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By W. S. Steinberg

Keywords: Pyrometallurgy, furnace, open slag bath, Evraz, Highveld In 1963, the full-scale engineering study for the development of an Iron, Steel, and Vanadium plant was initiated. This was the birth of Evraz Highveld and its process flow as it is known today. Highveld started out as a steel works that produced steel and vanadium-bearing slag by using a titaniferous magnetite iron ore mined from its own mine site near Steelpoort. The process utilized co-current rotary kilns for pre-reduction, and submerged-arc furnaces for the production of pig iron with approximately 1.15% vanadium. Because of various technical challenges that the submerged-arc furnaces experienced over the years, a decision was taken in 2004 to convert the furnaces to Open Slag Bath (OSB) operation, in order to enable the maximum production of iron and vanadium while improving the control over operational parameters. The conversion proved to be highly successful and, since 2005, three furnaces have been converted to OSB operation. The fourth furnace will be converted in the first half of 2011. The conversion to OSB furnaces not only yields higher vanadium recovery to the metal at the iron plant, but also improves the overall throughput of the steel plant. This is the result of a higher carbon content of the liquid iron from the OSB furnaces, eliminating the need for anthracite addition to the shaking ladle process. This reduces the blowing time by approximately 60%. The conversion of the furnaces to OSB configuration is seen as an enabling technology change and a prerequisite to the implementation of other plant improvements that are envisaged. The long-term vision of EHSV is to convert five furnaces to OSB mode, and permanently decommission the two remaining submerged-arc furnaces. This will allow EHSV to maintain current steel and vanadium production but at a significantly improved overall efficiency.

Jan 1, 2011

By J. Sammut, T. G. Joseph, R. Andreev, M. Curley

"Decisions regarding mining method and subsequent choice of excavator must take into account the quantitative factors of productivity, availability, and capital, operating, and maintenance costs. Dig performance was compared between a hydraulic excavator (HE) and electric rope shovel (RS) of similar size class (i.e., use the same amount of energy to excavate a unit quantity of the same material from a mining face), focusing on the quantitative factors above. Machine performance, normalized to bucket capacity, was assessed as a function of hours of service (60,000 hours per machine). Results showed higher production rates for the HE of similar capacity and age. In general, the RS exhibited lower service cost per volume capacity, though it had higher capital cost. The RS became more cost effective than the HE of similar capacity within approximately 30,000 hours of service. ¦ KEYWORDS Cost, Electric rope shovel (RS), Excavation, Hydraulic excavator (HE), Surface mining RÉSUMÉ Les décisions concernant la méthode minière à adopter et le choix ultérieur d’un engin d’ex¬cavation doivent tenir compte des facteurs quantitatifs de la productivité, de la disponibilité ainsi que des coûts d’investissement, d’exploitation et d’entretien. Cette étude compare les performances en termes d’excavation d’une excavatrice hydraulique et d’une pelle électrique à câbles de même taille (qui utili¬sent par exemple la même quantité d’énergie pour creuser une quantité unitaire du même matériau dans un front de taille), en se concentrant sur les facteurs quantitatifs susmentionnés. La performance de la machine, normalisée à la contenance du godet de volume unitaire, est évaluée en fonction des heures de service (60 000 heures d’activité par machine). Les résultats montrent des taux de production plus élevés pour l’excavatrice hydraulique d’une capacité et d’une ancienneté similaires. De manière générale, la pelle électrique à câbles affiche un coût d’entretien par capacité volumique inférieur, mais son coût d’in¬vestissement est plus élevé. La pelle électrique à câbles devient plus rentable que l’excavatrice hydrau¬lique d’une même capacité au bout d’environ 30 000 heures de fonctionnement. ¦ MOTS CLÉS coût, excavation, excavatrice hydraulique, exploitation à ciel ouvert, pelle électrique à cablesINTRODUCTION The most common excavating tools in surface mining operations are the hydraulic excavator (HE) and electric rope shovel (RS). In general, electric RSs are more reliable and cheaper to maintain (P&H Mining Equipment, 2007), but where complicated geological conditions exist, HEs are preferred because they are generally considered to be more mobile."

