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By Leonhard Schmid

INTRODUCTION In the region of Zurich several of the Swiss Interstate Highways meet and have to be linked to form a continuous network. The subalpine glacial topography with hills, ridges and lakes requires the construction of many tunnels (Figure 1). The Milchbuck Tunnel forms part of the inner arterial highway system of the city of Zurich. It passes underneath the ridge separating the Limmat and Glatt valleys. In its final configuration the tunnel will consist of two parallel three-lane tunnels (Figure 2). For the time being only one tunnel is constructed. This tunnel will be operated with two outbound (climbing) lanes and a single inbound (descending) lane (Figure 3). The owner, the Canton of Zurich, awarded the contract for the construction to a joint venture with the following three contractors: Locher & Cie AG (leader), Prader AG, A. Brunner's Erben, all located in Zurich. The actual freezing was performed by subcontractor Philipp Holzmann AG, Mannheim, West Germany. Electrowatt Engineering Services Ltd, Zurich, was design engineer and performed the construction supervision.

Jan 1, 1981

By Savita Schlesinger, Mike Hanna, Nathan Scalla, James O’Shaughnessy, Steve Miller

Loudoun Water’s Quarry A (Milestone Reservoir) project involves conversion of a rock quarry to a billion-gallon raw water reservoir. The project includes a new 40 MGD pump station, deep intake shaft, and three drill and blast intake tunnels for accessing the reservoir. Due to concerns regarding constructability and construction risks, the project design was paused while a Construction Manager At-Risk (CMAR) contractor was procured. The CMAR contractor was engaged collaboratively with the design team to provide risk and constructability input for refining the design. Aspects of the original design, design modifications, and benefits of the CMAR collaboration will be presented.

Jun 13, 2023

By E. Fritz

This paper reviews the history, developments and 10 milestones of the oxygen steelmaking processes, with a special focus on conventional autothermic converters, high-speed converters with a blowing rate up to 5 m3n/t min and allothermic converters with coal addition, post combustion and the possibility to increase the scrap rate up to 50%. Related operating results are introduced. A new process route, which is based on hot metal and chromium ore, is outlined. The cost advantage for the production of 304 stainless steel grade is higher than 100 USS/t. The synthesis of EAF and oxygen converter steelmaking, a comparison of decarburization rates, refining combustion burners for optimized oxygen-management in EAF and an example for a large advanced EAF are outlined. Possibilities of flexible steelmaking and the growth and outlook of worldwide oxygen steelmaking are described.

Jan 1, 2004

By John A. Allan

Introduction There are times when meditation on the past is worth while. Too often does it happen that in the busy routine there appears t9 be little time for reflection, and little good or benefit to be derived from what has already taken place, or what has become past achievement. Under conditions such as those that prevail at present, consideration is being given to many subjects that a few years ago were not looked upon as worthy of time or thought. The temporary lull in industrial development is permitting of a stock-taking investigation, a perusal of past activities, and a planning for future development with the return to normality. It is not proposed to include much new data in this address, but the endeavour will be made to survey, in resume, the sequence of events which led up to the birth of the mining industry in Canada, and to show how, as new discoveries were made, the centres of interest changed from time to time until mineral development extended across Canada from the Atlantic to the Pacific. It will appear, also, that external causes have accentuated mineral development at one time and retarded it at another. Early Records A, historical background to the mining industry extends even to an earlier date than the discovery by white men of that part of the continent of North America represented by Canada. It has been stated that the aborigines were still in the neolithic stage when the white man arrived. One metal only was known to the natives, and that was copper, obtained from possibly many parts of Canada, but particularly from the shores of lake Superior in Ontario, from the Coppermine river on the Arctic coast, and from die coastal regions of British Columbia.

