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By D. C. Panigrahi

Extensive field studies have been carried out to investigate the pillar fire problems in one coal mine in India. A Thermal IR gun and a Thermovision camera have been employed for thermal scanning to assess the state of heating in selected pillars. Special sampling set-ups have been designed to collect gas samples from the holes drilled into the selected pillars and the multigas detector is used to analyse the composition of samples in situ. In order to predict the spontaneous heating in coal pillars, different gas ratios have been calculated and it has been observed that some of the established gas ratios, viz. Graham?s ratio, Young?s ratio etc. have resulted in negative values in samples containing high amounts of methane. The modified gas ratios have been proposed which will be useful for predicting the pillar fires. These ratios may also be used for assessing the condition of fires in sealed-off areas.

Jan 1, 2004

The application and development of monitoring and control techniques of coal mines in China is mainly described in the paper.The techniques of mine control and monitoring system have been developed as an important means of production dispatch, command and management with ever-increasing coal production and gradual raising of the level of mechanization and centralization of continuous mining. The continuous stage monitoring and control system in China coal mines has been developed from the initial single fixed plant monitoring, and the technique of computers has also been applied in the system for productive and environmental monitoring, featuring a new type of mine control and monitoring equipment of China.

Jan 1, 1985

By G. Donald Emigh

WESTERN phosphate resources which lie in Ida- ho, Montana, Utah, and Wyoming, have seen great expansion of activity in recent years. Growth has been two-pronged: expansion in fertilizer use, and since 1949, into the elemental phosphorous industry. Elemental phosphorous, produced in the electric furnace, goes largely into chemical making. Phosphate ore was first recognized in the West about 1889. Production started in 1906, and for many years consisted of underground operations by small companies operating sporadically. In 1920 Anaconda Copper Mining Co. opened the underground Conda mine near Soda Springs in southeastern Idaho, and has maintained and increased its operations since then. About 1930 Montana Phosphate Products Co. began underground mining in Montana and has remained a steady producer. In 1945 San Francisco Chemical Co., one of the oldest companies in the western field, initiated strip mining at the Waterloo mine near Montpelier, Idaho, and later at Leefe mine near Sage Junction, Wyo. In1946 J. R. Simplot Co. began open pit mining at Gay mine near Fort Hall, Idaho. In 1950 Victor Chemical Works began underground development work in the area of Maiden Rock, south of Butte, Mont.: and has since mined there. Monsanto Chemical Co. began open pit mining near Soda Springs, Idaho, in 1951.

Jan 11, 1954

By D. Bessinger

The present paper provides a brief overview of the thermodynamics of titania rich slags, an outline of the Multi-Phase Equilibrium (MPE) package and its application to ilmenite smelting. Through assessment of published experimental data on various systems containing TiOx, it was found that despite considerable scatter in measured phase equilibria data for the binary Ti2O3-TiO2system,the behaviour of binary and higher order titania rich slags and oxide solid solutions phases could be represented by solution models in the MPE package. Results from the applications of the MPE model on the stability of solid phases and slag-refractory interactions will be presented and discussed. Parallels will be drawn between the predictions by the model and observations made during pilot plant tests. Key words: Thermodynamics, titania slags, ilmenite smelting, phase equilibria, refractory.

Jan 1, 2003

By Heather N. Dougherty

In the absence of values for each influencing parameter and a known relationship of input-output space, novel approaches should be implemented as proxy solutions to mathematically complicated problems. Proxy solutions can be in the form of linear or non-linear multiple regression equations. Predicting the performance of gob gas ventholes is one of these mathematically complicated problems as it is difficult to know the exact relationships between various parameters influencing gob gas venthole (GGV) performance from active and sealed (completed) longwall panels. In this paper, a discussion of the NIOSH-developed software suite for methane control and prediction (MCP) based on an artificial neural network (ANN) is presented. The application of the ANN-based software suite to develop algebraic relationships for gob gas venthole performance prediction in sealed and active longwall panels is sought. Output information obtained from the NIOSH-MCP software as a response to various input parameters were used to create an input-output database for total flow and methane percentage from GGVs operating in active mines during completed and sealed panel situations. Due to the multi-variable nature of the software, outputs generated using the software for various inputs were used to develop analytical equations first using linear and then second using non-linear multivariable regression techniques. The advantage of this method is its ability to better understand the significant parameters of the relationships between the inputs and outputs for gob gas venthole production in active and sealed panels and to be able to predict their performances using relatively simple analytical functions.

