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By Edmonds W, Jeffcoat R

The completion of the first two open hearth furnaces in the new No. 2 open hearth plant at Port Kembla will increase Australian production of steel by 350,000 tons of ingots per annum.The paper gives an outline of the essential features of open hearth design and auxiliary equipment required to operate the two modern open hearth furnaces at present being installed.INTRODUCTIONThe increasing demand for steel required by Australian secondary industries led to the decision to construct and operate No. 2 open hearth plant at Port Kembla. Two basic open hearth furnaces of the most modern design are under construction and it is anticipated that these units will be commissi.oned in September 1956. Australian steel capacity will thereby be increased by approximately 350,000 tons of ingots per annum.PLANT LAY-OUT AND CONSTRUCTIONIn the design and lay-out of this plant the emphasis has been on efficient material handling with simplicity of design and operation. Overseas methods were studied and these studies, together with experience gained at Newcastle and Port Kembla open hearth shops, enabled this plant to be built to a standard which compares favourably with any other in the industry.Initially two furnaces, each of 2,75 tons capacity, have been built, but provision has been made in. the design and lay-out to enable expansion to six furnaces.The location of the new plant in relation to the existing units will be noted in Fig. 5. It is one of the first units to be built in an area which will dovetail into a pattern for...

Jan 1, 1957

By Fitzhugh T. Lee

Results from the first part of a two-part investigation of the stability of highwalls in open-pit coal mines in the Paleocene Fort Union Formation of the western Powder River Basin of Wyoming and Montana indicate that these highwalls are subject to time-dependent deformation. Field investigations and laboratory physical properties tests of coal and overburden rocks suggest that several factors influence highwall stability. Some of these factors are rebound of overconsolidated rocks, desiccation, water, orientation and spacing of fractures, and strength and deformation properties. Factors of safety for a typical highwall in the study area (calculated by the finite element method) may be less than 1.0 when open fractures are present and the highwall has degraded. Although it is concluded that most open-pit highwalls in the Fort Union Formation within the study area have adequate short-term stability, these highwalls do deteriorate and become progressively less stable. Because of this, postmining failures are common and stability conditions could become critical if mining were delayed and then resumed after a period of several months. The second part of the investigation will utilize field measurements of rock-mass properties and instrumentation of actively mined highwalls to obtain data for comparison with the results of the initial investigation. Because the height of highwalls will increase as the more shallow coal is exhausted, these data will also be used to predict the behavior of slopes higher than those presently found in the western Powder River Basin.

Jan 1, 1977

By François Girard

La zone 1 de la mine Doyon (zone altérée), se situe à l?extrémité sud de la mine et est constituée d?une série de veines étroites à fort pendage et ayant des épontes de très faible résistance. Les épontes supérieure et inférieure ont des valeurs de RQD variant de 0 à 20 lors que les valeurs de RQD de la zone minéralisée se situent entre 20 et 40. Le minerai de la zone 1 s?étend sur environ 300 m de long et sur 900 m de profondeur avec des épaisseurs variant entre 2 et 15 m. Des méthodes de minage long-trous y sont utilisées avec des accès longitudinaux ou transverses selon l?épaisseur de la zone minéralisée. L?exploitation de la zone 1 a débuté en 1991 et plus de 1,7 millions de tonnes auront été extraites à la fin 2008. Plusieurs techniques y ont été testées que ce soit au niveau du développement ou du minage afin d?améliorer la sécurité des travailleurs, de réduire la dilution des chantiers et d?en augmenter la récupération. Différentes modifications ont été apportées aux dimensions et orientations des galeries, aux patrons de forage, aux techniques de sautages, au support de terrain, à la séquence de minage et aux méthodes de remblayage. Le texte suivant élabore sur plusieurs approches utilisées lors du minage de la zone 1.

Feb 1, 2008

By R. L. Handy

The objective of this research was to devise and test an apparatus to rapidly evaluate the cohesive and frictional strength of coal in situ, in order to increase the safety and percentage of coal recovery from underground coal mines. During the first year device was designed utilizing the bore-hole shear test principle from soil shear strength testing: Two opposing corrugated plates are forced outward to exert a controlled contact pressure against the sides of a previously bared hole, and then the plates are very slowly pulled along the axis of the hole to cause shearing of coal in contact with the plates. Results with the device are expressed in terms of a friction angle[_] and a cohesion c. The [ ] angles obtained from an Iowa coal arc in close agreement with and fall between results from triaxial and direct shear laboratory tests on the same coal. The measured cohesion was found to be much less than from the comparable laboratory tests. It may be increased by pre-stressing and other techniques to embed the shear plate teeth for the first shear test point.

