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By Adolf U. Honkala

Dundee Cement Company was incorporated in 1958. The equity capital for the venture was supplied by a Swiss firm called Holderbank Financier and a group of its principals. Holderbank Financier, a holding company, is a direct outgrowth of Holderbank Cement Company, a company founded in 1912 by the father of Dr Hans Gygi who is the president of Dundee Cement Company and a member of the Board of Holderbank Financier. From one plant in 1912 located in Zurich, Switzerland, Holderbank grew to its present size of 32 plants in 17 countries, having a capacity of 90 million barrels of cement per year. Dundee Cement Company constructed its first cement plant near the little town of Dundee, Michigan. This site was selected because there is an abundance of limestone and clay of the correct chemical composition for cement manufacture and the deposit was advantageously located near the large population centers of Detroit, Toledo, Cleveland, and Chicago. Construction of the 5. 5 million barrel, two kiln, plant was completed and the plant started up in the fall of 1959. After a year or two of the usual problems in a new plant and the expected difficulty of breaking into a nearly saturated market, Dundee began to prosper.

Jan 1, 1970

By R. R. Godard

The practice of dust abatement or control is not new to any operation of United States Steel Corporation. This report will review those activities, past and present, within the five operating districts of United States Steel-Coal Operations with specific reference to mechanical and continuous mining, and including both the health and safety aspects of the problem. Obviously, the first principle of dust control is to inhibit its formation If this is not practical, steps may be taken to prevent its becoming airborne. Airborne dust control can be realized by either collecting it at the point of generation, diluting it with large volumes of air to reduce concentration, settling it by various means, or with reference to ignition hazard only, render it incombustible by neutralization with an inert material. These basic principles have been verified by the work of many, including the Bureau of Mines, U. S. Department of Interior, Bituminous Coal Research, Inc., and the Mining Research Establishment of the National Coal Board of Great Britain. Their application to every day mining problems is best illustrated by the following examples.

Jan 1, 1967

By Arthur A. Brant

Your chairman has asked me to deal with questions of education relative to our present and projected trends in the field of mineral expiration. First comes our definition of education--and education is not the merely formal acquiring of academic knowledge, but the understanding, using and projection of knowledge into our channels of life and thought activity. This past year makes us realize the extent to which price and economic cut-off may stimulate or curtail exploration,, But exploration does not consist solely in the discovery of sources of material. There is just as inspiring and imaginative a territory in the develop¬ment of uses and application--and no one in our base metal industry but would hope that our educational processes would fertilize those springs of inspiration that lie dormant in us all, toward the- imaginative conception of new uses--lead roofing cloths or felts, non-tarnishable copper utensils, further zinc solid state application. Thus an educational pattern should seek to develop imagination and thinking beyond--the possibility of that small but oh so difficult step just ahead of the existing,

Jan 1, 1959

By C. P. Shen, H. C. Tsai, Bennie Chu, Y. S. Hsieh

The Pinglin tunnels are situated within the fold-and-thrust belt structural region in Taiwan, due to continent-arc collision and plate tectonic setting. The pilot tunnel TBM (§=4.8m) became stuck ten times with the standstills to date. The westbound main tunnel TBM (§=11.74m) was buried in a collapsing calamity. The main tunnel TBM shall identify and overcome the adverse geology with high volume of ground water ingress itself. This paper presents our experience and methodology through the adverse geology with Pinglin large TBM.

Jan 1, 1999

By A. Vien

MOCCA is a Multivariable Optimal Constrained Control Algorithm developed specifically for non-square industrial control applications with practical difficulties such as interactions, time delays, constraints, modelling development, etc. MOCCA consists of an off-line simulation/translation module, for tuning the control parameters, and an on-line module that implements the designed control law. This paper describes an evaluation of MOCCA on the Hemlo grinding circuit which comprises one open circuit ball mill and two closed circuit ball mills in series. In this case a 4x4 unconstrained control problem was considered. The manipulated variables included the fresh ore feed rate and three pump box water additions. The controlled variables were the grinding circuit product particle size and three pump box levels. In this application soft constraints were implemented through control action and control error weighting. The feedforward capability of MOCCA was used to compensate for a measured water flow disturbance to one of the pump boxes. MOCCA performed very well during plant evaluations when compared to the original classical multi-loop control strategy and proved to be quite robust. Perhaps most importantly, the process engineers and plant operators have a high level of comfort both in understanding MOCCA's general operating principles, and with its demonstrated performance.

