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By Robert E. Mazurak

Mines and plants for sale, downsizing, bankruptcies, consolidation, slab imports, minimill growth displacing traditional integrated steel-making. These are some issues for North American iron ore and integrated steel producers. But the blast furnace still remains the workhorse of the ironmaking industry. And direct reduction and other alternate ironmaking technologies have yet to make any serious inroads in North America. How come? This article addresses the current state of primary ironmaking in the changing North American steel industry, the direct reduction market and new technologies under development that may hold some promise.

Jan 1, 2003

By Tom Gonzales

At San Manuel, AZ, Magma Metals Co. operates an Outokumpu flash furnace, four Peirce-Smith converters and two anode casting wheels that are supported by six anode vessels. Process gasses from the flash furnace and converters are treated in a two-train/ double-contact sulfuric acid plant. The plant captures 98% of the sulfur. A new flash furnace was commissioned in July 1988. It has since processed more than 2.7 Mt (3 million st) of sulfide concentrate without a major rebuild. The company has gained unique experience in the operation of the flash furnace at high oxygen enrichments with low off-gas dust loadings. New procedures have been developed to maintain secondary material generation at equilibrium and for maintaining metallurgical control of operating parameters. Process flow description At Magma's San Manuel plant, concentrates and other copper-bearing material are blended and conveyed from two separate areas of the plant to three 420 t (465 st) capacity wet charge bins located above the rotary dryer. Flash furnace silica flux is conveyed to a 227-t (250-st) capacity fine flux bin located adjacent to the wet charge bins. The concentrate and flux are blended in controlled amounts and fed into a 168-t/ h (185-stph) gas-fired rotary dryer. The wet charge enters the dryer at 8% moisture and is dried to 0.2% moisture. The dried charge is pneumatically conveyed to a 580-t/h (640-stph) dry charge bin located above the flash furnace. Flash furnace charge is drawn from the bin by two drag conveyors at a concentrate feed rate of 145 t/h (160 stph). The charge is mixed with enriched combustion air and injected into the furnace reaction shaft. In the reaction shaft, the charge is oxidized to form matte, slag and a rich SO, off-gas.

Jan 1, 1992

By D. Bour, C. Nyikos, R. Curtice

Fire in a coal mine can be disastrous on many levels. In most cases, when a fire is detected, mining operations cease and all personnel are evacuated. Underground coal-mine fires are difficult to extinguish, can burn for a long time, and often result in an extended period of lost production. In a worst-case scenario, the mine is permanently sealed and abandoned, resulting in lost jobs, lost natural resources, and possible devastation of the local economy. In some cases, seals placed within the mine to isolate the fire could eliminate the need for sealing the entire mine and the subsequent extended delay in returning the mine to full operation. Previous attempts to place remote seals to extinguish mine fires in active mines have been largely unsuccessful. The West Elk mine experienced an underground fire in early 2000. The fire could not be accessed and extinguished from the active mine workings. A method of constructing seals remotely by drilling boreholes into the affected area was needed to help isolate and extinguish the fire. This paper describes the process by which remote seals were constructed that successfully isolated the fire and provided a means of extinguishing the fire by flooding the area with water. The period of lost production in the West Elk mine was considerably shorter than is typical in similar situations.

Jan 1, 2002

By D. Royston

SAG mill liner development draws primarily on practical experience from SAG milling operations supported by computer-based modeling of charge motion in SAG mills and on established good design practice. Liner design needs to respond to the process aspects of mill liner action that are critical to good SAG mill performance, i.e., the impact of shell liners on the grinding action and of grates and pulp lifters on pulp discharge. In recent years, the trend in large SAG mills has been to use wide-spaced shell lifters with large lifter face angles, primarily to reduce packing and ball/liner damage, and to use larger, hence fewer, mill liner parts to reduce downtime at liner change-outs.

Jan 1, 2007

By Martin Herrenknecht, Karin Bäppler

The last five years have seen a remarkable increase in tunnelling projects in both soft ground and hard rock applications. Part of the increase is a result of recent Research & Development efforts to improve Tunnel Boring Machine (TBM) adaptability, capability and reliability. This paper will review the latest innovations in the TBM industry and explain in detail the results of these innovations followed by a forecast where the technology will take the tunnelling industry in the future.

