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By William W. Adams

Reports for the calendar year 1923 that have been transmitted to the Bureau of Mines of the Department of the Interior by mine officials of the various coal-producing States show that accidents in and around the coal mines resulted in the death of 2,452 men. The output of coal during the year, as reported to the United States Geo- logical Survey, was 641,476,000 tons; hence the fatality rate per million tons was 3.82 as compared with 4.15 for 1922, a decline of about 8 per cent. The average rate for the decade ending with 1922 was 4.11. This reduction of 8 per cent in the fatal-accident rate per million tons is equivalent to the saving of 210 lives--that is, had the fatality rate of 1922 continued through 1923 the number of lives lost would have been 210 more than they actually were. Not only was there a net reduction in the fatality rate from all causes combined, but each of the main causes of coal-mine fatalities also showed a decline. Falls of roof and coal, which generally account for nearly half of all deaths in coal mines, were responsible for 1,158 fatalities in 1923, which represents a rate of 1.81 per million tons as compared with 1.90 in 1922. (See Table 2.) Haulage accidents underground usually cause about 17 per cent of all fatalities, and the reports for 1923 show that 413 deaths were due to this cause, indi- cating a rate of 0.64 per million tons, as against 0.71 for the previous year. Gas and dust explosions killed 372 men, the fatality rate being 0.58; the rate for 1922 was 0.65. Seventy-five deaths were due to electricity, for which class of accidents the fatality rate per million tons was 0.12 as compared with 0.16 the year before. Powder and other explosives caused 114 deaths, representing a rate of 0.18 as compared with 0.19 for 1922. Of the 2,452 fatal accidents during the year, 2,249 occurred under- ground, 46 in shafts, and 157 on the surface. At bituminous coal mines the number of deaths was 1,943, of which 1,816 were under- ground, 31 in shafts, and 96 on the surface. At the anthracite mines

Jan 1, 1923

By K. J. R. Ford, Botz. M. M.

Porphyry copper ores are frequently a source of low-grade gold ore, but gold in these ores is often associated with significant levels of cyanide-soluble copper. Cyanide leaching of such ores increases flowsheet complexity and operating costs, and requires thorough planning to satisfy environmental requirements for tailings disposal and mine closure. This paper presents a review of the chemistry of cyanide leaching of gold-copper porphyry ores, carbon adsorption phenomena and means of removing base metals from leach solution. The primary economic drivers behind the processing of such complex ores are also analyzed.

Jan 1, 2011

By V. B. Achanti, A. W. Khair

Laboratory studies were carried out at West Virginia University to investigate the rock fragmentation mechanism by continuous miners using an automated rotary cutting simulator. The primary factors influencing the fragmentation process were found to be: bit spacing, bit geometry, depth of cut and cutting drum rotational speed. This paper presents the influence of these parameters in achieving optimum energy consumption and minimizing dust generation during rock fragmentation process. Tree bits were used simultaneously on Indiana limestone while the bit tip angle was varied from 60° to 900. Bit spacing was varied from 2.54 cm (1 in.) to 5.08 cm (2 in.) while the cutting process was assessed for varying cutting depths. Restorable dust generated during the course of the experiments was analyzed utilizing cascade impactors. Assessment of these parameters has led to a better understanding of the cutting mechanism by continuous miners in terms of energy consumption and dust generation.

Feb 24, 1997

By James W. Martin

This user's manual analyzes the application, selection and performance of front-end loaders in mining operations which can effectively utilize their load-and-carry capability. All aspects of the application are considered starting with a discussion of the load-and-carry system and alternate material handling methods. Site conditions such as the geology of the formation, material characterisitics, alternative mine plans and working conditions are identified. Selection considerations include machine design characteristics, production capabilities and ownership and operating costs. Typical operating practices and safety procedures are discussed. Comprehensive machine specifications, together with a series of checklists and worksheets, are included for preliminary analysis.

