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By J. Griesel, P. H. F. Bouwer, K. Bisaka

Transalloys produces 160 000 tons of SiMn per annum from five AC submerged-arc furnaces. The lime-ore melt from two AC open-arc furnaces is contacted with SiMn to produce 50 000 tons of medium carbon FeMn per annum. Metallics in the slag are reclaimed in a jigging plant, which has been in operation since 1999. The flow of materials between the jigging plant and furnaces has been optimised. The amount of recycle slag in the feed of the SiMn furnaces has been decreased by more than 30% which still provides satisfactory stability of the furnace operation. The jigging plant has absorbed all the additional slag generated, to recover SiMn metal. A review of the raw materials used and operating parameters for SiMn production was also undertaken. Slag to metal ratios were decreased by more than 30% by reducing the slag recycle, removing magnesite from the recipe and introducing high-grade ore. Electrode penetration was improved by reducing coke levels and by utilising more reactive coal. The pitch circle diameter (PCD) was reduced to get a better operating stability on furnace no 5 using the MINSTRAL Control System. Energy consumption on the furnaces improved by more than 15% while SiMn production increased as a result by more than 18%.

Jan 1, 2004

By D. Allan Coutts

Demonstration projects using hydrogen as a fuel are becoming very common. Often these projects rely on project-specific risk evaluations to support project safety decisions. This is necessary because regulations, codes, and standards (hereafter referred to as standards) are just being developed. This paper will review some of the approaches being used in these evolving standards, and techniques which demonstration projects can implement to bridge the gap between current requirements and stakeholder desires. Many of the evolving standards for hydrogen-fuel use performance-based language, which establishes minimum performance and safety objectives, as compared with prescriptive-based language that prescribes specific design solutions. This is being done for several reasons including: (1) concern that establishing specific design solutions too early will stifle invention, (2) sparse performance data necessary to support selection of design approaches, and (3) a risk-adverse public which is unwilling to accept losses that were incurred in developing previous prescriptive design standards. The evolving standards often contain words such as: ?The manufacturer shall implement the measures and provide the information necessary to minimize the risk of endangering a person?s safety or health.? This typically implies that the manufacturer or project manager must produce and document an acceptable level of risk. If accomplished using comprehensive and systematic process the demonstration project risk assessment can ease the transition to widespread commercialization. An approach to adequately evaluate and document the safety risk will be presented.

May 1, 2007

By Reza Y. Khaksar

Presented is a rigorous solution for the three-dimensional stability analysis of vertical shafts (excavations) subjected to the self-weight of the soil based on the upper-bound theorem of limit analysis approach. A rigid-block translational collapse mechanism is assumed, with energy dissipation taking place along planar velocity discontinuities. This mechanism is optimized to obtain the critical failure mechanism giving the lowest factor of safety for stability of shafts. Based on comparisons with other solutions, the method is generally found to be accurate in predicting the stability of vertical cuts.

Jan 1, 2006

By William A. Beck

The Construction Aggregates Corp. operates a plant for processing sand and gravel from two deposits in Ottawa County, Mich. The bulk of the sand is obtained from a sand dune on the shore of Lake Michigan, and the gravel is dug from a glacial-drift deposit farther inland. Mining is done with draglines, and the material, both at the digging site and in the plant, is moved mainly by systems of conveyors. The Ferrysburg plant serves customers along the Great Lakes, which is unusual for a business normally local in character. Annual production exceeds 1-1/2 million tons of sand and gravel as concrete aggregate and 200,000 tons of core sand for foundry use.

