utilize the conventional mining system. The face drill is used to drill holes in the exposed face of the material, and the face is then "shot" by means of explo¬sives or high pressure air. The loose material then is ready for loading and transporting from the face to the preparation plant. Typical specifications for under¬ground face drills are listed in Table 1. Certain parameters should be established as to where the drill is to be used and what is expected of it. To create an awareness of some of the considerations that too often are overlooked, some questions are listed that should be asked in conjunction with the selection or application of the proposed drills. Energy System: Can the drill be supplied with the proper voltage to match the available or proposed elec¬trical power system of the mine? Is the system 250, 460, 500, 550, or 950 v; dc or ac; 3-phase; 60 or 50 Hz? Is the drill equipped with an adequate electric motor to handle the proposed duty cycle? Typical motor power on a single-boom drill would range from 25 to 40 kW (35 to 50 hp); the nominal power for a dual-boom

Jan 1, 1982

By D. A. Lowrie

Environmental concerns and increasing mine development costs have created a need for early information on gold recovery from its host environment. The habit, association, and approximate abundance of minerals which contain unacceptable metallic ions which may be released during process of concentration of gold should be identified in exploration drill core. One case of a "clean" gold orebody is described to show that early petrographic studies contributed to a rapid decision to mine a small deposit by open pit and to custom mill the ore in an already restricted effluent environment. A second example describes identification of an undesirable mercury content and resulting action taken.

Jan 1, 1985

By Terry McNulty

There are many potential pitfalls in the commercialization of innovative technology. The failures often are remembered longer than the successes, thereby serving as deterrents to subsequent attempts. The mineral industry's future depends on effective innovation. So it is essential that the causes of failure are understood. Innovation can be examined equally well in the context of geophysics, geology or mining. However the author's experience has been in mineral processing and chemical engineering. So the following discussion is limited to processes and/or plants for producing mineral concentrates, metals or inorganic chemicals. More of what follows has to do with underachievement or failure than success. But this article demonstrates that there is a strong element of predictability in the former. Furthermore, it is a credit to the minerals industry and to the engineering profession that a very high percentage of projects succeed in achieving design capacity and forecast operating costs. Innovation means the introduction of something new. In this article, the words "innovative technology" are used broadly. They include new processes and novel combinations of established unit operations, as well as novel types of processing equipment or largest-ever equipment models. The discussion of project outcomes is based on personal experience or on published information. Citations are given for technical publications that provide either project information or insights into the methodology used to analyze project performance. However, specific projects have not been identified due to the rather negative connotations of some of the conclusions drawn about the less favorable outcomes.

Jan 1, 1998

By A. Lashgari, V. Kecojevic

This paper presents research on the environmental impact of digging and loading equipment used in surface coal mining. Environmental impact was assessed through the measurement of equipment exhaust and dust emissions, and sound level. In this study, exhaust emission refers to carbon dioxide (CO2), carbon monoxide (CO), nitrogen oxides (NOx), sulfur oxides (SOx) and volatile organic compounds (VOCs). Dust generation refers to fine particles (PM2.5), inhalable particles (PM10) and total suspended particulate matter (TSP). Sound level refers to the sound pressure level at different distances from the equipment. Modeling of the environmental impact of digging and loading equipment was conducted using the Microsoft Visual Studio.NET software package. This research was a part of a broader project involving the development of a software system for the selection of productive, cost-efficient and ecofriendly mining systems, sponsored by the Appalachian Research Initiatives for Environmental Sciences (ARIES). This research may assist mining professionals in quantifying the environmental impact of digging and loading equipment, and developing strategies for reducing the overall impact of such equipment in surface mining.

Jan 1, 2013

By Shawn T. Sorrell

Phillips Coal Company (PCC) submitted the first surface mine permit application under the Office of Surface &lining approved regulatory program of the State of Louisiana. This application for the Oxbow Lignite Surface Mine which is located approximately 64 kilometers (40 miles) southeast of Shreveport, Louisiana was submitted in March 1981. The State of Louisiana Office of Conservation, Surface Mining Division, assigned this application number LSM-1, indicating it is the first one submitted in Louisiana history. The permit area for the Oxbow Mine encompasses 6,251 hectares (15,627 acres). Of this total permit area, 5,862 hectares (14,656 acres) were classified by soil type as prime farmland by the U.S. Soil Conservation Service (SCS). Prime farmland acreage in the permit area became a major central issue in our early planning stages and throughout the permitting process of the Oxbow Mine, due to the magnitude of acreage involved.

