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By Mark I. Copeland

This study was conducted by the Bureau of Mines to determine the effect of steel reheating practices in burning natural gas on the amount of silicon required to prevent the formation of copper on steels containing up to 1 wt-pct Cu. Formation of copper, which causes surface hot shortness, was readily prevented by as little as 0.3 wt-pct Si and by 2 vol-pct excess oxygen in the furnace atmosphere when reheating steels containing up to 0.8 wt-pct Cu. Up to 0.8 wt-pct Si content and careful control of reheating conditions were necessary for steels containing 1 wt-pct Cu. Best conditions for these steels were reheating to 2,200° F (1,205° C) in burning gases containing 2 vol-pct excess oxygen, and then to higher temperatures in gases of 6 vol-pct excess oxygen. Slag and mold wash were not detrimental on steels reheated for 8 hr by a soaking-pit-type furnace schedule, but they were problematical on steels heated for 2 hr by a pusher-type furnace schedule. The effect of silicon contents on scaling rates also was determined.

Jan 1, 1974

By A. López-Valdivieso, M. A. Corona-Arroyo, M. Llamas-Bueno

Magnetite (Fe3O4) ore is concentrated by low-magnetic-field drums to recover a magnetite concentrate that is low in silica (SiO2). The presence of SiO2 in the magnetite concentrate for steel production increases the steel processing costs, so a major challenge in magnetic concentration is to lower the SiO2 grade in the Fe concentrate. This work presents studies that were carried out on the removal of SiO2 from the magnetite concentration at the plant scale. Studies were performed with a three 36 × 96″ drum unit processing 46 ton/h of rougher magnetite concentrate. These studies showed that silica appears in the magnetite concentrate by three mechanisms, namely SiO2 entrainment in Fe3O4 chains, heterocoagulation between Fe3O4 and SiO2 particles, and mineral locking of SiO2 to Fe3O4. The SiO2 entrainment mechanism had the highest contribution (75%) to the SiO2 recovered in the Fe concentrate. Electrokinetic studies on Fe3O4 and SiO2 showed that heterocoagulation occurs because of the low negative zeta potential of the minerals at the pH of the plant slurry. This study also showed that a high percentage of ultrafine size SiO2 particles trapped in Fe3O4 agglomerates was not removed by the dilution water for the slurry fed to the drum. To lower the SiO2 recovery in the drum magnetic concentration process, work should be directed towards the removal of trapped SiO2 in Fe3O4 agglomerates.

By Benkendorff P. N

Cement production in Australia approximates 6.5 million tonnes per year. Cement clinker is sourced from 15 plants which operate 28 kilns. Cement grinding is conducted at 14 of the clinker plants plus 7 grinding plants. Average annual capacity per kiln or plant is lower than in many overseas countries, but kilns introduced since 1970's have been of larger size more in keeping with size trends overseas, although still smaller than the large units overseas. Substantial economies in capital and labour costs can be achieved in large production units, particularly with dry process kilns using precalcination techniques in which part of the fuel is introduced in the static preheater section ahead of the kiln while the balance is added to the kiln in a conventional manner. Precalcination techniques have been introduced to the Australian cement industry but as cement transport costs form a major part of supplying diverse market areas, the size of kilns is likely to remain less than maximum owing to balance with distribution costs. The cement industry uses significant amounts of thermal and electrical energy which can be minimised by proper selection of equipment and technology. Labour costs are also significant and can be contained by automation and computer control of the process.

