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By Louis J. Trostel

Refractories, called the Hidden Industry by The Refractories Institute, provide the temperature and chemically resistant linings for the multitude of vessels that are used today in high temperature processes ranging from giant iron-making blast furnaces to industrial incinerators to petrochemical cracking units to the smallest furnaces used by the jewelry trade. While these refractory linings are absolutely essential to the proper functioning of these processes, the linings are almost always on the inside of the vessels and thus hidden from the eyes of the public. Refractories are defined in Standard C71 of the American Society for Testing and Materials (ASTM), titled "Standard Definitions of Terms Relating to Refractories," as "nonmetallic materials having those chemical and physical properties that make them applicable for structures, or as components of systems, that are exposed to environments above 1 000°F (538°C)." This criterion of ability to withstand exposure to environments above 538OC is the critical distinction separating refractories from other ceramics, fibers, and coatings applicable only at lower temperatures. In addition to resisting temperature, the refractories must with- stand abrasion, chemical and slag attack, resist thermal shock, and carry sustained structural stresses at high operating temperatures for as long as years. The most common methods of classifying refractories are by forming method and composition. First are the traditional formed and fired bricks, batts, and the associated multitude of special shapes. These refractories are usually formed at room temperature, dried, and then fired to high temperatures to develop the final properties desired. Other formed refractories are chemically bonded or resin or tar bonded. To complete the formed refractory matrix, some fired refractory bricks and shapes are subsequently impregnated with resins or tars. Physical dimensions of these formed refractories are classified into two general categories: standard sizes and special shapes. The standard sizes are those in common usage in the United States described in ASTM Standard C909 "Dimensions of a Modular Series of Refractory Brick and Shapes" based on the 38 mm basic module as described in ASTM Standard C861 "Determining Metric Dimensions of Standard Series Refractory Brick and Shapes." The most common size is the "9-inch straight" 228 x 114 x 64 mm (9 x 4 ½ x 2 ½ in.) of the "2 ½ -inch" series or 228 x 114 x 76 mm (9 x 4 ½ x 3 in.) of the "3-inch" series. Bricks of nonstandard sizes are referred to as special shapes. Their use is required in specific furnaces for particular requirements or applications. In addition there is the large and growing group of refractories sold as unshaped mixtures that may be formed into their final shapes at the application site. These unshaped mixtures are sometimes referred to as specialties. The mixtures are prepared to be hydraulically cast, plastic or wet rammed, dry rammed, or dry vibrated into their final shapes. Some are designed to be projected through nozzles (or gunned) onto their forms. The refractory mortars used to lay up the shaped refractories fall into this group referred to as specialties. Prepared refractory grains also are sold. These are usually calcined or fused materials that are subsequently crushed and sized to a variety of specific carefully controlled grain sizes or size distributions. These grains include calcined fire clay, dead burned magnesite, periclase (fused magnesia), dead burned dolomite, kyanite, tabular and fused aluminas, fused zirconia, fused mullite, and calcined alumina-magnesia spinel. The primary composition groups of refractories are the 1) alumino-silicate refractories made largely from fire clay and high- alumina materials, 2) silica refractories made from quartzites and ganisters, and 3) basic refractories from magnesia (or magnesite) and chromia (also referred to as chrome ore), alone and in combination, and dolomite. Special refractories include carbon, zirconia, zircon, high purity alumina, mullite, silicon carbide, silicon nitride, and some borides. In addition there are groups of special insulating refractories.

Jan 1, 1994

By C. Cho

One problem with the application of neural networks to the multivariable control of mineral and extractive processing is deciding whether and how best to use them. The objective was to compare neural network control to more conventional strategies and find any advantages in terms of set point tracking, rise time, settling time, disturbance rejection, and other criteria. The procedure was to develop neural network controllers using both historic plant data and simulation models. We tried various neural network control patterns including both inverse and direct neural network plant models. These were compared to state space controllers that were, by nature, linear. For grinding and leaching circuits, a nonlinear neural network-based model predictive control strategy was superior to a state space-based linear quadratic Gaussian controller. We also learned the importance of incorporating state space into neural networks by making them recurrent--feeding certain output state variables into input nodes in the neural network. We concluded that neural network controllers can have better disturbance rejection, set point tracking, rise time, settling time, lower set point overshoot, and can be more foolproof and easy to implement in complex, multivariable plants.

