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By Forrest T. Moyer

INJURY experience and employment data are presented in this (chapter for metal and nonmetal mines, stone quarries, sand and gravel pits, iron-blast-furnace slag plants, and metallurgical plants (including ore-dressing and nonferrous reduction plants and refineries) in the United States. Employment and injury experience data for all mineral industries are given in volume III. The 1963 figures are preliminary and are subject to revision. METAL MINES Preliminary estimates for the metal-mining industry of a combined fatal and nonfatal injury-frequency rate of 32.34 per million man-hours in 1963 indicate only a slight change from the rate of 32.00 in 1962. Metal operations had 41 fatal and 3,110 nonfatal injuries during 1963.

Jan 1, 1964

By R. Q. Shotts, H. J. Hager, A. C. Richardson, G. D. Coe

"INTRODUCTION In the State of Alabama few mines produce coal clean enough to be marketed directly without being washed. This is particularly true where the coal is to be used for the production of metallurgical coke. In washing plants where single-compartment jigs alone are used to treat a large range of sizes, it has been found that the washed coal finer than 1/4-inch contains a large proportion of free impurities and is much higher in ash content than are the coarser sizes. To reduce the ash content of this fine material with jigs usually entails a greet reduction in capacity and a loss of coarse coal in the refuse. This investigation, conducted by the Southern Experiment Station of the United States Bureau of Mines in cooperation with the University of Alabama and the Alabama By-Products Corporation, was undertaken to determine whether the fine washed coal from jigs could be economically re-treated on coal washing tables.COALS TESTEDThrough,the cooperation of the Alabama By-Products Corporation, samples of fine-sized washed coal were obtained from their washeries at Bradford and Gamma.The Bradford mine, on the Black Creek bed, yields a low-ash, medium-volatile coal with fairly good coking properties. This coal is blended with coal from the Mary Lee bed for coking purposes and compensates for the high ash content of the latter. The Black Creek bed is about 30 inches thick and seam analyses show an ash content of from 2.0 to 4.0 per cent. In the Bradford mine the undercut is about 6 inches high, so that a large proportion of fines is produced."

Apr 1, 1932

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Jan 1, 1980

By R. P. Maloney

Since mining operations began in 1900, Government geologists and mining men have periodically recorded the presence of the minerals of mercury and antimony in the extensive gold placer deposits near Flat in the Iditarod district of the Yukon River region, Alaska. No serious effort was made to recover the cinnabar contained in the gold placer gravels, and there is no evidence that veins of cinnabar and stibnite exposed in the placer operations (as reported by the Geological Survey) were ever explored or developed. A large monzonitic intrusive, which is the dominant geologic feature of the immediate area, is believed to be the lode source of the valuable minerals in the placer deposits. In contact with the monzonite are argillite and quartzite, metamorphic products from the Cretaceous shales and sandstones.

Jan 1, 1962

By Ernest J. Conway

Seventy-four human factors research and development projects were identified for possible Bureau funding. The projects were based on (1) literature surveys, (2) reviews of accident statistics and reports, (3) interviews with equipment manufacturers, MSHA, and Bureau personnel, and (4) site visits to 26 mines. The projects are divided into the following categories: those related to (1) mobile equipment, (2) maintenance shops and areas, (3) plants and mills, (4) organizational factors, (5) safety programs/data, and (6) training. The projects were rated by industry and MSHA people in terms of benefit to the industry. Projects were placed into three categories of priority. The highest priority contained 25 projects with 26 in Category 2, and 23 projects in the lowest category.

Jan 1, 1982

By James Westfield

Bureau of Mines activities for safety and health in the mineral industries were reorganized during the fiscal year to provide direct supervision by the Assistant Director -Health and Safety. On December 19, 1954, the field offices conducting these activities were designated as district health and safety offices reporting to the Assistant Director. The functions of determining the causes of accidents and injuries in the mineral industries and recommending measures to eliminate them were continued, with satisfactory results in improved safety records. The inspection of coal mines and enforcement of the Federal Coal Mine Safety Act of 1952 were conducted as directed by the Congress, and safety conditions in the mines were notably improved. One coal-mine explosion classed as a major disaster occurred during the year. The causes of that explosion and means for preventing a recurrence were still under investigation because of the extreme difficulty in recovering several portions of the mine. Basic research on the nature of certain hazards and ways of eliminating them is continued. Training of individual workmen and supervisors in this knowledge is a major part of the work.

