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By Bob Miller

"All industries have parts and equipment that are exposed to some type of destructive wear. Hardfacing is a cost-effective tool that will minimize wear and increase service life. At first glance, hardfacing can be confusing and troublesome. In reality, it is not.Postle Industries, a manufacturer of hardfacing products, has found that the 22 answers to frequently asked questions may help operators select hardfacing products that are most appropriate for their application. The first 10 questions are addressed in these pages, the full list can seen at Mining Engineering online under the Web-Only Content section.1. What is hardfacing?Metal parts often fail their intended use not because they fracture, but because they wear by abrasion, impact, metal-to-metal contact or some other form of wear, which causes the parts to lose dimension and functionality. Hardfacing, also known as hard surfacing, is the application of a buildup or wear-resistant weld metal onto a part’s surface by means of welding to extend the life of the part. The weld metal may be applied as a solid surface or in a pattern, such as a waffle pattern, herringbone or dot pattern, etc.Hardfacing is becoming increasingly important for many industries to protect equipment that is exposed to wear and abrasion including parts used in mining, earthmoving and construction, oil and gas drilling and steel making and forging. Extending the life of wear parts can save thousands of dollars and improve productivity. Hardfacing can be used to recondition parts that have already been exposed to wear and have lost their useful life, or used in the manufacture of new parts to improve their life before they are put into service.There are three main types of hardfacing applications:• Build-up or rebuilding.• Hardfacing or overlay.• A combination of build-up and overlay.2. What base metals can be hardfaced?Carbon and low-alloy steels with carbon contents of less than 1 percent can be hardfaced. Medium carbon and low-alloy steels are very common since they provide higher strength than mild steels and better abrasion resistance. High carbon alloys may require a special buffer layer.The following base metals can be hardfaced:• Stainless steels.• Manganese steels.• Carbon and alloy steels.• Cast irons.• Nickel-base alloys.• Copper-base alloys."

Aug 1, 2016

By John H. Canterford

The adsorption of uranium onto Wyoming bentonite was measured in carbonate media over the range pH 8-11. Uranium was removed from solution onto the solids by a rapid reaction, proposed to be adsorption of the anionic uranyl tricarbonato complex onto edges of the clay platelets, and a slow reaction which may be precipitation of a hydroxide. The changes in uranium content of the aqueous and solid phases of a uranium ore carbonate leach slurry were also measured as the slurry was progressively diluted. There was an increase in the uranium content of the solids as the pH of the suspension was lowered, as was observed with the Wyoming bentonite. The results indicate the conditions that should be met with respect to pH control in order to prevent the problem of excessive uranium adsorption in the counter-current decantation washing circuit of a conventional leaching process, as well as in the leaching and restoration phases of carbonate solution mining.

Jan 1, 1983

By T. Sun, J. Kou, D. Tao

"The reduction behavior of low-grade lump hematite ore (100% 20-50 mm) has been evaluated by performing a series of coal-based direct reduction roasting tests followed by magnetic separation under different process conditions such as roasting time, temperature, reductant type and dosage, and grinding stage. To investigate mineralogical transformation and reduction characteristics of lump hematite ore, roasted ores and magnetic concentrates were analyzed by X-ray diffraction (XRD), scanning electron microscopy (SEM) with energy dispersive spectrometer (EDS) and polarizing microscope. The results have shown that a magnetic concentrate with a total iron (TFe) grade of 90.7% was produced at an iron recovery of 83.9% when lump hematite ore was reduced at 1,200° C for five hours using 35% lignite as a reductant followed by two stages of grinding, for 20 min and 30 min each, and low-intensity magnetic separation. The degree of reduction is closely related to the change in the internal structure of the roasted ore. Lignite with a higher fixed carbon content and lower ash generated roasted ore with a more highly porous structure, which provides better permeability of reducing gas. Magnetite, fayalite and wustite were the dominant intermediates of coal-based direct reduction of lump hematite ore. Parts of wustite reacted with SiO2 or Al2O3 in gangue and generated fayalite or hercynite. FeO in fayalite was replaced by CaO to produce wustite, which was finally reduced to metallic iron. However, Fe in fayalite and hercynite produced with low contents of CaO cannot be reduced into metallic iron. Introduction Low-grade hematite ore, characterized by low Fe content and high SiO2 content, cannot be treated by traditional mineral processing methods due to its nonmagnetic property and fine liberation size. The direct reduction (DR) roasting process has been studied and proven satisfactory in treating difficult-toprocess ores, such as low-grade nickel laterite oxide ore (O’Connor et al., 2006; Cao et al., 2010; Guo et al., 2011), high phosphorus oolitic hematite ore (Li et al., 2012; Yu et al., 2013), low-grade hematite ore (Wei et al., 2013;) and iron ore tailings (Li et al., 2010), which greatly expand the resources of usable iron ores (Srivastava and Kawatra, 2009). Therefore, the use of a DR process to treat low-grade hematite ore to produce direct reduced iron (DRI) is of great interest to many researchers of mineral processing and metallurgy (Weissberger et al., 1986)."

