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By Thomas P. Battle

Modern-day direct reduction of iron first developed as a small-scale, low capital and operating cost alternative to the blast furnace. Since commercialization of continuous DR technology in the late 1960s, the market for the products of direct reduction has grown to more than 74 million tonnes in 2012. The initial advantages of DR plants over BF facilities have grown over the years, for several reasons, including the increased size of DR modules, lower energy and emissions (particularly CO2), along with the flexibility to use a number of different reductants. The development of DR technology over the past forty years will be emphasized in this presentation, including recent developments that allow for even more direct sustainability comparisons with the iron blast furnace – and even combine the two technologies for improved synergies. Also briefly discussed will be the possibilities of using direct reduction for non-ferrous ores.

Jan 1, 2014

By Frederick C. Trutt

Research performed on arcing faults and their interactions with electrical insulating materials within coal-mine power system enclosures are described. This work was performed at The Pennsylvania State University from December 1, 1976 through August 31, 1978. The thrust of this research has been divided into several primary areas. These include the development of a theoretical procedure for computation of three-phase and line-to-line arcing fault currents as a function of time, formulation of arc and tracking models so that arc voltages and energies may be computed, development of a simulation for pressure and temperature rises when a fault interacts with an electrical insulating material within an enclosure, experimental evaluation of electrical insulating materials in terms of their tendency to support and maintain an arc as well as their potential contribution to enclosure pressure rises, and integration of the above research areas to form overall procedures for theoretical and experimental evaluation. During the course of this research, consideration has been given to the possible effects? of an internal methane-air explosion within an enclosure as well as the potential influence of utilization-voltage-level, conductor spacings, and enclosure venting. Conclusions and recommendations address potential means for protection against enclosure failure, internal design considerations, and low-power testing procedures which might be used to evaluate insulating materials to be utilized within an enclosure.

Jan 1, 1978

Newcrest Mining Limited (NML) owns and manages the Ridgeway Gold Mine (RGM) located outside Orange in the state of New South Wales. RGM is a new underground sublevel caving (SLC) operation that is ramping up production to 4 Mtpa. The success of the SLC method at RGM is strongly influenced by production drill and blast practices. Distinguishing features of the Ridgeway SLC operation include choke blasting against broken rock, drawpoint brow preservation, loading of blastholes with different in-hole bulk emulsion densities, precharging of production rings and routine drawpoint fragmentation assessment. These areas are described in the context of RGMÆs required blasting objectives, production drilling and charging activities and innovative practices.

Jan 1, 2002

By Robert Giglio

Looking back over the last 150 years or so, it is not hard to see that electricity has been a primary force in shaping human development. It has been a basic ingredient in our industrial revolutions that simultaneously improved the productivity, working and living conditions within our farms, factories, hospitals, offices and homes. Today, it has become an essential part of our daily life and our future. Amazingly, we keep finding new ways to use electricity to make our lives more safe, comfortable and productive. It is a great success story of human ingenuity, achievement and development. Demand for electricity The convenience and value of electricity has not gone unnoticed by consumers. According to the U.S. Department of Energy (DOE) (Energy Information Administration, 2009), electricity is the fastest growing form of energy in the world and during the next 20 years the world will likely consume twice as much of it as it does today. In 2008, almost 20,000 terawatt hours of electricity globally were consumed (Energy Information Administration, 2009). That is enough electricity to light up more than two million baseball stadiums or power more than 11 billion computers continuously for an entire year. The United States has the dubious distinction of be-ing the largest consumer of electricity in the world with enough power to provide each American with more than 3 kW of electricity ? that is about twice the power currently available to Europeans, eight times the power available to the Chinese and more than 25 times the power available to the citizens of India (American Coal Foundation, 2009).