Jan 1, 2010

By J. F. Leroux

The Gaspé smelter at Murdochville, Quebec, Canada introduced concentrate injection into elongated Peirce-Smith converters sized 1.96m x 12.5m (13 ft. by 41 ft.) in 1996, and commissioned a large, converter-like bath smelting vessel in April 1998. The new vessel, which is sized 4.27m x 16.1 5m (14ft. by 53ft.) has several interesting features designed to effectively utilize bath smelting technology for the requirements of the Gaspé smelter. For example, the vessel can operate on concentrate injection at upwards of 60-80 tph rate on an instantaneous basis, can operate as a large Peirce-Smith converter, while it is also fitted with matte and slag tapholes much akin to Noranda Process reactor, and includes a novel cold charge addition system. The new technology will eventually allow the capacity of the plant to increase from about 300,000 tonnes of concentrate per year to over 350,000 tonnes of concentrate per year while improving sulfur capture.

Jan 1, 1999

Development of New Comminution Testing Methodologies for Geometallurgical Mapping of Ore Hardness and Throughput The emerging discipline of 'geometallurgy' is becoming increasingly recognised as a discrete and high-value activity that reflects an ongoing trend towards more effective mine site integration and optimisation. Constrained sampling that reflects and defines inherent ore body variability is a key geometallurgical requirement. This requires use of larger numbers of low-cost physical testing which can be applied to small sample volumes suitable for defining natural variability. The AMIRA P843 'GeMIII' project (Geometallurgical Mapping and Mine Modelling) is a major industry-supported research initiative designed to develop new tools, methods and protocols to support geometallurgical integration. As part of this integrated research a new more rapid low-cost comminution test (GeM Comminution index) has been developed which can be employed as a front line tool for geometallurgical mapping purposes and predictive throughput modelling. The test has been designed to be inserted into routine assay sample preparation and is based on constrained jaw crushing protocols linked to analysis of resultant size distributions. Extensive validation and modelling has shown the GeM Comminution Index (Ci) is correlated with the Drop Weight index A*b and Bond Mill Work Index (BMWi). Large scale trials have been conducted within a commercial assay laboratory to demonstrate and optimise incorporation of the Ci test into routine sample preparation protocols. While Ci based estimates of A*b and BMWi are not as precise compared to larger volume more expensive test-work, the ability to undertake large numbers of tests typically in a systematic down-hole manner, provides a high level of data support through adjacency. A Ci based approach is highly suitable for variability mapping, domaining and selecting large composite samples for more precise testing. Within the context of the AMIRA P843 project this forms part of an integrated work flow designed to support geometallurgical integration. The development of a comminution test linked to routine assay sample preparation represents significant value adding to a process that in most cases is already going to be carried out. This paper introduces the Ci test concept and application to geometallurgical testing for throughput modelling

Sep 13, 2010

By Yasuo Ojima

A new copper continuous converting process was investigated to evaluate the possibility of its application in the commercial operation. The tests were performed both in the laboratory and in pilot plant scale. Bath smelting process with the use of the top submerged lance technology was applied in these tests. Furnace shape was modified to a lengthwise eylindrical one with a settling area. The furnace monitor was put in the settling area to check the furnace from inside, FeOx-Si02, FeOx-CaO and FeOx-CaO-Si02 based slag systems were used to check their efficiency, The optimum slag chemistry to have good metallurgical results was discussed and FeOx-CaO system with some Si02 content turned out to be preferable although it has not been practically used, In this pilot plant test feeding rate of I tIH of solid grain matte was charged consecutively for two weeks and continuous converting could be done successively. This process is expected to overcome the problems of existing processes and be easily applied in existing plants.