Jan 1, 2015

By Peter Johnson, David Barber, Lachlan Henderson

"The traditional approach to rail tunnel fire safety design is to follow NFPA 130, which assumes a major tunnel fire could occur and requires bi-directional emergency ventilation. There is no regard to the impact of ventilation on fire growth and smoke production. In Europe and other parts of the world, the need for tunnel ventilation systems to provide smoke management in the event of fire is being questioned. The European Commission’s Safety in Railway Tunnels TSI is based on a philosophy that improved running capability (preventing fires and other events stopping the train in the tunnel) and elevated fire performance of materials means the chances of a major fire in a tunnel is highly unlikely, with only small fires expected, and no tunnel ventilation required. This approach is reinforced by the International Tunneling Association which has recently published an Engineering Methodology for Performance Based Fire Safety Design on Underground Rail Systems, which includes a methodology that does not require assessment of tenability in tunnels, but requires a scenario based risk assessment to be undertaken to determine overall fire safety measures. Recent research by the University of Edinburgh has shown that forced airflow from a mechanical ventilation system may promote fire growth and increase smoke volumes much more than with natural ventilation. Whilst the concept of no mechanical ventilation (i.e. natural ventilation) is a new concept for some, for many rail tunnels it is worthy of serious further consideration. RAIL TUNNEL SMOKE MANAGEMENT AND STANDARDS Smoke management using mechanical bi-directional ventilation systems has been a central part of the fire safety design solution under NFPA 130 for rail tunnels since 1982. The current version of the standard, NFPA 130: 2014, states that mechanical ventilation should be fitted to rail tunnels of length greater than 305 meters and an engineering analysis should be undertaken for tunnels of length 61 to 305 meters to determine whether mechanical ventilation should be fitted. However, this approach is not necessarily reflected elsewhere in the world. In Europe in particular, mechanical ventilation systems for smoke control within rail tunnels have taken a much less central role within the standards framework."

Jan 1, 2016

The 28th annual American Mining Hall of Fame Awards Banquet and fundraiser sponsored by the Mining Foundation of the Southwest will be held at the Marriott University Park Hotel, Tucson, AZ on Saturday, Dec. 4, 2010. The Mining Foundation of the Southwest is a nonprofit organization whose objectives are public education about the mineral industries, and recognition of outstanding accomplishments in and contributions to the fields of mineral and fuel resources. Funds are being raised to the support the foundation?s educational programs. Among these is the Educational Outreach Program operated jointly by the foundation and the Arizona Department of Mines and Mineral Resources.

Jan 1, 2010

By Florian Häckel, Ulrich Schwarz-Schampera, Benjamin Bühring, Katja Schmidt, Dieter Garbe-Schönberg, KoschinskyM Andrea

"The Vanuatu island arc and its adjacent back-arc basins form part of the southern New Hebrides subduction system in the southwestern Pacific Ocean within a triangle defined by the Solomon Islands, New Caledonia and Fiji (Meffre & Crawford 2001). The back-arc region east of the volcanic front is characterized by three structural depressions namely Vate, Erromango, and Futuna (from N to S), also known as the Coriolis Troughs. Earlier studies of lava compositions reveal the occurrence of highly evolved alkali-rich dacites as well as ankaramite basalts within the individual troughs (McConachy et al. 2005).Here we present the first mineralogical and geochemical analyses of hydrothermal fluids and precipitates (sulfides, sulfates, Fe-oxyhydroxides), sediments, and volcanic rocks, sampled during the "Coriolis Volcanism and Vents" (COVOLVE) cruise SO229 in July 2013 aboard the German R/V Sonne. The samples were retrieved during several ROV Kiel 6000 dives directly from the newly discovered active vent sites at the neovolcanic Nifonea Ridge, and from multiple sites at water depths ranging between 200 to 2800 m within the Vate and Futuna Troughs as well as from the shallow water Epi Caldera NNE of the Coriolis Troughs (Fig. 1)."