Jan 1, 1933

A self-appointed, committee consisting of J. Waldo Smith, Chairman, Richard S. Buck, J. J. Carty, J. Parke Channing, E. L. Corthell, Alfred Craven, Thomas Crimmins, Gano Dunn, George Gibbs, Alex. C. Humphreys, F. L. Hutchinson, Charles Warren Hunt, D. S. Jacobus, John W. Lieb, William Barclay Parsons, George H. Pegram, Charles F. Rand, Calvin W. Rice, Robert Ridgway, William L. Saunders, Merritt H. Smith, Bradley Stoughton, and William H. Wiley, organized a course of seven free lectures on military engineering, which were given by Captains Thomas M. Robins, Richard T. Coiner, Edward D. Ardery, Corps of Engineers, United States Army, and which was under direction of Major General Leonard Wood. The United Engineering Society presented, without charge, the use of the auditorium for the purpose of these lectures, but the interest proved to be more than three times as much as had been expected, and it was therefore necessary to divide the courses into three parts, one of which was given in the afternoon in the auditorium of the United Engineering Societies Building, one in the evening in the same place, and another in the evening in the auditorium of, the American Society of Civil Engineers. These lectures occurred on Mondays, from Feb. 14 to Mar. 27, 1916. The subjects and speakers were as follows: Feb. 14, 1916: Organization and Duties of Engineers in War, and what Engineers in Civil Life will be called upon to do in the Defence Of the United States. Captain Thomas M. Robins, Corps of Engineers. Feb. 21, 1916: The Service of Reconnaissance Including Surveying, Mapping and Sketching, Photography and Map Reproduction. Captain Richard T. Coiner.

Jan 5, 1916

By Bahngrell W. Brown

IN an age when anything short of miraculous can and does happen it is entirely too easy to become labeled as a prophet. After the first wave of hysteria over atomic weapons died down there were crystal gazers enough in that field. The mining fraternity, always anxious to get back to normal anyway, looked, was duly impressed, and passed on to more mundane affairs. After all it was just another big blast in the stopes of life. After we "laymen" had seen the effects at Hiroshima and been granted a peek into the phenomenon of Numbers 4 and 5, we saw, indeed, that it was a tremendous but understandable weapon. Now it appears that we may fall heir to much of the defensive planning of the future. If, as our military planners tell us, it will be necessary to go underground for defense, then we are the true forerunners of a race of troglodytes. The underground belongs to us as to no other profession; the subsurface is our prerogative. Already the big mistakes in planning atomic defense are being made. It is within our ability now to correct them. Surveys are being made of natural caverns to be used as a basis for military planning. This is our first big mistake. Even if the natural caverns, many of which Nature has precariously carved from cherty and brittle limestones, could withstand the seismic force of a proximate blast without major roof failures, there is a more serious argument against the blanket use of natural caverns as a first line of defense. In addi-

Jan 1, 1946

By authority of the Secretary of War, and in response to frequent requests, the following suggested list of reading is issued by the War Department for the information of civilian engineers desiring to inform themselves on military subjects: These references have been selected, first, with a view to giving to engineers unfamiliar with the art of war a general survey of that sub-

Jan 1, 1916

By Charles De Witt

The ore treated at the reduction plant (called Yangdei) of the Chiksan -Mining Co., Korea, is brought from four of the company mines, and from the small tribute mines. The largest shipments conic from Sajunkohl mule, situated about a mile and a half from the mill (Fig. 1). The ore is quartz of medium hardness. The overage assay value in gold is $6.95 per ton. At the mine the ore is put into bin,, and is Mien trammed over an 8 per cent. grade to the tipple bins above the mill, where the ore is drawn through the hull holes as desired. The capacity of the tipple bins is about 3,500 tons. On, from Moonsukohl, Chung Tarrie, Yang Chun, and the tribute mines is brought in by bulls and bull wagons. The bulls carry from 350 to 800 lb.; the average wagon load is about 1,200 lb. (Fig. 2). One shovelful of ore out of every ten is taken as a sample. Considerable ore