Jan 1, 1962

By J. Böhlke, B. Friedrich, E. Hecker

The legislation for the disposal of heavy metals contaminated substances is still going to be tightened up in the future. The main criteria for the utilization or deposition of these residues are the content and the water solubility of these metals. Through this, the use of slags from the lead-and zinc-industry in road building may become limited or even not possible at all. From an economic point of view this would lead to Pb/Zn losses and costs for safe dumping. This paper investigates the feeding of the reducing agent via hollow electrode DC smelting and the yield of metal reduction. After carrying out thermodynamic calculations, the process window conditions for electric-arc furnace tests were determined. Doing this, the zinc could be reduced, evaporated and recovered as an oxidic intermediate product flue dust, while the lead was present either in flue dust or in metallic form. The zinc content in the final slag could be reduced by up to 90%. The slag product has undergone an eluation test which allows it to be used as building materials. Keywords: zinc reduction, lead reduction, hollow electrode, slag treatment, electric arc furnace

By L. J. Vincze

The high cost of constructing mineral processing plants in remote locations warrants a close examination of the alternatives available for reducing the amount of on-site construction work. Among the alternatives are portable process plants, modular design and barge mounted plants. Each alternative has certain advantages as well as limitations depending upon specific conditions. On the basis of practical experience and engineering analysis, the paper examines the potential benefits to be realized by these techniques and summarizes the conditions required to obtain them. The potential savings indicated by such studies should encourage consideration of innovative design features for new plants located in remote areas.

Jan 1, 1980

By Richard J. Mainiero

The Bureau of Mines conducted research to evaluate the optimum design for a rock-breaking explosive charge that could be fired unconfined in a gassy or dusty coal mine without the danger of igniting the flammable atmosphere. Charges of various shapes, with and without cavities, were tested in a gallery using 3-by 3-by l-ft concrete blocks as simulated boulders. For these tests the optimum charge, in terms of cost, weight, and convenience in handling, consisted of a flat l-1/2-lb charge of permissible explosive seven-eighths of an inch thick and 7 in in diameter encased in a l/2-in thick layer of fine salt (NaCI). This work demonstrated that it should be possible to produce an inexpensive explosive rock-breaker charge that would be safe to use in underground coal mines.

Jan 1, 1982

By H. Walqui

This paper describes operating gains resulting from standardizing operating and maintenance practices to improve the performance of the pebble crushing circuit at he Empire Concentrator. Past efforts have led to improved operating time but no additional throughput gains. New Operating standards and checklists were developed and introduced. The content and frequency of the review process indicators was then changed to take advantage of the new practices resulting in an increased feed rate and availability through the pebble crushing circuit.

Feb 27, 2013

By Hai Lin, Renshu Yang, Yongliang Li, Shizheng Fang

With the aim of solving the large deformation problem of surrounding rock in coal mine roadways with a thin sand-mudstone interbed roof, transportation roadway 1603 in Haoyuan Mine was considered. The failure mechanism of surrounding rock was studied through comprehensive on-site investigations, borehole image analysis, mineral composition analysis, and other means. Numerical simulations were performed to determine the influence of roof layer thickness, lateral pressure coefficient, and coal rib strength on the stability of the interbedded roof. The main reasons for support failure and deformation of the roadway are softening and swelling of the sand-mudstone interbed roof upon exposure to water, insufficient support capacity of the roof due to the soft coal rib, an unreasonable support scheme, or poor construction quality, which can reduce the bearing capacity of surrounding rock. Based on our analysis, a control strategy was devised for a thin coal-mudstone interbed roof. The support scheme combines long and short cable support, strengthening of the coal rib to consolidate the roof, and partially shotcrete grout, and was found to improve the overall mechanical strength of surrounding rock and maintain the stability of the thin sand-mudstone interbed roof. The results of the numerical simulations and monitoring data indicated that the proposed support scheme effectively controls the deformation of the surrounding rock of thin sand-mudstone interbed roof of coal mine roadways while maintaining the safety and stability of the surrounding rock and supporting structure.

Dec 12, 2022

By Moorrees C, Everson P

A detailed examination of carbonic acid leaching of crude iron-containing magnesia derived from Savage River magnesite shows that the rate and extent of magnesium and iron dissolution are affected by the slake time, leaching temperature, carbon dioxide pressure, pulp density and rate of agitation. In order to produce high-purity magnesia from the leachate by precipitation and calcination, the optimum leaching conditions, which are those that yield maximum magnesium and minimum iron dissolution, have to be a compromise in terms of the above parameters. For example, iron dissolution can be limited by leaching at an elevated temperature (-45°C), but because the maximum concentration of magnesium biearbonate decreases rapidly with an increase in temperature, it is necessary to use a low pulp density (-2 per cent solids) in order to achieve an acceptable degree of magnesium dissolution.Evidence is obtained that iron dissolution involves the formation of a soluble ferric bicarbonate complex that decomposes at elevated temperatures. The extent of iron dissolution is much higher than might be expected and it is probably because the original magnesite contains siderite in solid solution with the magnesite; on calcination, the hematite whieh is formed is in a very finely divided condition and hence more reactive.

