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By M. Hopf, E. Rossouw

Keywords: Pyrometallurgy, furnace, copper coolers, freeze lining, monitoring, Saveway The use of water-cooled copper components as sidewall elements of submerged arc furnaces and other pyrometallurgical applications has become increasingly common. The high cooling efficiency of copper has made it possible to increase the service life of furnace refractories when compared to conventional refractory linings. However even the self-healing effect of ?freezing? worn areas of the lining does not necessarily protect the copper coolers against wear or corrosion completely. In order to avoid furnace explosions, various methods have been used to monitor the wear of coolers. Unfortunately, these have not been able to consistently identify localized wear. Thos Begbie (South African) and SAVEWAY (German) jointly developed technology to embed a line sensor into the copper cooler during the casting process. This system allows an exhaustive monitoring of the copper cooler. A SAVELINE sensor is placed inside the copper-cooling panel between the water-cooling passage and the hot face of the panel. The sensor follows the meandering shape of the cooling water channels. In the first instance, the sensor provides analogue information as the thickness of the copper reduces. Secondly, this wear signal will be confirmed by a signal of interruption if the sensor is washed away. Because of the structure of the sensor, a self-diagnosis is possible and indications can be confirmed (double proofed). Subsequent to the manufacture of some test pieces, coolers for a large submerged arc furnace were manufactured. The sensorized coolers have been installed at the intermittent surface (slag line) where the largest amount of corrosion has been encountered. The system has been operating since December 2005 in what is considered one of the largest submerged arc furnaces in South Africa.

Jan 1, 2006

By Dyson N. F

Mixed cobalt-nickel sulphides precipitated from ammoniacal process liquors derived from nickel sulphide concentrates, mattes, and reduced nickeliferous laterites have been characterized.The mixed sulphides are prone to oxidation on standing and are rapidly leached under relatively mild conditions. The kinetics of the leaching reactions are controlled principally by temperature and oxygen partial pressure. Although the samples have different CO:Ni ratios and have undergone varying degrees of oxidation, there is little difference in their leaching behaviour. The results suggest that a single plant would be able to process mixed sulphides of varying composition. Any copper and zinc present in the mixed sulphides as impurities also go into solution and must be removed prior to recovery of the cobalt and nickel in metallic form.

Jan 1, 1981

By G A. Wellwood

What do all iron ore mines have in common? Perfect production days! Yes, those harmonious 24-hour periods when the stars align and the daily output number rockets past the long-term average to hit new heights. While perfect days are always welcome, the focusing question iswas that just a ‘flash in the pan’ (due to a special cause) or an indication of the process’s capability (with clues to the common causes) which, if addressed, could make every day perfect? In the context of today’s operating environment, with the need to maximise productivity at minimum cost, it’s an important question.Investigations reveal that the throughput difference between a perfect production day and the average is often in the order of 40 per cent, and that bulk solids handling (BSH) system deficiencies are the largest (>50 per cent) class of lost opportunity. Root causes for underperformance of elements in BSH systems can often be traced back to the detailed design and even study-stage oversights. Essentially baked into the fabricated plant, operations are effectively forced to accept them at the point of practical completion and then deal with the consequences for the life of the mine. Subsequent normalisation of these defects in the planning process reduces visibility and hence the impetus for long-term solutions in favour of lower targets and quick fixes to keep the show on the road. On an industry wide basis the design processes and assumptions responsible for BSH system underperformance become enshrined as common practice and hence repeated across sites and organisations.In addition to making the case for action, practical steps that can be taken to help realise the significant productivity prize and avoid the problems in first place are provided.CITATION:Wellwood, G A, 2017. One perfect (production) day – a bulk solids handling perspective, in Proceedings Iron Ore 2017, pp 443–452 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By Scott Turner

