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By C. Matthews, A. Vo

"Australia is one of the world’s leading exporters of bulk commodities and the extensive use of sampling equipment is key to the successful management of each mining operation. At the process plant, without a full understanding of the feed, product and tails, it is impossible to fully optimise the performance of the plant, such that the metallurgical balance is often open to error. At the port, a statistically correct, bias free and compliant sampling system is crucial to ensuring exported minerals are reflective of their true value and to avoid penalties. Over the last decade, as a result of the iron ore boom, there has been high demand for reliable, representative and standard compliant solids sample systems in Australia. This paper reviews several solids sampling applications at Australian mine sites, the challenges and experience gained and how the implementation of reliable representative sampling systems has provided better understanding of plant process performance, improved plant control and overall benefits to the operations.INTRODUCTION Mining is the primary contributor to the Australian economy with Australia ranking in the top 4 in economic resources for 21 primary industrial minerals in 2016 (Britt, et al., 2017). Australia is one of the world leaders in the export of the majority of its commodities including gold, copper and iron ore (Britt, et al., 2017). Therefore, a suitable and standard compliant sampling system is essential for evaluating plant performance and content verification. At the mine and at the port, the larger iron ore miners in Australia have developed stockpile models to predict the grade of their ore down to individual blocks of the stockpile. This allows the miner to create the right blend of material for sale to their customers and ensures they are not underselling their product or at risk of penalties for impurities or low grade. As an example, the average difference between the benchmark 62% Fe and low grade 58% Fe fines at the time of this report averaged US $30/tonne according to the Metal Bulletin Iron Ore Index. At a shipload of 180kt this would be a variation of US $5.4M. Whilst this is an extreme example, it highlights the economic importance of producing the correct grade product and a recognised representative sample of said product."

Jan 1, 2019

By Luben Savov

This paper presents recent research works on the removal of the tramp elements Cu, Sn, Zn and Pb from steel. The evaporation of Cu and Sn in iron-based melts treated at reduced pressure of the gas phase was studied in a vacuum induction melting furnace. The effect of chamber pressure, temperature and melt composition was investigated. Since the main source of contamination of steel with Sn and Zn is the recycling of tinplate and zinc coated steel, respectively, possibilities for the removal of meta1ic coatings in a scrap pre-treatment stage were studied, too. Tin was removed in the temperature range 400-5S0°C by treatment with reactive gases featuring high sulphur potential. Zinc can be removed by evaporation or by a combination of thermal and mechanical treatment. The paper discusses the thermodynamics of Pb in carbon-saturated iron melts, too.

Jan 1, 2001

By C. J. Cajka

Commodity agreements, trade liberalization, producer cartels, the New International Economic Order, price stabilization and access to supply are buzz words of the day. The international concern and dialogue on these concepts, often by a new breed of politically motivated experts, have generated intense interest in seeking an international solution to natural resource problems. While this momentum was maintained during the past year, the growing incidence of protectionist actions by several major nations has been eroding confidence in the global approach. The seriousness of current difficulties has created an urgent need for decisive action. At the same time, the limitations of the global approach have become more evident.

Jan 1, 1978

By B E. Hall, D B. Kahler

"'Optimisation' has become a catchcry among many mining companies looking to tell the market how mining businesses will be improved and shareholder value increased. Consequently, the term 'optimisation' has been adopted by many service providers as they look to assist mining companies in achieving their objectives. But the explosion of services and products being offered with the label 'optimisation' has created some confusion. Mining companies ask for help in 'optimising' and service providers offer their assistance because they have a product that has the word 'optimisation' in its title. This is of course an over-simplification, but not by much! The authors' discussions in recent years with both mining companies and service providers have uncovered a number of very different definitions of optimisation.This paper provides a framework for identifying the scope and approach of different mining optimisation products and services, particularly the distinction between optimisation of components of the operation and the business as a whole. The different types of business optimisation are discussed, highlighting the failings of the mining industry's typical approach of strategy selection (as opposed to strategy optimisation). Mining business optimisation is discussed as a wicked problem, with the implication of this on how strategy optimisation models should be used and what the objectives of a business optimisation study should be.Case studies are also included to illustrate how fully flexible strategy optimisation models have been applied to assist decision-makers understand the impacts of changes in one part of the operation on the whole mining and treatment process, from geological models to the sale of product to customers.CITATION:Kahler, D B and Hall, B E, 2016. Strategic decision-making in mining – business optimisation using flexible evaluation models, in Proceedings Project Evaluation 2016, pp 215–225 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 8, 2016