Jan 5, 1915

By A Thornton, D Engelhardt, J Woodg

Grinding is a critical part of nearly all mineral processing operations. It is the largest consumer of energy on the mine site (and thus indirectly a producer of greenhouse gas through the generation of electrical energy at the power station). Since comminution is one of the main consumers of electrical energy worldwide, efficient control of grinding mills is of paramount importance. Mill Auto-Pilot is a control system developed for SAG mills to stabilise load and power and improve the efficiency of control and increase throughput. A dynamic, mechanistic model of the grinding circuit is used to determine circuit parameters which can not normally be measured using conventional instrumentation. The circuit model is built from models of the unit operations (such as conveyors, SAG mills, cyclones, sumps, etc), and so captures the dynamic complexities and interactions of real circuit operation. CSA Mines at Cobar NSW accepted an offer to be the reference site for Mill Auto-Pilot and the system was installed in March 2004. In this application the model is used to predict mill load mass, mill solids residence time and cyclone underflow density. These parameters are used to control mill load, power and mill discharge density. The outcomes of the introduction of Mill Auto-Pilot at the CSA Mine are discussed.

Jan 1, 2004

By C. H. G. Bushell, James E. Lawver, William Barbarowicz

Proper use of automatic controls in the process industries is a combination of art and science. Although many phases of automatic control theory can be expressed by precise mathematical relationships, the final control arrangement usually requires considerable effort by trial and error before the optimum control circuit is found. The failure of flotation operators to recognize that control circuits require study and plant experimentation before satisfactory operation occurs has led to a popular misconception that flotation plants simply do not lend themselves to automation. This widespread belief has been overcome to some degree in recent years by the numerous installations of automatic controls that have paid their way by increasing profits in terms of increased recoveries, lowered costs, or higher grade concentrates. WHY CONTROL ? Any form of automation must be justified in terms of ultimate return on in- vestment by improving quality, by increasing plant throughput, or by reducing the total operating costs. Generally speaking, automatic controls rarely re- place a mill operator. They assist the operator in holding important variables within predetermined limits. Large tonnage operations usually can justify a great deal of automation because an increase in one or two units of recovery results in enormous savings compared to the capital and operating costs of controls. DETERMINATION OF CONTROL The first questions in considering plant automation are: 1) What variables must be controlled? 2) What are the optimum levels of the variables? The optimum operating conditions for any process are those which maximize profits. Many of the variables active in flotation processing can be determined by experimentation in the laboratory or pilot plant 10. Although laboratory experiments can pinpoint variables, the true optimum conditions existing at plant level usually must be determined by plant scale experiments. In recent years, the concepts of detailed experimental designs in the laboratory, followed by plant experiments, have reached the stage of maturity where

Jan 1, 1962

By Norman Weiss

The design of an ore-processing plant requires a high degree of cooperation among the geological, mining and metallurgical engineers. The purposes of this section are to provide mill design information most commonly needed by the mine planners and management, and to summarize the kinds of information that must be supplied to the mill designer to enable him to provide a suitable plant. 28.1-BASIS OF DESIGN NORMAN WEISS 28.1.1-SIZE OF PROJECT The size of the project generally is expressed in tons of ore milled per day, but company policies differ widely in this respect, a few adhering to this set figure but many expecting the design capacity to be liberal. To some companies that follow the latter practice a 25,000-tpd milling plant that cannot reach 30,000 or 35,000 tpd without major additions is a disappointment. The engineers responsible for planning the operation must know what is intended. Equally important are operating schedules, particularly the number of operating days per week and shifts per day for ore delivery, crushing, grinding and processing. Hours per shift also are an important factor in design, particularly in the case of ore delivery, and the percentage lost time expected for maintenance, cleanup, inspection, preventive maintenance shutdowns, and many others, has to be taken into account. Frequently, the ore deposit will vary in hardness and grade to such a degree that the capacity of the mill will vary widely from year to year and cannot be expressed as a fixed figure. but rather as an average over a calculable period, such as 10 yr, or as a specific daily capacity over the first 2 yr, next 4 yr, etc., or some similar projection. A good example of this kind of situation is Asarco's Mission operation 15 mi southwest of Tucson, Ariz., described by Weiss and Vincent.' where the major rock types differed widely in hardness, so that a change in the proportion of these types in the mill feed could have imposed difficult design problems if a constant tonnage rate had been expected. 28.1.2-EXPECTED LIFE The life of a mining operation depends upon the size of the deposit and the rate of mining. The latter is a policy decision based on an economic analysis which, in turn, is based on many factors.' From the point of view of mill planning, the estimated life of the operation determines many criteria and affects many decisions on strength of structures and degree of protection of men and materials, the quality of the materials-handling and process machinery, the type of delivery systems for ore to the mill and concentrates to the smelter or market, and many others. Costly installations that may be excellent investments for a 20-yr project may be wasteful for a 5-yr operation. An example is the comparison of different methods of crushing or grinding. Take single- vs. multiple-stage grinding-the former may be found more economical for a 5-yr operation, and the other, more costly, method more economical for a 15 to 20-vi- life.

