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Improving the Sustainability of Primary Metal Production - The Need for a Life Cycle Approach

Sep 13, 2010

By Ralph H. Whaite

The Bureau of Mines program for microfilming maps of abandoned mines in the Pennsylvania anthracite region is described. A catalog of the maps that have been microfilmed in the Eastern Middle anthracite field--the first area to be covered in the program--is presented. Additional catalogs will be published as significant mining areas are completed.

Dec 1, 1964

By Ryan W. Ulansky

This paper presents the conceptual design of a magnetically-levitated skip for use in an underground mine. A skip is used to move rock from an underground mine to its surface processing facility. Conventionally the skip is raised and lowered by cables, similar to an elevator. In a magnetically-levitated skip, the cable is replaced with a linear induction or synchronous motor to provide propulsion and levitation. Removal of the cables in a magnetically-levitated skip provides many advantages over a conventional system including the ability: to negotiate corners, to travel vertically in the shaft as well as horizontally to the mining face, and to move a very large volume of material using multiple skips in a small shaft. A magnetically-levitated skip is a safer, more environmentally-friendly, productive alternative to conventional skipping. It has the further advantage to decrease haulage distances for underground vehicles.

May 1, 2002

By S. Read, G. Cook

The Hoek-Brown failure criterion is often applied to a wider range of rocks than the isotropic rock masses to which it is strictly applicable. This paper evaluates the patterns of defects in rock masses using spherical projection contour plots of samples of randomly-generated orientations and datasets from mapping of New Zealand closely-jointed greywacke rock masses. Two indices from the contour plots - the area within the 1% contour (A1%) and maximum concentration (Cmax) are introduced for distinguishing uniform (isotropic), random or regular defect patterns. The indices provide a potential extension to current guidelines on the use of the Hoek-Brown failure criterion. The paper also outlines kinematic checks to assess the influence of defect clusters on rock mass strength. Das Hoek-Brown Bruchkriterium, das strikte nur fuer isotrope Gefuege gilt, findet oft einen viel weiteren Anwendungsbereich. Diese Arbeit bewertet diverse Dispersionsmuster der Defekte einer Gesteinsmasse. Wir vergleichen in sphaerischer Projektion (1) Beispiele zufaelliger Orientierung von Defekten und (2) Felddaten ueber neuseelaendisache engstaendig geklueftete Grauwacken. Die Projektionen werden durch die Indices A1% (Flaechenanteil des 1%-Bereichs) and Cmax (Hoechstkonzentration) gekennzeichnet, welche isotrope, zufaellige und regulaere Muster unterscheiden und die aktuellen Richtlinien zum Hoek-Brown Kriterium ergaenzen. Wir testen ferner Defektgruppen der Gesteine kinematisch auf ihren Einfluss auf Massenfestigkeit. Le critère de rupture de Hoek-Brown est souvent utilisé sur une variété de roches plus étendue que les masses rocheuses auxquelles il est strictement applicable. Ce travail évalue la distribution des défauts au sein d'une masse rocheuse en utilisant une projection sphérique des contours d'échantillons d'orientations générées aléatoirement et de données de cartographie provenant de greywackes à joints rapprochés de Nouvelle Zélande. Deux indices de cette projection - la zone des contours en dessous de 1 % (A1%) et celle de concentration maximum (Cmax) sont introduites pour distinguer les répartitions uniformes (isotropes), aléatoires ou régulières. Ces indices fournissent une extension potentielle aux règles d'utilisation du critère de rupture de Hoek-Brown. Ce travail utilisent également les contrôles cinématiques pour évaluer l'influence des groupes de défauts sur la résistance de la masse rocheuse.

Jan 1, 2003

By Daudi R. Waryoba

Keywords: Wire Drawing, OFHC Copper, Recrystallization, Orientation imaging Microscopy (OIM), Texture inhomogeneity Textural inhomogeneities have been investigated in oxygen free high conducting (OFHC) copper wire drawn at room temperature to a true strain of 2.31, and isothermally annealed at 250°C and 750°C for annealing times ranging from 10 s to 1 hr. Local orientations were mapped by means of orientation imaging microscopy (OIM). The microtexture of the drawn wires showed a strong <111> + weak <100> duplex fiber texture at the inner core, whereas the mid and surface regions had a comparatively weak texture. Annealing at 250°C resulted into a recrystallization which originated from the mid section, proceed towards the surface regions and ends in the inner core. Recrystallization resulted into a strong<100>+weak<111> duplex fiber texture. A similar textural inhomogeneity was observed during short annealing at 750°C. However, prolonged annealing gave rise to abnormal grain-growth that proceed from the inner core to the outer surfaces with a dominant <111> fiber component at the inner region and mixed components of <111>, <100>, and <112> at the outer surfaces.