Jan 1, 2005

By J. Luxford

The last decade has seen an enormous increase in the use of contractors right across the Australian mining industry. So much so that contractors now operate 33 of the 68 underground metalliferous mines around Australia and are making significant inroads into iron ore in the west and coal in the east. Safety used to be a low priority for many contractors. The picture has changed dramatically in recent years as most contractors take a far more professional approach to safety management. This paper examines the changes that have occurred and the requirements for effectively managing safety in a contracting environment.

Jan 1, 2000

By Timothy P. Smirnoff

Sustaining the region?s mobility needs, achieving projected economic growth, and maintain Midtown Manhattan as a center of regional, national and global importance has led to continued investment in commuter rail and transit infrastructure in New York City and resulted in design and construction of large underground caverns. The current plans for stations in Manhattan include New York Penn Station Expansion (NYPSE) caverns for Trans Hudson Express (THE) Tunnel Project for New Jersey Transit (NJ Transit) and the Port Authority of New York and New Jersey (PANYNJ), Metropolitan Transportation Authority Capital Construction Long Island Railroad (MTACC/LIRR) twin caverns for East Side Access (ESA) Project, and station caverns of the No. 7 Line Subway Extension Project and Second Avenue Subway Project for Metropolitan Transportation Authority Capital Construction/New York City Transit (MTACC/NYCT). This paper provides a general overview of these large caverns now in design or construction in Manhattan, the area?s geologic setting, the geotechnical factors considered and approaches commonly applied for cavern design.

By B. Beatty

Discussion by B. Beatty This is a response to M.J. Hrebar's paper, which tracks in detail the highly productive stripping capabilities of modern large bulldozers at two separate installations. It proves the old adage "economies of scale" and quantifies the advantage of being able to move large loads of dirt over comparatively short haul distances by sliding rather than carrying the load. This discussion examines whether a bulldozer is the most efficient way of using this geotechnical principle. Case 1 - Study eastern US: Contour coal stripping application The energy consumption for the Case 1 mining method (eastern US contour stripping operation) shows the D11 averaged 117 L (31 gal) of diesel fuel per scheduled hour, and produced 333.3 bank m3 (436 bank cu yd) per scheduled hour (0.351 L/m3). Assuming 1 L (0.26 gal) of diesel fuel contains 10.4 kW-hr of energy, the unit expenditure of fuel energy for Case 1 Study was 3.66 kWh/m3. Another way of shifting this material is by using an overburden slusher (OS), as shown in Fig. 1. The OS as shown in Fig. I. The OS is electrically powered and consists of a manned low wall winch (LW ), a remote controlled (radio telemetry) highwall winch (HW) and a hoe. The winches operate to pull the hoe back and forth across the pit. The hoe carries load in the forward direction ahead of a rear mounted blade and returns empty. A spreadsheet (Lotus 123) simulation package, BOSSIM, models the OS operation on a load by load basis over a wide range of pit configurations. The geometry shown in Fig. 2 of the paper was modeled using BOSSI M and the results are summarized in Table1. Table 1 shows a LW with 150 kW (200 hp) and a HW of 120 kW (160 hp) installed power, towing a 15-m3 (19-cu yd) hoe, would accomplish the Case 1 stripping task at about the same scheduled stripping rate (D11=333 m3/hr or 433 cu yd/ hour, OS=342 m3/hr or 447 cu yd/ hour). It was assumed the winches in this equipment have an electromechanical efficiency of 90%. This gives an average electrical energy expenditure rate of 151 kW-hr, and a unit energy expenditure level of 0.44 kWhr/m-3(0.57 cu yd/kWh)-an improvement of 8291%- over the D11 alternative. The energy comparison illustrates the importance of using more efficient electric power if possible, ahead of the internal combustion engine, and delivering power from a fixed ground position rather than through a moving track system. Another important energy observation is the comparative action of the dozer blade and the OS hoe. The former implement continuously digs and spills as it works the load forward. The OS hoe digs the load until full, the blade then lifts due to the contained load pressure and a shear plane forms under the mass, enabling it to slide forward in a force reduced - transporting mode. Economic comparison Table 2 operating cost per scheduled hour and unit cost comparison follows a format used in Tables 2 and 3 of Hrebar's paper and compares Case 1 Study with the OS alternative. Drill and blast costs are kept constant in both cases, although when larger OS units are considered, it is expected these costs will reduce because bigger hoe sizes will permit larger rocks to be transported efficiently.