Jan 1, 2009

By Stephen Njoloma, William Bracken, Harald Cordes, Ivan Hee

"DC Water’s First Street Tunnel (FST) is part of the $2.6 billion Clean Rivers Project designed to reduce the occurrence of combined sewer overflows into local waterways. Due to flood events in the Bloomingdale and LeDroit Park neighborhoods, the FST Project was accelerated by DC Water to mitigate future flooding by boosting storage capacity and thus relieving the undersized combined sewers.The FST Project was finalized in 2016 as a collaborative effort between DC Water, its consulting team consisting of Greeley & Hansen and McMillen Jacobs Associates, and the design-build team of Skanska, Jay Dee Contractors (SKJD) with WSP Parsons Brinckerhoff as the designer.Scope of project. The FST Project (Fig. 1) included four primary shaft sites, a large 6 m (20 ft) internal diameter, 823- m (2,700-ft) long bored tunnel and three adit connections from the off-line shafts to the large-diameter tunnel. The adits which vary in size and length, are the subject of this article. The Channing Street site (Fig. 2) was established as the main site for an Earth pressure balance tunnel boring machine (TBM) and included a 49-m (160-ft) deep shaft with slurry wall support of excavation and 20-m (65-ft) internal diameter final cast-in-place permanent concrete liner. The construction sites at Adams Street, V Street and Thomas Street each consisted of off-line shaft structures tied to near-surface sewer diversion chambers and ventilation facilities. These three off-line shafts were connected to the large bored TBM tunnel via adit tunnels. Each of the three adits had a portion or the entire length excavated by sequential excavation method (SEM) in frozen ground.The Adams Street adit (Fig. 3) was constructed in two phases. The first phase is the 23-m (75-ft) long and 5-m (16-ft) diameter section immediately outside the drop shaft which also serves as the deaeration chamber and was excavated by SEM. The second phase which is 91 m (300 ft) long and 3 m (10 ft) in diameter was excavated by Micro TBM (MTBM) launched from within the permanently lined deaeration chamber. MTBM excavation commenced toward a reception chamber that was excavated by SEM from the previously bored FST TBM tunnel. This SEM excavation had a 5 m (17 ft) diameter and a length of 4.5 m (15 ft)"

Jan 3, 2018

By Todd S. Webster, Matthew J. Pierce, Brad D. Krumel

With the Working Shafts and Starter Tunnel under way, it became apparent this 4.7-mile, 19-foot diameter wet weather tunnel was going to live up to its name. The shaft’s pre-excavation grouting was completed, and ground water inflows were slowing project progress. As the tunnel drive was approaching 50% complete a cooperative effort was underway between the owner, engineer, and contractor to raise the base of the Retrieval Shaft by 65 feet to avoid ground water infiltration construction challenges. The tunnel alignment needed to be raised in kind. The project was behind schedule and rethinking the cast-in-place adit work was next on the agenda due to the very wet environment in the tunnel. The race was on to finish the project within the owner’s time constraints while completing multiple redesign aspects of the tunnel alignment and associated adit construction. This paper will evaluate original design criteria and actual in-route design modifications and change management to meet the owner’s just-in-time schedule needs.

Dec 1, 2022

By J. C. Stankus

Many coal seams are associated with soft floor strata and during mine development if coal pillars are not properly designed, floor heave occurs and causes interruption of coal production. In the severe cases, the section or mine is abandoned. One of the methods for controlling floor heave is floor bolting. This paper describes the demonstration of floor bolting methods in a West Virginia coal mine. Three methods were used: (1) vertical full resin bolting, (2) floor truss bolting, and (3) floor truss bolting plus a floor cut at the center of the entry. The design of each method and the experimental results are discussed in detail.