Jan 1, 2005

By D. Harrington

Although for many years considerable attention has been given to devising safe and efficient methods of using explosives, with some success, relatively little has been done to provide satisfactory storage facilities for them. This was known long before the present war began, but it was emphasized during the past 30 months? inspections of explosive magazines by employees of the Bureau of Mines in administration of the Federal Explosives Act of December 26, 1941. These inspections have revealed woeful in adequacy as well as definite hazards and the urgent need for obtaining better storage facilities either by remodeling old magazines or constructing ink new ones that would afford suitable protection for the contents against theft, fire, deterioration, and detonation. The purpose of this paper is to offer suggestions and to show by sketches and drawings some of the fundamental features of suitable magazines. Type of construction and available materials differ with different; localities, but the information herein contained can be applied to most magazines, whether already constructed or the construct: on of which is planned. It is hoped that this information will be helpful and will aid persons who are trying to provide suitable storage for explosives end detonators. It is also hoped that States and cities will be made aware of the unbelievable laxity practiced in storing explosives in the United States and will take some remedial action.

Jan 1, 1945

By S. K. Chan, C. Badeen, S. Goldthorp, H. Feng, I. Alilovic, R. Turcotte

Over the last few decades, water-based explosives and their precursors, despite their apparent insensitivity, have been involved in a number of accidents around the world. A large proportion of these accidents occurred when these emulsions were pumped either for their manufacture, transport, or handling. In Canada, this has led to the development of “Guidelines for the Pumping of Water-Based Explosive”, which state that “using pumping pressures well below the laboratory measured minimum burning pressure (MBP) of the corresponding emulsions or watergels is a good safety practice”. However, in the above document, there is no description on how the MBP should be measured. In the last few years, a research program at the Canadian Explosives Research Laboratory (CERL) in collaboration with Orica has been focused on the development of a validated measurement protocol for realistic MBP measurements.

Jan 1, 2014

By R. H. Widmyer, G. M. Wood

This investigation was prompted by the absence of a simple, accurate method to predict optimum second stage separation pressure in three stage separation operations. Three stage separation as used here includes two separators plus the stock tank. The first stage pressure is usually fixed by gas sales conditions and the third stage is at atmospheric pressure. Thus, the second stage pressure is the only one that may be varied in-discriminantly during production operations. No variations in temperature were considered in this study, even though it will vary among systems, for a change in temperature has little effect on the optimum pressure. Optimum pressures may be determined from flash calculations, but these are tedious unless a computer is available. An early attempt to develop a simpler method&apos; yielded an equation which gave the optimum pressure only as a function of initial and final pressure. Experience, however, confirms theoretical relationships which show that composition as well as pressure and temperature must be a factor. This indicates that the basic relationship should be an equation of the form, where P, is second stage pressure, P, is first stage pressure, A is a function of P. (stock-tank pressure) and the system composition, and n is a function of the number of stages and the system composition. Fig. 1 shows the basic variation of P2 with P for a fixed system composition. A series of such figures clearly showed the effect of composition. The peak of each curve reflects that second stage pressure at which the stock-tank recovery (gal/MMcf) residue gas is a maximum value. DEVELOPMENT OF NEW CORRELATION Wellstreams having 17 different analyses, ranging from low gravity crude to condensate, were used to determine the effect of composition. Each wellstream was flashed through three stages to determine the optimum second stage pressure for each first stage pressure. Equilibrium vaporization ratios proposed by Latham and Campbell were used throughout. The heptane plus fraction, for simplicity, was assumed to have the properties of octane. The results were subjected to an empirical analysis in an attempt to develop a correlation- that would be (1) simple, (2) accurate, and (3) eliminate the need for any flash vaporization calculations. This analysis yielded two equations, one for wellstreams having a specific gravity greater than one (air = 1.0) and one for those less than one. For crude streams (specific gravFor condensate (specific gravity < 1.0),

