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By R. T. Jones

DC arc furnaces are widely used for steel scrap melting as well as for reductive smelting of ore fines. Industrial smelting applications include the smelting of chromite to produce ferrochromium, the smelting of ilmenite to produce titania slag and pig iron, and the recovery of cobalt from nonferrous smelter slags. A number of myths and misconceptions are widely held, especially regarding: the age of the technology, the use of a hollow electrode, arc stability and shape, arc and bath radiation, interaction between the arc and molten slag, electrical behaviour of arcs and slags, a comparison between AC and DC furnaces, DC reactors, the lifespan of bottom electrodes, and the applicability of DC arc furnaces to various metallurgical systems.

Jan 1, 2011

By Daniel Lakovic

"Mining operations can create a negative environmental impact, especially when considering the tailings that are produced through the processing of ores. Tailings are finely grained residues that form sludges. The tailings are deposited into giant basins, or sludge ponds, where they create a burden on the environmentby limiting the use of processed water.Tailings are one of the most important environmental liabilities for mining operations because of their large proportion in relation to the ore mined — generally 90 to 98 percent. To get to the valuable minerals, mining companies must move large amounts of rock. The rock is ground and then treated, usually with the addition of chemical solutions and large amounts of water. The lower the concentration of the valuable resources, the greater the proportion of accumulated excavated material sludge.Sustainable tailings management requires responsible handling, making it one of the mining industry’s greatest challenges. The proper technology should include consistent control of the environmental risks and impacts, as well as a proper relationship with the communities that surround the mining operations.The tailings, which can remain partly contaminated with chemicals, are pumped into the large sludge basins, which are secured by earthworks. During the mining operations, the basins must be stable enough to withstand the pressure of the stored excavated material. The storage option is still used, but it has failed on occasion. And when it does, it increases the risks to the environment and binds the unused process water. The more complex the availability of fresh water required for industrial use and for human consumption and their economic activities — for example, farming and agriculture — the more complex the conflicts that have the potential to shut down mining operations. With modern separation technology solutions, it’s possible to process the sludge and recover the processed water. However, the responsible use of the water is critical. Therefore, mining companies must rely on technologies that allow for proper reclamation of the water, whether re-using in their own processes or treating it to return it to the environment."

Dec 1, 2018

By N J. Welham

The Intec Copper Process is an environmentally advantageous hydrometallurgical process for the production of high purity copper and associated precious metals from copper sulphide concentrates. The process uses a mixed chloride-bromide lixiviant in an elegant cyclic circuit to leach the copper into solution, rejecting the iron as stable hematite rather than as unstable jarosite. After purification of the pregnant liquor, copper is electrowon at London Metal Exchange Grade A purity, while the anodic energy of the cell is stored as the soluble species, HalexTM, for recycle as the regenerated lixiviant to the leach circuit. Both gold and silver are leached and recovered directly from this cyclic process without resorting to cyanide leaching of the residue. No liquid emissions result from the Intec Copper Process, whilst spent air and water vapour from the leach are released to the atmosphere. The sulphur in the minerals reports to the solids residue in elemental form, without the need for expensive handling of voluminous gaseous sulphur dioxide streams found in smelters. A significant difference to competing smelting and hydrometallurgical processes is that any mercury entering the process from the sulphide concentrate feed is recovered rather than reporting directly to waste or polluting the environment. Outside the process circuit itself, the Intec Copper Process has several notable environmental advantages over competing technologies: Flexibility of scale with low capital and operating costs allow operation directly at the mill head at production rates as low as 15 000 tpa, significantly reducing environmental impacts from concentrates transport. The ability to handle low-grade and dirty concentrates often allows greater recoveries in the mill, improving both the economics and environmental acceptability of a mine by reducing metal losses to tailings. A comparison of the total energy requirements of the Intec Copper Process with those of competing technologies shows that the Intec Copper Process has the lowest energy consumption of any of the known hydrometallurgical processes, as well as improving upon pyrometallurgy under appropriate conditions.