Jan 1, 1993

By J. A. Finch

"Gas dispersion in flotation defines the efficiency of the process once the chemistry has been established. There are three measurements, superficial gas velocity, gas holdup, and bubble size, which along with the derived quantity bubble surface area flux, are used to define “gas dispersion.” Sensors for measuring gas dispersion in industrial machines have been developed. This communication describes the working principle of the techniques and illustrates their potential to detect problems and to improve the operation of individual cells, banks and circuits. IntroductionFlotation is the most widely used process to separate minerals and is finding increasing application in other chemical and environmental fields. The process exploits natural and induced hydrophobicity to collect selected particles on the surface of a bubble. Once the process chemistry to control hydrophobicity has been established, the efficiency depends on dispersion of air to generate the necessary bubble surface area. Bubble surface area flux, Sb, the interfacial area generated per unit time and unit area of the machine, is emerging as one of the most useful variables to quantify gas dispersion (Gorain et al., 1997, 1998) although not without its critics (Heiskenan et al., 2001).For a bubble population of mean size db at a superficial gas velocity (or rate) Jg, the bubble surface area flux can be derived from geometric considerations (Finch et al., 1999):"

Jan 1, 2002

By S. Deming

Coal is China's main source of energy. In 1988, 76.1% of commercial energy consumption was supplied by coal. To provide a rational utilization of its coal resources, China has paid considerable attention to coal preparation over the last 10 years. In 1980, there were only 105 washeries treating about 100 million tonnes of coal, but by 1988 there were 151 washeries treating 171 million tonnes per year. This paper describes the development of China's coal preparation industry; its growth, the equipment, and the technology. Statistics and information on the current status of the industry are also be presented.

Jan 1, 1991

By S. K. Gilman, V. E. Hugo

A common problem encountered in the mineral sands industry is that the mineralogical measurements used in defining the resource are not readily converted to metallurgical recoveries, which are used to predict the quantity of the final products. The problem stems from the different objectives of the exploration and metallurgical assessment programmes, and is often compounded by the use of different laboratory techniques and mineral definitions. Common mistakes include the misapplication of routine analysis, incorrect interpretation of mineral recovery, the confusion of mineral recovery with product yield and inconsistent definition of the same mineral. Experience has shown that unless these potential mistakes are identified, the measurement techniques used during exploration and metallurgical assessment are not compatible, often resulting in large errors in the prediction of mineral production. There are no easy solutions to the problem, as there is no universal assay technique which can cost effectively characterize all the mineral sands resources. The recommended course of action will therefore require several iterations to optimize the assay technique to suit the resource. Fundamental to the success of the measurement technique is the understanding of the mineralogy, its behaviour during mineral processing and the quality requirements for the final products.

Jan 1, 2003

By P Trout, B Macaulay

Ridgeway Gold Mine (RGM) is an underground sublevel caving (SLC) operation that is owned and managed by Newcrest Mining Limited (NML). Production drill and blast practices are critical to the success of the SLC method at RGM. SLC production ring precharging was introduced in November 2001 to enhance these practices and deliver safety, productivity and cost improvements. Current precharging practices require up to two rings to be loaded ahead of the ring to be blasted in each drawpoint. The explosive may be required to remain in the up-holes for periods of four weeks or more prior to blasting. During this æsleepÆ time it is subjected to repeated shock from the blasting ofadjacent rings and from rings in adjacent drawpoints. The project described in this paper was designed to gain an understanding of the factors affecting explosive performance in the precharging environment and to develop explosive products and operating practices that would meet RGMÆs requirements in terms ofsaf ety, reliability and blast outcomes. Several months oflaboratory and field testing were required to characterise the explosive and quantify the effect of post-loading blasting shock. These results were used to determine the most appropriate loading and sleep time criteria for RGMÆs precharging practices. In addition, the information is being used to guide the development of the next generation of emulsion explosives for use in underground precharging operations.