Sep 1, 2014

The Putnam Coal Mine, at design capacity, will be the third largest underground bituminous coal mine in the world and will feature the world's longest single flight belt conveyor. Construction is now in process; initial mining will commence in early 1969 and design capacity will be reached in 1971. I'm Jerry Workman, Assistant Mining Manager for the Coal Group of the Mining and Metals Division of Union Carbide Corporation, and I am acting as Project Manager for installation and start-up of the Putnam Mine. The Putnam Coal Mine reserves are located in south-central West Virginia and contain approximately 27,000 acres of prime Pittsburgh No. 8 coal; reserves are sufficient to support a 3.5 MM tons per year operation for over 30 years. The mine portal area is located some six miles inland from the Kanawha River. The river loading facility is located approximately 156 miles by way of river from the market.

Jan 1, 1968

By John B. Gustavson

This paper describes a case history of geochemical prospecting. An area of known mineralization was available for an orientation survey which led to the selection of elements and criteria for a reconnaissance survey in the area offsetting the known mineralization. Certain anomalies were found which were then made subject of confirmation sampling and of rock geochemical investigations. Inasmuch as the geochemical prospecting technique specifically led to a detailed area which now serves as a target for drilling and other exploration efforts, the geochemical prospecting part of the program is considered successfully concluded and, therefore, reported on here. Whether the target area will turn out to host the deposit or not is, of course, of utmost importance to the Company, but is of less importance to this paper. We will describe the concepts, the planning, the execution, the analysis and the interpretation of this typical geochemical prospecting case. A number of people on the staff of International Oil & Gas, Inc. have participated in this prospect, as have students from Southeast Missouri State University and their professor, Gary M. Lowell. In addition, the Missouri Geological Survey has been most helpful with records and letters on the century-old prospecting and mining in the general area. Many valuable discussions have also been held with geologists from the industry who, from time to time, have visited the area, examined the property and reviewed the status of the project. The support and interest from all these parties has made it possible to pursue and expand this exploration concept from one of being just "more of the same kind" to the most chal-1enging and exciting with which this author has ever been involved, namely the prospect for tin porphyry deposits in the mid-continent United States.

Jan 1, 1977

By Vladislav Kecojevic

Both Canada and the United States are endowed with significant reserves of mineral resources. Mining industries in these two countries have a strong safety and health culture; skilled, dedicated and well-paid workforce; applications of state-of-the art technologies and high productivity, strict environmental requirements and social responsibility. Both countries are global leaders in safe, economic, productive, environmentally responsible and sustainable mining practices. Mining schools/ departments in Canada and the United States provide a strong and comprehensive education and training, hands-on learning experience, with support for internships and co-op opportunities to prepare graduates for careers not only nationally but also in the global mining industry. While there are many similarities in their industries and mining schools, there are also some differences. This article examines the contribution of mining to the economy, the political climate, the regulatory framework, the investment climate, environmental regulations, the language, the perception of mining, news and press coverage, and the academic landscape in both countries. Opinions, observations and perspectives shared in this article are of the author, and do not necessarily reflect the views, policies or positions of any organization, employer or affiliated group.