Jan 1, 1973

By Tom Plouf, Deepak Malhotra

INTRODUCTION The U. S. mining industry experienced a severe recession in the early 1980's. This resulted in the realization that the domestic mining industry had to compete on a global basis and only the strong or the low-cost producers would survive. The economic viability of a mining company not only depended on maximizing mineral recovery but also on its ability to do so at minimum cost. Companies had to become more productive not only by cutting costs, but also by developing and/or evaluating new technologies in existing or new plants. Several innovative concepts, including in-pit crushing and conveying, fine crushing, improved classification equipment, flotation, column flotation, pressure filtration, etc., have been developed in recent years. This paper addresses the impact of new flotation concepts and equipment on mill design. MILL DESIGN PHILOSOPHY Modern mill design, especially for large capacity plants, has its foundation in minimizing capital and operating costs. Capital costs can be minimized by minimizing the various components of the capital cost: infrastructure, equipment, instrumentation, structural, initial spare parts costs, etc. All these costs are minimized by simplifying the mill design and/or process flowsheet. The simplified process flowsheet, where applicable, consists of a single stage primary crusher followed by a semiautogeneous - ball mill grinding circuit to produce feed for a flotation circuit. Multiple flotation circuits have been eliminated in most cases. These concepts minimize the cost and encourage the use of large capacity equipment while maintaining optimum metallurgical recovery. The philosophy of mill modernization/modification is generally driven by the desire to increase the mill capacity within the limits of the existing mill building. This need is facilitated by using large size flotation equipment and eliminating multiple parallel flotation circuits in order to minimize capital and operating costs. Conventional flotation machine development has paralleled this mill design philosophy. FLOTATION CELL DESIGN Since froth flotation has been the most widely used separation process for over half a century, one would expect that it would be possible to design and select flotation machines for specific applications based on scientific principles. But this has not been the case. Best judgment, experience and personal prejudice have played a key role in equipment selection. These factors, along with the difficulty of evaluating new concepts in commercial plants, has slowed progress in implementation and commercialization of innovative ideas and/or equipment. Conventional Flotation There have been no major technological advances in conventional flotation cell design in recent years. A recent flotation cell survey indicates that 'larger flotation cells are still the order of the day.”(1) A comprehensive review of design of flotation machines indicate that they have been mechanically redesigned and are generally simpler and easier to maintain and less expensive to manufacture. (2,3) The approximate chronological development of conventional cells from the 25 cubic foot cells to the 3000 cubic foot cells, which were recently installed at the Copperton concentrator of Utah Copper, is given in Table 1. Larger flotation cells are the obvious choice for new plants or plants looking for expansion because of the following reasons: • They have lower capital cost per unit volume • Installation costs are generally lower because fewer units require less space • Maintenance costs are lower because of fewer mechanisms • Power requirements (HP/ton dry feed) are generally lower • with increased flotation cell size as illustrated in Table 2 [Table 1. Conventional Flotation Cell Size Development Year Individual Cubic Cell Size, Feet 1925 25 1935 50 1960 100 1965 300 1970 500 1975 1,000 1980 1,500 1985 3,000]