Jan 1, 2005

By Engineering Staff

"This paper briefly describes the surface mining operations at Smoky River Coal Limited (formerly McIntyre Mines Limited, Coal Division) near Grande Cache, Alberta. Geology, mining methods, equipment, manpower and reclamation and environment topics are discussed. Introduction Smoky River Coal Limited, a wholly-owned subsidiary of McIntyre Mines Limited of Calgary, Alberta, produces a high quality, low sulphur, low volatile bituminous coking coal from its minesite located at west central Alberta, approximately 20 km from the town of Grande Cache and 360 km west of Edmonton (Fig. I). Most of the coal property is contained within a 30 km long by 20 km wide block lying in a northwest-southeast direction in mountainous terrain. Elevations vary from 920 m above sea level ·at the plant·site on the Smoky River to 1,600 mat the upper levels of current and proposed mining operations. A total of 11 coal seams have been identified. Only two seams, No. 4 Seam and No. 10 Seam are currently considered of major commercial value. These seams are recovered by both surface and underground mining. Approximately 650Jo of the plant feed coal is obtained from a conventional shovel/truck surface mine; the balance is mined underground by room-andpillar methods. Background In 1921, McIntyre Mines Limited acquired some 26,300 hectares of coal leases at Smoky River. Since then the leases were explored intermittently by different companies including McIntyre. In the mid-l 960s exploration activities increased and several feasibility studies were completed. Development of the area was undertaken by McIntyre in 1968 and, in August of the same year, a long-term contract was signed with a consortium of Japanese steel mills for delivery of 2 x 106 t of clean coking coal for 15 years commencing in 1970. Production was focussed on underground mining, using longwall methods."

Jan 1, 1985

By Jin He

Based on the simple-beam theory, a stress analysis model was established for undermining in multiple seam strip-pillar mining when the strip pillars were not columnized; the effects of various mining factors (e.g., mining depth, inter-burden thickness, recovery ratio, etc.) on inter-burden stability were analyzed; the changes in inter-burden stress distribution were investigated; and the important role that the inter-burden spacing and the mining width of the lower seams on inter-burden stability was studied. Finally, the actual practice used in Feng Feng Mine area was used as an example to demonstrate the rational mining width for a fixed mining depth.

Jan 1, 2006

By M. Paul

"INTRODUCTION In 1990, the uranium production of SDAG Wismut in East Germany was stopped. 45 years of inconsiderate destructive exploitation had scarred both landscape and nature. With the “Wismut law” which came into force in December 1991, the Federal Republic took responsibility of the remediation of the legacies from former uranium ore mining and milling in Saxony and Thuringia. A unique opportunity turned out in order to remove environmental damage, to enhance the life quality of the local population, to shape new landscapes and to advance the economic restart. (1) The results of nearly 25 years of remediation activity are evidence that this opportunity was used at all former SDAG (Sowjetisch-Deutsche Aktien-gesellschaft) Wismut sites. The reference project “Wismut“ has evolved into a joint project of all parties involved and radiates beyond the affected regions. This is particularly reflected by the Know-how transfer starting from Wismut and the increasing activities for third parties abroad.WATER MANAGEMENT AT WISMUT REHABILITATION Within the Wismut project, water management and conventional technical water treatment are by far the most cost-intensive long-term tasks of the remediation programme. Over the medium term, there is no viable alternative to the operation of active systems to catch and treat contaminated mine waters at the Ronneburg, Schlema, Königstein, Pöhla, Seelingstädt and Helmsdorf sites. Based on the status quo, this paper outlines the key issues of the Wismut GmbH water management strategy over the medium and long term. It is focused primarily on achieving protection goals for potentially impacted water bodies in the surroundings of Wismut sites and on optimising associated remediation expenditures as well as on creating the prerequisites for achieving low post-remedial care and maintenance or walk-away system status over the long term. (2) The applied mining practices during the active SDAG Wismut period have not been up to the high standards of modern mining operations and their requirement to leave former production premises and deposited residues in a condition that was not only physically but also chemically stable. Rather the emission of mine and seepage waters laden with high acidity, metal and salt content is a frequent corollary and difficult legacy of historic mining and processing operations (4, 5). As a consequence, the control or mitigation, respectively, of environmental impacts associated with contaminated mine waters ties up enormous public resources worldwide (6, 7)."