Jan 1, 1996

By R. Y. Wan

Newmont Gold Company has advantageously used the capabilities of mineral oxidizing bacteria to develop a process for pretreatment of low grade sulfidic and carbonaceous-sulfidic refractory gold ores. The biooxidation process results in the oxidation of the sulfidic minerals with increased exposure of gold for subsequent gold recovery. The biooxidized carbonaceous-sulfidic ores cannot be heap leached with cyanide because of the "preg-robbing" characteristics of the carbonaceous matters in the ores. An alternative heap leach process using ammonium thiosulfate was developed to extract gold from the "preg-robbing" biooxidized ores. The ammonium thiosulfate leach process has been successfully practiced both in laboratory and pilot plant testing. Satisfactory test results encourage the continuation of process development.

Jan 1, 1996

By Kal V. S. Sastry

Mathematical and expert system models are being used extensively for mineral process engineering. There exist no standardized methodologies for their computer implementation. In meeting this need, this paper introduces the concept of a process software model, or simply a software model and presents a two-step methodology for its development involving software model specification and development. The software model specification is to be performed after extensive discussions with the ultimate users of process software based on which the software model is developed. These software models provide a formal basis for the design and construction of software objects corresponding to the real world process objects.

Jan 1, 1994

By Jr. Lownie

Estimates of the cost of producing any commodity generally fall into several classes depending upon the motives and needs of the estimator. There are estimates intended to show how low costs might be with favorable conditions if everything goes well. At the other extreme, there are estimates which show how high costs might be if troubles develop. The estimates in this paper for the cost of producing direct reduced iron (DRI) are accompanied by discussion to point out how the final figures may be adjusted in either a promotional or a conservative direction. Because we do not have a specific process and a particular set of conditions in mind when discussing this subject today, this paper deals with the general situation, with considerable attention to how the estimates can be made more specific once one knows the particulars of a given situation.

Jan 1, 1978

By L. B. Phelps

This paper focuses on the use of an integrated mine planing software package entitled "REMINE" which was constructed to provide a project evaluation tool for analysis of remining projects. Coal remining constitutes the affecting of sites which have had a past history of mining and have a pre-existing pollutional discharge. Such sites require a Best Professional Judgement (BPJ) analysis. The program was written to provide such an analysis with flexibility in the mine plans which can be analyzed. The process required for a BPJ analysis will be detailed and mine plan simulation performed to demonstrate the analysis.

Jan 1, 1990

By S. Gupta

Froth flotation is a process commonly employed for the selective separation of phosphate from unwanted mineral. Column flotation has become widely accepted in the mineral processing industry, including phosphate industries, due to its ability to improve selectivity, lower operating cost, lower capital cost, and superior control. In this work, a hybrid model is developed that combines a physicochemical model with artificial neural networks. The physicochemical model is based on axial dispersion with first order collection rates. A new approach, in which both frankolite (the desired mineral containing phosphate) and gangue (undesired product) are modeled, enables prediction of grade of the recovered product. Thus, two basic parameters are required in this model: flotation rate constants for frankolite and gangue. Artificial neural networks are used to predict flotation rate constants. The model also takes into account the particle size distribution and predicts grade and recovery for each particle size range. The model then combines grade and recovery for each particle size range to determine the overall grade and recovery of the column. The model is validated against laboratory column data.

Jan 1, 1998

By G. L. Finfinger, F. E. McCall, A. A. Campoli, M. D. Zuber

Injecting pressurized water into a coalbed prior to mining reduces mining-generated respirable dust. Because of economic and geological barriers, water infusion for longwall dust control in the United States is now limited to the Pocahontas No. 3 Coalbed in Virginia. Water is pumped into the coalbed through underground boreholes that are drilled horizontally from the headgate toward the tailgate side of retreat longwall panels. This paper theorizes that the barriers to widespread utilization of water infusion for longwall dust control could be overcome by long-duration, low-pressure water infusion through vertical gob-gas boreholes. Currently, 43% of the 72 longwall mines in the United States employ vertical gob-gas boreholes. Computer coalbed-reservoir simulation suggests that one vertical surface borehole could infuse the same longwall panel area as four horizontal boreholes in the current water-infusion system for longwall dust control in the Pocahontas No. 3 Coalbed.