The present rapid growth of coal stripping in the United States is a curious reversal of the tendency of mining to proceed from outcrop to depth. A combination of technical and economic factors bas stimulated the use of stripping methods until today many million tons of coal We being recovered by open cuts from sites that an earlier generation of engineers would have passed by as not commercially mineable or, if workable at all, only by underground methods. The total quantity of bituminous coal and lignite mined in the United States by stripping in 1928, the latest year for which detailed figures are available, was 19,789,000 short tons. Of this, 71,000 tons came from small workings not equipped with power shovels and 587,000 tons from properties in which stripping and underground work were carried on at the same mine; but as neither of these types is representative of modern stripping practice, they will be omitted in the discussion that follows. The total from strip pits proper in 1928 was 19,131,000 tons, produced by 176 pits employing 385 steam or electric shovels.3 Figures by States are given in Table 1. Detailed statistics will be found in Economics of Strip Coal Mining; a study by O. E. Kiessling, to be published by the United States Bureau of Mines.

Jan 1, 1930

By T. Gupta, T. Ghosh

Rare earth elements (REEs) and their compounds are essential in a multitude of mundane and sophisticated applications such as renewable energy technologies, catalysts, medicine, and defense applications. The global supply deficit could be attributed to the destabilization of REE market that has, as a result, incentivized indigenous production of REEs. Cost-effective and environmentally benign opportunities are being explored for the production of REEs from non-conventional mineral sources including coal and coal by-products to stabilize the supply chain. Coal from Healy coal mine and Wishbone Hill deposits in Alaska have been quantified for REEs and were found to possess elevated total REE concentrations as compared to world average levels (60– 70 ppm). The objective of the study was to concentrate the REEs in the froth phase by froth-flotation of the fine size fraction (< 75 μm). A Box-Behnken design of experiment was employed to ascertain the main and interaction effects of operational parameters on response variable by analyzing 3D response surfaces. Experiments were carried out to maximize REE recovery and concentration by modeling and optimization of three operating variables (frother dosage, pulp density (% solids), and collector dosage). Based on the results, the optimum flotation conditions for maximum recovery at an elevated concentration of REEs in the froth fraction was obtained at 4.2% solids and 32.7 ppm of frother dosage for Healy sample and 10% solids and 37.9 ppm of frother dosage for Wishbone Hill coal sample. The quadratic relationship between the input and response variable was found to be independent of collector dosage suggesting good surface hydrophobicity and floatability of the two coal samples.

By Kazimierz Gwizdala

In the paper the method for estimation of settlement of vertically loaded piles in a group is presented. The method is generally based on the hybrid procedure with non-linear solution for single piles and with interaction between them for the low-strain shear modulus. Some attention is paid to the influence of deformation and strength parameters used in calculations. The applied model is verified in the framework of the research programme carried out recently in the Geotechnical Department of Gdansk Technical University. It concerns monitoring and analysing the settlements of the existing structures on piles. A comparison of calculation and measurements results for two tested buildings is presented as an example.

Jan 1, 2002

By Rainer Kahrger

This paper is a follow-up to the paper presented at the SME meeting in April of 1996. Since then, the El Abra facility has been started up, 9 months ahead of schedule, and has processed about 45 million tons of ore and produced over 700 million pounds of copper. For those unfamiliar with the El Abra materials handling and leaching facilities, a brief overview of the facility is provided. The paper will then deal in detail with such aspects of Conveyor 103, the long regenerative overland conveyor, including: actual running resistance starting and stopping procedures emergency brake test at 10,000 t/h Additionally, we shall take the opportunity to report on a catastrophic culvert collapse in October 1996, which stopped the conveyor abruptly at full speed and under high load condition, causing a belt breakage. We would like to use this opportunity to thank the management of El Abra and Cyprus Amax for providing assistance and allowing us to present this paper. The El Abra team deserves a great compliment for building this one billion dollar facility in record time in a remote area of a high-altitude desert with no existing infrastructure, and for bringing it so quickly up to full operating capacity. The El Abra management had to assemble a completely new operator team. Considering the above circumstances, it took a great effort by all involved to achieve success. The official performance test which was required by the lending banks was successfully concluded in November 1997.