Jan 1, 2016

By Erica McGlynn, Brian Negrea, Lance Jackson

There was no need for the people of Cleveland to ask “Where does the raw sewage go? We want to know!” because it was clear. The raw sewage was being discharged into Lake Erie during heavy rainfall events due to the outdated design of the combined sewer system. In efforts to resolve this ongoing issue for the City of Cleveland, the Northeast Ohio Regional Sewer District developed Project Clean Lake in collaboration with the US EPA. Project Clean Lake is a 25-year, $3 billion program consisting of seven large-diameter CSO storage tunnels to be constructed beneath the city’s existing infrastructure. The first four tunnels have been completed using traditional hard rock TBM excavation methods. The fifth tunnel, the Shoreline Storage Tunnel Project, presents unique challenges and complexities as it will be the first large-diameter EPB TBM to dig under the City of Cleveland. The project itself consists of one tunnel drive 14,100' (2.7 miles) in length, two pipe jacking tunnels, three large slurry wall shafts, two diversion structures, and three regulator reconstructions. Upon completion of the project, 12 permitted CSO locations along Lake Erie will be taken offline, reducing overflow volumes by approximately 350 million gallons per year. This paper will discuss the current status of construction and the chosen means and methods, including the myriad of nuanced differences between hard rock and EPB TBM tunneling methods. Particular attention will be given to the site preparation, setup, and organization; TBM assembly; and TBM launching practices.

Jun 13, 2023

By M. B. Kime

"A set of experimental batch leaching tests studied the effect of pH, time, temperature, and stirring speed on the relative Cu, Co, Ni, and Fe leaching yields of an oxidized copper-cobalt ore sample in an aqueous hydrochloric acid solution. The results were statistically analyzed and modelled using the structural equation modelling method. Models showed that Cu, Co, and Ni leaching yields were strong functions of the leaching time and leaching temperature, whereas the Fe leaching yield depended on the leaching temperature, stirring speed, and pH. Under optimum leaching conditions yields were 99.8% Cu, 82.4% Co, 91.3% Ni, and 30.6% Fe.RÉSUMÉ Une série d’essais expérimentaux de lixiviation en bâchée ont été menés pour étudier l’effet du pH, de la durée d’attaque, de la température et de la vitesse de brassage sur les rendements relatifs de lixiviation du cuivre (Cu), du cobalt (Co), du nickel (Ni) et du fer (Fe) d’un échantillon de minerai de cuivre-cobalt oxydé dans une solution aqueuse d’acide chlorhydrique. Les résultats ont été analysés et modélisés statistiquement à l’aide de la méthode de modélisation par équation structurelle (SEM, de l’anglais structural equation modelling). Les modèles ont montré que les rendements de lixiviation du Cu, du Co et du Ni dépendaient énormément de la durée d’attaque et de la température de la lixiviation ; le rendement de lixiviation du Fe, quant à lui, dépendait de la température de la lixiviation, de la vitesse de brassage et du pH. Dans des conditions optimales de lixiviation, les rendements étaient de 99,8 % pour le Cu, de 82,4 % pour le Co, de 91,3 % pour le Ni et de 30,6 % pour le Fe. INTRODUCTIONThe Katanga province in the Democratic Republic of Congo hosts the northwestern part of the Central African Copperbelt. This region abounds with large, rich deposits of sulfide and oxidized copper-cobalt ores. In general, the main valuable minerals present are malachite (CuCO3Cu(OH)2) and heterogenite (CoO(OH)). Common impurities found in heterogenite are Cu, Ni, Si, Al, Mn, and Fe. The substitution of Co by other cations (e.g., Cu, Ni, and Fe) has an influence on the crystallinity of heterogenite (Deliens, 1974). In general, well-crystallized varieties of heterogenite have lower impurity contents, whereas amorphous heterogenite types usually contain more impurities (Thys et al., 2009). Further, in heterogenite, Co can occur in the 2+ and 3+ oxidation states. The gangue generally consists of quartz (SiO2), talc (Mg3Si4O10(OH)2), kaolinite (SiO2·Al2O3·2H2O), limonite (Fe2O3·3H2O), and goethite (FeO(OH)). Oxidized copper-cobalt ores are often treated by hydrometallurgical methods, whereas sulfide ores are often treated by flotation or pyrometallurgy, depending on their grades. Hydrometallurgical methods typically entail selectively dissolving the metals of interest (Cu, Co, and Ni) in aqueous solutions (leaching), transferring the dissolved metals to an organic solution, and retransferring these to a second aqueous solution (solvent extraction). Copper and nickel are readily dissolved in an acidic aqueous media. In contrast, cobalt is difficult to dissolve, especially if it is present in the third oxidation state; however, this species becomes soluble after it is reduced to Co2+ (Mwema, Mpoyo, & Kafumbila, 2002; Kime & Makgoale, 2016)."