Jan 1, 1981

By Janet Torma-Krajewski

Research has shown that an ergonomics process that identifies risk factors, devises solutions to reduce musculoskeletal disorders (MSDs), and evaluates the effectiveness of the solutions can lower worker exposure to risk factors and MSDs and improve productivity. A review of the Mine Safety and Health Administration (MSHA) injury/illness database indicated that 46% of illnesses in 2004 were associated with repetitive trauma and 35% of nonfatal lost days involved material handling during 2001? 2004. Even though these statistics show that MSDs significantly contribute to occupational illnesses and injuries in the U.S. mining industry, few mining companies have implemented an ergonomics process. Despite the many unique challenges in the mining environment, three mining companies partnered with the MSD Prevention Team at the National Institute for Occupational Safety and Health?s Pittsburgh Research Laboratory to demonstrate that an ergonomics process could be systematically implemented and effectively integrated with existing safety and health programs. Because these three mining companies were very different in organization, culture, and size, the ergonomics processes had to be modified to meet the needs of each company. A description of how these three companies applied ergonomics and the tools and training used to implement their processes is given. Prior to discussing the case studies, general information on the elements of an ergonomics process is provided.

Feb 1, 2009

By Rodger C. Fry

Underground coal mining has been active within the East Mountain property since the mid 1950's. As a result, coal from two seams has been extracted within large areas allowing surface subsidence to occur. Monitoring of subsidence annually, began in 1981 using on the ground conventional monumentation, surveying and photogrammetric monitoring. The data collected has shown the time benefits of photogrammetry and the relationship between observed subsidence and the geometry of the mined out area below.

Jan 1, 1986

During the extensive research which has been conducted in the Metallurgy Department of the University of Melbourne, into the properties of lead and its dilute alloys, the Brinell test has been used for the determination of hardness.The work described herein represents part of an investigation into the influence of various factors on such determinations, particularly when carried out on different qualities of "pure" lead. It is intended to publish the more theoretical and controversial aspects of this research elsewhere.MATERIALS USED AND THEIR PREPARATION FOR TESTINGThe tests to be reported have been conducted on a specially pure electrolytic lead, and several brands of commercially "pure" lead. The analyses of the samples upon which most of the work has been carried out are given in Table 1.Note: Oxygen was not determined, but from the work of H. W. Worner, in the Rosenhain Memorial Laboratory, it appears probable that it was approximately 0-0003% in all samples.

Jan 1, 1940

By K Morrison

Australia’s ageing population means that by 2050 there will be 2.7 people of working age to support each Australian aged 65 years and over compared with five working people per retiree today and compared with 7.5 in 1970 (Swan, 2010). This means that there is going to be a greater demand on social services – for medical and aged care – from a smaller private income base. How will this gap be met? Australia is fortunate in that it has vast resources of mineral wealth; from iron ore, nickel and gas in Western Australia to the giant copper and uranium deposits at Olympic Dam in South Australia.The prospect of a meaningful profit based tax on this vast mineral wealth has been lost through Australian government’s handling of the issue in 2010 and with an industry fiercely opposed to the prospect of a mining tax. Hence, new ways of thinking are required. This paper looks at the issues facing the implementation of a novel scheme whereby Australia leases the mineral resources it extracts and thus derives income over the decades the metals are in-use in pipes, wires and structures with a premium paid for unreturned material or that used in dissipative applications. Applicable minerals could include copper, aluminium, nickel and rare earths. If Australia simply digs up and sells the metals once, the buyer becomes custodian of that resource and they benefit from controlling the future ‘above-ground’ resource stock.A complementary driver for a leasing scheme is the increasing importance of chain-of-custody following initiatives of the Responsible Jewellery Council with gold and diamonds, now with the potential to extend across commodities. The Australian minerals sector could thus position itself as a premium supplier with high social and environmental credentials.Recognising the implementation challenges, this paper includes a review of how such a system could be enforced to ensure that the metal is tracked throughout its life. It concludes with a discussion of the rates and terms should such agreements hold and suggestions for institutional arrangements for enforcing compliance.