Jan 1, 2002

By D. C. Dahlin, W. K. O’Connor, G. E. Rush, C. A. Summers, S. J. Gerdemann

The Albany Research Center (ARC) conducted studies of mechanical activation by conventional and ultra-fine grinding techniques to enhance olivine reactivity in mineral carbonation reactions. Activated olivine is one of several solid feed materials used at ARC in reactions with carbon dioxide to form carbonate minerals. This paper compares grinding techniques via energy demand data and product characteristics, including particle size distributions, surface areas, full width at half maximum (FWHM) XRD analyses, and particle morphology by SEM analyses. Reactivity was gauged by percent conversion to carbonate in subsequent carbonation tests.

Jan 1, 2004

By Miguel Reyes, Bruce Whisner, Joseph Bickson, Lincan Yan, David Yantek, Justin Srednicki, Nicholas Damiano, Eric Bauer

Built-in-place (BIP) refuge alternatives (RAs) are designed to provide a secure space for miners who cannot escape during a mine emergency. Heat and humidity buildup within RAs may expose miners to physiological hazards such as heat stress. To minimize the risk of heat stress, Title 30 Code of Federal Regulations (CFR), or 30 CFR, mandates a maximum allowable apparent temperature (AT) for an occupied RA of 35 °C (95 °F). The National Institute for Occupational Safety and Health (NIOSH) has conducted extensive research on the thermal environment of occupied RAs intended for use in underground coal mines. NIOSH research has demonstrated that a fully occupied BIP RA can exceed the AT limit by more than 5.6 °C (10 °F) in mines with elevated mine strata and air temperatures. In this circumstance, an RA cooling system could provide a solution. This paper provides an overview of test methodology and findings as well as guidance on improving the performance of a cryogenic air system prototype by optimizing the flow rate, increasing the tank storage capacity, and improving the efficiency of the heat exchanger of the cryogenic system. This may enable BIP RAs to meet the 35 °C (95 °F) AT limit in mines with elevated temperatures. The information in this paper is useful for RA manufacturers and mines that may choose to implement a cryogenic air system as a heat mitigation strategy.

By G. ALBORNOZ, S. Utili, A. AGOSTI, C. VALDERRAMA, R. PELL, N. Morales

The steepness of the slopes of an open pit mine has a substantial influence on the financial return of the mine. The paper proposes a novel design methodology where overall steeper pitwalls are employed without compromising the safety of the mine. In current design practice pitwall profiles are often planar in crosssection and the profile in between ramps especially tend to be planar and defined by a constant inter-ramp angle. Sometimes rock layers exhibiting different strengths require the inclination of the profile to vary with depth, but the inclination across each layer is usually constant. Here instead, a new geotechnical software, OptimalSlope, is employed to determine optimal pitwall profiles of depth varying inclination. OptimalSlope seeks the solution of a mathematical optimization problem where the overall steepness of the pitwall, from crest to toe, is maximized for an assigned lithology, geotechnical properties and Factor of Safety (FoS). Bench geometries (bench height, face inclination, minimum berm width) are imposed in the optimization as constraints which bind the maximum local inclination of the sought optimal profile together with any other constraints such as geological discontinuities that may influence slope failure. The obtained optimal profiles are always steeper than their planar counterparts (i.e. the planar profiles exhibiting the same FoS) up to 8 degrees depending on rock type and severity of constraints on local inclinations. The design of a copper mine is first carried out employing planar pitwalls, secondly adopting the optimal pitwall profiles determined by OptimalSlope. The adoption of optimal slope profiles leads to a 34% higher net present value and reductions of carbon footprint and energy consumption of 0.17 Mt CO2 eq and 82.5 million MJ respectively due to a 15% reduction of rockwaste volume.

Mar 2, 2022

By William D. Hissem

For those blasthole applications which require the use of holes ranging from 1” to 5.5” in diameter, the use of top hammer drills has been the equipment of choice for several generations of drillers. Pneumatic compressed air and hydraulic compressed oil systems represent the primary technologies which are available to the drilling practitioner. While both employ the same operating principals, the characteristics of performance, cost, and reliability can be markedly different between technologies and manufacturers.