Jan 1, 1956

By J. Härkki, R. Hiltunen

The Akanvaara intrusion (surface area 50-55 km2) in Savukoski, Northern Finland, hosts 23 distinct monocumulate layers of small euhedral chromite crystals enclosed in a silicate matrix. These chromitite layers have been divided into four groups; UC (upper chromitite), ULC (uppermost lower chromitite) LC (lower chromitite) and LLC (lowermost lower chromitite). The driving force for investigating the Akanvaara chromites and their reduction behaviour originated from their very low MgO content and relatively low Al2O3 content, giving them a unique quality which based on thermodynamics should facilitate the reduction. Another interesting feature is the high amount of V2O3 present especially in the upper chromitite. The chromites included in this study are from the UC and ULC layers (24.9 and 22.7 per cent Cr2O3 respectively). To obtain a better understanding of the reduction behaviour of Akanvaara samples in comparison to MgO-bearing chromitites, Kemi chromite from the ferrochrome works in Tornio, Finland, was included in the study as a reference sample. The reduction experiments were isothermal in a temperature range of 1000-1400°C in CO atmosphere. Experiments were also conducted with coke addition in pellets and briquettes in CO/Ar/H2 atmospheres. The results of the reduction experiments complemented with microanalytical research indicate that the Akanvaara chromites do reduce to a higher degree than the Kemi chromite. Although the aim was to characterize the mechanisms of reduction focusing on gas-solid reactions, the nature and amount of the gangue minerals was such that a considerable amount of slag phase was formed, which affected the reduction mechanisms extensively. The structural features together with low MgO and high FeO content in both Akanvaara chromites are important factors resulting in better reducibility than in the Kemi chromite.

Jan 1, 2004

By Gordon DM

Tyres account for 25-30 per cent of the operating costs of large capacity haul units as used in open-cut mines.Tyre operating costs can be substantially reduced and often contained in real terms by applying knowledge that is now available.This paper describes certain specific advances in tyre management, namely batching, bias adjustment, cumulative plotting and the so-called "pressure-temperature" system of tyre pressure control, originated on the Mt Newman Mining Company's Newman minesite, and discusses the contribution that each has made to improving tyre management and reducing costs.

Jan 1, 1983

By W. J. van Niekerk

Ballast Nedam is in Surinam constructing two bridges that will improve communications in the coastal region. The bridges will cross the Coppenam and Surinam rivers and will be founded on open-ended steel piles over 60 meters in length. The majority of piles are inclined and support prefabricated concrete girders forming the roadway. In most locations the stratum is consolidated cohesive layers extending to a depth in excess of 60 meters. For this reason, before pile driving operations commenced, it was decided that a number of test loads would be carried out determine the capacity of the piles. Loading tests were carried out on specially installed piles as well as on piles that would be used as working piles to support the structure. Working piles were dynamically tested using Pile Driving Analysis (PDA) equipment. This decision was based on the inclination of the piles, the cohesive nature of the soil and the increase of strength after the piles are driven. A good insight has been obtained into the real strength of the soil by comparing dynamic and static loading tests on vertical test piles. This made it possible to determine the required length of pile.

Jan 1, 2000

By G. A. Bezuidenhout, J. P. T. Kapusta, D. K. Chibwe

"Peirce-Smith converters (PSCs) are extensively used in the copper, nickel, and platinum group metals industries. The typical converting operation involves lateral purging of air into molten matte through a bank of tuyeres. This blowing operation occurs at low pressure from the blowers, resulting in a bubbling regime that is considered inefficient from both a process and an energy utilization perspective. Inherent drawbacks also include recurrent tuyere blockage, tuyere punching, and low oxygen efficiency.Western Platinum embarked on a full-scale industrial evaluation of generating a jetting regime by using sonic injection. Prior to industrialscale tests, a numerical assessment to ascertain the feasibility of implementing sonic injection into a PSC was conducted. The work included flow characterization at high-pressure injection achieving sonic velocity at the tuyere exit. The 2D and 3D simulations of the three-phase system were carried out using the volume of fluid method together with the RKE turbulence model to account for the multiphase and turbulent nature of the flow.This paper discusses the key findings in understanding plume extension, velocity distribution, shear wall stress analysis, and phase distribution characteristics in the system. Plant trials are also discussed with reference to the commercial aspects of a full-scale implementation of sonic injection in the smelter."

Jan 1, 2015

By Ivette E. Torres

Aruba, formerly a. part of the Netherlands Antilles, separated on January I, 1986, and became an autonomous part of the Netherlands. Full independence of the island from the Netherlands is scheduled for 1996. In this chapter, however, Aruba's statistics are included with those of the Netherlands Antilles. Tourism continued to be the main industry of the island, which continued to depend heavily on imports, mostly from the United States. During the year, the Government was preparing legislation to regulate the exploration of oil deposits in the relatively shallow sea around Aruba.