Jan 1, 1991

By Eric Ohl

Due to the world's ever increasing minerals and energy demands, process plants have to cope economically with ever growing throughput rates. This trend has accelerated the development of high capacity vibrating screens. Screens with screening areas of 30 to 50 square meter (322 to 540 square feet) and width of 5.5 meter (18') are technically possible and are being used presently with great success. This paper will concern itself with the general aspects of large screen design, by using modern technology and the latest findings with regards to fatigue strengths relative to the laws of vibration. It also will investigate the technical and economical limits of such designs.

Jan 1, 1983

By Michael Jatczak, Brett Robinson

The South Bay Ocean Outfall tunnel is located at the U.S./Mexico Border and is one link in a system designed to treat and dispose of raw sewage entering the Tijuana River Valley from Mexico. The 11 finished diameter tunnel extends 19,000’west from the bottom of a 200 deep, 36 diameter drop shaft. At the western terminus of the tunnel, a Riser shaft connects the tunnel to conveyance and diffuser pipes on the seabed. The tunnel runs through the San Diego Formation, consisting of clay, silt, sand, gravels, cobbles, and boulders. A Mitsubishi Earth Pressure Balance (EPB) Tunnel Boring Machine equipped with a large variety of monitoring and control devices was used. This paper will provide an overview of the Project’s construction, with special emphasis on the value of the electronic data acquisition system.

Jan 1, 1999

By Lester F. Sanford

Located in the Santa Cruz Mountains eight miles north of the City of Santa Cruz and inland from the coast, lies a typical beach sand consisting of quartz and feldspar grains of the Santa Harguerita formation of the middle tertiary age, Reserves of over twenty-five million tons of this sand form the deposit presently being harvested by Pacific Cement & Aggregates, a Division of Lone Star Cement Corporation. The deposit ranges from 350 to 700 feet above sea level and varies from two percent passing a 200 mesh screen to ten percent retained on a ¼ inch screen (see Figure '#l) In 1929 the first sand plant went into operation at this site. It was replaced by a new plant in 1937. This plant continued operation until the middle of 1965 when replaced by the modern plant described in this paper.

Jan 1, 1967

By Andrew W. Jenike

There used to be a time when bins were designed for total volume and placed in any available place of the plant. Poke holes were provided and feed was maintained by manual prodding, lancing, hammering, and by various mechanical flow-profiting devices. Little thought was given to what occurred inside the bins and why materials did not flow. Indeed, such mental effort was hard to justify while low-cost manual labor was plentiful, quality standards low, and rates of feed moderate. The past fifteen years have seen a drastic change in these conditions. We all know that labor for hard manual work is becoming unavailable at any wage, level. Standards of product uniformity are continuously rising. This uniformity is just as important in a fine ore feed to ball mills as it is in a cattle feed or in a flour mix. Rates of feed now frequently exceed 2,000 tons per hour per feeder. At that rate there is no time for, lancing or prodding. An efficient storage, plant contains a known available volume of bulk solid, and feeds it at the required time, at the prescribed rate, and without degradation of the product. A storage bin may also perform other functions such as blending of different grades, degasification of aerated, powders, isolation of different gaseous media. A contact bed of particles flowing by gravity in counter-current with a gas or liquid may be used as a continuous reactor. Gas or liquid pressures can be simply contained by, a sufficient head of flowing solid.

Jan 1, 1968

By P. R. Taylor

Three refractory gold concentrates have been tested to evaluate the effect of roasting with hydrated lime followed by cyanidation. The results indicate that it may be possible to roast in such a manner as to contain nearly all of the sulfur, arsenic and antimony in the roaster calcine. Cyanidation results indicate that the gold recoveries are greater than 80% for all three concentrates.

Jan 1, 1993

By Yehia M. Eyssa

A "straight wire" flow through magnetic ore separator has been designed, built and successfully used to separate magnetite from typical slurries. The purpose of these experiments was to simulate the high field profile of a "straight wire" superconducting magnetic separator which would be capable of separating weakly magnetic hematite ore from typical slurries. Magnetite was used as the test mineral because it experinces the same magnetic forces at low field as does hematite at high field. The present separator concept is based on the fact that there is a particle concentration profile due to the gravity field for low velocity turbulent flow. When a magnetic field force of -g is applied the concentration profile of the magnetic particles will be reversed leaving the nonmagnetic particles flowing alone at the bottom of the channel. By means of a divider at the end of the channel the concentrate is separated from the tailings. It is shown that the time needed to deflect hematite particles in a narrow cylindrical channel concentric with the superconducting wire is small enough so that high throughputs in the turbulent flow region are possible. In the case of a high field superconducting separator the centrifugal force could replace gravity by rotating the flow around the straight wire conductor.

Jan 1, 1974

By Bond. F. C.