Jan 1, 1998

By P. I. James, M. R. Baker

Este artículo analiza la nueva producción de cobre a partir de "minerales de desecho" de baja ley usando la tecnología de Blue Planet Strategies DEMET™ (Dynamic Electrode Mining Effluent Treatment, por sus siglas en inglés), que tiene como objetivo salvar la brecha de procesamiento entre la solución débil de lixiviación en operaciones de extracción por solventes/electrowinning (SX/EW), removiendo electroquímicamente los metales a partir de corrientes débiles y a la vez generando productos concentrados en metales objetivo en un análogo funcional de extracción por solventes (SX). Se estudió el tratamiento de la débil solución de lixiviación pregnant (PLS por sus siglas en inglés) y se usó para estimar los impactos económicos y de producción para una hipotética lixiviación en pilas de cobre brownfield y una operación aumentada DEMET usando SX/EW para tratar el "mineral de desecho." Se presenta la remoción de cobre a un 86% de eficiencia en las placas por debajo de 0,1 g/L de cobre con un consumo de energía de 0.55 kWh/lb de cobre y una concentración del producto mayor a 10 g Cu/L. El modelamiento arrojó aproximadamente $2/ lb para la producción total de cobre y costos de tratamiento menores o iguales a $1/lb con un inmediato aumento del margen bruto de operación del 12% para el brownfield incrementado. Se indicó también un aumento de la vida de la mina con un margen bruto promedio de 38% en la producción aumentada de "mineral de desecho" con valores de cobre de $3.25/lb.

Jan 1, 2014

By P. I. James, M. R. Baker

This paper examines new copper production from waste-grade ore using Blue Planet Strategies’ DEMET™ (Dynamic Electrode Mining Effluent Treatment) technology, which aims to bridge the practical weak pregnant leach solution (PLS) processing gap in heap leach-solvent extraction/electrowinning (SX/EW) operations by electrochemically removing metals from weak streams and generating product streams strengthened in target metals in a functional analog to SX. Weak PLS treatment was studied and used to estimate the economic and production impacts for a representative hypothetical brownfield copper heap leaching and DEMET-augmented SX/ EW operation to utilize "waste ore." Copper removal at 86% plating efficiency to below 0.1 g/L copper with power consumption of 0.55 kWh/lb copper and product strengths of over 10 g/L copper are presented. Modeling yielded approximately $2/lb total copper production and = $1/lb treatment costs with an immediate operation gross margin increase of 12% for the augmented brownfield. Potential mine life extension with an average 38% gross margin on "waste ore" augmented production at copper values of $3.25/lb was also indicated.

Jan 1, 2014

By Sean Gallagher

The human body is remarkably adaptable and capable of performance in a wide variety of environments and circumstances. It cannot be said, however, that the body is capable of performing equally well under all conditions. In fact, when faced with certain types of tasks or environmental demands, the body may have to adapt using methods that result in substantial performance limitations. Such a phenomenon is evident when workers must adopt unusual or restricted postures during performance of physically demanding work tasks. For the purposes of this discussion, the term "unusual posture" will be considered as any working posture other than typical standing or sitting positions. The term "restricted posture" designates postures that are forced upon workers due to restrictions in workspace. The vast majority of ergonomics research has focused on establishing design criteria for work involving standing (e.g., Snook and Ciriello, 1991; Waters et al., 1993) or seated postures (e.g., Grandjean, 1988), and understandably so. However, it must be recognized that there are numerous jobs (e.g., underground miners, aircraft baggage handlers, plumbers, agricultural workers, mechanics, etc.) where workers must perform in less desirable postures such as kneeling, stooping, squatting, and lying down (Haselgrave et al., 1997). Unfortunately, experience has shown that many ergonomics techniques used to analyze or design standing or sitting workstations often do not adapt well to situations where a restricted