Jan 1, 1995

By William R. Yernberg

The combined 75th Annual Minnesota Section of SME meeting and 63rd Annual University of Minnesota Mining Symposium was held April 9 and 10, 2002, in Duluth, MN. This year’s theme was “Keys to the Future: Imagination, Innovation and Technology.” The meeting consisted of plenary and technical sessions and a special General Manager’s Session. The technical paper presentations included concurrent mining and mineral processing sessions. In the General Manager’s Session, representatives from the region’s taconite operations presented the current status, concerns and future plans for each of their operations.

Jan 1, 2002

A series of flotation experiments were carried out in a 2.25-dm3 laboratory-scale Rushton turbine cell using hydrophobic quartz particles. Flotation was performed at a constant mean bubble diameter over a range of superficial gas velocities and impeller rotational speeds. The overall flotation rate constant increased linearly with increasing superficial gas velocity (and hence bubble surface area flux). The rate constant also increased linearly with increasing energy dissipation, until a maximum value was reached. A further increase in energy dissipation had little effect on the rate constant. The dependency of the rate constant on energy dissipation is a reflection of the size range and hydrophobicity of the particles used in this study. The flotation rate constant increased with increasing particle size, except at the highest energy dissipation value examined, for which the flotation rate of the larger particles reached a plateau and, in some cases, decreased. Good agreement was obtained between the experimental results and those predicted by a fundamental flotation model using experimentally measured values for mean energy dissipation and the Sauter mean bubble diameter. The bubble velocity was adjusted to obtain the best fit to the experimental data. The inferred bubble velocity, based on the flotation model, was found to increase with increasing superficial gas velocity (and bubble surface area flux) and was found to decrease with increasing impeller rotational speed. While the inferred bubble velocities were significantly lower than experimentally measured bubble velocities, and, except at low superficial gas velocity values, significantly higher than the bubble swarm velocity calculated from gas holdup measurements, similar trends with impeller rotational speed and superficial gas velocity were observed in all cases.

Jan 1, 2007

By Lloyd M. English

During the past 30 years, the research arena has changed significantly in all fields, mining included. The relative representation of the topics of research, how the research is performed and who has performed the research have all changed. Although there are a lot of subjective ideas and anecdotal "analyses" concerning these changes, there has been no actual study of these trends to verify the facts. This study was divided into six five-¬year periods for the purposes of comparison. Some of the trends analyzed are co-authorship, research areas, research sponsors and cooperative efforts. In today's research arena, 30 years is a long time. Technology has advanced more rapidly than in any time previously and that pace continues to increase. There are more researchers, more tools for research and an increasing number of companies, agencies and institutions engaged in research. The pace of change and its impact is often discussed and debated at professional meetings and in institutions that engage in research. These conversations will often influence the research decisions of the participants in directions to take or subjects to pursue.

Jan 1, 1995

By G. Bierie

The conveying of bulk materials is prone to problems. These problems can reduce the capacity and efficiency of the plant, and even threaten the health and safety of the workforce. This presentation will look at new conveyor technologies systems, and how, used separately or in combination, they can improve material handling.