Jan 1, 2003

By L. Bichler, C. J. Verdon

In this work, the effect of doping yttria stabilized zirconia (YSZ) with 5, 10 and 15 mol% erbium oxide (Er2O3, erbia) was investigated using spark plasma sintering (SPS) technique. Sintering was carried out at 1300°C with 30 and 60MPa uniaxial pressures and a 5min hold time. Densification kinetics were studied using displacement response from the SPS machine. As-sintered microstructure characterization was carried out via scanning electron microscopy (SEM) and X-ray diffraction (XRD) techniques, while chemical composition was characterized by energy dispersive X-ray spectroscopy (EDS). The results suggest that sintering carried out at 60MPa produced high density composites even though erbia dopants were found to inhibit material densification and grain growth during sintering. 5, 10 and 15mol% erbia- YSZ had cubic crystal structures, as verified by XRD analysis.

Jan 1, 2014

By J. A. Finch

"Much progress has been made over the last several years in the ability to measure flotation cell hydrodynamic parameters in both the laboratory and plant. These techniques have allowed fundamental research to proceed to determine the effects that frother chemistry has on the main hydrodynamic parameters (gas hold up, bubble size) as well as on the amount of froth generation and water content of froth. A research program was begun that brought together a team consisting of private companies and a University with expertise in hydrodynamic characterization (McGill), flotation reagent applications (Flottec) and chemical synthesis (Sasol N.A.) with the purpose of characterizing frother chemistries with two goals in mind: Determine which frother chemistry can provide optimized cell hydrodynamics; and, create new frother chemistries with specific hydrodynamic properties.This paper describes the key steps that were taken that led to the development of new frother chemistry for use in flotation.The first step was the characterization of the major frother chemical families in a two phase system. The parameters measured were gas hold up, bubble size, froth height and water carrying rate at different concentrations and gas velocities.Analysis of the data indicated that definite patterns existed between frother chemistry and hydrodynamics and showed that frothers could be grouped into classes. More importantly, by modifying known frothers through chemical reaction it was shown that these frothers could be moved from one class to another. As a result of this better understanding of the interdependence of hydrodynamic and chemical properties, a new frother chemistry was proposed that was predicted to perform similarly to MIBC.The new frother was synthesized and hydrodynamic testing confirmed that the chemical performed similar to MIBC. Laboratory flotation tests were conducted on two different ore types that also confirmed the similar performance of the new chemical and MIBC. Subsequently, the new product was placed on a plant for a short period of time. The results showed that the product was an excellent frother but increased the flotation rate slightly more than MIBC at the same addition rate.Further research showed that the new frother chemistry was a family of products. By changing the reaction the resultant products could be made to be slightly weaker or stronger than MIBC but that this chemistry cannot provide hydrodynamic/froth characteristics similar to strong frothers like glycols and glycol ethers. Further work is planned to conduct longer plant trials to confirm the efficacy of this new frother family."

Jan 1, 2007

By Michael S. Zhdanov

One of the major problems of mineral exploration is the ability to reliably distinguish between uneconomic mineral deposits and economic mineralization. While the mining industry uses many geophysical methods to locate the mineral deposits, until recently, there was no reliable technology for mineral resources identification and characterization. The main goal of this project is to develop a new geophysical technique for subsurface material characterization, mineral exploration and mineral discrimination, based on electromagnetic methods. The proposed new technique is based on examining the spectral induced polarization effects in electromagnetic data using the modern distributed acquisition systems and advanced methods of 3-D modeling and inversion. The recovered parameters of the relaxation model will be used for the discrimination of different rocks, and in this way will provide an ability to distinguish between uneconomic mineral deposits and zones of economic mineralization using geophysical remote sensing technology (Zonge, 1976). The proposed research and development is undertaken using multi-partner collaboration between the University of Utah, four major mining companies, Kennecott Exploration, BHP Billiton World Exploration Inc., Placer Dome Inc., Phelps Dodge Exploration, and Zonge Engineering Inc., which is equipment manufacturer and service provider to the mining industry. The multi-partner collaboration between the academic institution, the University of Utah, and mining industry helps to identify the appropriate mining target and conduct the field experiment for practical demonstration of the developed new technology, which is an important part of the this project.