Jan 1, 2019

By Godofredo F. Barrios

For years urethane screen surfaces have been used in a wide range of wet screening applications where openings from as fine as 100 microns and coarser have been used. The purpose of this paper is to expose the reader to new developments in both screen surface and screening equipment technologies which allow an end user to consider urethane screen surfaces for fine screening applications. These technologies allow an end user to use the inherent advantages of urethane with regards to wear resistance while also realizing the benefits that a high oper area urethane screen surface can bring. These benefits include non blinding characteristics and feed capacities that which rival that of traditional stainless steel surfaces. The paper will highlight the features of this patented urethane screen surface technology and the screening machines they are used in conjunction with. There will also be a presentation of case studies of commercial installations where these technologies are utilized. These case studies are from the base metals industry therefore relevance to the conference is direct and not inferred. Included in the paper will also be constraints which must be taken into account when considering urethane screen surfaces such as temperature and chemical attacks. This paper will expose potential end users to a possibility of using screens to achieve extremely accurate size separations in applications where screens were previously not considered. The paper will explain and demonstrate that prior concerns of screen surface blinding, high screen surface consumption rates and large screen surface area requirements can be eliminated by proper utilization of high open area urethane screen surfaces.

Jan 1, 2007

By Ronald T. Mayerle

In 1986, at the request of the U.S. Bureau of Land Management, the U.S. Bureau of Mines studied a 20,500-acre part of the 104,085-acre Rincon Wilderness Study Area (OR-002-082) in order to evaluate its identified mineral resources. The wilderness study area is located in Harney County, OR, about 12 miles west from Fields. No mineral resources were identified within the study area. A literature search found no records of mining or minerals exploration, nor did a ground search find any evidence of mining-related activity. Of seven alluvial samples taken from the major drainages of the study area, all were barren except one. This sample, taken from a dry streambed along the southern boundary, contained $0.07 gold per cubic yard; however, this small amount of gold is of no economic significance, and the source is probably outside the study area. The Pueblo-Steens mining district extends to within 4 miles east of the study area. No evidence of geological environments similar to those that were responsible for the formation of resources or occurrences of metals and nonmetals within the district is known within the study area.

Jan 1, 1987

By Dawson CF

About 17% of the world's present day oil supplies comes from wells drilled in the continental shelf of some 28 countries. The demand for oil is increasing each year and is expected to quintuple in the next decade. In the same period, the demand for gas will climb to at least 20 times its present rate. In the next decade, the percentage of oil and gas obtained from offshore is expected to rise to nearly half the world's consumption. The offshore oil industry is currently striving to achieve new technological advances in the field of deep ocean operations, especially in face of adverse seas. While the emphasis was put on drilling vessels for exploration, the industry was slow in developing effective offshore construction vessels. Until a year ago, construction vessels were but large barges with construction equipment mounted on their decks. These vessels all shared the same severe limitation: When the sea exceeds a five-foot wave height (and in some cases as little as three feet) the conventional construction barge is forced to suspend operations. In face of an oncoming storm they must run for shelter. Their utilization, therefore, is limited and in rough weather areas, such as the North Sea or the Bass Strait is lower than 50%.

Jan 1, 1970

By Abhinav Karanam, Lukas Bichler

Yttria Stabilized Zirconia (YSZ) is a promising thermal insulator for high temperature environments due to its thermal stability and chemical inertness. As was demonstrated with other technical ceramics (e.g., Alumina), addition of Single-Wall Carbon Nanotubes (CNTs) to a ceramic matrix may significantly enhance the mechanical properties of the composite ceramic. In this work, 8 mol% YSZ with 0.2, 0.5 and 1wt% CNTs composites were prepared via Spark Plasma Sintering process. The densification, Vicker’s microhardness, specific gravity and microstructure evolution of the composites were investigated. The results suggest that the addition of up to 1wt% CNTs to YSZ yielded optimal combination of the studied properties. At higher addition levels, the specific gravity decreased and clustering of CNTs occurred, leading to poor densification and a relative loss of performance.