Jan 1, 2007

By Jerry T. Shelby

Surface and underground mining operations require equipment with high power output ratings. Haul trucks, loaders, dozers, and other equipment need increasing horse-power to meet production demands. To get more horsepower out of the engines driving the equipment, most manufacturers use turbocharging. Detroit Diesel puts the number at about 90% turbocharged, while Caterpillar estimates 75% to 80% of all its equipment is turbocharged. Turbocharging increases the power output and overall engine efficiency. But it presents some maintenance and operational problems that were not factors when only naturally aspirated engines (nonturbocharged) dominated the scene. A turbocharger is an exhaust-driven air compressor. Using the waste energy in the engine exhaust, a turbine wheel is driven. This wheel is connected by a common shaft to a compressor wheel. The shaft is supported by two plain bearings, or bushings. As the turbine wheel is rotated, the compressor wheel continually compresses the intake air to the cylinders. Compressing the intake air means that more air can be put into the cylinder to burn more fuel. The more fuel the engine can completely burn or combust, the more horsepower the engine can produce. Even though the turbocharger is a relatively simple device, it is a sensitive engine component. It requires special consideration at engine start-up and shutdown. Being freewheeling and exhaust driven, turbochargers can experience temperatures of 540°C 1000°F) and rotational speeds of more than 100,000 rpm. Due to those temperatures and speeds, lubrication is critical to the operation and life of a turbocharger. The turbo is located high on the engine, with the oil supply running through an external line from the sump. The recommended practice is to start the engine and allow it to idle for a few minutes before any revving or loading. This allows the oil to reach the turbo and properly lubricate the bearings before high rotational speeds are seen. Turbo oil supply lines can be as long as 1.5 m (5 ft). Depending on ambient temperatures and oil viscosity, it can take as long as 30 seconds for oil to reach the spinning turbo. However, as little as five seconds without oil can damage the turbo's bearings, reducing its life and overall efficiency. Lubrication problems seen at shut-down can also significantly affect turbo life and efficiency. Manufacturers recommend an idling period of five to seven minutes before engine shutdown. This allows the turbo to slow down and cool off somewhat to help prevent oil coking and bearing damage. When the engine stops, so does the oil supply. There is very little oil left on the bearing surfaces and in the turbo oil supply passages. The immediate heat transfer from the turbine wheel to shaft, bearings, and turbo body literally cooks what is left. This high heat without oil flow can cause bearing deformation by actually melting some of the bearing material. The rapid oil oxidation and coking will restrict oil passages, damage bearings and shaft. Besides heat soaking, there is another problem. If the turbo is spinning at high speeds when the engine is shutdown, the turbo must spin-down to a stop without oil flow. With the large size of turbos used on mining equipment, this spindown time without oil can be for as long as 10 to 20 seconds. Fortunately, lack of lubrication at start-up and shutdown and the subsequent bearing damage can be prevented by oil injection devices. These devices hold a reservoir of engine oil. The oil is injected to the turbocharger bearings immediately on start-up and for several minutes after shutdown. Oil injection devices are spring loaded, hydraulic accumulators. They are actuated at start-up by a solenoid wired to the starter motor. Engine oil pressure charges the accumulator during normal operation. Upon shut-down and loss of oil pressure, the device provides oil to the turbo for about two or three minutes. With an oil injection device, the engine can be started and immediately driven without fear of turbo damage. Also, an abrupt shutdown will not damage the turbocharger since the device will continue to lubricate for two or three minutes. A word of caution. Be sure the oil injection device provides positive oil displacement (pressurized oil flow). Do not use a gravity-flow device. Unless it is a true accumulator, the device could starve the turbo for oil on start-up, Ask for start-up and shut-down pressures and delivery times before considering installation. Keep the oil clean, and follow the manufacturer's recommended oil change intervals. These intervals are usually shorter than with naturally aspirated engines. Use oil with a CD rating designed for diesel applications. A multiviscosity oil is preferable. Use a synthetic engine oil, such as Mobil's Delvac 1, Gulf's Super Duty II, or Chevron's Sub-zero Fluid. Synthetics have much better flow properties at low temperatures. They also have greater oxidation stability (they can take the high heat of turbo-bearing lubrication. And they produce fewer deposits because they are more thermally stable. But synthetic oils do cost more - two or three times more. One additional point - maintain the air intake system. Since all mining is usually in a dusty environment, air filters should be changed regularly and intake systems should be checked for leaks. All intake air passes through the turbo. Any dirt or abrasives entering the turbo will damage the unit and shorten its life. While mining is a heavy duty business with severe operating conditions, you can get the life from your turbocharger that you expect by following a few simple steps: • equip the turbo with an oil-injection device to provide lubrication on start-up and shutdown; • change the oil and filters regularly; and • use the proper oil-synthetic, if possible.

Jan 3, 1987

By B. Gigas, M. Preston, M. Giralico

Optimized mixer settler designs will now handle total flows of over 6,000 m3/hr.Computational Fluid Dynamics (CFD) is a timely and predictable tool for design development. Lightnin has the capability of using numerical analysis methodology to evaluate flow patterns and phase separation. CFD can show performance differences between changes, in mix tanks, in settler geometry, and in liquid depth, against variable flow rates. Understanding the differences allows the development of optimized designs. This paper focuses on the major design components of the mixer settler and how technological advances will lead to further improvements, when designing for today’s largest flow plants.

Jan 1, 2004

By N. R. Allen, J. D. Steenkamp

Oxidative roasting is applied on an industrial scale to beneficiate ilmenite concentrates from South African East Coast heavy minerals deposits - the aim is to increase the magnetic susceptibility of ilmenite to allow magnetic separation from chromite. The intention of this paper is to give researchers new to the field an overview of the beneficiation of ilmenite through roasting and magnetic separation, touching on the relevant fundamental aspects of magnetism.