Jan 1, 2005

By Kubo H, Ninomiya R, Ojiro T, Sato T

New high-strength Zn alloys for moulds are demanded from the automobile and electric industries in Japan, because the s rength of Zn moulds is still not high enough for the mass production. There are two approaches to improve the strength of Zn alloys. One is to increase the Al content. ZA alloys (ZA-8, ZA-12, ZA-27) were developed through this approach. The other is to increase the Cu content. But it is known that an increase in Cu generally depresses the castability of Zn alloys, so that the alloys with increased Cu have been rarely studied until now. In this study a reconciliation between the strengthening and the castability of Zn alloys by enriching both with Al and Cu has been attempted. Accordingly we have studied on the Zn alloys containing 4 to 25 mass per cent Al and to 24 mass per cent Cu have been studied. Their fluidity, which primarily corresponds to the castability of the alloy, were measured first and 19 alloys were selected based upon their fluidities and casting temperatures. Mainly the mechanical properties of all 19 alloys were tested and some were found to be excellent in both strength and castability. Z1009 (Zn-IOAI-9Cu-0.02Mg alloy) cast in a sand mould has the tensile strength of 360 MPa while ZAS (Zn-4AI-3Cu-0.04Mg alloy), which is the most popular alloy for moulds, is 215 MPa. Z2520 (Zn-25AI-20Cu-0.02Mg alloy) cast in a sand mould has a Vickers hardness of 178, compared to 107 for ZAS and 104 for ZA-27 (Zn-27AI-2Cu-0.02Mg). Furthermore the castability of Z1009 is as good as that of ZAS. The underside shrinkage occuring in casting ZA-27 is restrained in Z2520.

Jan 1, 1993

By Jean-Christophe Ehrström, Fanny Mas

"A specific test set-up has been developed to study at the lab-scale the high-temperature behavior of aluminium alloys in conditions close to those experienced by thick plates during hot-rolling. A particular attention is paid to reproducing both the stress triaxiality and strain fields that exist in plate during rolling. In addition to standard ductility measurements by means of secondary tensile tests (STT), multi-step plane strain compression (PSC) tests have been performed to mimic hot-rolling pass schedules. Tool and sample geometries were adapted to allow low h/a ratios (h= average specimen thickness, a= tool width) and thus guarantee depressive stress conditions at the center of the specimen during most of the test. Such conditions resulting in porosity opening can then be used to investigate the impact of rolling conditions on damage evolution. The mechanical testing was combined with post-mortem high-resolution ultrasonic scans allowing to detect small amounts of damage and quantify its evolution as a function of processing parameters such as strain and temperature. The test set-up was validated on two 2050-type AlCuLi alloys with different susceptibilities to high temperature embrittlement.INTRODUCTION Aluminium thick plates are widely used in the aerospace industry, mainly as semi-products to be machined for internal structure parts of wings (spars, ribs) and fuselage (frame). The conversion route of such products always involves a hot-rolling step, the conditions of which (temperature, speed, pass schedule) have to be optimized to maximize both mechanical properties and final plate quality. This goal cannot always be efficiently achieved by full-scale industrial trials as (a) cost limits the number of possible test conditions and (b) it is often difficult to change one parameter alone. That is why there is a need for laboratory-scale tests able to mimic the rolling process in terms of temperature, strain rate, stress triaxiality and deformation. Most laboratory hot-rolling mills do not adequately simulate industrial processing routes, especially in terms of heat loss, deformation speed and rolling geometry (maximum roll gap vs. work roll diameter). Concerning thick plate, it is of interest to achieve both similar deformation and L/h ratio (L=arc of contact, h=mean gauge) per pass as the industrial schedule because they are simultaneously involved in damage evolution and void closure during hot forming processes (Saby, 2014)."