Jan 1, 1989

By Sivilay Sayavong, David Puller, Julian Gatward, David Hard, Martin Stanley

"AbstractThe Thames Water Tideway Tunnels programme involves the upgrade of London’s combined sewer and storm water system. The first section is the Lee Tunnel between the Beckton Sewage Treatment Works (STW) and the Abbey Mills Pumping Station. This will intercept the overflows currently discharging to the River Lee and has the capacity to store and transfer 350,000m3 of storm water and sewage. The project required 4 shafts and a 6.9km 7.2m diameter tunnel. The shafts are some of the largest ever constructed in the UK, with diaphragm walls up to 98m deep and 1800mm thick. As a result of the innovative methods of diaphragm wall design and construction adopted the 4 very large and deep shafts were able to be excavated and completed safely, with minimal water ingress and with extremely high quality.MVB, a joint venture of Morgan Sindall, Vinci Construction Grands Projets and Bachy Soletanche are delivering the £635m contract with Thames Water’s Project Management Team in a collaborative manner under an NEC contract. Mott MacDonald, Morgan Sindall UnPS & Bachy Soletanche are acting as designers.Some of the important advances in diaphragm walling made included:??Diaphragm wall design to both EC2 & EC7 taking into considering the assessment of chalk stiffness, high hoop stresses, large multiple openings and non-axisymmetric loadings.??Formation of shafts as a faceted circle from a series of overlapping panels, with primary panels up to 7.2m wide demanding concrete volumes up to 1300m3 be poured in one go. Overlapping secondary single bite panels cut into the grade C50/60 concrete.??Excavation of the full geological stratigraphy of London making bentonite management complex.??Panel verticality of 1:300 required over the full depth. The results achieved this and in many cases exceeded expectations with some panels coming in at up to 1 in 800 with the majority at 1 in 400 to 1 in 500. The project is also the first in the Soletanche Bachy Group to take data from the ultrasonic drilling monitor used to check the verticalty in electronic format in order to create 3D CAD as-built drawings.??Each diaphragm wall panel was reinforced over its full depth. Up to 18 separate pieces of reinforcing cage had to be installed in primary panels. Cages underwent a full range of temporary works designs to check that lifting, splicing and placing could all be undertaken safely. Fibreglass was used in the tunnel portals in the shafts to ease breakthroughs."

Jan 1, 2014

By H. Cay, J. Zachwieja, T. Esplin, R. Ravenelle, T. Olsen-Tank

Barrick Goldstrike mine utilizes a carbon-in-leach (CIL) circuit to simultaneously leach gold into solution with cyanide and adsorb the gold-cyanide complex onto activated carbon for further refinement. If the gold bearing ore contains a significant amount of native carbonaceous material, gold cyanide can be adsorbed at these sites instead of onto the desired activated carbon and the gold is effectively lost to tailings in a detrimental process known as "preg-robbing." The preg-rob effect is considerably reduced by treating the ore with a surfactant, which is hypothesized to adsorb to and passivate the native carbon surfaces. Past laboratory and pilot studies have consistently demonstrated significant gains in gold recovery after treating carbonaceous ore with surfactant. With success in bench and pilot scale testing, a plant trial was conducted at Barrick Goldstrike to evaluate the feasibility of using an alkoxylated fatty amine surfactant (Ethomeen T/12) to aid in the leaching of high preg-robbing ores. This paper analyzes the performance of the surfactant during the plant trial in addition to the problems that occurred during the trial period. Suggestions for improvement are also discussed.

Jan 1, 2014

By Tim Edwards, Richard Triglavcanin, Ian Arbuthnot, Darren Colwell, Brad Garraway, Ken Roberts

"In the mineral processing industries, there is an increasing need to design thickeners which are able to produce high density underflows usually referred to as “paste”.The behaviour of a flocculated suspension in compression needs to be well understood in order to arrive at a reliable thickener tank configuration (i.e. diameter, cone angle and depth) for a required paste result.As a suspension approaches paste consistency, it’s fluid characteristics change markedly. It develops a high yield stress, and may have an increased tendency to form agglomerates, which lead to a phenomenon known as “rotating beds”, “donuts”, or “islands”. These characteristics present challenges to the designer of the rake mechanism.The subject paper addresses the requirements for designing a paste thickener, covering the following topics:o Testwork for thickener sizingo Design of rake mechanismso Suspension rheology and effect on designo Case studiesTESTWORK AND SIZING FOR PASTE THICKENERSThickening slurries to the maximum possible density (paste) is becoming increasingly common. Applications such as Autoclave feed thickeners, paste backfill and some counter current washing (CCD) circuits are all examples of potential paste thickening applications. The principle of paste thickeners is that the compression zone is much deeper than on either high rate (HRT) or high compression (HCT) units; generally 3 metres or more. As the compression zone gets deeper, theunderflow density for a given flux rate (tph/m2) increases, as a result of two factors:1. Longer bed settling time. Settling flocs move relative to one another and release interstitial fluid when they are in compression. Increasing bed residence time achieves higher density underflow as more fluid is removed.2. The nett weight of the bed creates a compressive force on the settling flocs. This force increases with depth, so that the flocs at the bottom of the bed experience the highest compressive force. This represents the driving force to expel interstitial fluid and hence increase bed density."