Nov 22, 2011

By C. H. Schack

Extractive metallurgy techniques currently employed to recover silver from primary ores and secondary scrap were reviewed and evaluated to identify and delineate metallurgical problems whose resolution would increase the supply of silver from domestic materials. The survey revealed that practically all primary silver is recovered by froth flotation concentration of various types of ores, followed by smelting and refining of the separate lead, copper, and zinc concentrates. Silver losses during the complex processing are, with rare exception, inconsequential. Furthermore, any silver production gain from base metal ores, which contribute about two-thirds of the total primary silver, is directly dependent no improvement in the market for the base metals. Statistical data on new and old silver scrap are wholly inadequate to make reliable conclusions about scrap processing problems and the possibility of increasing the recovery of silver from the many forms of secondary silver-bearing materials. The available information indicates (1) that efficient silver reclamation practices are employed by the larger users of silver, and (2) that recovery of additional secondary silver involves solution of problems of collection rather than of processing. Several possibilities exist for limited increases in silver production from primary ores by improvement in metallurgical practices. Specifically, research is needed to (1) solve the problem of recovering silver from the copper ores of the Copper Range district, Michigan; and (2) devise economically feasible methods for recovery of silver from presently marginal or submarginal ores char because of grade, location, and frequently complex nature cannot presently be exploited by conventional techniques.

Jan 1, 1965

By K. E. Waters, J. E. Nesset, F. Rosenblum, R. Langlois, J. A. Finch

"Some sulphide mineral mixtures when exposed to air and a warm and humid environment can exhibit a self-generating temperature rise, referred to as self-heating or spontaneous heating. The observed self-heating derives from the oxidation reactions of the active sulphides. In previous publications by the authors, it was proposed that the self-heating of sulphides proceed in three distinct stages; namely, Stage A, Stage B and Stage C. In Stage A (<100OC) the sulphides, in the presence of moisture are oxidized, generating heat through a series of sequential reactions and forming elemental sulphur as one of the products. In Stage B (>100OC) the elemental sulphur produced in Stage A is further oxidized to generate additional heat and SO2. Stage C (>~380OC), sometimes referred to as thermal runaway or roasting, is not addressed in this paper. This communication focuses on the type and role of elemental sulphur found in Stages A and B, and the sequence of reactions that is occurring in Stage A. The sequence is divided into two phases, the first based on galvanic interaction between the sulphide minerals that generates an acidic environment but little heat, and the second involving the production of H2S which rapidly oxidizes to produce heat and elemental sulphur. To date, data suggest that the primary oxidation product formed in Stage A is the stable orthorhombic a-S8 form of elemental sulphur. Above 96OC the a-S8 transforms to a monoclinic ß-S8 structure which is less stable and will readily oxidize to generate heat and SO2. Above 159OC a proportion of the ß-S8 sulphur will transition to a polymeric Sµ form of sulphur which can readily volatilize. INTRODUCTION Some particulate and granular materials, when exposed to appropriate atmospheric and physical conditions, can exhibit a self-induced temperature rise resulting from accumulated heat due to internal exothermic oxidation reactions. This phenomenon is commonly referred to as self-heating or spontaneous heating. Under favorable physical and environmental conditions, these reactions can elevate the temperature of a given material from ambient to the point of auto-ignition. Self-heating behaviour should not be equated to pyrophoric behaviour which describes a group of materials (e.g. certain finely powdered metals) that will ignite spontaneously in air below 55OC. There are numerous materials such as coals, hay, forestry wood products, food products to name a few that can exhibit self-heating behaviour. This publication continues the focus of the authors on the self-heating of sulphide mineral mixtures. Many of the metals of commercial use found in nature are in the form of these sulphides which must be mined, crushed, ground and concentrated prior to smelting or hydrometallurgical processing in order to produce primary metal. The issues of sulphide self-heating therefore pertain to the mining and processing of metals."