Jan 1, 1973

By Leslie Burnside

Homestake Mining Co. set out to complete final reclamation at a former open-pit gold mine in west central Nevada. The goal was to exceed regulatory standards by satisfying the company's own high corporate standards for successful reclamation. Homestake's completion requirements challenged available technology due to the unsuitability of heap material as a growth medium, the harsh environmental conditions of the site and the region's lack of native growth medium. Accomplishing these goals required enlisting a multidisciplinary project team to develop, test and implement appropriate and cost-effective revegetation alternatives.

Jan 1, 1999

By Frank B. Fulkerson

Aluminum production in the Pacific Northwest has a new potential for expansion and increased stability of operation. This new potential results from greater availability of power; lower freight rates on alumina and aluminum; good market prospects for the metal, including western aluminum market expansion following a decline in defense requirements in the 1950's; and possibility of developing bauxite deposits in the Pacific Basin as well as other mineral resources. INTRODUCTION This is a report of a special study by the Bureau of Mines of the primary aluminum industry of the Pacific Northwest. It outlines developments relative to the United States as a whole.

Jan 1, 1962

By Basil Dimitriades

The roles of hydrocarbons and nitrogen oxides in smog formation were investigated by the Bureau of Mines. Samples of automobile exhaust with varying HC and NOx levels were irradiated in a smog chamber under conditions that resulted in smog levels similar to those observed in the atmosphere. Results were used to define the patterns that describe the dependence of a number of smog manifestations on HC and on NOx. Using these dependence data and some simplifying assumptions, estimates were made of the ranges within which HC and NOx must lie in order to obtain specified levels of air quality.

Jan 1, 1970

By Stan Merjan

Composite piles with precast concrete tapered pile tips (TPT Composite Piles - U.S. and foreign patents) are a new and important addition to the piling types available to the construction industry. TPT Piles were invented by Stanley Merjan, Vice President of Underpinning & Foundation Constructors, Inc.. U. F. C. installs these piles in the Northeast United States and licenses piling contractors in other parts of the country. TPT Piles have been developed for use in sandy subsoils at depths to 70 feet or greater. The TPT system (see Figure 1) is simple. A pile stem of conventional material (shell, pipe, steel, wood, precast concrete) is connected to a socket formed in a precast concrete tapered pile tip (TPT). This composite assembly is then driven as a unit by ordinary pile driving methods until adequate driving resistance (established by formula or load tests) is met in a suitable soil strata. This driving resistance develops from the displacement and densification produced by the TPT. Many combinations of tip shapes and stems are available to suit particular job requirements with respect to subsoil conditions and pile capacities. TPT Piles should be considered for use on a wide variety of jobs. The advantages offered by a TPT installation include: ? High capacity piles in marginal soils ? Minimal lengths required to produce these capacities ? The use of conventional pile driving equipment and procedures ? Pile inspection techniques that are the same as for ordinary pile driving Furthermore, TPT piles are economical due to a combination of a low cost per ton of pile capacity and high productivity, both of which lead to significant savings in foundation costs and time required to complete foundation work.

Jan 1, 1987

By Guangyi Sun

Wall rock classification method for coal mine support is the main factor affecting mine support. It is greatly affected by the combined effect of randomness, fuzziness and human being's incomplete knowledge. There are several coal rock classification methods. Using different rock classification methods the same engineering rock mass can be classified into different classification leading to different construction practices.

Jan 1, 2005

By A. A. Beland, R. J. Dawson, S. Shewchuk

"Shovel buckets, scraper blades, dipper teeth, mine car wheels and hammermills are examples of equipment which require routine maintenance due to abrasion. Service life can be extended by the use 0/hard/acing and buildup materials. Mining and milling applications are described and field welding procedures discussed.A high-stress abrasion test used to select hard/acing and buildup materials/or hammers in a hammermill is described in detail. Field tests of the selected alloys confirmed their performance, and maintenance records showed a significant saving in down time and cost.The relationship between the abrasion resistance of the alloys and their hardness, work hardening, composition and microstructure is summarized. IntroductionLarge volumes of ore are handled daily by the mining industry. The abrasive nature of most ores results in extensive wear to both handling and processing equipment. If such wear is neglected it may cause lost production time and also, in extreme cases, require the complete replacement of expensive equipment. The well-planned maintenance of components subject to abrasive wear by means of buildup materials and hard facing can result in substantial economic benefits. Such benefits can , however, only be realized through the correct choice of welding process, consumables and deposition methods available to maintenance personnel. Hardfacing MethodsHardfacing is applied by a variety of methods; the three most widely used being arc welding, oxyfuel gas and thermal spraying. Table 1 summarizes the major processes used within each method. Filler metals in the form of rod, wire or powder are necessary to fulfill the individual requirements of each process. The filler rods are available in the cast form or, in the case of ductile metals or alloys, as wrought rod or tube. All types are supplied bare or flux covered. Wire is supplied in two forms, drawn flux cored and drawn solid. Powder filler metals are available in many metals or alloys; they may be simple mechanical mixtures or prefused and atomized alloys made to a specific size range and shape for optimum results for each applicable process."