Jan 1, 2005

By Antônio Demouthie de Sales Rolim Esmeraldo

As indústrias de cerâmica vermelha têm grande importância na região assim como a mineração e beneficiamento de calcário laminado representam um importante segmento econômico do Estado do Ceará, entretanto produzem uma grande quantidade de resíduos, que poluem e agridem o meio ambiente. Assim, esse trabalho tem por objetivo a caracterização da incorporação do resíduo da Pedra Cariri avaliando sua aplicabilidade como matéria-prima cerâmica alternativa para a produção de telhas cerâmicas. Foram formuladas composições contendo o resíduo e confeccionados corpos-de-prova por prensagem. Os corpos-de-prova foram queimados e, em seguida, foram determinados a cor após a queima, perda ao fogo, retração linear, absorção de água, porosidade aparente e o módulo de ruptura à flexão. Obteve-se uma com avermelhada, com um tom mais claro nas que tiveram a pedra cariri na massa. Também foi visto uma porosidade, juntamente com uma absorção em nível aceitável para tijolos cerâmicos e a tensão de ruptura aumentou em 5% e decaiu em 10%. Após todos os testes feitos, provou-se que o resíduo tem a possibilidade de ser usado na incorporação de até 5% de resíduo em formulações para a produção de telhas cerâmicas.

Aug 17, 2017

By K. J. Ladwig

The Bureau of Mines conducted a field investigation of the water quality in inundated underground coal mines in the Northern Anthracite Field, eastern Pennsylvania. Water samples were collected at multiple depths from nine abandoned mine shafts in the Wyoming Basin, ranging from 68 to 650 m (223 to 2,132 ft) in depth and intersecting as many as seven mined seams in a single shaft. The shafts were also monitored for fluid resistivity, fluid temperature, Eh, and pH using downhole instrumentation. The monitoring program showed that the formerly highly acidic mine water is now slightly alkaline. Sulfate concentrations decreased as much as 74 pct in the flooded workings and 54 pct at a mine water discharge from values reported in 1964 and 1968, respectively. These data are consistent with the inhibition of pyrite oxidation and gradual flushing of oxidation products in flooded mine environments. The monitoring program also revealed significant vertical stratification in water quality in five of the nine shafts, each characterized by two easily recognizable zones. The transitions between zones were sharp, marked by rapid changes in Eh, pH, and ionic composition, the upper zones being less contaminated than the lower zones. The development of stratification appears to be a function of shallow localized flow conditions, arising primarily from the relative positions of mine openings and structural features of the coalbeds.

Jan 1, 1984

By Derek. C. Arnold

In order to meet increasing demands for water supply in the next millennium, the Government of the Hong Kong Special Administrative Region have identified the need for a major new water treatment and transfer scheme. The project now under construction will comprise a 1.2 km long raw water aqueduct, a major new 0.25million cubic metres per day water treatment works (with space for upgrading to 1.2Mm³/d), a 12.1 km long treated water aqueduct and a primary service reservoir. In order to meet increasing demands for water supply in the next millennium, the Government of the Hong Kong Special Administrative Region have identified the need for a major new water treatment and transfer scheme. The project now under construction will comprise a 1.2 km long raw water aqueduct, a major new 0.25million cubic metres per day water treatment works (with space for upgrading to 1.2Mm³/d), a 12.1 km long treated water aqueduct and a primary service reservoir.