Nov 1, 2025

By William Gleason

"With desert temperatures climbing high at Caterpillar’s Tinaja Hills Demonstration and Learning Center near Tucson, AZ in September, a group of editors were given a reprieve from the sun and stepped inside the new Cat Minestar Command Center. The movie theater-like temperatures inside were a welcome relief, and the computer screens stationed around the room were an indication of not just how much things have evolved in the mining equipment sector, but also a peek into the future of where mining is headed.Equipment manufacturers like Caterpillar have always had to deal with peaks and valleys in demand that come with mining, perhaps never more so than in the last five years. Sudhanshu Singh, global product manager for Caterpillar, said that in one month in 2012, at the height of the mining Super Cycle, Caterpillar produced more than 150 large mining trucks (haul trucks that carry 136 t/150 st or more). By contrast, Caterpillar produced about 80 of those trucks in the full year of 2016. Between 2012 and 2016, Caterpillar saw its profits drop by 40 percent.“This shows how cyclical the industry is, and it is a testament to the strength of Caterpillar to be able to tolerate the wide swings,” said Singh. Demand for commodities is once again on the rise as are commodity prices with many signs pointing toward a recovery for the mining sector, and Caterpillar has positioned itself for the recovery. During its 2017 press event in September, company officials emphasized that Caterpillar has added strength in its technology divisions by forming new partnerships and adjusting its operating plan.“At the heart of our enterprise strategy is the operating & execution (O&E) model, a strategic framework to identify areas of the business that either create or consume the most value,” said Caterpillar chief executive officer, Jim Umpleby. “Using the O&E model as a guide, we gain a deeper understanding of where we have a competitive advantage, which is key to generating high returns.”"

Jan 11, 2017

By Paul D. Tomlingson

The difficult and often harsh working environment of the mining industry can stress both personnel and equipment to the extreme. Often, the unintended consequences of this environment lead to confrontations between departments, as each goes about its tasks of mining, maintaining or supporting these activities. On occasion, the confrontations may result in criticism of other departments for perceived or real sins or omissions. The offended department may not be able to change the circumstances, but can only complain while frustration persists. The most effective solutions are the actions of the mine manager. By establishing mutually supporting roles of each department and specifying conditions for the interactive conduct of maintenance, the mine manager can better assure that the inherent problems of the mining environment are neutralized.

Jan 1, 2011

By Frederick C. Moore

This paper describes the original planning which actually resulted in the opening of a new aggregate plant located in central New York State. This plant, which is now named the Skaneateles Plant of The General Crushed Stone Company is unique in that the plant itself is a departure not only in design but in concept of operation from the normal aggregate plant the company has operated in the past. Whether or not the concepts which resulted in the Skaneateles Plant are economically feasible remain to be proven by the next few years of operation. By way of background data about our company which will help set the stage for this presentation, we currently operate seventeen stone quarries in the states of New York, Pennsylvania and Virginia. These quarries range in size from 200,000 tons per year to 1,500,000 tons per year with a total annual stone production of approximately 7,500,000 tons. We also produce about 1,250,000 tons of sand and gravel at six sand and gravel plants, 300,000 cubic yards of ready mix concrete, 1,500,000 tons of bituminous concrete, aglime and other minor construction materials. In many cases we are our own best customer consuming a large percentage of the total production of our own aggregates in our various ready mix and blacktop plants. Up to the concept of the Skaneateles Plant our operating facilities have been of the permanent type as opposed to the moveable or portable type plant. The steps involved in the case history of Skaneateles will begin with the basic economic requirements, market research, geologic surveys, land acquisition, zoning and financing and carry through to the final design and construction. We will attempt to show what some of the problems were, how we interpretted them and how we proceeded to solve them. The current results are apparent and can be analysed. The success of the total concepts of the Skaneateles Plant remains for future analysis.

Jan 1, 1968

By J. de Bakker

It hardly needs to be repeated that if coal is to continue as America’s premier source of cheap energy, it is absolutely necessary that the carbon dioxide from its combustion somehow be sequestered. A promising method proposed to accomplish this is the “indirect” carbonation of serpentine in a concentrated magnesium chloride brine. Indirect carbonation could be also applied to precipitate magnesium in lateritic nickel processing: this would not only solve magnesium-control problems in laterite hydrometallurgy, but also reduce its energy requirements and create CO2-sequestration credits. Fifty-five percent of the electricity generated in the United States comes from coal-fired power plants, and American coal reserves can last over 500 years at 1990-level consumption1. Coal is therefore both abundant and cheap: it could (and in fact probably will) continue to be an affordable source of energy, both for producing electricity and as a feedstock for liquid hydrocarbon production by Fischer-Tropsch reactions. As a result, it is important to find a workable method of permanently sequestering CO2.