Jan 1, 1980

By Mehmet Canbazoglu, Kaarlo Haavanlammi, Hannu Laitala

Cobalt is currently a critical metal because of the increasing number of electrical vehicles forecast for production. Copper and zinc are base metals that are used in many everyday applications, including vehicle production. Eti Bakir Co. Mazidagi Phosphate Plants in the Mazidagi district of Mardin, Turkey is a multi-product facility that produces cobalt, copper, and zinc, as well as fertilizers, from the roaster calcine. Roaster off gas is treated in a sulfuric acid plant (SAP) and the acid itself is utilized in fertilizer production. The comminution circuit, roaster, SAP, and calcine leaching process were developed by Outotec and integrated with the fertilizer production process implemented by Eti Bakir A.Ş. This paper describes the hydrometallurgical calcine leaching process used at the plant, with a focus on the oxidative pressure leaching of the cobalt, zinc, and copper-containing calcine. The cold and hot commissioning phases of the pressure leaching autoclave start-up are discussed together with experiences from the ramp-up period. The production processes of the copper cathode and cobalt and zinc-containing salts are also presented together with some of the plant’s operating parameters. INTRODUCTION The ETI Bakir A.S. fertilizer plant, Turkey, is located in Mardin Province near the border with Syria, (Figure 1). The leaching plant project was started in 2012. The purpose of the plant is to separate the valuable metals from the calcine produced by the pyrite roasters, which are used to produce a SO2 containing gas for the new sulfuric acid plant. Fertilizer production requires sulfuric acid, and for this reason a sulfuric acid plant was built; customer already had access to pyrite concentrate, which is used as the roaster feed. During the engineering phase of the roaster and acid plants it was noticed that the roasted calcine contained considerable amounts of valuable metals like cobalt, copper, and zinc. To recover these metals, a calcine leaching process was developed at the Outotec Research Center in Pori, Finland. The main process connections of the Mazidagi site are shown in Figure 2.

Jan 1, 2019

By Robert J. Rothwell

Underground mining of coal by longwall mining methods has not been a predominant technique in Ohio. To date, only five mines in the state utilize this method, however, the technique has sparked a certain amount of controversy. As a mining technique, longwalling was introduced into southeastern Ohio in the early 1970's but it did not attract public attention until the mines began moving into privately held surface lands. This occurred coincidentally at about the same time that the state of Ohio began to regulate the environmental impacts of underground mining. Prior to the passage of the Surface Mining Control and Reclamation Act in 1977, (SMCRA), Ohio's reclamation law, Chapter 1513 Ohio Revised Code (O.R.C. 1513) did not regulate underground coal mines. As a result of SMCRA, the Ohio Statute was amended in 1978, to include regulation of the surface effects of subsidence. The inevitable result was that existing mines were immediately subject to regulations that were not considered during the initial mine planning process. (For an excellent survey of Ohio Laws that deal with coal mine subsidence, see Zima, 1985. ) The problem faced at that time by both the coal industry and the Ohio Division of Reclamation (the agency within ODNR charged with implementing O.R.C. Ch. 1513.1, was that of attempting to superimpose permitting requirements, and design performance standards onto mines that' had been operational for a number of years.

Jan 1, 1986

By S. Frimpong

Hydraulic shovels are widely used for primary production in surface mining operations. Variability in material diggability, unstructured mining environments and limited space and operator inefficiency affect the performance of these shovel excavators. Dynamic models of the hydraulic shovels are essential for understanding and improving machine performance. This paper contributes to this subject area by advancing hydraulic shovel kinematics and dynamics using the modified Newton-Euler method. A virtual simulator is developed to simulate the hydraulic shovel performance in the ADAMS environment. The simulator is validated with data on shovel geometry and the physical and mechanical properties of a formation in a surface mining environment. The results indicate that a shorter digging time increases the shovel operating power requirements, and that the required peak power increases by 100% when the digging time reduces by 50%. Simulation results also show that a shallow trajectory facilitates the digging process, with 50% reduction in peak power requirements compared to a deep one. This simulator provides a powerful tool for performance monitoring, excavation process designs and structural optimization of hydraulic excavators. This work also forms the basis for developing comprehensive simulator models for automated shovel operations in constrained mining environments.