Jan 1, 1998

In order to appreciate fully the place of palaeontology within the general framework of the geological sciences, consideration must be given to the time, about 150 years ago, just before the study of fossils was beginning to be applied to geological problems. At theend of the eighteenth century, almost all geologists recognised that fossils were the remains of animals and plants that had lived at the time when the rocks in which they occur were formed. It was also realized that many-some geologists thought all-rocks hadbeen formed under water, but as regards the order of succession in which these rocks had originated, and the relative ages of rocks found in different parts of the world or even of one country, only the haziest and most contradictory ideas existed.Around the turn from the eighteenth to the nineteenth century, a widely taught system of theories was that of the German professor, Abraham Gottlob Werner, who believed that the surface of the earth had once been covered by a universal ocean at whose bottom all rocks had been deposited. As the level of this ocean gradually subsided, older rocks-so Werner taught-are now generally found in the mountains or at great depth below the younger rocks; this was his &quot;Primitive Division&quot; which included granite, gneiss, schists, slates, basalt, porphyry and other igneous and metamorphic rocks, all of which he believed to be of sedimentary origin. Younger rocks, according to Werner, were formed at successively lower levels as the water receded. Next in age he placed a &quot;Transition System&quot; of limestones and greywackes; still younger the so-called &quot;Floetz Division,&quot; which included sandstone, limestone, gypsum, salt, coal, but also some basalt, porphyry and other rocks; youngest were the alluvial deposits of recent clays, loams, sands and gravel. Thus, in the Wernerian system the age of a rock was determined on the basis of its petrographic properties and the height of its occurrence relative to sea-level.Here and there these ideas survived well into the nineteenth century. As late as 1825, Charles Darwin listened to lectures by Professor Jamieson, one of the last proponents of Wernerian theories in England. The fact that entirely different kinds of fossils occurredin rocks which were regarded as contemporaneous did not worry the theoreticians.It is, therefore, noteworthy and significant that the value of fossils for the interpretation of geological events was demonstrated to the geologists by an engineer and surveyor, WiIIiam Smith, who, although no professional geologist, has often been called the &quot;Father of English Geology.&quot; His professional work, which was mainly concerned with drainage and irrigation projects, took Smith to all parts of England, where he sometimes journeyed as much as 10,000 miles in 11 year. Smith was a keen observer and, unhampered by theoretical speculations, he noted the occurrence of fossils and collected specimens wherever he went. Before long he realized that the same kind of fossils followed each other in successive layers of rocks in much the same way in different parts of England, and soon he was able, by looking at fossils collected by other people, to tell from what...

Jan 1, 1950

The notes from which this paper has been prepared were set down at the time of the author&apos;s departure from Australia in 1935. Mr. Frank Forman, Government Geologist of Western Australia, who has very kindly read the paper in manuscript, affirms that the views here set forth are now accepted by most geologists. Thus, Forman&apos;s recent presidential address before the Royal Society of Western Australia (1937) mentions sediments in the Kalgoorlie Series &quot;including banded jaspers and jaspilites.&quot;While it may, therefore, be superfluous to belabour the question further at this time, Mr. Forman has encouraged the author to publish this paper as a summary or both past and present views.To those specially interested in the subject of the paper, a study of pertinent Plates attached to Western Australian Geological Survey Bulletin No. 71, 1917, is suggested.The type of rock which is variously called &quot;jasper bar,&quot; jaspilite, or &quot;ferruginous quartzite&quot; is familiar to all mining men who have worked in the West Australian goldfields.In its typical form it is a &quot;striped&quot; rock consisting of alternate layers of white or pinkish silica with red to brown bands of iron-bearing silica.In the course of geological work in many parts of Western Australia I studied exposures of jasper bar and was repeatedly impressed with the similarity of much of the material to the sedimentary &quot;banded iron formation&quot; of Canada. It was, therefore, a surprise to learn that the jasper bars were not generally regarded in Australia as sedimentary horizons. It is true that Honman offered convincing evidence of the sedimentary origin of the jaspers...