Jan 1, 2018

By P. A. Cox

The purpose of the initial research performed under this contract was to determine the margins of safety in explosion-proof (XP) enclosures, which were designed and certified according to the current schedule (Schedule 2G). Results from this work provide baseline data on the current schedule, from which a new schedule can be formulated to give equal or greater levels of safety. Results and discoveries in the initial work led to an expansion of the contract to cover, additionally, weld quality in enclosure fabrication, reliability of enclosures with windows and lenses, and performance tests for enclosure qualification. Finite element calculations and hydrostatic tests revealed wide variations in the margins of safety in the enclosures studied; however, only one enclosure had a safety factor which was less than one. Results from a weld quality survey led to the recommendation of AWS Welding Standard D14.4 for the fabrication of XP enclosures. Based on other work, accelerated aging tests were recommended for qualifying plastics and adhesives that are used in some enclosures, and a Structural Performance Test was developed to test enclosure strength for a minimum static pressure of 150 psig.

Jan 1, 1982

By D. B. RUSHhIORE

I. INTRODUCTION. OF primary importance in mine-installations is the hoist, which has a very direct bearing on the successful operation of a mine. Conditions vary greatly with different mines, and especially in different localities. Such factors as depth, incline, the number of levels, permissible or desirable speeds, conditions of ore, etc., are always more or less special in each case. Veins of ore are never exactly duplicated, and the nature of the ground through which shafts are sunk may considerably modify permissible values. As mining-laws are made by the different States, they necessarily vary somewhat, and, even when not fully observed, they introduce factors which qualify the conditions of hoisting men and ore. The amount of timbering required is often of importance as relating to hoisting-conditions. Methods of loading ore affect the time required, as also does the question of the use of cars or skips. Safety-precautions must be very carefully considered, and the number of men in each mine, the number of compartments, and often the method of removing water from the mine, must. have careful consideration. While a general discussion of the subject. of hoisting is possible, most cases are entirely special, and can be considered only in connection with the peculiar conditions pertaining to that particular installation. The cost of installation of the hoisting-plant may be an appreciable amount, while the cost of raising the ore may be but a small part of the total operating-charge. In many cases, however, the output of the mine is limited by the capacity of the hoist, and the latter thus becomes of the first importance. * Presented also, by mutual agreement, at the meeting of the American Institute of Electrical Engineers, New York, N. Y., Mar. 11, 1910.

May 1, 1910

By S. K. Schwartz

"This paper describes the general layout of the environmental monitoring scheme at Devco &apos;s No. 26 Colliery, including wall face ventilation, fan performance and methane drainage, and then goes on to discuss the sensors, the outstation layout, the surf ace control room and the protection of the system.IntroductionCape Breton coal mines have been pioneers in the use of the latest technology in mining coal on this continent. To mention just one example, continuous methane monitoring at the coal face was started in 1976 and the idea of automatically stopping the face conveyor during high gas levels using the face signalling system was conceived and developed by CBDC engineers.With the introduction of remote environmental monitoring, No. 26 Colliery will be the first underground coal mine in Canada and possibly in North America to have computer-based comprehensive environmental monitoring.Traditionally, surveillance of the mine environment has been based mainly on periodic checks by portable or hand-held monitors. Although this method proved adequate, it has some limitations, namely:1) restricted &apos;number of observations and samples;2) relatively long time between taking measurements and availability of results for assessment.With remote monitoring, the above limitations are overcome because (a) monitoring is continuous and (b) monitored data are updated quickly (typically 5-7 sec.). Remote monitoring also provides a centralized &apos;information center&apos; at the surface from where the entire mine environment can be monitored. Details of modes in which data can be displayed and features available at the location will be discussed later in the paper."