By Barrie A. Wigmore

There are two aspects of financing western coal development -- whether there is going to be enough money to finance the prospective large development of the industry, and the specific techniques of raising money for that development. To take the first question of whether there is going to be enough money around to finance your industry, I think it is quite clear that the restrictions on the development of western coal are going to be non- financial. Environmental impact problems are creating the greatest delay in coal mine development, at the moment; but getting enough personnel, mining equipment, railroad equipment, and failure of the Department of Interior to act on leasing federal coal lands all appear likely to create significant bottle- necks in the development of western coal -- larger bottlenecks than financing. Financing appears straightforward for the industry. There are many projections of the financing required to meet Project Independence goals. The National Academy of Engineers estimated that development of 500 million tons per annum of western coal would be necessary by 1985 to meet the Project Independence goals which might require $20 billion of capital spending. It is generally agreed that 500 million tons a year is not a realistic possibility. Carl Bagge?s estimate of production of 250 million tons a year by 1983 appears a more reasonable projection. Development

Jan 1, 1976

By P. D. Kondos, J. R. Goode

Given the global inventory of low grade and refractory gold deposits, processes that could turn these challenged deposits into mines are of considerable interest. Such gold deposits have low value and potentially high operating costs and so they pose special challenges for the mining engineer and metallurgist. Conventionally, refractory gold ores have been processed by whole ore pressure oxidation and roasting, or flotation followed by roasting, pressure oxidation or bio-oxidation of the concentrate. Halide-based processes have recently been developed that might be applied to concentrates. Low grade refractory gold ores have been processed using heap bio-oxidation followed by cyanide heap leaching or milling. Other processes are emerging. Barrick has completed an inventory of emerging technologies (1). A summary of the current status of these developments will be presented with the view that, with additional development, some of these technologies or a combination thereof may unlock the value of these deposits.

Jan 1, 2005

By M. A. Reyes, L. Yan

Heat and humidity buildup withn refuge alternatives (RAs) may expose occupants to physiological hazards such as heat stress. The Mine Safety and Health Administration (MSHA) regulations require RAs in underground coal mines to provide a lifesustaining environment for miners trapped underground when escape is impossible. RAs are required to sustain life for 96 h while maintaining an apparent temperature (AT) below 95 °F (35 °C). The National Institute for Occupational Safety and Health (NIOSH) tested a 10-person tent-type RA, a 23-person tent-type RA, and a 6-person metal-type RA in its underground coal mine facilities to investigate the thermal environment over a 96-h period. The test results showed that mine air and mine strata temperatures surrounding an RA occupied by simulated miners (SMs) increased over the 96-h test period. The test results suggest that RA manufacturers should consider this increase in temperatures when calculating and evaluating RA components during surface and laboratory tests. The findings can equip stakeholders with additional considerations for calculating the interior heat and humidity temperature profiles for occupied RAs not tested in situ.