Jan 1, 1989

By Norman Weiss

THE need for more efficient utilization of labor in the metal-mining industry has been the subject of several recent editorials in the mining press, and one attractive possibility for such improvement lies in the designing of future milling plants particularly with economy of man-power in mind. We are accustomed to think of mill design as the selection and coordinated arrangement of process equipment, but if labor is to be efficiently utilized it must be given early consideration in planning the new mill. There are three good reasons for economizing in labor: (I) to reduce costs, not only in the form of wages but also in housing, hospital, welfare, and other obligations that a company accepts when a new man is added to the payroll; (2) to prepare for recurrent periods of manpower shortage, during which a well-designed plant can manage to get along with skeleton crews; (3) because a milling plant that must depend upon an inordinately large labor force for its operation and maintenance is certain to be inefficient in other respects, for many of the shortcomings in design that make necessary the excessive use of labor are generally not corrected merely by having too many men. A simple example of this is a poorly designed ore-feeding system: if this is inadequate to the extent that one man must be constantly unclogging feed chutes, it may help the situation to put two men or three at this task instead of one, but the feed rate will still be inconstant. First of the factors that affect labor saving is the location of the mill. This is often determined by transportation costs alone, and as a result the mill may be placed close to the mine regardless of the nature of the terrain. The designer must then adapt his layout to the conditions, favorable or not. This happens often at small properties, where capital investment may seem more important than operating expense. In most instances, however, a mill site carefully selected for the advantages it gives the designer in laying out the plant is the most economical in the long run, even if it involves a slight increase in cost of ore haulage. Given some freedom of choice, the design engineer may be able to find just the piece of ground that provides the proper gradient for the needs of the flowsheet, permits installation of essential yards and trackage, and perhaps supplies an excellent site for a tailing dam. Further justification for having placed the mill not too close to the mine sometimes emerges only years later as an opportunity to treat ores from other properties. When it is known from the beginning that the new mill will serve a number of scattered mines, a free choice of mill site is naturally stimulated. The most important single factor in limiting the labor requirements of a mill is its materials-handling system for bring-

Jan 1, 1946

By Robert S. Shoemaker

The development of a metallurgical project is a business venture rather than a technical exercise, and its real objective is to obtain the maximum return on investment consistent with the limitations imposed by company policy and the requirements of society. Demand for profits is the driving force for technical advances and naturally leads to improvements in processes, equipment and plant designs. In the mineral dressing field there have been virtually no new processes developed since the introduction of flotation, and the steady erosion of profits by inflation has been offset only by increasing equipment size. Unfortunately, in recent years, plant designers have not always utilized the largest equipment or the opportunities for functional and economic design presented by the development of larger equipment. Lower cost plants can be developed providing that unrealistic restraints arising from the prejudice of past practices are avoided. As an illustration of this premise, three different approaches were taken toward the design of a clearly delineated but hypothetical copper concentrator of 20, 000 tons per day capacity. While the same flowsheet was used in each case, designs were produced for a conventional plant, an alternate using the largest available equipment, and a third scheme utilizing large equipment and the most functional design which could be developed, including features derived from many plants in many different industries. Capital costs were developed for the three separate designs based on a location in the southwestern United States. Ancillary facilities were identical in each case and included a mine truck shop, a maintenance shop, a general office, and a nominal starter dam for tailings disposal within 5000 feet of the plant. Water supply within 1000 feet of the plant, and power furnished to the property boundary has been assumed in each case. The flowsheet of the three plants is shown in Figure 1 and represents the treatment of a typical sulfide copper ore by three- stage crushing followed by single-stage ball milling. Concentration is by flotation roughing and scavenging followed by regrinding of the concentrates and two stages of cleaning.