Jan 1, 2018

By Andreas Cestonaro

Roll grade evolution in plate mill applications is traditionally following the development in hot strip mills. New grades normally find their way into service only after being successfully implemented in hot strip production. The majority of the plate mills worldwide are using work roll grades that have been invented before the 1980’s. But today the demands in the mills are pushed by sophisticated product mixes and longer rolling campaigns. The result of this development is a higher wear rate on the work rolls and as a consequence roll hardness is increased and advanced roll materials are used. The backup rolls are also affected by this. The wear rate is higher and the mechanical impact in terms of contact pressure and work hardening is increasing. This paper outlines the results of the roll grade development at Gontermann-Peipers and introduces new materials for work and backup rolls for plate mills.

Jul 30, 2018

By C Balci, D Tumac, A Sheterpour-Mamaghani, E Dogan, A Kocbay, T Erdogan, A Gumus, H Copur, E Altintas

Excavation of vertical and/or inclined shafts in the underground structures requiring careful design and planning. Raise Boring Machines (RBMs) are commonly used for excavation of shafts for different purposes such as ventilation, orepass, and human-material transportation. Proper selection and accurate performance prediction of RBMs are two main parameters affecting the cost estimation and planning/scheduling. Indentation test is one of the most preferred methods that can be used to predict advance rate of RBMs. This study aims at suggestion of new prediction model for instantaneous penetration rate of RBMs based on indentation tests. Different rock (core) samples (with different geological origins) are obtained from the raise boring application projects in Turkey; then, the indentation tests are carried out on them by using a real-life insert (button), which is used in reamerhead cutters investigated in this study. Finally, the statistical relationships between the field performance and the indentation indices are investigated. The study indicates that the brittleness index (the ratio of maximum applied force to corresponding penetration) can be used to predict instantaneous penetration rate of RBMs used in the vertical raise bored shafts excavating rocks having uniaxial compressive strength lower than 100 MPa.

Nov 29, 2022

By G. M. Rao, P. N. Deo

Graphite is soft and easily floatable but it is quite difficult to obtain high purity concentrate at coarse sizes. Chemical treatment can produce high grade concentrate but it is an expensive process. Graphite containing plus 96% fixed carbon (FC) with coarse flakes commands high price in international market. Such graphite concentrate containing plus 96% FC was produced in Indian Bureau of Mines (IBM) by using newly developed reagent (mixture of different hydrocarbons and terpenes, IBM/D7) instead of commonly used frothers viz. pine oil, MIBC, kerosine etc. and regrinding in a special type of mill with special grinding media instead of grinding in a conventional ball/ rod mill followed by cleaning. Both the new reagent (frother) and special grinding media are inexpensive and readily available. The process is under patenting. This paper focuses application of this new grinding methodology for flake size protection, and the new reagent for selective flotation of high purity graphite.

Jan 1, 1995

By T. J. Batchler, T. M. Barczak

The Code of Federal Regulations (CFR) requires that the transverse load capacity of stoppings be equal to or greater than traditionally accepted in mine controls, which for block stoppings is generally accepted as 39 psf as referenced in the preamble to the CFR standard. This measure is based on physical testing of a freestanding wall in accordance with ASTM E 72 specifications, where our past research has shown that the dominant parameter is the tensile strength of the sealant. A new protocol based on rigid arch loading of the structure is proposed to determine the true transverse load capacity of block stoppings. Arching is achieved by the restraint of the stopping against the mine roof and floor, whereby compressive forces are developed within the wall. A laboratory procedure using the NIOSH Mine Roof Simulator (MRS) to simulate rigid arching of block stoppings was developed and results verified through full-scale in-mine tests. The rigid arch tests have demonstrated transverse load capacities more than an order of magnitude higher than the ASTM E 72 evaluation method from which the 39-psf requirement is derived. More importantly, the rigid arch tests have shown that the load capability is dependent on the physical properties of the block and geometric properties of the wall and not the sealant.