Jan 1, 1982

By Alton G. Woody

Like so many installations of its type approaching middle age, the ore processing and shipping facilities in Puerto Ordaz, Venezuela, have taken a lot of twists and turns in their lifetime. The object of this paper is to lead you through these twists and turns and some of the reasoning for them. The need for additional sources of iron are in the United States became evident during the time of the second world war. An exploration team from U. S. Steel located further high quality direct shipping iron are in commercial quantities near Ciudad Bolivar, Venezuela in 1947. Basic decisions were made to develop these reserves for export via the Orinoco River through a new shipping port to be built at the confluence of the Orinoco and Caroni Rivers. The basic concept was for the ore to be loaded directly to ocean going vessels. This was something of a gamble since the basic economics depended upon successfully opening up the main channel of the Orinoco River to deepwater vessels, and the Bethlehem Steel mine in the same area was already working with shallow draft river boats and a transfer station on the coast. Always, the basic philosophy has tended to be to plan with expansion in mind. The original conveyor systems were 1.52 m (60 inches) wide with 200 idlers, whereas 1.07 m (42 inches) or 1.22 m (48 inches) wide conveyors could have carried any production foreseen at the time of installation. Stockpiles have been located and designed with room for expansion. Basic designs have had dotted line future expansion blocked in.

Jan 1, 1978

By Leonard H. Hoyle

The American Society of Association Executives is a professional society composed of nearly 10,000 individuals who serve as salaried executives on the staffs of more than 6,500 associations. Represented is the full range of international, national, regional, state and local associations...including trade associations, professional societies, philanthropic organizations and others. The dramatic growth of ASAE during the past 15 years is a manifestation of the growth of the association movement during the past two decades. This is not to imply that associations are a new phenomenon, because they have existed for thousands of years. Ancient civilizations show evidence of groups formed for mutual protection and advancement. In the transition from ancient to medieval time, trade associations and guilds came to serve an important function for the craftsmen and merchants they represented, encouraging the growth of new industries, improved processes and education.

Jan 1, 1981

By M. S. Celik

Salt-type minerals are usually floated with anionic and cationic collectors. Flotation of a number of systems has been reported to remarkably increase above the concentrations where surface precipitation of collector-metal salt is initiated. Some studies attribute this phenomenon to heterocoagulation of oppositely charged collector colloid and mineral particles. In this study, examples are given on boron minerals to demonstrate that the high flotation region occurs when particles, colloidal precipitates and bubbles acquire a similar charge which induces Van der Waals interactions resulting in hydrophobic bonding.

Jan 1, 1995

By Hans G. Machel

In low-temperature diagenetic environments (0 c T c 60 - 80°C), elemental sulfur forms by six common processes: via (1) inorganic oxidation of H2S by molecular oxygen, (2) inorganic oxidation of H2S by ferric iron compounds, (3) polysulfide disproportion- ation; and via the microbial metabolic actions of (4) colorless sulfur bacteria, (5) colored sulfur bacteria, and (6) some types of thiobacilli. Economically viable deposits of native sulfur usually are formed by only one process: inorganic oxidation of H2S by molecular oxygen. The amount of elemental sulfur is also limited by three common processes that destroy it in low- temperature diagenetic environments: bacterial reduction, bacterial oxidation, and inorganic oxidation. In high-temperature diagenetic environments (80 - 10o°C c T c 150 - 200°C), particularly in sour gas reservoirs, there are seven common processes forming elemental sulfur: (1) SOdH2S reaction, (2) H2S- hydrocarbon reaction, (3) polysulfide disproportionation, (4) catalytic H2S decomposition, (5) C02-H2S reaction, (6) chlorinification, and (7) exsolution of physically dissolved elemental sulfur. Natural processes that destroy or remove elemental sulfur in such settings are hydrocarbon sulfurization, polysulfide formation, and advection. In most sour gas reservoirs, relatively small quantities of elemental sulfur occur as a free phase (solid or liquid). However, elemental sulfur often precipitates in copious amounts from the reservoir fluids via exsolution and polysulfide disproportionation during production of sour gas reservoirs. By extension, elemental sulfur may precipitate from reservoir fluids in relatively large quantities upon uplift and erosion of deep sour gas reservoirs, or from advection of sulfurous fluids into shallower settings via faults or other high-permeability pathways.