Jan 1, 1939

By P. Goosen, A. Paterson, E. Paulsen

Ticor South Africa is currently involved in the mining and processing of a heavy mineral oredeposit at Hillendale Mine on the KwaZulu-Natal north coast. The orebody is characterized by a high ultra fine fraction (-45µm) that has a variable rheological behaviour when subjected to shear and hydration. Experience at Hillendale has shown that the ultra fine mineral tailings are sensitive to shear history in terms of shear intensity and shear duration as well as hydration history. This phenomenon expresses itself right through the primary beneficiation process influencing the mineral separation, but is especially prevalent on the residue disposal i.e. slurry transport and deposition on the tailings impoundment. Tube viscometer test work was conducted on the flocculated fine tailings that indicated that there was a change in rheology as a result of shear. This paper presents the results of the on-site test work conducted at the mine to measure the rheology at various stages in the process.

Jan 1, 2003

By M Nehring, E Topal

Nowadays mining projects are seeking new versions of evaluation that are based on the flexibility in the project. Real option valuation (ROV) is one of the modern evaluation methods that provides a tool to adapt and revise mining projects under uncertainty and future variable movements. Most evaluation approaches simply assume that some variables are fixed, such as production rate, variable cost, fixed cost and lifetime of project. The first section of this paper reviews a comprehensive study of ROV in mining projects. The paper then introduces a new model that solves problems where previous methods lacked. The new method endeavours to find maximum mining project value by adding total cost as a function of production rate into ROV. The second section has been applied to a new model on the Century zinc mine in north-west Queensland, thus illustrating the future overview of that mine. The new version of ROV gave a significant positive value for the Century Mine, when the closure and reopening options where available throughout the life of the mine. Consequently, the new method evaluates real options to add value to mining projects, maximising projectÆs value, estimating cost function, optimising production rates and offers opportunities in projects to amplify gains or to mitigate losses.

Jan 1, 2009

By Whiten W. J

An investigation on the breakage characteristics of closely sized orc samples at different levels of input energy was carried out to determine an appearance function for possible use in ball mill modelling. A consistent pattern of breakage behaviour was observed and the resultant size distributions could be described by a one-parameter, (&apos;t&apos;), family of curves. For each particle size range tested, this parameter &apos;t&apos; has an exponential relationship with input energy below an upper energy limit. A tentative linear relationship between the input energy at a constant value of &apos;t&apos; and the work-index leads to reconstruction of &apos;I&apos; - input-energy curves from the work-index values. To normalise the efrect of particle size and input energy, multidimensional cubic spline regression was performed on thc entire range of data. The results indicated that the parameter &apos;t&apos; can be determined, reasonably accurately, as a function of Ln (input energy, kWh/tonne) and Ln (particle size, mm) for input energies between 0.5 and 8.0 kWh/tonne.

Jan 1, 1983

By A. L. Martikainen

In fluctuating airflow, continuous air velocity recording is the most reliable method of air velocity measurement. It allows for fast recognition of changes and the calculation of long-term averages. Also, it enables the mine operator to identify when the airflow has decreased to a point requiring action. Using ultrasonic anemometers provides an accurate option for continuous air velocity monitoring. This paper provides information about the effect of common obstructions in underground mining on air velocity readings. Stationary and moving obstructions are used to represent workers and equipment that would cause discrepancies in measured airflow. Also, it is important to know how large of a sample size is required to ensure reasonable accuracy of results. Statistical analysis is used to evaluate the required sample size. The sampling procedure is further studied by comparing two different sample rates. The results show that obstructions provide noticeable differences in air velocity measurements. Also, movement of obstructions can be recognized from changes in results. Surprisingly small sample sizes provide reliable air velocity information. Standard sample rates are found to be suitable for the underground environment.