Jan 1, 2014

By A. Bois-Brochu, G. Morin, G. Marin, M. C. Parr, J. Carignan

The presence of an alpha case on titanium parts produced by investment casting is problematic and has to be eliminated. The traditional techniques for the evaluation of its thickness are metallographic measurements and micro-hardness profiles. To obtain a better understanding of how the alpha case is formed with the underlying objective of limiting its depth, the present study proposes to characterize the microstructure and the chemical composition of the alpha case. Electron microprobe analyzer (EMPA) linescans were used to quantify the oxygen and substitutional elements that come from the mould and promote the alpha case formation. The chemical profiles were correlated with metallographic and microhardness measurements. For microstructure, optical microscopy (etched and polarized light analysis) was used. For phase analysis, samples were mechanically polished step by step and analysed using X-ray diffraction and optical microscopy. Furthermore, surface analysis techniques such as XPS and Auger Microscopy were evaluated but results were found to be inconclusive because the formation of the oxide layer was faster than its ablation and the matrix could thus not be analysed. The alpha case was observed on a Ti-6Al-4V step block casting.

Jan 1, 2014

By Ralph Harris, Xia Qi, Frank Komsic

"Gold cyanidation kinetics which are often limited in commercial operations by the rate of oxygen dissolution from gas bubbles into the slurry, are discussed. Emerging technologies for improving the rate of oxygen dissolution are compared and the gas efficiency, energy use and operating performance of inverted cones and a device based on a jet diffuser are examined. The effect of solids loading is also reviewed and a relationship between operating parameters and the kilograms oxygen dissolved per kilowatt-hour is presented.Inverted cones are shown to create slurry settling problems at high gas flow rates and surface tension lowering agents are shown not to greatly improve the overall rates of oxygen dissolution.The novel jet diffuser technology operates at a range of gas to liquid ratios that improves its energy use over conventional technology and the performance of a number of designs are discussed.Gas efficiencies as high as 35% were observed with the novel diffusers at 40 cm diffuser immersion and are expected to increase at greater immersions. Energy use of 1.8 kg 02 I kWh were estimated for prototype full size diffusers operating at 100 cm immersion. Energy use of 3.S kg 02 /kWh is conservatively expected at 600 cm immersion.IntroductionGold ExtractionGold that can not be recovered by gravity separation can be recovered by either the Merrill-Crow process or the newer carbon in pulp (CIP) or carbon in leach (CIL) processes 1. Reductions in operating costs and improvements in gold recovery are central mill operating strategies. The present paper examines the potential for improvement that can be achieved in the gold cyanidation step of gold recovery. This paper introduces a number of emerging technologies and provides a basis for comparison of the performance. It shows that the basis for comparison of a particular technology depends on the type of gold extraction circuit employed and the type of reactants employed."

Jan 1, 1996

By B Hiebl, J Martens, L Petzold

A research team at the Iron and Steelmaking department at Primetals Technologies has established new upgrading measures for improving the efficiency of the beneficiation process in ironmaking plants, relying largely on pre-existing equipment. After the upgrade, the iron content in the final iron ore concentrate was shown to be significantly higher. Remarkably, the costs for employing the respective measures are surprisingly low.This case study is based on a Kazakh iron and steel producer, whose beneficiation process is currently generating a magnetite concentrate with a final iron content of 65.65 per cent. The study shows that the implementation of Primetals Technologies’ intelligent modification measures to the current beneficiation process, the realisation of more effective dewatering, and the utilisation of an innovative binder lead to an increased iron content in the resulting pellets, reaching a concentration of 69.17 per cent (iron ore concentrate) and 66.5 per cent (pellets).The current operation consists of three closed circuit grinding stages, four stages of low intensity magnetic separation, vacuum disc filters and straight-grate pelletising. By dividing the slurry after the second stage of grinding and the third stage of low intensity magnetic separation, it is possible to divert the more iron-rich fines before they would enter the third grinding stage and the fourth stage of magnetic separation. This then reduces the load on the existing third stage ball mill. Afterwards, the ground material is treated in an additional low intensity magnetic separator and mixed with the previously diverted fraction of the fines. An improved filtration procedure, combined with the application of a highly sophisticated binder, further reduces the amount of additives needed, so that a genuine direct reduced (DR)-grade iron concentrate is produced as a result.All laboratory, pilot and pelletising test work was executed at Primetals Technologies’ laboratories in Austria.CITATION:Martens, J, Petzold, L and Hiebl, B, 2017. Enabling iron ore concentrate for the production of direct reduced iron with pre-existing beneficiation lines, in Proceedings Iron Ore 2017, pp 227–232 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By Kathryn C. Sole, Owen Tinkler