By Engineering Staff

In 1958, the Iron Ore Company of Canada decided to proceed with the Carol Project. The ore deposits in the area are part of the highly metamorphosed southern zone of the Labrador Trough. They lie along the shore of W a bush lake, in the western part of Newfoundland-Labrador, 190 miles north of Sept-Iles. The project is designed to mine, by open-pit methods, 17,200,000 long tons of crude ore, grading 37 per cent iron, per year. This ore will be beneficiated to produce 7,000,000 long tons of concentrate, grading 66 per cent iron, of which 5,500,000 long tons will be pelletized. Production is scheduled to commence this summer. Initially, ore will be taken from 45-foot benches in the Smallwood mine, using jet-piercing production drills and large-scale blasting with "slurry" explosives. Four 13-yard electric shovels will muck the broken ore into 100-ton trailer trucks. The trailers will be hauled to two 2,000-ton loading pockets, which feed the ore into 100-ton railcars. Four ore trains, each comprised

Jan 1, 1962

By S. W. Marcuson, P. J. Mackey

The 1973 Oil Embargo and succeeding disruptions in supply had a profound effect on energy costs and consumption patterns in the developed world. This was especially true in the USA where post World War II growth, fueled by low-cost imported oil, left the country dependent on uninterrupted oil shipments from the volatile Middle East. In this atmosphere, Professor H.H. Kellogg of Columbia University, convinced of the necessity of good environmental stewardship by the writings of the era’s leading environmentalists, developed a methodology for evaluating energy and process efficiency of metallurgical processes and wrote a series of papers describing and applying the techniques. One of these, "Energy Use in Sulfide Smelting of Copper" is recognized as a seminal work which both described the state of energy usage in copper smelting in the mid-1970’s and portended future developments. The background to these papers is examined and the current and past Cu-Ni matte smelting practices in Canada are examined in the context of the results. Data from early 20th century publications describing reverberatory and blast furnace operation is employed to show that energy consumption for much of the century was several multiples higher than that calculated for best reverberatory operation in the 1970’s.

Jan 1, 2015

By Denis Shishin

The pyrometallurgical production and recycling of non-ferrous metals involves the use of complex feed stocks, having awide range of chemical compositions from sources that include mineral sulphide concentrates, high value obsolete materials and process wastes. The commercial viabilities of these operations hinge on the ability to extract value from these materials. Increasingly, modern computer-based tools are used to describe and predict process outcomes, including mass and heat balances, the partitioning of elements and phase equilibria. At the heart of these predictive tools are thermodynamic databases that describe the fundamental chemical properties of a system and all the components present. A comprehensive research program has been established to develop an accurate, self-consistent thermodynamic database describing all gas-slag-matte-metal-speiss-solid phases in the system Cu2O-PbO-ZnO-Al2O3- CaO-MgO-FeO-Fe2O3-SiO2-S-(As-Bi-Sb-Sn-Ag-Au). The database can be used in conjunction with the FactSage computer platform. The accuracy of the database and its application to industrial practice is demonstrated.

By B. W. Williams

The crack propagation behaviour of Zr-2.5Nb pressure tube material was studied through comparison of the measured behaviour with the predicted response from finite element analysis. Three-dimensional finite element simulations of compact tension specimens were performed using the crack tip opening angle as a fracture criterion to allow for crack propagation. To obtain reasonable agreement with the measured behaviour, it was important to capture both the anisotropic plastic deformation behaviour of the Zr-2.5Nb material through use of the Hill-48 yield criterion and damage due to void growth, nucleation, and coalescence through the use of a Gurson-based constitutive model in the simulations.

Jan 1, 2010

By L. Trytten, S. Bass, P. Nawrocki, J. Mercer

The Sherritt Fort Site nickel refinery and fertilizer plant has been operating continuously since 1954. The ammonia leach process uses ammonia and sulphuric acid, producing nickel and cobalt and an ammonium sulphate byproduct. One of the features of an ammonium sulphate based process is the aggressive nature of ammonium sulphate to concrete and structural steel. After six decades of operation, portions of the structural steel and concrete at the Sherritt facility have become degraded. Infrastructure replacement programs started in earnest more than a decade ago with pipe racks and electrical infrastructure, and have now progressed into building steel. Replacing and repairing this infrastructure within the tight constraints of an operating plant poses several difficult challenges. This paper will outline the approach taken to accomplish this difficult work, and discuss key learnings from the ongoing program.