Introduction Although autogenous grinding applications date back to the early years of mineral processing when tumbling-type mills were first used, there has been a renewed interest in this type of grinding over the past few decades. A review of the historical aspects of autogenous grinding is provided which follows the development of the various types of mills and processes. Wet and dry grinding operations using either autogenous or semiautogenous mills, including the Aerofall mill, are described. Em¬phasis has been placed on the test work required to evaluate the feasibility of using autogenous or semiautogenous grinding for a spe¬cific application. The factors which must be considered to establish the appropriate design criteria for these types of grinding circuits are discussed in detail. Successful application of these grinding circuits results from a thorough test program, a careful analysis of the test results, and a practical engineering approach to the design of the process flowsheet and milling equipment. Certain pebble milling applications, where the pebbles consist of the ore or rock itself, can be classified as autogenous pebble mill grinding, or better known as ore-pebble mill grinding. In the generic sense, pebble milling includes those grinding operations using a tum¬bling mill in which the grinding media consists of various types of pebbles, either ore or other pebbles, instead of metal balls. Conse¬quently, this subject is covered separately in Chapter 5, Pebble Mills. Operating data from many of the installations located throughout the world are included in this chapter. Our appreciation is extended to those companies who contributed this important information. History of Autogenous Grinding F. C. BOND Autogenous grinding, the grinding of ore by itself rather than by special metallic or nonmetallic grinding bodies distinct from the ore, has an old and honorable place in the art of mineral processing. It antedates the use of the rod mill and is only a few years younger than the development of the continuously fed rotating tumbling mill in which it is accomplished. Its history71, 72 is inextricably bound up with that of gold mining. Every important early development of autogenous grinding took place on ores of gold, except in one case of silver ore. In common with many other features of modern mineral processing, autogenous grinding would have been greatly retarded if the winning of gold had been so small a part of mining in the past as it is today. Gold unlocked the secrets of rock-on-rock grinding. In years past gold ores were crushed in stamp batteries and then flowed over copper plates covered with mercury which amalgamated the gold. The McArthur Forrest cyanide process for the dissolution of gold in a dilute alkaline cyanide solution appeared in 1890. With finer grinding it recovered more gold than could be won by amalgama¬tion alone. The first response was to stamp in cyanide solution and finer mesh screens guarding the stamp discharge. However, the fine screens greatly restricted the tonnage stamped, and they wore out rapidly. Rotating tumbling mills70, 73 were the obvious choice to grind the coarse product from stamps. Many of these were Gates tube mills; more than 1,000 of these were sold between 1907 and 1913. They were made in 6, 51h, and 5 ft diam, with lengths of 20 and 22 ft. The 5 x 22-ft size was the most popular. The term tube mill did not refer to the mill shape, but included all tumbling mills using grinding pebbles. The flint or chert rocks found along the coasts of Denmark and Normandy are probably the most durable and resistant to abrasive and tumbling wear of any on earth. They were much used in the early tube mills. The early linings were all silex or Danish flint blocks, cemented into place with portland cement. Local hard stones or cast iron blocks were also used later. The cast iron liners carried lifters and were not bolted to the shell, but were held in a tight circle against it by steel wedges hammered home between them. The first ribbed metal liners designed to hold grinding pebbles pounded into them by the mill action were developed at El Oro, Mexico, about 1905. These and the Forbes, Komata, and Tonopah types, as well as the Osborne type developed in South Africa within about five years, were very successful in reducing liner wear. They sometimes lasted two years or more, and equalled or exceeded the life of silex lining at a lower cost. Some of the types were patented. The pioneer name recorded in the history of autogenous grinding is that of Kenneth L. Graham. In 1907 at the Geldenhuis Deep Ltd. mine near Johannesburg, he ran a comparative test on two tube mills. One mill used pieces of the common gold ore, or banket, and the other used the customary imported Danish pebbles as grinding media. He published the first account of autogenous grinding.'' In a test lasting 81 days the ore pebbles showed a definite saving over the Danish pebbles. Graham's historic paper also describes the invention of B. Chew of the Crown Deep Mines of the first trammel to be attached to a grinding mill discharge. The first known account of autogenous grind¬ing printed outside of South Africa was the description of the Graham test in Mining and Scientific Press's The use of grate- vs. overflow¬discharge was also described at this time." The news of this successful test appears to have had immediate effect, for by the end of 1908 the number of tube mills on the Rand had increased from 72 to 120.76 Presumably, most of these mills were now using autogenous grinding. The ore was principally a hard conglomerate of quartz peb¬bles cemented by silica, and was eminently suitable for use as a grind¬ing media. It is unfortunate that in South Africa the new autogenous process continued to be called by its old name of pebble milling, since the name does not distinguish between grinding with ore and grinding with extraneous pebbles. For increased clarity the former is called rock pebble milling. The first historical stage in the development was what is now designated as secondary autogenous grinding, or rock pebble milling. It consists of grinding a feed all passing 'A in. or finer with ore pebbles about 2 to 4 in. in diameter. The next stage to develop was that now called intermediate autogenous grinding, where larger amounts of larger pebbles about 5 in. in size were used to grind ore which had been crushed to about rod mill feed size or somewhat finer. It was developed on the Rand and in other places where coarse stamp screens were used to increase mill tonnage. In many cases the early secondary and intermediate autogenous mills have now been replaced by conventional ball mills and rod mill-ball mill circuits, with the object of further increasing grinding capacity. The third stage to develop is designated as wet primary autogenous grinding, in which run-of-mine ore or a primary crusher product is all fed to the autogenous mill together. It developed many years later indepen¬dently in the United States and in South Africa. The fourth and most recent stage is that of dry primary autogenous grinding, which developed in the United States and Canada. All four stages originated in gold mining. The first use of commercial autogenous grinding outside of the Rand apparently took place five years later in 1912 at the Santa Gertrudis gold mine at Pachuca, 55 miles northeast of Mexico City. This was followed closely by an installation at Goldfields, Nevada, in 1914-1915. The first name associated with autogenous grinding