Jan 1, 1982

By Richard G. Geyer

One aspect of a program to improve the chances of survival following coal mine disasters is the development of a communications sys tem which will allow surviving miners to make their circumstances known to rescue teams. At present, it appears that an electromagnetic system may be most practical. The development and design of an effective electromagnetic communications link for signalling between mine workings and the surface requires knowledge of pertinent physical properties of the rocks overlying the mine workings and the characteristics of the ambient noise against which a communications signal must be recognized. Knowledge of the overburden electrical transmission properties is useful not only for determining a practical operating transmitter frequency at a given mine, but also for ensuring the best possible electromagnetic coupling for routine or emergency communication purposes. Field studies of the electrical transmission properties of the overburden of coal mines in Colorado, Illinois, and Pennsylvania generally show that a relatively uniform and unimodal electrical conductivity distribution exists provided that the region has not been subject to considerable structural or metamorphic deformation such as that observed in the Gary District of West Virginia. Measurement s of ambient surf ace electromagnetic noise levels at several mines in Colorado, Illinois, and West Virginia were taken and analyzed and are presented in the form of amplitude histogram plots both as a function of frequency and time of day. These amplitude histograms may be used in conjunction with overburden resistivity data in implementing an uplink communications beacon system which will yield a specified signal- to-noise ratio at the surf ace. Numerous C .W. field transmission tests were made in various coal mining environments with use made of either a buried vertical-axis transmitting loop or a short insulated grounded current line. These transmission tests were made from 20 Hz to 20,000 Hz in frequency and at several geographic surface receiving sites. The results of these field measurements show, in general, good agreement with theoretically calculated results. Since the produced surf ace magnetic field from a buried vertical-axis loop source or the produced surface horizontal electric field from a buried horizontal current line show better agreement with theoretical results, they could be used for beacon location system. One criterion would be in detecting the equatorial and polar null lines of the horizontal electric field component which is normal to the direction of emplacement of a buried transmitting line current source. A second criterion would be in the surface mapping of the maximum in the vertical magnetic field directly over a vertical-axis loop transmitter and the associated null is the vertical magnetic field at a horizontal offset distance which is about 1.4 times the depth of burial of the transmitter. Finally, a third criterion would lie in the surface mapping of the null in the horizontal magnetic field directly over the vertical-axis beacon and the associated maximum in the horizontal magnetic field at an offset distance from the transmitter axis of half the depth of burial of the loop transmitter. In mapping the vertical magnetic field over a buried vertical-axis loop transmitter, the size effect of the transmitter loop must be taken Into account when the separation distances between the transmitter and receiving sensor are less than ten times the effective radius of the source loop; increasing the size of the transmitting source relative to the source-receiver separation distance shifts the null in the vertical magnetic field to greater offsets. In mapping either the vertical or horizontal magnetic field over a buried vertical-axis loop transmitter, care should be exercised in ascertaining that measured nulls and maxima are along radials through the axis of the buried source loop. For the main part, coupling experiments show that ambient electromagnetic noise in coal mining districts is less of a problem above 1000 Hertz. But secondary and perhaps undesirable maxima and null phenomena (as well as penetration problems) would occur in many coal mine provinces in the behavior of the surface horizontal magnetic field (over a buried vertical-axis loop transmitter) if transmission frequencies as high as 10 kHertz were used.

Jan 1, 1974

By R. S. Dean

"It has long been recognized that the properties of polycrystalline substances are not the same as those of single crystals. These differences are especially marked in metels and metallic minerals, and are of greatest practical importance in metal working and ore treatment. The property changes encountered in passing from a metal single crystal to a poly-crystalline aggregate are the same as are produced by cold-working a metal or by the precipitation of a disperse phase. Hence, we may logically assume that the property changes are all due directly or indirectly to the formation of interfacial area or internal surface. Our problem, then, is to ascertain the physicochemical state of the metal atoms at such internal surface and show how this physicochemical condition accounts for the pronounced changes of mechanical, magnetic, and electrical properties that accompany increased internal surface.GENERAL CONCEPT OF INTERNAL SURFACEIn 1678, Huyghens attempted to explain the double refraction of calcite by postulating that crystals were built from a regular arrangement of ellipsoidal particles. Over 100 years later, Abbé Hauy concluded from his studies of cleavage that crystals might be built from small units, but the units were of the same shape as the entire crystal. This idea, which was prevalent in mineralogical thought before the advent of X-ray spectrometry, was discarded when the great success of Bragg made it appear that the chemical atoms were in reality the elements of structure. In the further development of X-ray technique, however, C. G. Darwin, in England, and P. P. Ewald, in Germany, found it necessary to postulate crystal units con¬taining many atoms. The latter gave the name of mosaic crystals to those so constituted. The individual units are supposed to Possess the ideal atomic arrangements revealed by the X-ray but are not oriented with respect to one another."