Jan 1, 2011

The additional information that Clarke and Taylor (1982) provide about the important but poorly documented Ardlethan deposit is, of course, very welcome. However their contention that structural considerations, in conjunction with petrology, alter the interpretation of the mineralogical and geochemical data presented previously (Scott, 1981) is not accompanied by adequate supporting evidence. Indeed characteristics of the orebodies studied invalidate their arguments.Heterogeneity between matrix and fragments is not a problem in the South Cherry and Ardwest orebodies because most samples are comprised entirely of interlocking hydrothermal assemblages with a fabric and mineralogy that is uniform through both former breccia fragments and matrix. In hand specimen, the rock superficially resembles altered granite and, as indicated by Clarke and Taylor (1982), a brecciated texture is difficult to discern. In thin section, relict brecciated textures can be observed as localized changes in the grainsize or in the distribution of minerals that outline former breccia fragments (P. J. Eadington, 1982, personal communication).Because of the intense brecciation and comminution of rocks (fragments &lt; 10 mm are usual) in the South Cherry and Ardwest breccia bodies, hydrothermal recrystallization was complete, resulting in homogenization of fragments and matrix. Furthermore, the amount of sample analysed (-100 g for drill core and 2-3 kg for hand specimens) is sufficiently large to be representative of both former breccia fragments and matrix. The Carpathia and Stackpool orebodies, with their abundance of sedimentary fragments, have alteration superimposed on a heterogeneous fabric, and were not studied. Thus the problems of differentiating between fragments and matrix (Clarke and Taylor, 1982) are irrelevant to the particular orebodies described in my paper.Within the alteration halo, which is several hundred metres wide (Paterson, 1976), the very uniformity of the alteration assemblages implies that subsequent, postmineralization brecciation is of only minor significance.Indeed tourmaline pipes in the Ardwest pit are less than several metres across (Clarke, 1979) and produce minimal alteration in the surrounding rocks. Therefore the interpretation of the mineralogical zonation is not compromised by the recognition of several periods of brecciation.

Jan 1, 1982

By M. Fan, M. Mankosa, G. Luttrell

"Column and other non-conventional flotation approaches continue to provide benefits where conventional flotation processes have exhibited limited success. This is particularly evident with respect to flotation of ultrafine and coarse particles. Advancements in air sparging technology have provided the ability to produce finer bubbles than previously possible. The generation of finer bubbles coupled with the froth washing capabilities of a flotation column has demonstrated improvements in ultrafine particle recovery while simultaneously producing a high-grade float product. On the other side of the spectrum, the use of these sparging technologies while applying flotation fundamentals to a fluidized-bed reactor has increased the maximum floatable particle size up to and in excess of 3 mm. Benefits of higher recoveries and reduced reagent consumption have resulted from the use of these technologies. An additional benefit includes a reduction in plant grinding requirements. As such, this paper describes the application of Cavitation-Tube sparger technology and fluidized-bed flotation (HydroFloat). A review of data from industrial and pilot-scale applications is also provided.INTRODUCTIONConventional (mechanical) froth flotation is considered the workhorse of the minerals processing industry. This low-cost process makes it possible to selectively recover minerals by exploiting the difference in surface characteristics (e.g., wettability) of the valuable component and the waste material. Unfortunately, the upper particle size limit for flotation rarely exceeds 0.600 mm, and is typically maintained at less than 0.300 mm for most industrial applications. For many commercial base metal plants, the particle size range for optimum recovery is typically between 0.01 and 0.1 mm (Lynch et al., 1981). This finding is not novel. In fact, the effect of particle size on flotation recovery was studied as early as 1931 by Gaudin et al. who showed that coarse (+0.250 mm) and extremely fine particles (-0.010 mm) are more difficult to recover than particles of an intermediate size. The loss of recovery is due to inherent limitations associated with the flotation process, including bubble-particle adhesion and collision, detachment, buoyancy, and transport."