Jan 1, 2015

By Dakota Faulkner

Unexpected roof falls often occur in the entries or intersections of active mining sections in underground mines. For large roof falls (greater than 20 ft in height), it becomes dangerous and impractical to clean up the rock debris and re-bolt the newly exposed roof strata. To help mine operators rehabilitate the roof fall areas in a quick, safe, and economic manner, Jennmar Corporation and Keystone Mining Services, LLC (KMS) designed, tested, and developed various impact-resistant (IR) steel set designs, as initially detailed in the proceedings of the 30th International Conference on Ground Control in Mining (ICGCM). Since then, the IR steel sets have been successfully installed in more than 100 roof falls in 43 different coal mines. Significant data has been obtained from these installations, enabling further refinement to and improvement on the design. This paper (1) updates drop test results of the IR lagging panel, (2) presents a case study of the performance of IR arch sets installed 56 months ago at a roof fall rehabilitation site, (3) demonstrates capacity evaluation of the IR steel set, and (4) outlines a preliminary applicability evaluation guideline of the IR steel set for a given roof fall condition. Field evaluation and structural numerical analysis indicate that impact capacity of the system is significantly higher than that of the IR lagging panel, as originally determined. It is concluded that, when evaluating the applicability of an IR steel set, ground control engineers should consider the IR lagging and steel set as an entire system and make a reasonable engineering decision based on actual roof fall geotechnical conditions.

Jan 1, 2014

By M. M. Fine

This report presents the results of laboratory mineral-dressing investigations by the Bureau of Mines of 14 individual or composite character samples from deposits in the Batesville manganese district. It will be noted that some concentrates have met or approached analytical specifications for metallurgical manganese ore although great variations in both physical and chemical composition from once deposit to another make each a new problem. In most cases it is evident that a substantial loss of manganese has occurred in the various slime and tailing products. An important aspect of this work is the research being conducted on manganese-bearing limestones. Recent reconnaissance indicates that this resource constitutes one of the major domestic reserves of manganese. Laboratory study has shown that ferrograde concentrates can be recovered from samples of manganese-bearing limestones from two properties. Research on samples from other areas is still underway.

Jan 1, 1957

By M. R. Shahan, C. E. Seaman, S. E. Mischler, T. W. Beck

"Float dust deposits in coal mine return airways pose a risk in the event of a methane ignition. Controlling airborne dust prior to deposition in the return would make current rock dusting practices more effective and reduce risks of coal dust-fueled explosions. The goal of this NIOSH study is to determine the potential of open-air water sprays to reduce concentrations of airborne float coal dust (<75 µm diameter) in longwall face airstreams. This study evaluated unconfined water sprays in a featureless tunnel ventilated at a typical longwall face velocity. Experiments were conducted for two nozzle orientations and two water pressures for hollow cone, full cone, flat fan, air atomizing, and hydraulic atomizing spray nozzles. Gravimetric samples show that airborne float dust removal efficiencies averaged 19.6 percent for all sprays under all conditions. The results indicate that the preferred spray nozzle is operated at high fluid pressures to produce smaller droplets and move more air. These findings can be used to select sprays and design spray arrays to control airborne float dust over the entire longwall ventilated opening. INTRODUCTION Coal mining processes produce airborne dust that naturally deposits on the floor, roof, and ribs of mine airways. These fine dust particles, termed float coal dust when smaller than 75 microns in diameter, are deposited in return entries of coal mines and can be re-entrained by pressure waves induced by methane-air explosions (Rice et al., 1911; Nagy, 1981; NIOSH, 2006). These particles are also those most likely to participate in coal dust-fueled explosions, which can potentiate and propagate explosions resulting in extensive damage. In order to meet compliance requirements of at least 80 percent incombustible content in the composition of material deposited in mine entries (CFR, 2016), coal mines apply an inerting agent, specifically, rock dust (Harris et al., 2009). Should methane be present in the mine atmosphere, the required fraction of incombustible content is further increased by 0.4 percent for each 0.1 percent methane. The removal of airborne float coal dust (AFCD) prior to deposition is an approach intended to make current rock dusting practices more effective by increasing the proportion of inert material to combustible material, resulting in a lower risk of coal dust-fueled explosions. Water sprays are both effective and widely accepted as a method for controlling underground coal mine dust. In fact, water sprays are considered to be the most economical and technically feasible means of reducing dust concentrations in underground coal mines (Courtney and Cheng, 1977; Barker and Humphreys, 1996). Sprays are used in several ways to control dust in mining processes: inhibiting dust formation, immobilizing dust to prevent it from becoming airborne, and capturing airborne dust (Cheng, 1973). Reductions in airborne dust concentrations have frequently been attributed to inertial impaction between water droplets and dust particles, forming larger agglomerates which then quickly precipitate out of the airstream (McPherson, 1993). Inertial impaction activity is generally accepted as the major capture mechanism for airborne particles larger than 0.5 µm in diameter. It is this mechanism that is evaluated in this study."