Jan 1, 1971

By Allan D. Taylor, Robert S. Shoemaker

Adopting as a principle the phrase "the mill of yesterday should not be built with the high cost money of today," the authors have designed a hypothetical concentrator which could be built for a typical southwestern United States (or other similar area) copper ore. Many of the design features could also be used for other ores in other climates. Functional design, large equipment, and outdoor type of construction have been combined in a concentrator (which includes all ancilliary facilities such as truck and maintenance shops, offices, warehouse, nominal tailings disposal, and water supply) which could be built today for substantially less than the cost of comparable but conventional plants.

Jan 1, 1973

PRACTICAL PROBLEMS AND BASIC PRINCIPLES ranging from ore testing to cost estimation get a working over from top men in the minerals beneficiation field. The Minerals Beneficiation Division developed this symposium for presentation at the 1953 Los Angeles General Meeting to assist the many people who think that having a new plant necessitates a lot of trouble and dismay. The papers and free discussion from the floor give ways and means of approaching a new plant that will relieve the strain on the organization, if adequate attention is put on the program before work begins - that is if thought is given to the program itself, before tackling the actual mill design.

Jan 9, 1953

By O. W. Walvoord

Mill design of the past will not necessarily dictate mill design of the future. There have been many advances and changes in the last few decades, many of which have been extensive and remarkable. Almost certainly, there will be still greater changes in the near future. Minerals beneficiation, for example, as it relates to future mill design, is likely to experience the greatest progress. Gravity separation, though one of the older arts, is in a continuous state of refinement. Flotation, having celebrated its 50th anniversary in 1961, has yet to be surpassed in its contribution to the art of mineral dressing. Ion-exchange, too, will flourish.

Jan 1, 1971

By T. O. Breitling

Two significant problems In mill design are environmental control and cost reduction. Environmental control is predicted to be 5-10% of total plant costs in some parts of the U.S. Operating and design companies will assign this new "unit operation" a place in the early flow sheets. More advanced environmental control will add to both capital and operating costs, so mill designers will strive to reduce other costs.

Jan 1, 1970

By Dan B. Kivari

One of the key operations in any milling circuit is grinding. Over the last two decades, large diameter Semi-Autogenous Grinding (SAG) mills have become the preferred primary grinding mills. The drive systems became more complex as the size of the mills became larger, during which time operating and design experience for SAG mill accumulated. Considerable reliance is now placed in power electronics to provide flexibility in SAG mill operation to meet the demands of lower operating costs. Whereas earlier most SAG mills were designed to operate at fixed speeds, present day SAG mills can operate at a fixed speed or variable speed through the use of an AC synchronous motor or DC motor. However, this flexibility comes with an increase in capital and operating costs. Since the capital and operating costs of a project directly affect the project's rate of return, the selection of a SAG mill and its drive system should depend, in part, on the impact that the extra cost makes on the project. This impact can be measured by performing an economic analysis based on Net Present Cost (NPC) calculations. Although the NPC calculation is an important factor in the grinding mill selection, other factors such as reliability of mill drives and power source are important elements in the decision making process. This paper examines how the NPC calculation, plus reliability and power source, influence SAG mill selection.

Jan 1, 1991

By Dan B. Kivari

A key operation of any milling circuit is grinding. Over the last two decades, large diameter semiautogenous grinding (SAG) mills have become the preferred primary grinding mills. The drive systems became more complex as the size of the mills became larger, during which time operating and design experience for SAG mill accumulated. Considerable reliance is now placed in power electronics to provide flexibility in SAG mill operation to meet the demands of lower operating costs. Most earlier SAG mills were designed to operate at fixed speeds. Present day SAG mills can operate at a fixed speed or variable speed through the use of an ac synchronous motor or dc motor. This flexibility, however, comes with an increase in capital and operating costs. Since the capital and operating costs of a project directly affect the project's rate of return, the selection of a SAG mill and its drive system should depend, in part, on the impact that the extra cost makes on the project. This impact can be measured by performing an economic analysis based on net present cost (NPC) calculations. Although the NPC calculation is an important factor in the grinding mill selection, other factors, such as reliability of mill drives and power source, are important elements in the decision making process. This article examines how the NPC calculation, plus reliability and power source, influence SAG mill selection.

Jan 1, 1992