Jan 1, 1997

By Irina Melekestseva, Beltenev. Victor, Victor Ivanov

"One of the major problems discussed over the last years is a possibility of mining of seafloor massive sulfide deposits. In spite of the pessimistic points of view on their commercial development, they are still of great interest and continue to be studied (Hannington et al., 2011). Recently, Barriga (2012) paid special attention to the underestimated amount of massive sulfide hydrothermal fields and pointed to the importance of the buried fields and subseafloor mineralization.This study examines the geochemistry of seafloor and subseafloor precipitates collected at the Peterburgskoe (19°52´ N) and Irinovskoe (13°20´ N) hydrothermal fields (MAR) during the 34th cruise of the R/V Professor Logatchev in 2011. These fields were discovered by the Polar Marine Geosurvey Expedition in 2010 and 2011, respectively (Shilov et al., 2011; Beltenev et al., 2012). The Peterburgskoe field, associated with basalts, is located 16 km west of the main rift valley at the depth of 2800-3100 m at the junction of a large non-transform discontinuity with the second rift ridge parallel to the rift valley. The Irinovskoe field occurs at depths of 2700-2850 m and has a northwestern satellite sulfide site, both confined to an oceanic core complex (MacLeod et al., 2009), which includes mafic and ultramafic rocks. The details of geological structure of the fields may be found in the relevant papers.Diverse samples were collected from the hydrothermal fields: seafloor massive sulfides, Fe-hydroxide crusts, SiO2-rich sulfide-bearing precipitates, and subseafloor mineralized rocks (Melekestseva et al., 2014a). Massive sulfides may be subdivided on the Fe-rich and Cu-rich types. The marcasite-pyrite, pyrite, hydroxide-marcasite, and chalcopyrite-pyrite (Fe-rich) mineral types are dominant in the Peterburgskoe field at lesser amounts of sphalerite-hydroxide-chalcopyrite and pyrite-covellite-chalcopyrite (Cu-rich) massive sulfides. The mineralized sulfide-talc-carbonate-chlorite, chlorite-sulfide-quartz, and hematite-sulfide-quartz rocks host stringer-disseminated sulfides including chalcopyrite, covellite, and pyrite."

Sep 1, 2014

By B. J. Arnold

Coal blending inherently means homogenizing a mixture of coals so that, overall, the properties of the blend meet some specifications for maintaining power plant performance and emission requirements. In common practice, however, coal blending is at best coal mixing. If necessary, more sophisticated blending systems can produce a more homogeneous feed by using accurate weighing devices and on-line coal analyzers coupled with sampling systems. Blending can be accomplished at the mine, on stockpiles, and from bins, bunkers, and silos.

Jan 1, 1994

By L. W. Laage

MFIRE is a mine ventilation and fire interaction computer simulation program. It allows transient state ventilation simulation and features mass based flow rates, natural ventilation, air recirculation, fan curve fitting, airflow reversal and product of combustion tracking. MFIRE was designed to accommodate the needs of the mining industry for routine ventilation calculations and mine emergency planning. This paper describes recent work by the Bureau and MTU to improve MFIRE by incorporating humidity in the mass flow and heat exchange calculations, a data file preparation program and variable reference density in the network calculations. Recent bug fixes are also discussed.

Jan 1, 1993

By S. B. Hildebrand

One of the highest costs associated with insitu leaching of copper is electric power. The ReGeneration Project addressed this cost issue with a research and development project for BHP Copper. The project involved the installation of a reverse pump/turbine for the removal of excessive fluid pressure and the production of useful electric power. The motivation for the project was that a reverse pump/turbine unit could not only remove the excess hydraulic pressure, but when connected to an induction .generator, would produce electric power, which could be easily connected to the local power gird, thus reducing operating costs. The project was successful in removing excess fluid pressure and producing electricity. The unit is operating today, producing useful 2,300 volt power at a rate of approximately 128 kilowatts.

Jan 1, 1998

By Daniel R. Stewart, Ralph R. Sacrison

The function of the geological engineer is to assist in mine planning and operations by collecting, interpreting, and applying geologic data to the solution of engineering problems. The geologist supports this effort by collecting additional geologic information specifically useful to the engineer. This use of geologic information reinforces the value of mine geology to the mining process beyond the traditional role of orebody definition. Work discussed includes: evaluation of caving strategies at the Climax and Henderson mines, support definition and slope stability at the Climax mine, and some uses of geology in cavability estimation for the Mount Emmons project.

Jan 1, 1992

By D. Lynn, D. Arthur

Infrastructures continue to age and drinking water supplies are becoming scarce in the San Fernando Valley of Los Angeles, California. Frontier-Kemper Constructors, Inc. (FKCI) was engaged by the Los Angeles Department of Water and Power (LADWP) to complete the River Supply Conduit Improvement Upper Reach—Unit 7 Project (RSC7). Two tunnel sections were bored using a 2.64 meter diameter Microtunnel Boring Machine (MTBM) and a 4.12 meter diameter Earth Pressure Balance Tunnel Boring Machine (EPBTBM) to excavate approximately 3,733 meters (3.7 km) of tunnels through highly abrasive late-Pleistocene-age Quaternary alluvial deposits (Old Alluvium) and Holocene age Young Alluvium deposits above the water table. This paper discusses the challenges encountered managing the TBM’s equipment degradation, use of soil conditioners, cutterhead wear, torque and advance rates while maintaining the necessary face-pressures and parameters to limit over excavation and ground settlement.