Jan 1, 2017

By Jan Wolf

The iron ore industry presently utilizes two types of de-posits. The first are the high grade deposits generally located in remote areas and, secondly, the low grade de-posits which are normally found nearer to the steel-making centers. The high grade deposits produce a direct shipping ore which has an iron content which may be close to the maxi-mum 70% of Fe. These deposits have reserves which are ex-pressed in billions of tons. The ore needs little or no up-grading and where this is performed is restricted to ore washing. With the large demand for iron ore pellets, plus a national drive to perform as much of the upgrading as possible in the native country, there is a trend to erecting pellet plants at the mine location~ Large iron ore suppliers such as Australia, Brazil, Venezuela and Liberia already have pellet plants in operation, and there are new plants projected or expansion projects under study. The low grade ores are mined at locations closer to steel mills such as in Minnesota, Michigan and Canada. These low grade ores require methods of beneficiation to obtain a commercially accept-able product with the modern beneficiation techniques it is no~, possible to produce iron ore pellets of 68% Fe and 4.5% silica from ores containing as low as 26% Fe. Figure 1 gives a general picture of the types of iron ores and their beneficiation. The final product of the high grade ore is a coarse concentrate, sinter product or pellets. The final product of the low grade ores is pellets and, in some cases, coarse concentrates.

Jan 1, 1971

By Eliodor Stoian

PRESSURE information has earned a place of recognition to almost everyone interested in oil and gas production. This interest is due chiefly to the multitude of uses to which it can be put. A sub-surface pressure test, conducted for as little as $60, may yield data worth many times its cost. To the uninformed, the testing techniques may seem complex. Fundamentally, however, they consist merely of the application of common sense. At one time, sub-surface pressure data were used only in identifying individual well problems and in finding appropriate solutions. Today, it is generally acknowledged that sub-surface pres-sure .data are essential for the proper evaluation and exploitation of oil and gas pools. The following is a review of significant applications of sub-surface data with regard to: (A).-Development (B) .-Completion and work-overs (C) .-Production (D) .-Reservoir engineering (E).-Proration (F) .Other applications of pressure data of a more general nature.

Jan 1, 1958

In this paper we present the results of preliminary investigations into the applicability of new laboratory scale tests for the prediction of operating gap and specific throughput in high pressure grinding rolls (HPGR). The work is a part of the CAMIRO HPGR research program being conducted at the University of British Columbia, which aims to develop a suite of small-scale tests and procedures for the selection and sizing of HPGRs. A focus of the presented study is to test sample types in terms of their terra-mechanics based characteristics and relate them to specific throughput and gap results from pilot HPGR testing on the same samples.

Jan 1, 2012

By J. A. Luppens

Five years ago, Phillips Coal Company decided replacing mainframe/workstation programs with a new package of PC software was clearly the best solution for computer reserve modelling. The system chosen was actually three programs distinguished by their power, cost, flexibility and integration, and ease of learning and use. Phase I involves the use of the "StratiFact" program for borehole data management and seam correlation. This phase is probably the most neglected, yet critical aspect of reserve evaluation. Phase II employs the "PC/Cores" package for modelling and volumetrics. Phase m is "PC-Cut" which provides mine planning tools including an automated cut generator.

Jan 1, 1996

By E. J. Peterson

Oil shale retorting induces mineral and chemical reactions to occur on the macroscopic and microscopic levels in the kerogen-bearing marlstone. The nature and extent of the reactions is dependent upon process variables such as maximum temperature, time at temperature, atmosphere, and raw shale composition. This report describes the investigation of the mineral, chemical, and trace element release properties of spent shales retrieved from an experimental in situ retort at Occidental Oil Shale, Inc. &apos;s Logan Wash site in Garfield County, Colorado. Correlation between mineralogy of the spent materials and the mobility of major, minor, and trace elements are indicated, and relationships with important process parameters are discussed. The progress .of carbonate decomposition reactions and silicat ion reactions is indicative of the processing conditions experienced by the shale materials and influences the mobility of major, minor, and trace elements when the solids are contacted by water. Shale minerals that are exposed to the extreme conditions reached in underground retorting form high temperature product phases including akermanite-gehlenite and diopside-augite solid solutions, kalsilite, monticellite, and forsterite. The persistence of relatively thermally stable phases, such as quartz, orthoclase, and albite provide insight into the extremes of processing conditions experienced by the spent shales. Leachate compositions suggest that several trace elements, including vanadium, boron, fluoride, and arsenic are not rendered immobile by the formation of the high-temperature silicate produce phase akermanite-gehlenite.