Jan 1, 1985

By J. M. Pachter

Property sales and acquisition are prominent features of today's coal industry. Before selling or buying a site, a company must know the property's economic net worth. Any evaluation of economic net worth would be inadequate if determinations of a property's environmental liabilities and costs were omitted. Short-term and long-term costs can result from liabilities related to reclamation, water treatment, subsidence, and hazardous waste disposal. A structured, interdisciplinary approach can aid in the delineation, summation, and scheduling of these costs and liabilities.

Jan 1, 1986

By Henry W. Brandt

What is the most practical method for storing a huge quantity of crude oil for a long period of time to assure availability if conditions curtail the source of supply? Underground storage is a logical answer. But can abandoned mines be used for this purpose? That is the proposal Fenix & Scisson International, Inc. submitted to the S.F.F. Association (acting in behalf of the Department of Industries of the Republic of South Africa), Johannesburg, South Africa, in October 1966. This engineering and contracting firm with headquarters in Tulsa, Oklahoma, specializes in underground storage; and based upon previous experiences their engineers were reasonably certain that a mine could be used for storing crude oil. The answer subsequently proved to be "yes." The result was con- version of a coal mine to provide storage for a quantity of crude oil which is the equivalent of a sizeable oil field. The total cost of purchasing, testing, and converting the mine was less than 15 percent of the cost of conventional steel tanks. Operating and maintenance costs are proving to be about 2 percent of those experienced at two large tank farms owned and operated by the Association.

Jan 1, 1973

By Michael Gay, W. H. Hansmire, G. Rippentrop, V. S. Romero

The new Tren Urbano heavy rail transit project in San Juan, Puerto Rico has one very significant part, the Río Piedras Contract, being constructed underground. This paper will give an overview of the tunneling work that started construction in1997. Design-Build procurement for tunneling is addressed. The new and modern transit system in San Juan will be 17.2 km (10.7 mi)long and have 16 stations in its first segment of construction, which is due to open in 2001. The line connects the city center district of Santurce to the outlying suburban municipality of Bayamón. All construction is being done under design-build contracts as a demonstration project funded by the Commonwealth of Puerto Rico and the Federal Transit Administration (FTA). The Río Piedras Contract is completely underground and involves practically all types of construction in soft ground. One station is built as cut-and-cover at the University of Puerto Rico. One portion has twin tunnels to be driven with an Earth Pressure Balance Machine (EPBM) and lined with one-pass precast concrete segments. Another has four short tunnel drives at a turnout that will be constructed with an initial support of shotcrete and lattice girders (i.e., the New Austrian Tunneling Method of construction). The most complex construction is the Río Piedras Station, which is being built as a stacked drift with a total of 15 individual tunnel drifts. After being sequentially excavated and concreted, they will form the arch of the 19 m (62 ft.) wide by 16 m (53 ft.) high cavern station. This structure is excavated in soil with less than 5 m (16 ft.) of cover to overlying historic buildings.