Jan 1, 1983

Distinguished guests ladies and Gentlemen. As many of you know, before I became a Labour Member of Parliament, I had an unusual career path for a politician, in that I spent quite a few years working in the business community. In other words, I was mainstreamed before I was institutionalised. Given that some of this time was spent working for the then Macraes Mining Company Limited, now Gold and Resource Developments NL, I feel that I may have a perspective on how things are seen, on both sides of the fence. In terms of public perception and esteem I am not sure which career option was the step up and which was the step down. So far what I have found very familiar, is that in both roles there is a gulf between the reality and the perception of that reality - a gulf that is both huge and hard to bridge. I think it is a point worth making here amongst another busy industry cluster, that we can all too easily get so embroiled in the day to day activities, that we lose sight of how this might look to those running on a different treadmill. I can still remember scratching my head at the beginning of some days, as I worked to get new mining projects started that I knew were going to bring real jobs and economic benefit to New Zealand, but ending the day feeling like I may instead have been proposing bringing back both strip mining and slavery. If I learnt one valuable lesson out of that time it was this: .... mining has become so publicly demonised on the road to ecological nirvana, that even attempting a lucid dialogue on mining issues, with some, is incredibly difficult.

Jan 1, 2000

By S. E. Cook

This article uses the case of the Royal Bafokeng Nation to argue that royalties and dividends from mineral resources, if managed well, can provide direct benefits to the surrounding community even while the state collects its share of mining revenues through taxation. The key to this model is the effective management of the resource income flowing into community coffers. Where some of this income may fund urgent interventions in the community, a portion of the income can also be used to establish an intergenerational wealth fund to meet the needs of future generations. As a depleting resource, minerals like gold and platinum are not a sustainable source of income, and must be replaced over time by more regenerative income streams. These strategies and dynamics are manifest in the Royal Bafokeng Nation?s status as both community and quasi-municipality, a labour hosting and a labour sending community, a mine operator and a mine owner. The Royal Bafokeng Nation also owns one of South Africa?s largest community-based investment companies, which channels revenue derived from platinum deposits into a broad investment portfolio that in turn funds an aggressive social development program for 150,000 people living in twenty-nine rural villages.

Jan 1, 2013

By A. G. Galaitsis

This report summarizes the work performed under the USBM Contract No. J0245001. The purpose of this work was to expand and improve the scope and accuracy of the method developed under USBM Contract No. J0113056 for the prediction of the number of overexposed workers in the mining industry. A significant portion of the noise data were acquired during mine visits-that took place in the-course of this contract. These data were obtained with time-resolved dosimeters which among other things store a time history of the sampled noise for an eight hour work period. The remainder of the noise data have been obtained from MSHA files and from other BoM-sponsored projects. The report reviews the prediction model, discusses the model's assumptions and approximations, describes the function of the developed software, offers typical examples on the use of the software and includes plots of the newly acquired noise data records.

Jan 1, 1986

By Swapan Bhattacharya

United States federal and state regulatory authorities require underground mine operators to adopt adequate measures to minimize material damage to the surface caused by nine subsidence. This paper presents an approach to define and determine the extent of material damage due to subsidence from underground coal mining. The basic steps involved in the development of adequate criteria have been enumerated together with the approaches and methodologies used.

Jan 1, 1984

By Mario Morin

The application of underground pre-concentration technology to narrow vein mining has the potential to change the entire economics of bulk mining methods when used in narrow vein situations. The rejection of waste at or near the face means that a higher-grade ore can be sent to surface. The waste rock can be reused directly as backfill. Swelling of the muck through blasting means that only 60 to 65% can be used as fill. Planning and scheduling of the fill usage is key to the success of this method. Through the use of simulation and system analysis, this paper examines the planning and scheduling implications of underground pre-concentration when applied to traditional narrow vein mining methods (cut-and-fill /drift-and-fill, longhole, AVOCA). It considers the logistical factors that represent potential system bottlenecks that are key to understanding the correct implementation and control strategies.