Jan 1, 1981

By J. J. Forbes

The Act of Congress authorizing the establishment of the United States Bureau of Mines became effective July 1, 1910. One of the most important duties Congress delegated to the Bureau in this Act was the study of health and safety conditions in the mineral industries. Early investigations of these conditions revealed the need of prompt Care of injured employees, as, under the difficulties inherent in their occupation, seemingly unimportant wounds if not treated promptly might become infected and cause permanent disability or even death. Many seriously injured persons brought out of mines and plants by fellow workers ignorant of approved methods of giving first aid or of safe means of transportation have been caused suffering and have had injuries accentuated to such a degree as to bring about permanent disability or death. The need of general instruction in first aid thus became apparent. BRIEF HISTORY OF FIRST-AID WORK The education of miners in the United States in first aid probably was conducted systematically first by the anthracite industry in Pennsylvania. Subsequently, first-aid training was carried on actively in Alabama and Indiana. Meanwhile, a general training campaign was carried on among industrial workers by the American Red Cross Society; when the Bureau of Mines began its nation-wide campaign of instructing employees of the mineral industries, the Red Cross turned over that part of its industrial training work to the Bureau but continued to cooperate by furnishing surgeons as judges in important first-aid contests and demonstr tions and assisted for a number of years in determining training methods.

Jan 1, 1937

By Wm. Snow, J. R. Wallace, E. P. Duchemin

"GeneralA NOT INCONSIDERABLE proportion of the Canadian economy is dependent on the coal mining industry. This is particularly true of the eastern portion of Canada and especially so of the ( authors') province of Nova Scotia. Much has been said about the trying economic straits of the coal industry in Nova Scotia ( 1), faced, as it is, with difficult mining problems, with considerable distance from large markets, and with •competition from other (and usually foreign) fuels. It is of particular interest, at this time, therefore, to discuss one of the larger outlets for coal -that of the production of metallurgical coke.Scope of PaperWhile the title of this paper indicates that it deals with Metallurgical Coke in Canada, the authors beg leave to treat the Canadian industry very briefly and to deal specifically with coal, •coke, and smelting problems with which they are familiar, namely, the operation of the Dominion Steel and Coal Corporation in the Sydney, N.S., area. No mention is made of metallurgical coke for use in the •many foundries in Canada or in the non-ferrons metallurgical industries.Coal and Coke StatisticsA few statistics of the total output of .Canadian coal, production of metallurgical coke, and similar figures for the Dosco holdings (Sydney area only) are shown in Table I."

Jan 1, 1955

By W. N. Roman

This paper will examine the challenges involved in ventilating and cooling South African mines, with particular emphasis on solutions to the issues of heat (generally associated with depth), mechanization and energy efficiency. Comparisons will be made with other international mining areas. Some of the deepest mines in the world are to be found in the South African goldfields. The Mponeng mine is approaching 4,000 m below surface, with virgin rock temperatures (VRT) of between 60°C and 70°C. Mining at these depths has only been possible with the use of large refrigeration plants supplying cold air, water and ice to the workings. In the Bushveld Igneous Complex, where most of South Africa?s platinum mines are located, similar VRTs are being experienced at significantly shallower depths. This is due to the different geothermal properties of the host rock between the two areas. Existing mines are being forced to go deeper and new underground mines are being planned and constructed in other areas with widely differing thermal conditions. South African metal mining has traditionally been labour intensive for historical reasons as well as for the narrow tabular nature of many ore bodies. Due to cost pressures and labour problems, some mines have been investigating the possibility of using mechanized equipment, both diesel and electric, to increase production and to improve efficiency. Studies have been carried out to determine the effect of the additional equipment on the overall ventilation system and some of the conclusions are discussed. The use of diesel equipment adds heat and pollutants to the ventilation air but, although electrical equipment has a lesser effect on the ventilation systems, it is generally less favoured due to claims of lower flexibility/manoeuvrability. Mechanization holds the promise of more concentrated mining activities but, with higher localized ventilation and cooling needs. Systems which will control the provision of air and cooling more effectively are required and are being implemented. In the 1990s and early 2000s, the South African economy experienced significant growth which was not matched by the growth in infrastructure. Consequently, at present there is a shortage of electricity generation capacity which affects large industrial consumers, including mines. Increasing levels of heat and mechanization will require more electrical energy for ventilation and cooling. There are many initiatives underway to save power or to shift consumption to periods of national low demand and these will be described.

Aug 1, 2013