Jan 1, 1999

By Donald P. Schlick

Gentlemen, today I would like to talk to you about metal and nonmetal mine health and safety--past, present and future. Briefly, I will comment on the past because it is important to an understanding of our present activity and our plans for the future. Federal inspection of noncoal mines was not authorized until 1966, when congress passed the federal metal and nonmetal mine health and safety act; public law 89-577, with the passage of this act, the federal inspector, for the first time, had the delegated authority and responsibility to enforce health and safety regulations designed to prevent personal injuries and occupational diseases, the new law also provided for the education and training of our miners; assistance to the operator through the transmission of technical and scientific information and assistance and equally important, the law made provision for state participation in the congressional mandate to prevent injuries and save lives in the mineral industry, Before I tell you about our program and our future plans, I want you to know that I am here to listen as well as to talk! In my view, the only kind of communication that is meaningful is two-way communication. Our nationwide progress in metal and nonmetal mine health and safety during 1972 cannot be measured in reduced fatalities or injuries. The unforeseen tragedy that took pace in Kellogg, Idaho, in may of last year mode that almost a certainty.

Jan 1, 1973

By Jason Saldanha, Andrew Evans, Jonathan Baber

"INTRODUCTION The need for a new road crossing at Silvertown is the result of three key drivers:- •,Severe congestion and delay at the Blackwall Tunnel and surrounding road network; •,A lack of network resilience and reliability resulting from a lack of alternative road crossings in east London and the impacts of unplanned closures; and •,The need to support substantial economic development in east and south-east London (jobs and homes) These drivers directly informed the main objectives for a road-based river-crossing solution. The traffic-related problems at Blackwall Tunnel are long-standing and before Transport for London (TfL) assumed control for the strategic road network in London in 2000 the Department for Transport (formerly Dept of Transport) had investigated various relief options including a third tunnel bore and new bridge. This resulted in a new crossing alignment being safeguarded (by direction of the Secretary of State for Transport) and this was refreshed in 2001 in favor of TfL. In recent years (since 2009) TfL as part of the East London River Crossings Programme has undertaken detailed optioneering and feasibility work to address the above ‘need’. This led to the conclusion that a new road tunnel would offer the best solution in preference to bridge, ferry or demand management options. In 2012, in response to a formal request by the Mayor of London, the Secretary of State for Transport confirmed a new road crossing at Silvertown as a Nationally Significant Infrastructure Project (NSIP) by Section 35 direction under the Planning Act 2008. This NSIP designation meant that TfL as scheme promoter must comply with the National Rail and Road Networks National Policy Statement (NNNPS) and must seek the necessary powers to build and operate the crossing by means of a Development Consent Order (DCO) under the Planning Act 2008."

Jan 1, 2016

By James D. Bennett

During the past decade many U.S. industries have realized the importance of a total loss control program; the bituminous coal mining industry is no exception to this trend. Oftentimes, we realize that the circumstances surrounding a "near miss" (an incident which does not result in personal injury or property damage) are practically identical to those associated with a fatality, disabling injury, or major property damage. And, many organizations suffer enormous financial losses in cases where no one is injured or property damaged but costly delays in production result. Detailed analyses of both injury and non-injury cases can provide valuable input into those engineering, behavioral, and management controls that are necessary to prevent their recurrence. The purpose of this paper is to describe a comprehensive loss control surveillance system (LCSS) that will enhance management control in preventing personnel, property, and production losses, thereby, maximizing profit. The next section describes the components of this LCSS. Then, we present one practical example of how this valuable management tool can be used to minimize loss through safety and training programs.

Jan 1, 1985

By Peter C. Ashbrook

The Regional Copper-Nickel Study was initiated in large part because of fears that copper-nickel development might cause adverse effects on the environment from air pollutants such as sulfur dioxide (SOZ) emissions from a smelter, and water pollutants such as acid mine drainage. The Study comprehensively examined the potential for ad- verse effects on the environment and possible mitigation measures on both a local and regional scale by first characterizing existing air and water quality, and existing sources of pollution, and then developing hypothetical development scenarios to model potential adverse effects. This paper gives a brief overview of the Study's findings concerning air and water resources.

Jan 1, 1980

By Randhir S. Sehgal

After some decades of lying low and being treated as a second rate fuel, coal is back in the news. Production is rising. Predictions are for an ever expanding use, and they differ only in their rates of increase. Even the FBI is involved in trying to stop fraudulent sales of non-existent coal lands and leases to the innocent. In short, we have a nearly chaotic boom on our hands. Obviously our energy production base is in the process of undergoing a major shift, and the process will present many problems. However, there is little doubt that the industry has the basic strength and organization to be able to deal with the new issues that will arise as a result of these shifts in production and use of coal. After all, it does produce nearly 800 M tpy now, and coal is the single biggest fuel for generation of electricity. This role of coal is illustrated in the table below, which shows the coal equivalent quantities of various fuels used in the production of electricity.

Jan 1, 1980