Jan 1, 2010

By Anthony T. Iannacchione

The Roof Fall Risk Index (RFRI) is a new method introduced by the National Institute for Occupational Safety and Health (NIOSH) to assist the underground stone mine operator in 1) assessing defects the mine strata and 2) rating the relative roof fall risk these defects pose. The RFRI utilizes observational techniques to identify defects in the roof strata caused by local geologic, stress, and mining conditions. Assessment values for ten defined defect categories provides the foundation for estimating a range of risk conditions between 0 and 100 that define the potential for a roof fall. This paper examines how the defect information is collected using two field verification sites and proposes methods to analyze the RFRI data. These examples provide information on how well the method replicates observed conditions and how it might be applied in practice.

Jan 1, 2006

By Peter Cunningham

General Description of Projects The objective is to streamline data transfer within our Process Control and Business Systems for the purposes of tracking actual production, reducing manual record keeping, improving process control and improving vehicle maintenance. This presentation focuses on two implementations of mobile equipment data acquisition systems which make use of industry standard data models and data transport protocols. Pilots are part of the Mines Technology Roadmap to improve our mining operations ?Enabling technologies and pilot of key systems

May 1, 2013

By Walter C. Lorenz

In connection with its renewed study seeking solutions to problems created by release of acid water from bituminous coal mines, the Bureau of Mines recently surveyed reports already written on the subject. This publication is based on that search. The Problem Poor distribution of water is evident on an ordinary geographic map of the United States. The more abundant supplies of surface water appear to be centered in the northeast, the southeast, and the central humid areas of the country. It is in the midst of this abundant surface water, in the Ohio River Valley, that most of the bituminous coal is mined. Varied industry has located in the valley to use the coal and the river. The coal is a source of power and o raw material. The river provides transportation for raw and finished materials; equally important, it provides the water that is used for cooling and processing in manufacturing. It also serves as a vehicle for the disposal of waste.

Jan 1, 1962

By Paul A. Roy

The North Shore Connector Project for the Port Authority of Allegheny County constructs twin Tunnel Boring Machine (TBM) tunnels through cohesive soils and rock beneath the Allegheny River and a narrow city street in Pittsburgh, PA. The tunnel alignment includes an historic building on shallow foundations, modern buildings on deep foundations, and an office building constructed directly over the alignment during the design of the tunnel sections. This paper provides an overview and update of the general site conditions, TBM tunnel design, and support of excavation for the TBM launching pit. Deformation limits, ground improvement, monitoring and mitigation plans are also discussed.

Jan 1, 2008

Bio-Oxidation of Arsenic and Stibium Bearing Gold Ores Bio-oxidation of arsenic and stibium bearing gold ores with acidithiobacillus ferrooxidans was studied. The preoxidation results show that the best bio-oxidation technical parameters are the initial pH in the range of 1.8&nbsp;~&nbsp;2.0, particle sizes under 0.074&nbsp;mm, temperature in the range of 25¦C&nbsp;~&nbsp;30¦C and rotating speed of the orbital incubator in 100 rpm&nbsp;~&nbsp;160 rpm. The leaching results show that If the ore, of which contain 10.37 per cent arsenic and 36.81 per cent stibium, is not bio-oxidised, gold leaching is only about 41 per cent, after 8 days oxidised, the result is about 76.55&nbsp;per cent, which improved about 35.62 points. The relationship between gold leaching and arsenic oxidation is direct proportion, furthermore, it needs only partly oxidise and higher gold leaching could be get, for example, gold leaching is over 90 per cent when asenic oxidation is 60 per cent. The results will provide theoretical and technological supports of bio-oxidation arsenopyrite for pretreating refractory gold ores.

Sep 13, 2010