Jan 1, 1999

By Derek Ettie

"In the Hydrometallurgical processes, the presence of the so-called "crud" is a constant challenge in solvent extraction. Crud is a stable emulsion which forms along the interface between the aqueous and organic phase. The spread is influenced by the following parameters: first, wind blows the dust and impurities into the open sedimentation tanks. Second, the undissolved solids such as sand transported in the PLS causing problems in conjunction with incorrect agitator design.The crud fraction can decisively impact the efficiency of the hydrometallurgical extraction because the phase interface can constitute a large fraction and the sedimentation tanks cannot react flexibly to it. In the downstream process of the series-connected sedimentation tanks, they are thus all contaminated with crud. At the same time, the necessary mass transport is significantly impeded at the phase boundary between organic phase and aqueous phase due to the crud formation.The transfer of the organic phase into the electrolysis cell can result in a "burnout" of the cathode. The carryover of this electrolyte into the extraction can cause problems with the pH regulation. The carry-over of the organic components into the raffinate also leads to contamination of the leaching circuit. The continuous treatment of the crud with a 3-phase decanter centrifuge is extremely effective in combating this problem. This technology splits all three phases from each other and they are consequently continuously separated. All subsequent process steps exhibit a stable, uniform effectiveness. The main advantage for the customer is that fluctuations in the process are eliminated and the organic phase can be recirculated back to the extraction. The recycling of the solvent alone justifies the investment in less than 6 months as examples from South Africa and Chile show.To operate solvent recovery in daily operation fully automated online at the optimum limit, the decanter centrifuge is equipped with a concentration-dependent pond adjustment called DControl® by this means, we can guarantee our customers the maximum possible solvent recovery and minimize the solvent costs in this process step. This system is presented in detail in this paper."

Jan 1, 2014

By Gennaro G. Marino

Documented case histories of surface ground movements from mine subsidence were utilized to help determine when the initial collapse of the overburden occurred above longwall panels. By studying this relationship between initial movement at the surface and the amount of face advance, the least-complex conditions exist for empirically assessing the span capacity of the overburden. The objective of this work was to obtain a better understanding of the overburden response to longwall mining. This knowledge will give a better insight on the long-term effects that different overburden types have on the stability and the subsidence potential of room and pillar mines, as well as, the influence of the overburden on subsidence over longwall panels. Theory on the overburden span capacity was developed and correlated to field observations. Data were used on the overburden lithology, depth, width, and face advance of the panel, and the subsidence conditions that were noted on the surface. The subsidence measured on the surface was used to determine when complete failure in the overburden rock had occurred. According to spans predicted by theory and the subsidence measured in the field, the competent lower units failed at a face advance less than when significant subsidence was observed on the surface. In each case studied, there were competent lower beds; however, the full overburden weight was not sustained to the point of subsidence. The best correlation with the surface movement was found with the most shallow, competent bed. Elastic plate solutions with various support conditions were found to best monitor the surface subsidence of these upper roof units.

Jan 1, 1988

By da Silva C A, Tenorio J. A S, de Assis R M, de Oliveira J R

For Fe-Mn alloy production, two reactions are responsible for this process: the MnO reduction in the slag and the carbon dissolution in the bath. The smelting-reduction process has been studied as alternative route to be used to produce alloy so as steel. This technical paper presents some initial studies to be used to determine the main ways that one can have for the mechanisms for this reaction. The limited factors like mass transport or chemical reaction were analysed. The Mn content in the bath were varied and it was concluded that by increasing the former, dissolution of Mn into the bath was increased, so as a reduction of MnO in the slag. For carbon dissolution, it was used a experiment with a stationary bar, this one was added into the bath, after ten minutes probes were catched, by temperature 1600¦C, for the dissolution of MnO, one graphite crucible was employed, after 45 min the slag and alloy were analysed. After the experimental part, some curves were plotted against time, based on these graphics, and kinetic analysis was made.