Jan 1, 1989

THOUGH the literature on the chamber process is considerable, it mostly refers to European conditions. Owing to the demand for acid for flotation and leaching at the mine, it may be necessary to work the process under other conditions. Consequently, some results obtained during the chlorination days at Mount Morgan, within the Tropic of Capricorn, may be useful for reference when working in a similar climate. Though the chambers must be protected against tropical storms, thorough ventilation should be provided, with plenty of space between the chambers, which are almost invariably crowded together. Not only does the space assist in the cooling of the chambers, but it is very desirable during repairs, when lead andtimber have to be hoisted up. The connecting flues between the chambers, which are fairly efficient mixers and condensers, should be round, supported from above, and with the least possible timber about them. Their position and arrangement deserve careful attention. Lattice work will be sufficient protection for the sides of the chambers, and the roof should be high and well ventilated. The Mount Morgan plant, crowded and not well situated, consisted of seven chambers (four over 50 ft. in length), one Glover tower 7 ft. 2 in sq. x 20 ft. high, one Gay Lussac 9 ft. sq. x 30 ft. higb, also one 5 ft. diam. x 25 ft. high. There was one pipe column 4: ft. sq. x 14 ft. 6 in. high. The chambers were run as one unit, and were much lower than those usually constructed in Europe-less than 15 ft. high. Provided that suitable timber can be obtained, 20 ft. is quite low enough. It should be quite satisfactory to use round poles for the studs, and so admit more air space between studs andlead.

Jan 1, 1920

By K. E. Waters, J. E. Nesset, F. Rosenblum, R. Langlois, J. A. Finch

"Some sulphide mineral mixtures when exposed to air and a warm and humid environment can exhibit a self-generating temperature rise, referred to as self-heating or spontaneous heating. The observed self-heating derives from the oxidation reactions of the active sulphides. In previous publications by the authors, it was proposed that the self-heating of sulphides proceed in three distinct stages; namely, Stage A, Stage B and Stage C. In Stage A (<100OC) the sulphides, in the presence of moisture are oxidized, generating heat through a series of sequential reactions and forming elemental sulphur as one of the products. In Stage B (>100OC) the elemental sulphur produced in Stage A is further oxidized to generate additional heat and SO2. Stage C (>~380OC), sometimes referred to as thermal runaway or roasting, is not addressed in this paper. This communication focuses on the type and role of elemental sulphur found in Stages A and B, and the sequence of reactions that is occurring in Stage A. The sequence is divided into two phases, the first based on galvanic interaction between the sulphide minerals that generates an acidic environment but little heat, and the second involving the production of H2S which rapidly oxidizes to produce heat and elemental sulphur. To date, data suggest that the primary oxidation product formed in Stage A is the stable orthorhombic a-S8 form of elemental sulphur. Above 96OC the a-S8 transforms to a monoclinic ß-S8 structure which is less stable and will readily oxidize to generate heat and SO2. Above 159OC a proportion of the ß-S8 sulphur will transition to a polymeric Sµ form of sulphur which can readily volatilize. INTRODUCTION Some particulate and granular materials, when exposed to appropriate atmospheric and physical conditions, can exhibit a self-induced temperature rise resulting from accumulated heat due to internal exothermic oxidation reactions. This phenomenon is commonly referred to as self-heating or spontaneous heating. Under favorable physical and environmental conditions, these reactions can elevate the temperature of a given material from ambient to the point of auto-ignition. Self-heating behaviour should not be equated to pyrophoric behaviour which describes a group of materials (e.g. certain finely powdered metals) that will ignite spontaneously in air below 55OC. There are numerous materials such as coals, hay, forestry wood products, food products to name a few that can exhibit self-heating behaviour. This publication continues the focus of the authors on the self-heating of sulphide mineral mixtures. Many of the metals of commercial use found in nature are in the form of these sulphides which must be mined, crushed, ground and concentrated prior to smelting or hydrometallurgical processing in order to produce primary metal. The issues of sulphide self-heating therefore pertain to the mining and processing of metals."

Jan 1, 2018

By R. L. Guerguerian

Nowadays, most grinding mills driven by a wrap-around ring motor are operating successfully. Some of the earlier problems could be attributed to the lateral stiffness and stability of their bearings. As a result, modifications to the bearings included the rearrangement of the shoes, or the addition of more shoes, closer to the horizontal centerline. This technical paper reports a study of the effects of bearings on the lateral stiffness of grinding mills driven by a wrap-around ring motor. The discussions cover the design of the four shoe trunnion bearings and examine the effects of the angular location of the shoes.