By W. Hustrulid

"In recognition of his inspiring dedication to the mining industry through education, research contributions and dissemination of practical knowledge, exceptional leadership and excellence in mining engineering practice and for his lecture, “You can't make a silk purse out of a sow's ear.” Recipient of the 2002 D.C. Jackling Award Introduction It is always difficult to decide on the most appropriate title to give to a paper or talk. It is a particularly difficult decision in the case of the Jackling Lecture, because the title becomes part of the award citation. I hope that the significance of this unusual title will become crystal clear as you read the pages that follow. However, to assist you in this journey, I will provide the following few words of guidance. In making a cake, you need the proper ingredients. If one or more of them are missing, it will not be a cake. In addition, the quality of the cake depends on the quality of the ingredients. In my lecture, the "cake" is the U.S. mining industry of the future. A national perspective President George W. Bush in his State of the Union Address (Bush, 2002) delivered on January 29, 2002, defined three national objectives: •win the war on terrorism, •protect the homeland and •revitalize the economy. Under the heading "revitalize the economy," he indicated the importance of "good jobs" and "energy production" by saying: "Good jobs begin with good schools. Good jobs also depend on reliable and affordable energy. This Congress must act to encourage conservation, promote technology, build infrastructure and it must act to increase energy production at home so America is less dependent on foreign oil." I wish that he would have broadened his focus and stated instead that: "This Congress must act to encourage conservation, promote technology, build infrastructure, and it must act to increase materials production at home so America is less dependent on foreign sources." With regard to jobs, all jobs are not equal. To paraphrase John Reeves of MidContinent Resources (Reeves, 2002): "If our nation is to prosper, we all cannot make a living by doing each other's wash. Some of us, at least, must be actively engaged in the primary production of raw materials from the riches of the earth and other Americans must turn those materials into consumer products." The unfortunate trend in our country has been to neglect the primary production of basic materials, even those coming next in line. We have left those responsibilities to others while we concentrate instead on performing various services, i.e., doing each other's wash and flipping burgers. This cannot continue. It must be remembered, especially by those in leadership positions, that all "jobs" are not created equal. Some jobs are much more essential to the security and wellbeing of our country than others. We must be sure that the important ones are in place. We cannot produce the basic materials that our nation requires without access to those materials. This leads to my Proposition 1: You cannot have a viable mining industry without a clearly enunciated, positive U.S. materials policy. Background regarding U.S. materials policy Resources for freedom. In January 1951, President Truman created the President's Materials Policy Commission, with William S. Paley as chairman. As expressed in the invitation letter from the president to Paley: This commission, within the executive office of the president, is to study the broader and longer-range aspects of the nation's materials problems as distinct from the immediate defense needs. The task of the commission is to make an objective inquiry into all major aspects of the problem of assuring an adequate supply of production materials for our long-range needs and to make recommendations that will assist me in formulating a comprehensive policy on such materials. The commission should study, together with any other aspects deemed by it to be pertinent, such questions relating to production materials as: - the long-range requirements outlook; - the long-range supply outlook; - the prospect and estimated extent of shortages; - the consistency and adequacy of existing government policies, plans and programs; and - the consistency and adequacy of private industry practices.

Jan 1, 2003

By B Olsson, B Reynolds, R Norman

An unprecedented growth in demand for coal exports has placed pressure on multi-user coal chains to guarantee that their capacity expansion projects will meet the required demand. These projects, however, are taking place in an increasingly complex commercial and technical environment - competing rail and coal terminal service providers as well as a myriad of competing mine operators, all needing to operate in an increasingly integrated manner to get the most out of expensive shared assets.Increasing system complexity and integration has driven the need for more holistic and sophisticated analysis tools. The capacity of coal chain subsystems, such as mine, rail and port, can no longer be determined effectively in isolation. Understanding the nature of the interactions between these subsystems, their sensitivity to uncertainty and the resultant capacity of the integrated system is the key to both maximising value and minimising risk.Recently, TSG has worked closely together with the Integrated Logistics Company and a number of key stakeholders in the Dalrymple Bay Coal Chain to develop independent system master plans. These master plans have provided a quantitative and rational assessment of coal chain capacity in its current state and a prediction of its capacity once a pipeline of committed capacity improvements is in place. This paper provides an overview of the study and a comprehensive guide to the process required to effectively achieve valuable strategic insights in a challenging multi-user stakeholder environment.CITATION:Reynolds, B, Olsson, B and Norman, R, 2012. Using independent system simulation to mitigate risk in the Dalrymple Bay Coal Chain, in Proceedings Project Evaluation 2012 , pp 77-84 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 24, 2012

By W. E. Stephens, A. J. Boyce, D. Lowry

Paper presented at Mineralisation in the Caledonides, the Mike Gallagher memorial meeting held in Edinburgh, 27-28 June 1996. An integration of S isotopic, fluid and mineralogical data for granitoid-related mineralisation showed that the porphyry systems had a predominantly subcrustal magma source, but the inner magma pulse of two-mica granite in the Fleet pluton was derived mainly from reduced sediments. The porphyry-style mineralisation formed from boiling fluids at high crustal levels, with a moderately saline fluid percolating down to the upper veins as they cooled but not penetrating the deeper Talnotry deposit. Veins in peripheral greywackes have a significant magmatic component but also incorporated CO2-rich components and metals released by dewatering of host sediments in response to granitoid intrusion. The low grade of regional metamorphism resulted in the significant fluid input from country rocks which led to the more exotic mineral compositions, especially where argillaceous sediments were involved