"Although the first large-scale application of copper recovery by solvent extraction (SX) took place in Zambia in the early 1970s, it is only in the last decade that this technology has become widely employed in this part of the world and is now a mainstay unit operation in most copper hydrometallurgical flowsheets. The mineralogy of the ores in the African Copper Belt, and hence the characteristics of the African leach liquors, differ significantly from those in Chile and the south-western USA, where copper SX has had a long and successful history. These differences provide operators, metallurgists, reagent vendors and engineers with many challenges: new approaches are needed to adapt this technology for successful implementation in this region. This paper examines typical operating practice in the African Copper Belt, discusses differences compared with other parts of the world and looks at some of the challenges and opportunities presented by these flowsheets. INTRODUCTION Following the success of the Rancher’s Bluebird and Bagdad solvent extraction and electrowinning (SX–EW) operations in Arizona in the late 1960s, the Tailings Leach Plant at Chingola, Zambia became the first large-scale copper SX plant in the world, commissioned in 1974. Despite the equipment design now being outdated, this plant still continues to operate successfully, indicating the versatility and adaptability of this technology. Today, there are some 75 copper SX operations worldwide with cathode production above 10 kt/a. The top ten producers currently account for some 40% of the global 4.3 Mt/a SX–EW copper production. South America (predominantly Chile and Peru) is the largest copper cathode-producing region, with annual production of some 2 Mt. The Central African Copper Belt (Zambia and the Democratic Republic of Congo (DRC)) is second, with cathode production of 1.2 Mt/a and North America (USA and Mexico) third, producing close to 0.8 Mt/a Cu (Cytec data, 2014). The remaining 0.35 Mt/a comes from all other regions combined (referred to as “Rest-of-World”). Current and future operations in Zambia and the DRC are summarised in Figure 1. The industry in this region is characterised by a large number of small (3 to 20 kt/a) plants, mainly Chinese-owned, and a few very large (>200 kt/a) operations, owned by major multinational corporations. This paper examines typical operating practice in the African Copper Belt, discusses the differences compared with other parts of the world and looks at some of the challenges presented by the conditions, as well as innovations in flowsheets, reagents and operating conditions that have been introduced in these circuits."

Jan 1, 2015

By Oliver Zach

To know as much as possible about the condition of the refractory material (lining thickness, slag layer, build ups, ...) in an high temperature furnace is very important due to the safety and economic impacts. The new CONSCAN system offers the possibility to measure the inner surface of an furnace, and based on this results to calculate the thickness of the refractory lining, slag layer, build ups,.... The CONSCAN System provides this results as figures and graphics. This system is also working under hot conditions so it is not necessary to cool down the furnace. Based on these results the process control and the refractory lining concept could be optimized for maximum campaign life of the furnace.

Jan 1, 2006

Enterprise Optimisation is a methodology for increasing the value of mining and mineral processing operations through better long-term planning decisions. It involves a combination of ten mechanisms which deal with decisions at different stages of the value chain. A decision made at any point in the chain potentially affects the decision for all other points in the chain. The key, therefore, is to optimise them simultaneously. The Enterprise Optimisation approach can be shown to produce increases of five per cent to 35 per cent or more in net present value (NPV), even when several optimisation methods have already been applied. This paper steps through an example case study, illustrating the effect of each mechanism and how they can work together to develop greatly improved results. This example results in a series of counter-intuitive outcomes, which challenges conventional management practices and typical organisational objectives based on organisational silos.