Jun 13, 2021

By Jean-Luc Cornet

Advances in conveyor technology over the past decade have enabled the design and erection of very long overland belt conveyors. Such conveyors usually require head and tail drives to lower the belt tension and belt strength required. This paper provides an overview of the problems encountered in controlling the head and tail drives on such conveyors and some of the solutions developed by CDI for several such projects.

Jan 1, 2002

By M. Charles Gilbert

Basement rocks in southern Oklahoma are divided into two groups. One group is the Lower Cambrian Wichita Igneous Province, a diverse igneous suite that crops out in the western Arbuckle Mountains and in the Wichita Mountains. These largely bimodal igneous rocks were emplaced in an intracratonic-rift environment. The other group, the older, is a set of Precambrian rocks of the Eastern Arbuckle Province, yielding ages between 1,350 and 1,400 Ma, exposed in the core of the eastern Arbuckle Mountains. These are deeply eroded mesozonal granitic rocks and associated granitic gneisses cut by numerous dikes ranging in composition from diabase to rhyolite. The southern Oklahoma igneous rocks have long been utilized mostly as dimension and crushed stone. Most of the early quarries were in granite of various red hues for monuments and facing stones. Large crushed-stone quarries are now exploiting both granite and rhyolite, which is used chiefly as aggregate and railroad ballast. The exposed basement rocks in Oklahoma represent an underdeveloped and accessible resource.

Jan 1, 1999

By Henry H. Roos

NTRODUCTION In the mining industry, a "drill jumbo" is a drilling unit equipped with one or more rock drills and mounted on a mechanical conveyance. Jumbos range from single¬drill ring drills mounted on simple steel skids to sophisti¬cated multiple-drill units mounted on diesel engine powered carriers and equipped with automatic controls and sound-abatement cabs. Individual types of jumbos usually are designed for specific tasks such as fan drilling in sublevel caving operations. Some units, such as development jumbos, can be utilized for several functions in addition to their normal applications, e.g., for production drilling in room-and-pillar operations, stoping in cut-and-fill mining, etc. Mine operators can purchase individual components from manufacturers, assembling these components into a jumbo suitable for specific conditions. However, this requires that mine personnel have good engineering and mechanical abilities. Although manufacturers of jumbos maintain facilities for designing machines to meet con¬ditions created by new mining methods and unusual ap¬plications, the cost of the engineering and experimental work for new types of jumbos should be evaluated in terms of both costs and benefits; it may be advantageous to plan the mining operation so that existing and proven units can be utilized. GENERAL SELECTION CRITERIA Since the operating conditions vary in underground mines, the design of a jumbo must be selected to cope with the individual characteristics of the mine. The necessary considerations include access space into the working areas, grades expected to be encountered, radii of the curves, ambient temperatures, the characteristics of the rock, the acidity or alkalinity (pH rating) of the mine water, etc. Access to Mine Workings The mine workings must be accessible to the selected jumbo. Frequently, a jumbo must be disassembled at least partially to pass through the mine shafts. There¬fore, a bolted construction allowing disassembly into pieces of suitable size and weight is desirable in most applications. Type of Undercarriage Generally, a crawler-type undercarriage should not be used in trackless mines having acidic mine water. The acidic water causes an electrolytic action between the individual crawler parts and causes rapid corrosion and early failures. Propulsion A two-wheel drive on a pneumatic-tired jumbo is marginal for grades exceeding 12%. A four-wheel drive unit with good weight distribution is capable of operat¬ing on grades of up to 35%. At least 30% of the gross vehicle weight (GVW) should be carried on the steering axle; otherwise, the steering tires may not have sufficient traction on loose road surfaces and may "plow" instead of steer. To assure stable operation in mines with steep grades, the height of the center of gravity of the jumbo should be considered. It should not make the unit prone to rolling over on the steep grades that may be encoun¬tered. Turning Ability In confined working areas, a skid-steering or crawler unit has the best maneuverability. An articulated carrier is preferable when base-rotated parallel booms are being utilized. A rigid-frame jumbo with automotive steering is compact and economical, having lower maintenance requirements than the other two types. However, the turning radius of a rigid-frame unit is wider than either the skid-steering or articulated units, and this wider turning radius may be detrimental in mines with narrow drifts. JUMBO COMPONENTS Rail Undercarriages A mine with a rail-transportation system generally utilizes drill jumbos that are mounted on rail-type under¬carriages. With a light load and good weight distribu¬tion, this carrier may consist of a simple two-axle four-wheel platform onto which the boom-mounting brackets are attached. As the depth of the round and the penetration rates increase, the weight of the equip¬ment installed on the chassis also increases. The greatest problem with a heavy overhung load is balancing the carrier; a three-boom unit may require a substantial amount of counterweighting to maintain an acceptable 70% to 30% axle-load balance. Although lengthening the wheelbase helps balance the unit, a long wheelbase increases the turning radius, often creating problems on curves and sometimes requiring a swivel truck-type chassis. A good rule of thumb for a simple four-wheel undercarriage is to maintain a wheelbase length to track gage-width ratio that does not exceed 2.5 to 1.0. For a larger ratio, a swivel truck should be utilized. Swing-out outriggers or roof jacks help keep a jumbo in place during the drilling cycle. Usually, a rail-mounted jumbo is not self-propelled. Instead, it is maneuvered into place by a locomotive. Occasionally, several headings are being advanced in close proximity, and a self-propelled jumbo is con¬venient. In electrified mines, such a jumbo utilizes conventional battery-powered traction gear; in dieselized mines, hydrostatic drive components offer good flexi¬bility. The tractive power requirements of a typical rail jumbo may be calculated from the formula: HP = [(RR + GR) X Sl/[33,000 X Em X Eh]