Jan 1, 1992

By Murray D. Lester

The relationship between bauxite and energy has two distinct aspects. On the one hand, since virtually all of the bauxite that is mined winds up as aluminum metal, the economic health and future of the bauxite industry and of the bauxite-producing countries depend on the continuing vigour and competitiveness of aluminum against alternative metals and materials. The price of aluminum is, in turn, particularly dependent on the price of energy. Hence, the need for bauxite is ultimately affected by the price of energy. The second aspect relates to location of the bauxite industry. There is no shortage of bauxite resources in the world. For various reasons, as we shall see, there is a growing tendency toward the integration of bauxite mining, bauxite refining and aluminum smelting in those countries that have the resources both of bauxite and of energy necessary to support the entire production chain. Thus, the availability of attractive energy supplies will increasingly favour development of bauxite mining: the traditional export of bauxite as a simple raw material is likely to diminish in relative terms. In short, both the amount of bauxite mined and where this mining will take place are related to energy considerations. Let us first have a brief look at the four basic activities that are involved in our integrated operations: A. The bauxite is mined and moved to an ore plant. This step does not require more than relatively modest amounts of energy normally associated with excavation, loading and shipping of any bulk material. We need about four or five tonnes of bauxite for every tonne of metal produced.

Jan 1, 1984

By H. W. Breathitt

World demand for phosphate rock has increased significantly in the past fifteen years. Prior to the early 1960's, most of the world production was obtained from Florida, North Africa, and Kola. As the 1960's arrived, new mines in North Florida and Eastern North Carolina, as well as expanded production in the Western United States, .increased domestic production. Many new mines overseas have also become significant. This includes countries such as Senegal, Togo, Israel, Spanish Sahara, and Jordan. Limited production, often as by-products, has been noted in South Africa, Brazil, and other countries. In recent years, and even recent months, we have learned of many new areas being considered as potential sources of phosphate rock. This includes Australia, Saudi Arabia, Mexico, Colombia, and Brazil. Many other developing countries have discoveries and are considering their new deposits, often with difficult beneficiation problems, as potential sources of phosphate. These factors all relate to expanded world, population and the demand for more fertilizer products to produce food. In this paper, four areas of the world with different types of phosphate deposits are briefly reviewed to contrast the ore beneficiation problems to Florida procedures--long considered the "standard" of the industry, at least for most of the United States' domestic production. Agrico has three large operating mines in Florida with total production capacity exceeding seven million tons per year. Here, pebble phosphate (+14 mesh material) is produced without the use of flotation, whereas all of the material finer than 14 mesh is subjected to flotation beneficiation to upgrade into high grade concentrates.

Jan 1, 1977

By PDF

The adsorption of ethoxylated sulfonates and nonionics of the same ethoxylation number?on a low-ash coal has been studied. The surfactant adsorption has been investigated as a function of concentration, pH, temperature and ionic strength for three homologues. Zeta potential of coal particles and surface tension of supernatants has been concurrently determined to eludicate the orientation of sudactant molecules on the coal surface as well as the mechanism of adsorption process. The adsorption data are utilized to calculate thermodynamic parameters such as the free energy of adsorption and isoteric heats of adsorption.

Jan 1, 1988

By Rodney R. Krause

In attempting to tell the general public about the coal industry's land reclamation efforts, we have often said, "We're not doing things by the book, because we're still writing it." Like any good catchphrase, the statement is not only striking but true. It is particularly true in the mountains of Appalachia, where the problems of mining; and of reclamation are made more intense by the nature of the terrain. Mining and reclaiming the land "by the book' --which is to say by the methods of contour mining traditionally used in hill country--hasn't worked too well. So a lot of conscientious coal operators and associations are trying new methods--new ways of mining, new machines for seeding and planting, and new species to seed. Not all their experience can be transplanted to other areas, and of course I don't believe that Appalachia is the only place where new methods are being developed. Nevertheless, there's enough action in Appalachia to make a detailed examination rewarding, so let's focus on the hills to see what's new.