Jan 1, 2007

By M. P. A. Hames, D. R. Beaumont

INTRODUCTION Legend has it that when Isembard Kingdom Brunel was confronted with the cost and consequences of one of his bridges having failed, he responded cheerfully that the event had saved investors and taxpayers a fortune because it prevented him from repeating the same design at several other locations. To meet the demands of rejuvenating and expanding the transportation system in an era of industrial growth Brunel and his contemporaries introduced bold designs and many innovations. Great advances in design and construction techniques resulted, yet these too had their practical limits as the story tells. In the gold mining industry today we face the same challenge of expansion, yet designers must respond mindful of economic restraints. Is innovation the answer? It has two meanings; to bring in novelties and to make changes. Distinguishing between improvement and novelties, or simply recognizing the benefits and limitations of new ideas over proven technology is part of good design. This paper will illustrate the practical aspects of selecting appropriate solutions to a design problem by examining a variety of examples common throughout the industry. Since a variety of engineering disciplines contribute to the design of a gold processing plant, and each has some old wisdom to impart or new development to boast this paper is divided into the different areas of expertise involved.

Jan 1, 1987

By Anthony M. Bauer

It is the nature of mining to reshape the landscape. Mining is an earth moving process with many of the same activities associated with the regrading of a site for a shopping center, drainage channel, housing project or ballfield. The difference exists only in purpose and duration of activity. The purpose of mining is to, produce a valuable product. The purpose of regrading for construction of a project is to create a predetermined landscape for a specific end use. In both situations the objective is to move earth materials as efficiently as possible. The question is then raised, if similarities exist, can mining operations be directed to shape predetermined landscapes as an integral part of its earth moving activity. This paper will explore the opportunities and issues of shaping sand, gravel and hardrock construction aggregate sites for productive end uses. It is based upon the premise that, as an earth moving operation, the process of extracting sand and gravel includes an inherent capability to shape productive lands as an integral part of the mining operation. In the course of any mining operation non-commercial materials, including overburden, fines and excess sand are handled to extract and process the commercial products. This activity exists regardless of whether or not there is a plan to reclaim the land. Moving this dirt is a basic operational cost. This cost need not be significantly increased when the material is deposited to shape land rather than be stock- piled just to clear the way for mining the deposit. Moving of dirt to create useable land can be guided by the same criteria used to remove the dirt from the deposit: for example, limiting the- hauling distance. Over a period of time earth handling costs can be reduced by minimizing the need to transport the stockpiled material a second time to the new landform location.

Jan 1, 1984

By Manuel Pérez-Tello, María M. Salazar-Campoy, Óscar Rodríguez-Hoyos

A common problem during the operation of the Kaldo furnace is the formation of accretions and blockage of the injection lance due to splashing. This typically occurs during the processing of anodic slimes for the production of doré. In this work, a 1:7 scale model of the Kaldo furnace currently in operation at Metalúrgica de Cobre, Mexico, was built in transparent acrylic plastic. Water and colored oil were used to represent the doré and slag, respectively. The model was used to determine the maximum penetration distance of the injection lance under a variety of experimental conditions at room temperature. Input variables included two types of oil, rotation speed, inclination angle, and the fraction of the vessel volume occupied by the liquids (φ). A mathematical correlation for the dimensionless maximum penetration distance of the injection lance d ∗ as a function of φ, the Froude number of the liquids in the vessel (Fr), the Reynolds number of the gas jet (Re), and the oil-to-water kinematic viscosity ratio (η)was developed. Reasonable agreement between the calculated and experimental values was obtained. Digital images showed that splashing was caused by the turbulent gas jet impinging upon the free surface of the liquids, whereas the cascade effect was negligible. The results of this work have been useful to improve the operation of an industrial Kaldo reactor.