Jan 1, 2000

Drilling and blasting are an essential part of most mining operations, and are commonly major operating cost centres. The effectiveness of blasting can have a significant influence on all subsequent activities, and hence overall operating costs. Drilling and blasting systems must be compatible with the overall mining method, to minimise total costs and ensure operational efficiency. Selection of suitable equipment and techniques requires an understanding of the total operation, plus current skills in specialised technologies. This paper examines the contribution of drilling and blasting to total costs, including the balance between capital and operating costs. The use of computer modelling is discussed, to demonstrate how blast performance and costs can be predicted and alternatives analysed. Case studies illustrate how cost savings can be made in operating mines, and alternative systems evaluated to optimise new projects.

Jan 1, 1990

By J. G. Price

"The paper reviews state-of-the art welding processes and consumables for structural and pressure equipment applications in offshore environments, particularly the Arctic. Optimum selection of consumables will be discussed with regard to the facility to meet tentative toughness requirements in weldments. Finally, the development of welding procedure specifications will be considered in relation to the prevention of hot or cold cracking and lamellar tearing.Welding RequirementsGeneralThe exploitation of Canadian frontier oil and gas reserves will require a fleet of various types of offshore structures. These will include fixed jacket types and semi-submersibles for the East Coast with huge man-made islands and icebreakers for the Arctic regions. Both these regions will also require supply and drill ships plus subsea pipelines and cargo tankers for transportation. Clearly the welding of these items will plays large part in the over-all integrity and safety of exploration and production operations.The required development in structural steels and pressure vessel steels, for current and future offshore structures, to improve properties, particularly toughness for lower temperature service, has also prompted welding researchers to develop process and consumable combinations to match the parent plate specifications. This development has had to consider particular aspects of weldability such as a low susceptibility to cold cracking and preventing low HAZ toughness. Current research has centred on attempts to increase HAZ toughness with higher heat input welding of newly developed structural steels.The installation of Arctic region pipelines has provided a sound base for future, more complex fabrications in the most severe service temperatures in the Canadian frontier although few of the installations have been designed to the lowest possible exposed temperature of -62°C."

Jan 1, 1987

The two candidates in the upcoming presidential election in the United States each say that they have their own solution to the nation?s energy problems - solutions that will increase the amount of energy available, lessen the nation?s dependence on foreign sources and reduce the amount of pollution released to the atmosphere. Democratic nominee Sen. Barack Obama and Republican candidate Sen. John McCain both advocate research funding for coal-to-liquids and clean coal technologies. McCain also supports increased oil and gas drilling offshore. And Obama has even made some noises in that direction, although his plan leans heavily on the increased use of renewable energy sources. The energy debate is not new to this election. Congress and whichever party is in the White House has for years been trying to craft a comprehensive energy policy. One difference in this latest debate is that the increased use of nuclear energy has gained more attention. Current President George W. Bush has said he favors the increased use of nuclear power as part of the nation?s energy package. And McCain said he supports the building of more nuclear power plants. Obama has not said much about that. The American public is also showing signs of changing its stance on nuclear energy. To be sure, images of Three Mile Island and Chernobyl are still alive in some minds. However, the American public has said it wants cheaper energy and they want it produced more cleanly. With nuclear, the nation can have both. In the United States, nuclear accounts for slightly less than 20 percent of the electrical power used (see interview with Gary Steele of Energy Fuels on page 27). Globally, that figure is about 15 percent. And there are several nations that derive better than half of their power from nuclear sources. Add to that the world?s increasing need for more energy and the future of nuclear is bright.