Jan 1, 1970

By D. S. Kimbal

The McCoy/Cove mine is located 48 km (30 miles) south of Battle Mountain, Nevada, USA, in the Fish Creek Mountains at an elevation of 1548 m (5080 ft), see Figure 1. Joseph H. McCoy first discovered gold at this location in 1914. This discovery led to the Gold Dome Mine which produced the first gold from this area in 1928. After the Gold Dome era, the land remained relatively dormant until Houston oil and Minerals Corporation purchased the claims from the Summa corporation and defined an ore body at the present day McCoy pit. In 1986 Tenneco Minerals (formerly Houston oil and Minerals corporation), sold the McCoy mine and adjoining claims to Echo Bay Minerals corporation. The Cove ore body was discovered soon after the sale to Echo Bay. Echo Bay expanded the heap leach operation and built the present mill which began processing ore in the fall of 1989.

Jan 1, 1993

By R. L. Russell

Production at Freeport Indonesia's Ertsberg open pit copper/gold mine started in 1972 at a rate of 7500 t/d. Mill throughput remained at that rate for a number of years until the discovery of the Ertsberg East (GBT) orebody. This discovery prompted three successive expansion stages from 1981 to 1988 that boosted production to 20,000 t/d. The discovery of the huge Grasberg porphyry copper deposit in 1988 launched a new era of much larger expansions. The first of these involved installation of a fourth primary mill in 1989 to bring production up to 32,000 t/d and was immediately followed by an expansion of the crushing and screening plant and the addition of a new south concentrator to bring production to 57,000 t/d in 1991. The addition of a primary ball mill and the changeout of the original Denver flotation cells in 1993 has served to optimize current production at a level of 66,000 t/d. A major expansion is now in progress. This includes construction of another new concentrator to house a SAG mill circuit and large Wemco flotation cells in an area created by the removal of 6,000,000t of glacial material. This current expansion, with a planned completion in 1995, will take production to 115,000 t/d. This paper describes the evolution of the Freeport Indonesia (FI) concentrator to-date and will then go into an in-depth discussion of the 66,000 and 115,000 t/d expansions.

Jan 1, 1994

By James P. Ludwig

While we are all aware of the need for reclamation of mine sites, few managers and engineers seem to be aware that good reclamation begins with the earliest plans for mining and processing of ores. Far too often the attitude that reclamation is an add-on to worry about at the end of the mining process dominates the thinking of mine engineers and management, A common result is that the reclamationist can be faced with mining and waste disposal designs that are nearly impossible to deal with effectively from an ecological perspective. Everyone of us has been victimized by the down time and maintainence cost that resulted from the purchase of an outwardly attractive, but poorly designed piece of equipment. When confronted by design defects in equipment, a distraught owner can always trade it in, call a consumer advocate, or follow up one of the "lemon laws" at either the federal or state level. A poorly designed mine for reclamation purposes usually cannot be treated either with ease or cost effectiveness. Good reclamation can be effectively prevented by the designs used when the mine was planned. The purpose of this paper is to share some of the experiences our firm has had with reclamation projects at mines in the Upper Midwest as these were influenced or controlled by mine design decisions. My aim is to sensitize mine planners and managers to planning processes they should consider, and hopefully use, early in the mining process to assure successful reclamation during and after mining. Many of the examples I will cite are from experience gained at the recently closed Jackson County Iron Company taconite operation at Black River Falls, Wisconsin. I am particularly grateful to Mr. Vern Metzger, mine manager at JCIC, for his unflagging support of good reclamation practices, employee training programs (which have included reclamation techniques), and his forebearance to put up with our group of ecologists. I realize that this was a time when there were significant internal and external pressures to cut all costs including reclamation efforts. The collaboration has been successful as you will soon see.

Jan 1, 1984

By D. J. Beeby

California's Surface Mining and Reclamation Act (SMARA) was passed in 1975 to identify and protect mineral resources in areas of high land use conflict and ensure reclamation of mined lands. Under SMARA, aggregate resource availability is quantified and compared to forecasted demand in specific market regions. Fifteen regions studied thus far cover 51,800 km2 (20,000 sq miles) and contain 45 Gt (50 billion st) of high-quality aggregate resources that have been legally designated as "regionally significant," providing a measure of protection previously unavailable. SMARA reports and state testimony at local hearings have supplied objective information and helped reduce conflict in mine permitting decisions.