Jan 1, 2005

By Jose R. Hernandez-Aguilar, Jeet Basi

"The study evaluated the impact on overall circuit metallurgy of improving the performance of the two flotation columns that make up the final Mo cleaning stage in the Cu/Mo separation circuit at Highland Valley Copper mine. The results showed that a key factor to improve the overall circuit metallurgy was to control the size of the bubbles generated in the columns. When a large proportion of small (< 1 mm) bubbles were generated, the production rate of solids-in-concentrate increased by a factor of 4-5 compared to typical production figures without compromising concentrate quality. This increase in concentrate production rate reduced the circulating load in the circuit causing a significant increase of Mo recovery. A statistical analysis of historical production data showed a strong relationship between final concentrate production rate and overall Mo recovery. This relationship along with the results from this study indicated an opportunity to increase the recovery of Mo from 90% (typical) to 94% without downgrading concentrate grade. This 4% increase represents about 14,000 lbs or $500,000 worth of Mo each month at current metal prices.To provide a rational interpretation of the results, this study also examined whether the model of Gorain et al. (1997; 1998; 1999) could explain the increase of Mo recovery seemingly resulting from the decrease of bubble size. The data showed that the model predictions did not agree with the experimental data, i.e., for a given change (decrease) of bubble size, the predictions underestimated significantly the observed recovery increase. An interpretation based on the fundamental analysis of Finch and Dobby (1990) and Hernandez-Aguilar et al. (2005) is proposed to explain the discrepancy between measurements and predictions obtained from Gorain et al.’s model.INTRODUCTIONIt is generally accepted that the size of the bubbles generated in a flotation cell – a concept usually referred to as “bubble size” – has a significant effect on metallurgical performance. However, a significant number of mineral processing practitioners often question, with valid reasons, the practical benefits of implementing process improvement strategies based on controlling bubble size. “Small” bubbles are often considered to be “favourable”, but how small they need to be for a particular case, or how to adjust operating conditions to control a target bubble size, or whether the bubbles need to be smaller in the first place are questions that usually remain unanswered. Two reasons explain this situation."

Jan 1, 2009

By D. P. Venter

When Oryx Mine down-scaled in 1994, focus was placed on development, with the primary aim being the exposure and proving of ore reserves. In order to achieve this aim, development ends had to be advanced to reef at the maximum possible rate. This in turn called for support methods which could keep up with the advancing faces, taking up minimum space and time for installation, while providing on the face a real coverage and effective long-term support. In the majority of the development ends which were located in fairly competent ground, the grouted rod development support proved to be adequate until such time as secondary support in the form of meshing and lacing could be installed. The ends developing towards the eastern boundary of the mine, especially in the ?C? block, encountered extremely adverse ground conditions due to the presence of smectite zones within the footwall quartzites. Smectites are a group of montmorillonite clay materials, mainly composed of hydrous aluminosilicates. They occur as minute platy crystals in the rock mass and are especially notable for their ability to absorb liquids. Generally, the zones are found in between the bedding planes of the host rock, and may vary considerably in thickness over short distances. Wherever the smectites were exposed by the development blasting, the rockwalls weathered as the smectites absorbed water and the condition of the tunnel rockwalls deteriorated rapidly. When the smectites were left exposed and allowed to weather, it became almost impossible to install secondary permanent support such as meshing and lacing at a later stage. To minimise the exposure time and subsequent deterioration of the smectite zones, it was recommended that all development ends encountering smectites be shotcreted as soon as possible after blasting. In developing a shotcreting support methodology, both a drycreting and wetcreting system were investigated. The situation at the time ruled out the use of a wetcreting system on the basis of the extensive and costly infrastructure required, as well as its limited manoeuverability. Instead, it was decided to opt for as maller scale but more manoeuverable drycreting system. The system utilized a number of portable drycrete machines with pre-bagged cement, which could support several development ends in close proximity. Initial trials using normal 30 MPa shotcrete on 19level proved successful and the system was implemented.