May 1, 1938

Numerical models play a significant role in the design of safe underground mining excavations and support systems. Advances in the capabilities of numerical modeling software, together with ever increasing computational speeds, have made it possible to investigate the very nature of the large-scale rock mass and its response to mining excavations. The improved understanding of the rock response obtained from modeling enhances our designs, resulting in greater stability and safety of the mining excavations. To help advance the state of the art in this field, the National Institute for Occupational Safety and Health organized the International Workshop on Numerical Modeling for Underground Mine Excavation Design. The workshop was held in Asheville, NC, on June 28, 2009, in association with the 43rd U.S. Rock Mechanics Symposium. The proceedings include 10 papers from leading rock mechanics and numerical modeling experts in the United States, Canada, Australia, and Germany. The papers address a wide range of issues, including various numerical modeling approaches, rock mass modeling, and applications in coal and metal mines.

Jun 1, 2009

By M. Michael, A. Felber

"Mining activities, especially underground mining operations, create great demands on utilized haulage means which cover a variety of different horizontal and vertical distances. In the course of the continuous optimization of the haulage process, the application of textile machine elements, in particular synthetic fiber ropes, offers new opportunities. Therefore the current level of knowledge needs to be improved based on extensive analyses. For the estimation of the scope of these analyses, different fields of application and occurring environmental influences which have an impact on synthetic fiber ropes during their use in underground mining have to be evaluated. The Chair Underground Mining Methods of the TU Bergakademie Freiberg works on a scientific project concerning the use of synthetic fiber ropes in underground mining operations. This paper focuses on the potential application of synthetic fiber ropes in haulage systems in underground mining and exposes critical influences as an outcome of the working environment. These first investigations are the basis for the development of an appropriate experimental series. SYNTHETIC FIBER ROPES FOR UNDERGROUND MINING OPERATIONS The main idea is to optimize underground haulage means to develop even more economic systems. The new and lightweight design of single machine elements seems to be the first step to accomplish this goal. An example is the lightweight design of shaft hoisting ropes. The commonly used steel wire ropes are very heavy and are endangered to snap due to their own weight when reaching a distinguishing length. Thus they may not or only conditionally be used for deep mining operations utilizing shaft haulage. Ropes made of high-tech synthetic fibers weigh only an eighth of steel wire ropes while displaying the same tensile strength. This relation is shown in Figure 1, based on the comparison of fiber strength and density. This could offer new opportunities for deep mining operations, which are anticipated by many mining companies. /1/"