Oct 1, 2004

By Brian Gar Wingfield

Bulk explosive systems have developed from the infancy stages in the early sixties to a sophisticated process of the nineties. With ever changing bulk explosives technology, bulk delivery and loading systems needed to keep pace. Efficiency, as compared with packaged loading, was the keyword allowing faster loading of trucks and shots. Efficiency was also improved by the explosives coupling factor that bulk loading permitted.

Jan 1, 1991

The Small Pebble Process for Reducing Ball and Power Consumption in Secondary Grinding Ball mills are used widely for secondary grinding. A mixture of ball sizes can be used to optimise grinding efficiency, but the use of balls smaller than about 30 mm in diameter is not normally viable, particularly when alloy steel is required. Preliminary testing of the grinding efficiency of various combinations of 40 mm steel balls and crushed stone in the size range 7 to 25 mm was carried out in a 300 mm diameter mill, which has accurate power measurement.The primary interest was to assess the potential benefit of adding small pebbles (from a primary circuit crusher or mill) to a secondary ball mill, to reduce ball consumption and to improve grinding efficiency. The optimum proportion of pebbles was found to be about 25 per cent by volume. This mixture produced about the same amount of fines as balls alone, but with lower power consumption, due to the lower density of the pebbles. The net result was a 12 per cent saving in power and a 25 per cent saving in ball consumption. The production of fines was partly due to pebble wear. The use of portions of 15 mm balls, (ceramic and steel), was also tested for comparison. A few batch pilot-scale tests were conducted in a 1.2 m diameter, 0.31 m long mill to test the viability of the pebbles at a larger scale. The pilot-scale tests confirmed the reduction in power and that the rate of production of fines was the same as that obtained with balls. The same residence time was used and this implies that pebbles can be added to an existing full-scale ball mill, with no loss in capacity. Samples of secondary mill feed and pebbles were obtained from a copper mine and the steady-state consumption of pebbles was determined by locked-cycle laboratory-scale tests. These tests demonstrated that mill power could be reduced by up 13 per cent and that the consumption of 40 mm balls could be reduced by up to 38 per cent, while maintaining the same throughput and product size. The rate of pebble addition was about 4 per cent of the primary circuit feed rate. Application has been made for patent protection.

Sep 13, 2010

By Bruce McDonald

This report contains the Phase I findings of a study to select and test devices for preventing lack of alertness in haulage truck drivers. The extent of the problem was determined by visiting surface metal and nonmetal mines, interviewing drivers and safety personnel and reviewing accident reports. A number of devices for detecting a lack of alertness were considered and three were recommended for testing in actual operation.

Jan 1, 1977

By J. H. East, D. Harrington

"INTRODUCTION Shaft mines, coal and noncoal alike, have a common hoisting problem that remains largely unsolved - how to obtain a mechanical device that will suspend a cage or skip in a mine shaft if the hoisting rope should break or become detached from the cage or skip and that will function effectively under all conditions of service. Safety catches, or safety dogs, as they are commonly named, are installed on nearly all mine cages and many skips operating in American mines, but often, if the hoisting rope breaks, the cage or skip falls to the bottom of the shaft in spite of safety devices, causing much property damage and often fatalities.Available information relative to safety catches for mine cages and skips, desirable characteristics of safety catches and methods of testing safety catches to determine whether they are functioning correctly has been assembled in this publication for the convenience of those responsible for the safe operation of mine cages end skips and, more particularly, to focus attention on the need for a device that actually will stop and suspend a falling cage or skip under all conditions of use and do it without killing or maiming the occupants."

Feb 1, 1948

This paper is concerned with the blasting of rock in mining. The most common purpose of blasting rock is to cast it or to disrupt its structure sufficiently for effective digging and subsequent removal.

Jan 1, 1991