Jan 1, 1999

By E J. Hofmann, J E. Hofmann, A J. Hofmann-Fritz

"With its Head Quarters in Perth, global heavy engineering company Hofmann Engineering is one of the largest family owned engineering companies in Australia. The company has pioneered a number of new manufacturing processes and design improvements for components of large comminution equipment.Some of these innovations are: Innovative design improvements of high pressure grinding roll (HPGR) forged steel tyres. Hofmann Engineering has developed unique patented tungsten carbide stud and edge protection designs which improve wear life and introduce quick and cost effective replacement options to further extend the life of the tyre. Development of forged fabricated mill heads using rolled and welded high tensile steel plate as an alternative to cast conical mill heads. Establishment of Australian capability to manufacture and export up to 42 ft. (12.8 m) diameter SAG mill shells. Techniques for fast track, product improved replacements of cracked or damaged mill gears, including in situ profile & wear measurements of girth gears using portable coordinate measuring machine (CMM) technology, forged rim steel and induction hardening technology. Gear and pinion mechanical drive designs to 24 MW or higher for SAG mills of 38 ft. to 42 ft. (11.6 m - 12.8 m) diameter as reliable alternatives to gearless drives.The paper presents case studies from the Australian heavy manufacturing facilities of Hofmann Engineering on large, high powered equipment for both the domestic and export markets.CITATION:Hofmann, E J, Hofmann, J E and Hofmann-Fritz, A J, 2013. Australian innovations in high pressure grinding rolls and large grinding mill manufacture, in Proceedings MetPlant 2013, pp 141-151 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jul 15, 2013

A Simulation Study on Two-Stage Grinding with High-Pressure Roller Mills By the application of high-pressure roller mill (HPRM) in the field of mineral processing, computer simulation can be used to predict overall performance of a grinding circuit based on data obtained from HPRM comminution test in pilot scale or industrial scale. Using the model developed by Klymowsky and Liu for HPRM comminution and an extended Plitt's model for classification, steady-state of a closed circuit grinding can be calculated by means of a virtual locked-cycle-test conducted on computer. This paper presents the result of a simulation study on two-stage grinding with HPRM as the comminution device. The emphasis is put on the influences of circuit-configuration and way of recirculating classifier's coarse-product on the overall circuit performance. The results show that two-stage grinding with HPRM has its merit and flexibility in meeting demands of various grinding tasks in mineral processing.

Sep 13, 2010

By B. P. Faulkner, M. Weinecke

Svedala started a development program in 1997 to develop a process to convert waste tires into valuable commodities. A review of numerous approaches revealed short-comings in the various approaches either process, mechanical, combination of factors, or trying to emphasis the production of low value products. A market study revealed that a process that could produce a good grade of carbon black would be economically feasible. This paper discusses the laboratory and pilot plant development and commercial plant design.

Jan 1, 2001

By Edwan Anderson Ariza Echeverri

O aumento das exigências para reduzir o consumo de combustível e aumentar a segurança dos passageiros tem estimulado o desenvolvimento da nova geração de aços de alta resistência. Esses objetivos tornam-se atingíveis com a redução do peso dos componentes de aço do veiculo, pelo uso de chapas mais finas e resistentes, mas não menos dúcteis. Com esse propósito, no presente trabalho pretendeu-se analisar os efeitos de diferentes rotas de processamento: estampagem a quente, têmpera e partição e o inovador processo que combina a deformação a quente com a têmpera e partição. Os ciclos térmicos foram projetados para obter a maior fração de austenita retida, além de ferrita e martensita. Para cada amostra tratada, amostras de tração de tamanho reduzido foram extraídas de amostras previamente tratadas em simulador termomecânico avançado Gleeble 3S50. A microestrutura foi analisada por microscopia óptica e eletrônica de varredura. Com o novo processo combinado acredita-se que seja possível atingir uma boa associação de propriedades para a nova geração de aços de alta resistência pela transformação da austenita retida metaestável em martensita induzida por deformação, contribuindo para a absorção de energia durante impacto.