By Armin W. Stuedlein, Youssef Bougataya

Early stage design of driven piles primarily relies on static analysis based on one or a combination of total and effective stress approaches, the latter known as the method to estimate axial capacity. A database of 85 piles driven in the Puget Sound Lowland region and monitored at End of Driving (EOD) and Beginning of Restrike (BOR) was compiled along with capacities estimated using the CAPWAP procedure. Established soil profiles based on borings with standard penetration tests (SPT), cone penetration tests, and geologic maps were matched with their corresponding unit shaft resistance profiles from the CAPWAP procedure and resulted in more than 1,200 observations. In this study, eight new models were developed to predict the coefficients at EOD and BOR, based on the corresponding USCS categorization. Each coefficient model is formulated using a three-parameter exponential function, calibrated to capture the profile of coefficients with depth. These models could benefit the designer by providing them with a simple, empirical model that accounts for soil type and setup in a smooth, continuous function with depth. A parallel analysis was performed to assess the accuracy and variability of the formulated prediction models to facilitate implementation in load and resistance factor design (LRFD). INTRODUCTION The design of the axial capacity of driven piles during the planning stages of a project is typically based on a static analysis approach. The goals of this approach are to predict the components of capacity, consisting of the shaft and toe bearing resistances, and to assess project concept feasibility and preliminary lengths. In most cases, this analysis is based on empirically-developed methods, such as the total stress method, also known as the method (Tomlinson 1987) or the effective stress method known as the method (Esrig and Kirby 1979; Fellenius 1991). Many other methods, such as those based on in-situ test results exist and rely on correlations of blow counts from the standard penetration test (SPT), and cone tip and sleeve friction resistance from the cone penetration test (CPT), to shaft and toe pile resistances (Schmertmann 1978; Meyerhof 1976; Nottingham and Schmertmann 1975; Nordlund 1963; Eslami and Fellenius, 1997; De Ruiter and Beringen 1979). Although these methods were generally developed using data from specific geological regions, they are often recommended in national design manuals (e.g., FHWA, Hannigan et al. 2006).

Jan 1, 2018

By José Fagundes Jr., Juliano Braz Possatti, Bruno Câmara Vieira, Gabriel Godinho Alves, Bruno Bastos da Silva Murad, Cristina Maria de Oliveira Roque

Driven by market trends, increasing environmental accountability, government regulations and fostered by the Company’s strategic plan, ArcelorMittal Tubarão has developed new steel products to deliver better solutions to fit each customer’s needs. This often translates in higher strength, more complex and dimensionally challenging (thinner and wider) steels to attend a broad array of goals, such as reduction of vehicles fuel consumption and carbon emissions, increase in fatigue performance of heat treated parts, higher load capacity per net weight in vessels or wagons and lower supplying lead time as ArcelorMittal Tubarão establishes itself as a domestic option for so far imported grades. Based on the annual Product Development Plan, a structured workflow involves technical discussions from an operational point of view about safety issues, metallurgical project, steel grade family definitions, offline simulations prior to field trials, deformation resistance and process parameters adjustments and scheduling strategy. As a result of the increasing synergy between the areas, the share of new materials developed in recent years has been sustainably increased up to 15% in 2018, adding value to the final product without impact on hot rolled coil output and with a low cobble index.

Oct 1, 2019

The green field discovery of a two million ounce high-grade refractory gold ore deposit in the Indonesian Province of Sulawesi Utara, led Newmont to utilise its proven technical expertise in dry grinding and whole ore roasting to develop a 2000 tonne per day, 160 000 ounce per year operation in this remote and picturesque location.Located at an elevation of 250 in above sea level and ten kilometres to a deep water natural harbour, the hard rock open pit mine, process plant and infrastructure facilities were built to budget at a capital cost of US$132 million. The plant was commissioned with oxide ore, with the first gold poured in March 1996 and with refractory ore in January 1997. The operation rapidly met its production targets because of extensive forward planning and training programs developed for the local workforce. The presence of steep topography, fertile coastal plains, high rainfall, high seismicity of this location led to the decision to dispose of neutralised tailings in deep water off the coast instead of impounding tailings in a dam. This paper describes the development of the project and the challenges in developing a gold operation in a remote location which lacked infrastructure, the steps taken to ensure a smooth commissioning, and the selection of the workforce to operate a technically sophisticated facility.

Jan 1, 1997