Jan 1, 2005

By D. H. McCain

Through a unique partnership between the Colorado Mine Safety and Training Program (CMSTP), the Colorado Rock Products Association (CRPA) and the Higher Education and Advanced Technology (HEAT) Center, a video packed, dazzling CD-ROM training program was developed for new miners entering the aggregate industry. Why this product was developed, and why the aggregate industry, will be discussed along with the challenges faced throughout the project. Cooperation from every one involved including MSHA made this the product of which all other training materials in the mining industry will be measured against in the 21st Century. This product's versatility and wide application makes it a tool that is as critical to a mine's success as any earth moving machine. Developed with both state and federal grant moneys allows this product to be affordable to small operators and independent contractors. The quality of this two CD-ROM set rivals any commercially made CD-ROM training.

Jan 1, 2001

By S. J. Boone, A. Poschmann, C. Pound, A. Pace

San Diego’s Stadium Conglomerate consists of poorly cemented cobbles, gravel, sand, silt and clay. Conventional laboratory and in-situ testing is not suitable for characterizing its engineering properties. Although the formation is often considered a “rock” its behavior is more readily modeled using soil mechanics. Static and seismic design of a tunnel for the Mission Valley East light rail extension required that the stress-strain characteristics of the ground be identified over a broad strain range. Geophysical methods and field plate load testing were used to develop a full non-linear stress-strain model of the expected ground behavior. Quantification of the coarse material distribution was also required for selection of tunneling methods and construction considerations.

Jan 1, 2001

By C. Sun

The Leeville underground mine has been in operation since 2006 and currently produces 3,500 tons of ore per day with an average gold grade of 0.34 opt. The mine has a large horizontal extent of 2,500 feet by 500 feet and a vertical extent of 20 to 200 feet. Based on the characteristics of the ore bodies, a long-hole stope and cut-and-fill mining methods are used at the deposits which are divided into several mining zones. Cemented rock fill (CRF) is used as the backfill in the open stope. CRF design includes the aggregate design, the ratio of cement and fly ash design, and strengths for the long-hole stope and cut-and-fill. In the aggregate design, the particle size distribution is one of the most influential aggregate characteristics in determining how it will perform as a basic backfill material. Gradation helps determine durability, porosity, cement and water requirements, strength, and shrinkage. To cut the backfill cost, fly ash usually is added into the binder to replace some part of cement. However, adding fly ash can affect the strength of the backfill. The reasonable percentage of fly ash is also important for making a good and low cost backfill. Based on the different mining method, the different backfill with different strength is designed. A systematic quality control procedure for aggregate and backfill is followed. After four yeas application, CRF system in Leeville achieved very good results.

Jan 1, 2011

By S. Maurhofer

The Uetliberg Tunnel in Switzerland is the longest tunnel in Zurich?s new Western Bypass Expressway, connecting the Birmensdorf bypass in the west with the existing Zurich-Chur national motorway in the east. Thus the tunnel links the Zurich-West motorway interchange with the Zurich-South interchange (shown in Figure 1). The Uetliberg Tunnel project comprises two parallel tubes, each about 4.4 km long. The two tunnel tubes are connected every 300 m by a transverse walkway and every 900 m by a transverse roadway (Figure 2). The SOS niches are spaced 150 m apart. Portal stations with machinery rooms are located at the west and east portals. The tunnel falls with a gradient of 1.6% from the west portal at Wannenboden to the east portal at Gänziloo. The Project costs are about CHF 1.12 billion. The carcass construction started in March 2001. The Opening of the Uetliberg Tunnel is planed in spring 2009.

By Robert A. Cummings, Madan M. Singh

In April 1984 a subsidence depression formed directly beneath a two-story frame residence, near Linton, IN, causing 2 ft of separation between the floor and walls, and damaging both the foundation and interior of the building. The Office of Surface Mining undertook the rehabilitation of the area under its emergency response program. This paper describes the investigation performed to determine the cause, severity, and extent of the problem. Abandoned mine workings were found approximately 55 to 60 ft below the house. Based on the findings, remedial measures were prescribed. An abatement program consisting of grouting the mine voids was recommended, and specifications prepared. These were implemented, and the area has been successfully stabilized.

Jan 1, 1986