By Manuel Pérez-Tello, María M. Salazar-Campoy, Óscar Rodríguez-Hoyos

A common problem during the operation of the Kaldo furnace is the formation of accretions and blockage of the injection lance due to splashing. This typically occurs during the processing of anodic slimes for the production of doré. In this work, a 1:7 scale model of the Kaldo furnace currently in operation at Metalúrgica de Cobre, Mexico, was built in transparent acrylic plastic. Water and colored oil were used to represent the doré and slag, respectively. The model was used to determine the maximum penetration distance of the injection lance under a variety of experimental conditions at room temperature. Input variables included two types of oil, rotation speed, inclination angle, and the fraction of the vessel volume occupied by the liquids (φ). A mathematical correlation for the dimensionless maximum penetration distance of the injection lance d ∗ as a function of φ, the Froude number of the liquids in the vessel (Fr), the Reynolds number of the gas jet (Re), and the oil-to-water kinematic viscosity ratio (η)was developed. Reasonable agreement between the calculated and experimental values was obtained. Digital images showed that splashing was caused by the turbulent gas jet impinging upon the free surface of the liquids, whereas the cascade effect was negligible. The results of this work have been useful to improve the operation of an industrial Kaldo reactor.

By Gary MacDonald

What is the primary function of an impact assessment? Many people at the International Association of Impact Assessment?s (IAIA) annual conference said that it is time to return to the fundamentals and consider the underlying drivers of impact assessments ? human health, safety and security. This fall, managers struggling with those fundamentals will receive extra support when a new course focusing on health and socially responsible security is launched online and in British Columbia, Canada, home to many of the world?s junior miners. Now in its 33rd year, the IAIA conference recently held in Calgary, Canada, typically brings together a range of professionals who work in the impact assessment field, including academics, as well as people conducting applied disciplines, such as social and environmental performance management. It is a chance for people grappling with how to assess impacts from projects (for example, dams, mining and other extractive projects), to compare notes and to talk about developments in how to measure, track and report on them. The comments about returning to fundamentals rose as participants talked about the ongoing and increasingly recognized divergence between three main impact assessment streams: environmental, social and health (EIA, SIA and HIA, respectively). Discussions in sessions and in the corridors included calls for streamlining, for integration, for improvement and sharing of practice ? particularly in the HIA stream, where those deeply engaged in the health discipline questioned how HIAs and their intended outcome of protecting human health can be better integrated into the EIAs or SIAs that dominate the impact assessment realm. EIAs and SIAs have become the main tool, particularly from a permitting perspective for large-scale mines, but seem to leave projects with little real information about what they need to do. Human health is not the only concern re-emerging. Although not reflected at the conference, there appears to be an emerging understanding of the need to link the determinants of health with socially responsible security practices. Companies conducting independent social performance assessments for international financial institutions based on the International Finance Corporation?s Environmental and Social Performance Standards increasingly wrestle with both community health and security issues as extractive companies encounter challenging social environments around the world. Once again, the intended outcome is to better protect human health, including avoiding health impacts from conflict, abuses and violence.

Aug 1, 2013

By Tom Michaud, Rob Albinger, Ian Turner, Michael Rispin

Data transmission, communication, tracking, and the connection of equipment such as gas detectors, cameras, and collision avoidance systems in today's tunnel industry are critical pieces of the constructor's infrastructure. Reliability, flexibility, redundancy, and cost-effectiveness are key in selecting and implementing inte- grated systems. Both wired and wireless components are used to deliver custom solutions and can involve interconnectivity between backbones. Systems integration is important as industry adopts proven technologies from other industries. Case stud- ies are given showing how tailor-made approaches deliver needed functionality, with varying degrees of com- plexity, in various classifications of environment, in order to meet a project need.

Jun 23, 2024

By Robert McIvor, Sami Makni, Andreia Rosa, Claude Gagnon

In response to the Natural Resources Canada “Crush It Challenge,” Corem partnered with the University of British Columbia and led a project to develop and demonstrate the use of high-pressure grinding to replace the workhorse of the industry, wet ball milling. Two plant case studies, a small tonnage gold recovery operation and a large tonnage copper recovery operation, were carried out. Plant circuit performances were compared to pilot plants operated on the same circuit feed setup to represent the novel equipment and flowsheet that was developed to produce separation circuit feed. Numerous obstacles to industrial implementation of high-pressure grinding in this role which were recognized at the outset of the work were successfully addressed. In both cases, comminution equipment energy savings alone and final stage total circuit energy savings exceeded 60% and 50%, respectively. Downstream mineral separation performance was the same or better.

Nov 28, 2023