Jan 1, 1998

By Colin Hardie, Erik Bartsch, Guy Comeau

"The Xstrata Nickel Raglan Concentrator, located at the northern limit of Quebec’s Nunavik region has been in operation since 1997. Originally designed to process 800,000 tonnes per year of high grade nickel ore, plant capacity is currently approaching 1,200,000 tonnes per year due to an Optimization Project (FAG to SAG conversion) in 2005 and many recent processimprovements.In 2006, the Raglan Metallurgical Group with assistance from the Xstrata Process Support group decided to make SAG control one of its priorities in order to further increase throughput and improve stability. The original primary mill control logic delivered by the Optimisation Project in 2005 consisted of a simple PID loop controlling the mill charge (bearing pressure) through feed rate changes. Due to the multivariable, non-linear and disturbance dominated nature of the SAG circuit it was quickly found that this traditional PID control strategy was not able to adequately control the mill; resulting in poor stability, frequent operator interventions and less than optimum performance.This paper describes the successful integration of advanced field systems such as mill feed image analysis (Wipfrag) and crusher gap controller (ASRi), into a multi-variable fuzzy logic SAG mill controller. The process of how a strategy for control was developed and implemented directly in the existing control system (exploiting standard system capabilities) is discussed. It is also shown how this approach has provided mill automation which is simple, robust (despite erratic feed characteristics), and delivers both an increase in throughput and a reduction of variability.INTRODUCTIONOriginally commissioned as a Fully Autogenous Grinding (FAG) circuit in 1997, preparations to convert the Katinniq Concentrator Mill to SAG had in fact commenced as early as 1999, but were halted owing to alternative process improvements which achieved up to 1Mtpa as early as 2000. Up until this time, plant process controls had remained more or less static; modifications having been limited to those required by new equipment. Primary mill process controls and related measurements were at this stage limited to:"

Jan 1, 2008

By James R. Aggson

This Bureau of Mines report describes floor heave ground control problems that have been encountered in a new underground coal mine in West Virginia. Previous experience in the coal seam, the results of physical property investigations, and in situ rock stress determinations are discussed. The apparent cause of the ground control problems is the existence of a high, biaxial, horizontal stress field coupled with a floor member that has time-dependent deformation characteristics, A theoretical analysis of the failure process is developed. The analysis is assisted by finite element techniques. Mine design recommendations based on this analysis are presented.

Jan 1, 1978

By P. C. Carrasco

Knowing the origin of the relevant and irrelevant components of the nugget effect is essential to optimize the process under study. This paper describes the causes of the nugget effect and, its dependency on the sample support, sampling density, and on the QA/QC procedures. Several examples of natural and ?human? nugget effect are given. A method to estimate the magnitude of the relevant and irrelevant components is suggested. Finally, the economic consequences of misunderstanding the nugget effect are analysed.

Jan 1, 2010

By Graham Davey

High-speed stirred milling is a relatively new method of grinding in the metalliferous process industries. However, it has been widely used in the industrial mineral field for more than 30 years. Many existing metallurgical operations are looking to maximize economic return from existing deposits this requires new thinking and technologies. The operating experience of two copper operations is discussed here to show the effect of the introduction of the Metso Stirred Media Detritor (SMD), a new type of high speed stirred mill. Both operations have derived significant metallurgical benefits from this new technology. The benefits and process difficulties are explained. The initial drive in high speed stirred milling technology was toward ultra fine grinding where the mill product has an 80 percent passing size of 15 µm (937mesh) or less. More recently, a number of installations have occurred in a more conventional regrind setting. Few conventional copper concentrators require such fine grinding to attain satisfactory copper grades and recoveries. So other advantages must be considered here rather than just the ability to grind fine with good power efficiency.

Jan 1, 2004

By George T. Faust

The petrographer engaged in examining the products resulting from the beneficiation of ores and rock minerals is constantly required to develop new means and methods of assaying microscopically the results of such operations. From time to time investigators have published descriptions of apparatus that have aided in solving problems in processes f physical separation. Thus, in 191.9, Coghill and Bonardi 31 published a paper covering the application of the binocular microscope and camera lucida to the microscopic analysis of pulverized ores. Similar work has been published by Schneiderhohn 4/, Schwartz 5/, and Head and his associates6/, 7/, 8/. The present paper goes further and considers application of the polarizing comparison-microscope to problems directly concerned with mineral dressing where it is desirable to compare analogous products, and in addition it suggests new uses in various related fields. This work was conducted under the cooperative agreements of the Southern Experiment Station of the Federal Bureau of Mines and. the University of Alabama.

Jan 1, 1940