Aug 16, 2017

The main orebody of the Bodangora mine is a metalliferous quartz reef within a major fault plane in the strongly folded and faulted volcanic rocks of the Ordovician-Silurian Oakdale Formation. The similarity of the type of mineralization to that of other pyrometasomatic deposits in this area suggests that the mineralizing fluids originated in the nearby Wuuluman Granite.The associated Mitchell's Creek West or Dick's reef is discussed briefly.

Jan 1, 1970

By A. Amiel

Tarkwa Gold Mine is owned by Gold Fields Ghana, IAMGOLD and the Government of the Republic of Ghana in a 71%, 19% and 10% ratio. The mine is operated by Gold Fields Ghana. This large, low-grade, open pit, gold mining operation is located in Tarkwa, in the Western Region of Ghana, approximately 320 kilometres by road, west of Accra, the capital of Ghana, West Africa. In the Financial year ended June 2007, the operation mined a total of 108 million tons of which 22 million tons was ore. The mined ore is processed through three gyratory crushers supplying two heap leach pads (north and south) and a carbon-in-leach (CIL) plant. Before the 6 Sigma project commenced, the current fragmentation was resulting in sub-optimal feed size to these crushers. It was decided to use 6 Sigma methodology to improve the fragmentation. A defect was defined as a fragmentation analysis indicating less than 95% passing 750 mm. The objective was to improve fragmentation in order to achieve a constant throughput to the north heap leach crusher of 1500 t/h, a 5% increase in pit loading efficiency and a 50% decrease in rock breaker hours, equipment damage costs and in-pit sheeting costs respectively. However, this was not to be achieved at the expense of grade control as Tarkwa is exploiting a low grade, high volume deposit and therefore ore dilution must be kept to a minimum. This paper is intended to take the reader through the various 6 Sigma phases of the project (define?measure?analyse ?improve?control), which have resulted in a 10% reduction in loading times, of which half has been attributed to improved fragmentation, as well as a substantial increase in blasted stocks. The focus has been on both drilling and blasting parameters as both processes had to be taken into account. These parameters are technical but personnel factors were also identified and dealt with as they arose. In order to measure the impact of any change in the process parameters on the fragmentation size distribution, cameras have been acquired. One has been installed looking into the bowl of the north crusher and the other one was dedicated to field observation, of individual blasts. Both are used for ongoing fragmentation analysis. At Tarkwa, mining efficiency is strongly dependent on good fragmentation as well as the presence of unblasted ?toes? on the pit floors. Crusher throughput depends on an acceptable ore fragment size. Compliance with plan for actual hole depths was temporarily monitored by manual hole dipping, but this is now being replaced with a fully automated drill data management system developed by Sandvik and Modular Mining. The Six Sigma methodologies, using control charts based on data collected in the field, allowed the mine to improve methods for the control of blasted material. It also enforced the implementation of a quality control programme encompassing the entire drill and blast process.

Jan 1, 2008

China has made great progress in thick coal seam mining, commonly characterized by longwall top-coal caving mining and single-pass longwall mining with a large cutting height. At present, the maximum mining thickness of longwall top-coal caving reaches 20 m while that of single-pass longwall mining approaches 8.8 m. The top-coal caving–related technologies have significantly improved the mining efficiency of thick coal seams and have also made a great contribution to the centralized underground mining of coal. Thus, the number of underground coal mines is greatly reduced in China. However, due to the increase of the mining height and the changes in mining operations, the overburden movement caused by the mining of thick coal seams is more intense, and the influence scope is larger, which brings a series of new problems on ground control of longwall faces. In order to enhance ground control and improve the mining efficiency of thick coal seams

Jul 28, 2020

By R. G. Hamm

A brief outline covering the shovels and draglines in use in the open-pit mines of Western Canada, including British Columbia, Alberta and the Yukon, is given, followed by the procedure for the selection of the correct wire rope for each application. Such fa ctors as wire rope constructions, lay directions and types of cores are mentioned. Once the correct wire rope has been selected, there are variousfactors that can affect the service fife ofthe rope and the reduction ofdown-time during rope change-overs. Factors such as hairpin winding, types of Becket loops, and shovel drum and bail adaptors are described.

Jan 1, 1979