Jan 1, 2015

By J. W. van der Merwe, A. S. Bolokang, M. J. Phasha, V. J. Matjeke, C. Moopanar

"Excessive wear rates on railway wheels can result in rolling-stock derailments. If wear is detected early the possible derailments can be prevented by prematurely replacing wheelsets, although the inventory cost and maintenance downtime remain a challenge. In the current study, wheels were introduced and monitored in-service for two years to investigate the cause of excessive wear rates. The wear rates and stresses were calculated for the wheels suitable for a maximum load of 26 t per axle. Microstructural and mechanical properties were analysed. As expected, the general microstructure of all the wheels tested was pearlitic. Although all the wheels complied with the tensile strength requirements, stress calculations confirmed material distortion on excessively worn wheels whereas trial wheels revealed yield strength exceeding the yield criterion. High wear rates observed on the wheels were a result of low yield strength relative to the load per axle. The typical wear mechanism found was due to a combination of rolling contact fatigue and abrasive brake wear. Despite compliance of the wheels with existing requirements regarding material and mechanical properties (hardness, ultimate tensile strength), it is recommended that the yield strength must also be taken into consideration as a critical parameter.IntroductionRailway wheels are used to support the wagon mass and guide the wagon along the tracks (Park, 1974). The wheels and rails must be able to tolerate the applied tangential forces in order to effect wagon dynamic performance and reduce material deformation (Ghidini et al., 1994; RSE_TE_SPC_0045, 2011; AAR M107/M 208 Specification, 2011. Over the past ten years, the South African coal wagon maintenance depot has experienced excessive hollow wheel wear rates on the heavy haul line wheels. The maximum load of Jumbo wagons on the coal line is 104 t, or 26 t per axle. Although the maintenance intervention cycle for wheelsets was two years, between February 2011 and August 2012 some wheels experienced excessive hollow wear. Hollow wear is regarded as wear exceeding 2 mm on the central portion of the wheel tread (RSE_TE_SPC_0045, 2011). This happened despite the fact that these wheels were manufactured and certified according to the requirements of AAR M107/208 standard for carbon steel wheels (AAR M107/M 208 Specification,. 2011) and the local wheel RS/ME/SP 021 standard specification (RS / ME / SP / 021 REV 5 (2013). The AAR standard only specifies a minimum hardness as a required mechanical property and the local standard specifies hardness and minimum tensile strength only. In general, an increase in hardness will improve the rolling/sliding wear resistance of steel. This relationship of hardness and wear resistance was found to be true only in a situation where solid and similar alloys are in contact (Singh, Khatirkar and Sapate, 2015). The sliding wear resistance of a material is usually estimated using Archard’s equation (Liu and Li, 2001)."

Jan 1, 2016

The key aspects of process metallurgy that distinguish platinum group metal (PGM) concentrate smelting from that of other base metal sulphide concentrates are presented. These differences include considerably higher input chrome and magnesia contents that directly raise the slag liquidus temperature and have the potential to increase accumulations of refractory spinels. Most importantly, the higher processing temperature required for PGM smelting, and the resulting very high matte superheat lead to considerably more onerous smelting conditions than those typical of other smelting operations. This has presented challenges to furnace design and integrity, especially when coupled with the progressive intensification of smelting, involving doubling, and then redoubling, of furnace power input over the past 20 years. These power increases have been enabled by increasingly more advanced furnace cooling and structural technologies. Key technologies include strong constant-force spring-loaded bindings acting in three dimensions to minimize infiltration of superheated matte into brick joints, and robust well-cooled tapholes for reliably tapping the superheated matte. The result has been substantially improved productivity, and reduced smelting capital cost outlay per unit of production. A significant challenge that was not anticipated, presented itself in the form of insidious corrosion of the furnace lining, and especially high-intensity copper cooling elements. Investigation of corrosion in related industries eventually identified &apos;chloride-accelerated sulphidation&apos;, and this term has been retained as it generically describes the most pertinent aspects of the accelerated low-temperature wear of copper coolers observed in PGM smelting. In addition to discussing the corrosion mechanism, this paper describes a number of solutions that were developed jointly by Anglo American Platinum and Hatch to address the copper corrosion problem. First, new monitoring technologies allowed furnaces to be operated more safely for a longer period of time. Second, a system for replacing corroded coolers from outside the furnace during a fast &apos;hot&apos; shutdown minimized the impact on furnace operating factor and hearth life. Finally, a corrosion-resistant graphite-protected cooler design significantly improved furnace campaign life, and heralds a more lasting solution to cooler corrosion in PGM furnaces.

Jan 1, 2012

By Victor Romero, Steve Redmond

All Rights Reserved. Printed in the United States of America. Information contained in this work has been obtained by SME, Inc. from sources believed to be reliable. However, neither SME nor its authors guarantee the accuracy or completeness of any information published herein, and neither SME nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that SME and its authors are supplying information but are not attempting to render engineering or other professional services. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. Any statement or views presented here are those of individual authors and are not necessarily those of the SME. The mention of trade names for commercial products does not imply the approval or endorsement of SME.

Dec 1, 2011