Jan 1, 1987

By Syd S. Peng

Introduction Modern longwall mining, introduced to the US coal industry in the mid-1960s, is the latest coal mining technique. Today, longwall mining produces more than 15% of all underground coal production. The growth of longwall mining in the US is slow. However, nearly two decades of longwall mining have demonstrated that its benefits outweigh the disadvantages. Longwall Advantages Production and Economics - A typical longwall production ranges mostly from 0.9 to 1.8 kt (1000 to 2000 st) of clean coal per shift. This is about three to six times the production of comparable continuous mining units. Furthermore, there are much less rejects in longwall mining, typically 15% to 25%. It must be noted, however, that a new longwall with an inexperienced crew may produce less, depending on mining conditions. But as experience gains, production increases rapidly. Due to its high production, the cost per ton of coal mined over the mine's lifetime is cheaper with longwall mining than with continuous mining. A study on a conceptual mine of 25 year life using actual operational data (Dangerfield, 1981) concluded that the cost per ton of coal mined is 32% cheaper by longwall than by continuous mining. Another benefit from its high production potential is that it enables the production to be concentrated in a few longwall faces versus many units of continuous mining required to achieve a similar production. As a result, mine organization and management simplify considerably. Safety and Savings - Most US longwalls use shield supports that cover the roof with solid canopy and isolate a gob completely from the face area. Thus, if the supports are properly selected and operated, the potential for roof fall accident is almost zero. Furthermore, it is not unusual that a well-run longwall face is much more orderly and cleaner that most well-run machine shops. The ventilation system for longwall mining is the most ideal type. It is simple and unique. No auxiliary fans are required. The fresh air sweeps through the whole face. Its volume and velocity can be adjusted as demanded. Recovery - In spite of multiple entries layout for US longwall panels, the longwall method recovers up to 40% more coal than the continuous mining method (Dangerfield, 1981). The typical recovery for longwall mining is 70% to 85% versus 45% to 80% for continuous mining. Versatility - Longwall mining has been employed successfully in seam heights ranging from 0.8 to 3.7 m (2.7 to 12 ft); in seam inclinations from horizontal to 35°; in overburden depths from 46 to 914 m (150 to 3000 ft); in single or multiple seam mining; and in uniform or irregular seam characteristics. For seam height less than 1.2 m (4 ft), the plow is used instead of a shearer. However, in spite of recent developments, the plow still is unsuitable for hard coal seams. Slow Acceptance How come longwall mining, with so many advantages, has not spread more rapidly? Undoubtedly, the major reason is the large capital investment required. Under normal market conditions, the capital required for a longwall panel ranges from $7 to $11 million. Another factor is the uncertainty of its applicability to any specific coal seam of interest where longwall has not been used or operated successfully. Although longwall mining elsewhere has proven its applicability to wide-ranging seam conditions, there have been several failures in the past two decades. Analyses of those cases show that most failures can be attributed to inexperience, both operational and technical, including equipment selection. Therefore, personnel training on the longwall mining technique is absolutely necessary before its initial operation. Some earlier statements about adverse surface subsidence associated with longwall mining were misleading. Research has proven that surface subsidence under longwall mining is controllable and predictable. And, if longwall mining was mandatory since the onset of coal mining in the US, there would be no surface subsidence problems over abandoned mined land today. It is a blessing that surface subsidence occurs

Jan 3, 1985

By Connor Meinke, Shaihroz Khan, Kevin Erwin, Rajiv Chandramohan, Muhammad Usman Siddiqui

High-quality sample selection for metallurgical test work is essential to a geometallurgy study, but the large multidimensional dataset makes sample selection a daunting task, as classifying the dataset while respecting its heterogeneity is difficult. This paper presents a streamlined approach for sample selection, utilizing custom-built tools in Python to standardize the methodology, saving time and costs. This approach uses the cumulative sum method, principal component analysis, and k-means clustering method to elegantly cluster the data and select representative samples. A case study is used to demonstrate the effectiveness of the methodology by selecting 40 samples for flotation test work.

Feb 1, 2024