Dec 6, 2010

By Mohab Sabry

Pile foundations are used extensively around the world to support both inland and offshore structures, including important structures such as nuclear plants and oil drilling platforms. The limit of the pile depth is currently predicted during the pile deriving process, given no chance for the designer to predict accurately the capacity of these piles prior installation. Furthermore, after pile installation, designer may not be able to modify the pile group design by increasing the number of piles and or changing the geometry of the pile group. This paper presents a numerical model for the case of single piles driven in homogenous sand using finite element technique and the theory of cavity expansion. The model is capable of simulating all the construction stages of concrete piles up to the maximum depth, which can be driven in sand and accordingly the capacity, which can be attained by these piles. The program "PLAXIS" is used to perform the proposed analysis. This model simulates the process of pile driving in terms of the changes in the earth pressure and the overconsolidation ratio acting along the pile's shaft. Based on the results of the present investigation, these depths can be predicted based on the pile geometry and the sand properties. Charts are given to provide these depths for given pile/soil conditions.

Jan 1, 2006

The MINER Act of 2006 mandated that all underground coal mines must install and maintain refuge chambers. Refuge chambers serve as a temporary shelter in case of emergency. Several factors affect the performance of a refuge chamber: heat production inside the chamber and introduction of CO when chamber doors are opened are two major factors. This study examines the CO purging process and to determine total air quantity and time necessary to lower the CO con-centration to safe levels for different inlet/outlet configurations using three-dimensional simulation technique. The study uses Reynolds Averaged Navier Stokes and continuity equations along with the spe-cies transport model assuming uniform air mixing. The heat transfer of any kind is neglected and the purging process is assumed to take place isothermally. The standard k-e model is utilized for simulating turbulence in the flow field. This research provides useful guidelines in developing an efficient strategy for purging refuge chamber. Keywords: Airlock chamber, Purging, Carbon monoxide, Turbulence

Feb 27, 2013

By Richard J. Mainiero, Michael J. Sapko, Marcia L. Harris

Since 1988, there have been thirteen documented incidents in the United States and Canada in which carbon monoxide (CO) is suspected to have migrated through near surface strata into structures or other enclosed spaces as a result of nearby trench blasting or surface mine blasting. From these incidents, there are thirty suspected or medically verified CO poisonings and one fatality associated with these incidents. To better understand the variables contributing to this hazard, the National Institute for Occupational Safety and Health (NIOSH) carried out a small- scale field study to identify key factors that may contribute to the migration of CO through the ground. NIOSH conducted single- hole heavily confined experimental test shots to measure the radial pressure pulse as it propagated through surrounding monitoring holes to determine if a relationship existed between the pressure pulse and resulting CO measurements afterwards. NIOSH also monitored blasts at an airport construction site. Following the detonations, the concentrations of CO, nitric oxide (NO), and nitrogen dioxide (NO2) were monitored for several days in the surrounding satellite holes. The peak CO measurements relative to distances from the shots were compared. Pressure histories and peak particle velocities (PPV) were measured at monitoring boreholes. It was found that the differential pressures recorded within the boreholes give some indication as to the likelihood of CO appearing, whereas the PPV measurements do not seem to be as good an indicator for potential CO migration. In this limited study, changes in barometric pressure had very little influence on removing the trapped detonation products, whereas applying a vacuum to the monitoring holes was effective in reducing the entrapped CO concentration.

Jan 1, 2005

By D Beahm

Introduction The Energy Metals Corporation (EMC) holds numerous mineral properties in the northern portion of the Great Divide Basin including the JAB Property, one of several potential properties being planned for development as a satellite facility to the greater Antelope Uranium Project. A National Instrument 43-101 Technical Report has been completed for the JAB property. This report estimates total measured and indicated mineral resources on the property totaling 3,555,022 pounds U3O8 contained in 2,400,875 tons at an average grade of 0.073 % U3O8 at a .25 GT cutoff in accordance with CIM Standards on Mineral Resources and Reserves. The JAB Property is located in Sections 13, 14, 15, 16, 21, 22, and 23, Township 26 North, Range 94 West, approximately Latitude 42o 14’ North and Longitude 108o 00’ West (Figure 1, Location Map). This property consists of unpatented mining lode claims and Wyoming State mineral leases comprising approximately 2,100 acres.