Jan 1, 2008

By Tim Hughes, Steve Gannon, Jennifer Abols

"In the past year, two very innovative gold ore processing plants have been designed, built and commissioned by Gekko Systems Pty Ltd. The first plant in Vietnam utilizes conventional crushing and ball milling followed by gravity concentration (Inline Pressure Jig (IPJ) and Falcon concentrator), flotation, intensive leaching (GFIL), the first industrial scale use of AuRIX®1001 ion exchange resin and a cyanide destruction circuit. The second plant, in Australia, uses a 3 stage crushing circuit to crush the gold ore to minus 1mm, followed by gravity concentration utilising a rougher, scavenger, cleaner circuit of IPJ’s and a Falcon concentrator. A direct smeltable gold concentrate is produced as well as a lower grade concentrate for future intensive leaching or sale. Both plants were designed and built within very tight time frames and budgetary constraints. The experience gained during the plants’ design, commissioning and operation are discussed.INTRODUCTIONGekko Systems (Gekko) is a leader in the development of innovative technology for gravity recovery and intensive cyanidation. It provides low cost and metallurgically optimal solutions for its customers. It has also led the trend away from whole ore cyanidation (CIP/CIL) towards gravity/intensive cyanidation (GIL) and gravity/flotation/intensive cyanidation (GFIL) plants. These types of plants offer low capital costs, low environmental impact and maximum return to investors (Rob J Longley et al, 2002). Key to this type of flowsheet is the application of a continuous concentrate unit, such as the InLine Pressure Jig (IPJ), which is designed to produce high gold gravity recoveries at a coarse grind (Sandy Gray, 2003). When combined with other gravity devices, and/or flotation, and intensive cyanidation, using the Gekko InLine Leach Reactor (ILR), very high overall recoveries can be achieved.In 2004, Gekko launched a new range of products called Gekko Modular Systems. The idea was to provide off the shelf, complete solutions for the separation and recovery of complex and free gold as well as the pre-concentration of diamonds. A series of modules were designed that incorporated Gekko manufactured as well as outsourced equipment. Gekko now offers modules ranging from feeding and conveying to crushing, gravity recovery, flotation, intensive cyanidation, refining and detox (see Figure 1)."

Jan 1, 2007

By L. Mabiza

Keywords: Pyrometallurgy, furnace, sulphur, SO2, off-gas, Zimplats Zimplats embarked on an off-gas sampling campaign in December 2009 to characterise the concentration of SO2 in the off-gas from their 13 MW furnace. In excess of forty isokinetic samples (US EPA Method 8) were taken over seven days. The aim of the sampling campaign was to increase the understanding of factors that influence sulphur release from sulphide concentrates in an electric furnace. Specifically, detailed monitoring was conducted over various operating conditions to evaluate: ? The relationship between SO2 and feed rate (i.e. furnace power) ? The relationship between SO2 and ingress (i.e. furnace freeboard pressure) ? The impact of concentrate bed thickness on SO2 (i.e. blacktop) ? The effect of events such as tapping and converter slag return on SO2 ? The desulphurization reactions that take place in the blacktop A model was developed to predict the SO2 content in furnace off-gas for a particular set of operating conditions. In order to evaluate the impact of random, uncorrelated changes in concentrate composition, ingress and power (feed rate) on the SO2 content of the off-gas, a Monte Carlo approach was adopted whereby concentrate composition, power, and ingress were allowed to vary randomly around selected set-points. The model is primarily based on the release of ?labile? sulphur from the partial thermal dissociation of sulphide minerals with an over-stoichiometric sulphur content (e.g., Fe7S8 decomposition to FeS and S). The main findings of this work suggest that labile sulphur does not fully account for the measured SO2 content of the off-gas, and that limited oxidation of sulphides during melting also contributes to the SO2 content. Details of sulphide oxidation reactions in the furnace remain unclear, and it is currently not possible to provide a theoretical framework for the relationship between the extent of oxidation and variables such as temperature, gas composition, particle size, and residence time in the furnace black top. Through the use of the Monte Carlo model it was, however, possible to constrain the extent of sulphide oxidation to about 1%. This work has shown in practice what was expected in concept, that SO2 in off-gas is proportional to furnace power and ingress rate. The model that was developed consistently slightly under-predicts the quantity of SO2 generated. It also highlights that more work is required to better understand the analytical methods used to analyse for SO2 in off-gas.

Jan 1, 2011

By J. A. Every-Brown

Case studies are presented of three derelict sites in Kent and Essex that provide a good cross-section of opportunities for second-generation commercial uses of former chalk, limestone, clay and gravel workings. A 240 ha abandoned chalk quarry at Grays in Essex, now known as Chafford Hundred, is undergoing mixed development to include leisure facilities, a range of housing and commercial areas and an enhanced environment. The 120 ha of Stone Marshes now comprises the Crossways business park and the Dartford international ferry terminal. Reclamation and servicing required more work than had been anticipated and the fact that the area was within the green belt added to the delays, but Blue Circle was eventually able to provide a comprehensive development of the entire area to a high environmental standard. Stone Pit 1 landfill, at Dartford in Kent, is a former chalk quarry 40 ha in area and with an original average depth of 35 m. Landfilling commenced in 1976 and during the period 1979-1984 the site operator designed, developed and installed a gas collection and flaring system. From 1986 a gas plant supplied up to 5 000 000 therm/yr of landfill gas to a local cement works and in 1989 a 1 MW power generation scheme, later expanded to 3 MW, was commissioned. Gas is currently also supplied to a metal refining company for use in internal combustion engines

Aug 1, 1994