Jan 1, 2017

By J. K. Borchardt

The use of statistical design to optimize deinking process design has been studied for the flotation deinking of newspapers. The interactions of two variables are often important in determining flotation deinking efficiency. The interactions can be synergistic or antagonistic. These interactions would not be discovered using the traditional method of varying one parameter and holding the other variables constant. An experiment design in which two or more process parameters are varied simultaneously is required to identify these interactions. A considerable number of conclusions could be drawn about the relative importance of process variables on ink particle size distribution, ink removal efficiency, and flotation yield loss in a flotation deinking process. However, these findings could be influenced by the deinking surfactant and the ink chemistry.

Jan 1, 2001

By N. S. Kim

Silver paste including nano sized particles maintains conductivity in high temperatures without forming oxide layers. In the industry, printing process produces wasted silver paste inside the cylinder and on silk-screen. Pyrometallugical silver recycling methods have environmental problems and do not extract pure silver after removing polymer and organic materials during the extraction process. In this study a simple wet process, of recycling the waste silver paste, using ammonia, was conducted. Silver ion extraction yield was increased using oxidant in the ammonia solution. Possible extraction yields, such as pH, concentration, temperature of ammonia, oxidant concentration and the extraction time. The particles that were obtained after the extraction process will be used as porous hydrophobic catalytic and applied to AI mask and hydrophobic ink. Keywords: Waste silver paste; Ammonia; Hydrophobic porous support

Jan 1, 2009

By Fumihiko Sumiya, Kunihisa Katsuyama, Yuji Ogata, Yuji Wada, Yukio Katoh, Yoshikazu Hirosaki

In our previous work, the results of photographic observation using a high speed framing camera showed that the difference between precursor air shock wave velocity and detonation velocity was primary factor for the channel effect. It is assumed that the decreasing precursor air shock wave velocity can prevent the channel effect in charge hole.

Jan 1, 1996

By Noel A. Warner

Modern steelmaking is based on direct use of oxygen in high intensity batch reactors. A totally new approach is proposed in this paper, based on the view that pursuit of high intensity is unlikely to lead to successful coal-based continuous steelmaking. By substituting carbon dioxide and water vapor as the oxidants rather than using oxygen directly, the intensity is greatly reduced. Accordingly, subsurface formation of carbon monoxide bubbles can be avoided by careful manipulation of the three participating rate processes, gaseous diffusion, interfacial chemical kinetics and liquid phase mass transfer. Steelmaking can then be carried out without explosive ejection of molten droplets and the generation of micro-spray but rather in a controlled and fume less fashion. The vital component is the introduction of generic melt circulation technology. Three melt circulation loops in series are envisaged. Starting with a composite feed of iron ore fines, pulverized coal and lime flux, a metallized solid raft floating on molten iron is propelled out of the ironmaking loop onto the first of two downstream steelmaking loops. In the first, a liquid slag is formed, primary decarburization is undertaken not with oxygen but rather with CO2 and H2O and the melt is desulfurized. The semi-product stream enters the third melt circulation loop, where open-channel decarburization is effected along with dephosphorization to yield a low carbon steel product. Alternatively, the melt leaves the last loop to irrigate a packed tower countercurrent to argon at around 100 mbar to continuously produce ultra-low carbon (ULC) steel.

Jan 1, 2003