Jan 1, 1982

By R. Hemp

This paper describes work carried out to obtain a heat balance in the B3 shaft longwall stope at Blyvooruitzicht gold mine. Recordings were made of the temperature of the air and chilled water entering and leaving the section during three periods, August 1 September 1977, November 1 December 1977 and March 1978. These recordings, together with numerous other measurements were used to determine the rate at which heat was being removed from the section by the various fluids flowing through the section. The rate at which heat was entering the section was then calculated, by considering each source in turn. These two sets of figures made it possible to draw up a heat balance, and also obviously gave vital information on the magnitudes of the various heat sources and on the methods used to remove heat. In general reasonable heat balances were obtained, the errors being in the range -6 per cent to +22 per cent.

Jan 1, 1980

By Thomas V. Mullen

Some 146 kt (4.69 billion oz) of gold have been mined throughout history. Of this, 70% has been mined in this century alone, with 17% produced from 1985 through 1996 (Fig. 1 and Table 1). Until the mid-19th century, placers were the chief source of gold. Advancements in mining, metallurgy and geological thinking have resulted in underground mining (first of veins plus stockworks and later of Rand-type deposits) becoming the principal source of gold. With the demise of the South African deposits and the move towards lower grade ores, the primary source of gold will be from disseminated deposits exploited through large, open-pit mines. For the past 200 years, there has been a fairly constant ratio of about 31 g (1 oz) of gold to each person alive. If this ratio is to be maintained, annual gold production will have to rise from about 2.3 kt/a (73.9 million oz/year) to more than 3.1 kt/a (99.7 million oz/year) by the year 2000. To effect this increase, an unforeseen breakthrough in exploration or metallurgy is needed. Barring this, there will be pressure for an increase in the price of gold. This article traces the historical production of gold from 4000 B.C. - the earliest record of gold mining - to today and relates this 6,000-year record to advances in geological thinking, mining engineering and extractive metallurgy. It also proposes that man's thirst for gold, reflected in the price he will pay for gold, and his ability to find, mine and refine gold have combined to effect an equilibrium based loosely on the historical ratio of 31 g (1 oz) of cumulative gold production per each man or woman alive.

Jan 1, 1998

By M. J. Virnig, Marc Le Vier, Rong Yu Wan, Jan D. Miller

Although most gold production from primary resources is achieved by cyanidation, many research activities have focused on alternative processes using noncyanide lixiviants. Such research has been prompted by environmental concerns and problems associated with the processing of refractory gold ores. Numerous research projects have been conducted to search for a noncyanide hydrometallurgical process for gold extraction. In this paper, a technical review of gold recovery from noncyanide solutions is presented, and new results are reported. Gold recovery techniques that are considered include activated carbon adsorption, cementation, solvent extraction, ion exchange, and reduction-precipitation.

Jan 1, 1993