Jan 1, 2007

By H. U. Ross

"INTRODUCTION Extensive studies have been carried on pure gold to determine the various factors that affect its dissolution in alkaline cyanide solutions. With the extension of milling to refractory ores more intensive investigations on the effect of impurities in the ore on the dissolution kinetics are needed. The present work describes experiments carried on refractory flotation tailings with the object to determine how the recovery of gold could be increased. The effect of arsenic and antimony in the ore and the excessive use of lime are discussed. Control of cyanide losses is also dealt with.MECHANISM OF THE GOLD DISSOLUTION REACTION In aqueous cyanide solutions, gold is believed to be dissolved by one of the following reactions:4Au + 8NaCN + O2 + 2H20 = 4NaAu (CN)2 + 4NaOH (1)2Au + 4NaCN + 2 + 2H20 = 2NaAu (CN)2 + 2NaOH + H202 (2)2Au + 4NaCN + H202 = 2NaAu (CN)2 + 2NaOH (3) The first of these, known as the Elsner Equation is supported by )4 3,2,1(several authors while others(5,6) support reactions 2 and 3 known as the Bodlander Equations. According to Habashi(7), the overall reaction for the dissolution process is as shown in equation 2. Most of the workers agree that hydrogen peroxide is produced in the course of the reaction."

Jan 1, 1973

By J. G. van der Watt

Due to increasing concerns of global rare earth element shortfalls in the near future, possible alternative sources of rare earth elements have recently become of economic interest. One such alternative is decanting acid mine water originating primarily from abandoned old mines in the Witwatersrand region of the Republic of South Africa. In this study, a novel way of rare earth element removal from the acid mine drainage was employed, making use of bentonite clay, which has very good adsorbent properties, as a rare earth element carrier material. The process can be economically viable only, if the elements can be selectively removed from the bentonite clay carrier material so as to yield reusable clay. Acid leaching was proposed to liberate the adsorbed rare earth elements from the bentonite clay. Accordingly, acid leaching experiments were performed to study the desorption of three commonly-found rare earth elements, namely neodymium, samarium, and dysprosium, from bentonite clay in the presence of sulphuric and hydrochloric acid. It was established that the three rare earth element species could be selectively removed as a group from iron, magnesium, and manganese metals through the careful manipulation of the pH. An investigation into the kinetic aspects of the rare earth element desorption process from the bentonite clay was also undertaken. The applicability of various kinetic models such as zero-order, pseudo first-order, pseudo second-order, elovich, parabolic diffusion, and power function were tested to describe the time-dependent desorption of rare earth elements from bentonite clay. It was determined that the pseudo second-order kinetic model represented the dissolution processes for neodymium, samarium, and dysprosium from bentonite clay the most accurately.

Jan 1, 2012

By J. A. Organiscak

This paper examines methods for limiting occupational silica exposures for roof bolting personnel in underground coal mining. A canopy air curtain and an air tube were evaluated as means to provide filtered air over the breathing zone of these personnel. Laboratory testing showed that dust reductions beneath the air curtain and air tube approached 60 percent and 40 percent, respectively, with low interference air velocities. The data also showed that dust reductions were highest for positions closest to the device and that these levels decreased with distance. This paper also evaluates a metal rake, a flexible insert, and a rigid insert for cleaning the roof bolter dust collector box. Less dust was produced when using the rigid insert. Surprisingly, the flexible insert was sometimes no better than scraping or raking the dust onto the mine floor. However, little dust got on the coveralls when using either of the inserts.

By John Brulia

You’ve probably heard the old expression, “The more things change, the more they stay the same.” But the adage doesn’t seem to hold much water when it comes to making a telephone call on the road. Thirty years ago, a “powder hound” had to stop his 2-wheel drive vehicle at either a roadside diner or a telephone booth to make a call using a public telephone. But, fast-forward to 2007, and a contemporary “explosives engineer” driving his or her 4-wheel drive vehicle simply makes a call “on-the-fly.” The fundamental difference between these two eras is the result of the introduction and the proliferation of cellular or wireless technology. On the one hand, this fundamental difference is much welcomed in the form of personal and business conveniences; and improved productivity. On the other hand, this fundamental difference creates a new set of un-welcomed conditions causing a potential “digital danger.”

Jan 1, 2008