Jun 19, 1905

By Arthur L. Murray

"During recent months much criticism as to the efficiency of mine labor has been heard from various, sections of the country. No doubt much of this criticism has been well founded. The present lack of efficiency and of stability is due primarily to a spirit of restlessness and partial irresponsibility engendered during the transition from war conditions to peace time conditions. This spirit or unrest not only among the laboring classes but in every branch of the human family following a period of intense nervous tension in a nation appears to be a natural sequence of war and beyond the control of man. This condition will gradually disappear, and the majority of our people will again assume their natural order of living, but labor will for a considerable period be sensitive to these influences, whether they be exerted for good or for evil. Employers of labor should take cognizance of this fact and bend every effort towards the development of measures that promote efficiency and permanence of the working force.Labor efficiency depends upon many and varied factors. Some of these factors as applied to mine labor are briefly enumerated in the following paragraph:Selection and Placement of Manpower:In the selection of men the two main considerations are physical ability and adaptability. The laws of mechanics should be applied in the selection of men as in the selection of machinery. If a machine is required for a certain class of work, the type of machine known to be mechanically fit for such work is selected. Likewise, men should be selected with regard to their physical and temperamental fitness for the kind of work expected of them."

Apr 1, 1920

By Gerald H. Groenewold

Reclamation of surface-mined landscapes is commonly defined only in terms of biological productivity. Other critical concerns associated with surface mining include the long-term quality of groundwater and stability of the postmining landscape. Meaningful reclamation design must address all these concerns. Reconnaissance of postmining landscapes indicates that three types of instability occur in these settings. These include: area-wide settling, localized collapse, and piping. Area-wide settling is most pronounced during the first year after contouring but appears in precontouring valley areas where frozen materials are contoured with a dozer. Although severe in some settings, development typically ends within one year. Piping appears to be a severe and long-term problem in some settings. Piping usually begins soon after contouring ceases and may continue for several years. In some postmining landscapes, piping has only started to develop after as many as five years of apparent stability. Piping is controlled by a combination of physical and chemical conditions in the spoil. A key factor is the presence of highly dispersive materials in the near surface. The design of a stable postmining landscape requires the integration of severe critical factors. These include: 1) detailed knowledge of the distribution of overburden materials with emphasis upon the delineation of highly sodic sediments; 2) proper equipment selection; and 3) a consideration of climatic factors. For reclamation to be successful, it must consider the entire landscape, not merely the soil zone. Any approach short of this will lead, at best, to temporary solutions.

Jan 1, 1980

By B Robertson

Over the 40 years that the author has been engaged in the Australian underground coal mining industry, there has been a continuous improvement in safety performance as the sector has grown in size and productivity. The underground environment hosts many hazards with significant risk profiles that are kept in check by effective health and safety management systems that have evolved largely following major underground disasters. Observations are made on the changes observed for specific aspects of the underground coal sector, with particular reference to ventilation issues, and predications are made as to the needs of the future.CITATION:Robertson, B, 2013. Past achievements and future challenges in the underground coal sector, in Proceedings The Australian Mine Ventilation Conference , pp 27-32 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 1, 2013

By Les Philips

National Institute for Safety and Health?s (NIOSH, USA) Office of Mine Safety and Mine Safety and Health (OMSHR) has definitions for: -Proximity Detection as detection of personnel, vehicles and other objects near a machine using some type of sensor technology -Proximity Warning (aka Collision Warning) as detection of personnel, vehicles and other objects near a machine resulting in alarms that ?Warn the operator only ?Warn the operator and nearby personnel (two-way) -Collision Avoidance as the processing of sensor information resulting in control signals or actions that alter machine status/movement to avoid a collision by ?Computer control ?Human control

May 1, 2013