By W. G. Sandell, L. C. Bauerle, K. C. Dean

"INTRODUCTION As a part of the wartime activities of the Bureau of Mines, metallurgical services were extended to other Government agncies engaged in purchasing and stock-piling some of the more critical and strategic materials. At the request of Dr. Alan M. Bateman, special representative of the Metals Reserve Company, metallurgical studies were made on three samples of oxide tin ore from, the States of Zacatecas and Guanajuato, Mexico. The samples were submitted for testing by A. Porraz of the Financiera Miners, S. A., institution Financiera, Edificio Guardiola, Despachos 500-507, Mexico, D. F.The samples as received were marked Nos. 1, 2, and 3 and described as follows:Sample 1. - Origin: Mining camp ""El Naranjo,"" municipality of Sombrerete, State of Zacatecas, Mexico. This sample was partly concentrated by washing and as received was all minus 10-mesh in size.Sample 2. - Origin: Deposits in Sierra. Fria and Juan Cherey, municipality, of Jerez,State of Zacatecas, Mexico. This sample represented run of-mine ore.Sample 3. - Origin: Mine ""La Frontere, "" Ranch of San Pedro del loya, State of Guanajuato, Mexico. This run-of-mine sample was low in tin content but came from a highly mineralized tin field."

Jun 1, 1947

By U. A. Peuker, T. Mütze, F. Shayo, A. Wikedzi

"Buzwagi Gold Mine (BGM) is operated by Acacia Mining and located in the Lake Victoria Goldfields of central Tanzania. The mine treats a sulphide copper-gold ore to produce gold in form of doré bars and a concentrate containing gold, copper and silver. The BGM comminution circuit includes a primary crushing stage with a gyratory crusher and two grinding circuits using a Semi-Autogenous Grinding (SAG) mill and a ball mill. Currently, the grinding circuits are inefficient in achieving the aspired product fineness of xP,80 = 125 µm even at low to normal throughputs (450-600 t/h). An optimization study of the circuit performance was conducted to improve product fineness through circuit surveys, experimental lab work and simulations. The analysis of survey data revealed inefficient grinding operation characterized by ball mill product (xP,80 > 400 µm) coarser than designed and higher hydrocyclone cut sizes (xT > 200 µm), too. In MODSIM several options were simulated such as reduction of vortex finder and apex diameters, reduction of SAG screen aperture, and modification of cyclone feed density. An improvement of product fineness could be achieved by simulation of the cumulative changes but it was also concluded that the current equipment cannot achieve the target. Further simulations showed that a second ball mill might help to achieve the desired fineness as well as an increase of grinding throughput by up to 26 %. INTRODUCTION Simulation of comminution, particularly grinding and classification, has received great attention for many years, due to the fact that the unit operation is by far the most important both in terms of energy consumption as well as overall plant performance (King, 2001; Wills et al., 2006). The use of simulation is advantageous due to low cost as well as its ability to consider many variables simultaneously. Moreover, there are some benefits for optimizing grinding operations by simulation like decreased unit operating costs, increased capacity, and improved performance of downstream processes due to improved feed size distribution. This paper presents an optimization study for the grinding efficiency at Buzwagi Gold Mine. This was achieved through three full scale circuit surveys, lab work and simulations with MODSIM."

Jan 1, 2018

By W. W. Adams

[Sales of explosives - permissible explosives5/ other high explosives, and black blasting powder - in the United States during the calendar year 1937 reached a combined total that slightly exceeded the quantity sold in 1936. A larger output was reported for permissible and other high explosives but a smaller for black powder. Production of the three classes of explosives totaled 404,744,294 pounds, more than 3 percent over 1336. The total quantity produced included 49,579,441 pounds of permissible, 288,924,253 pounds of other high ex- plosives, 36,403,950 pounds of black powder in pellet form, and 23,836,550 pounds of black powder in granular form. Sales of granular black powder declined 26 percent compared with 1936 and of pellet black powder 12 percent; gales of permissible explosives increased nearly 4 percent and of other high explosives 10 percent]

Jan 1, 1938

By François G. Bernardeau

Cement-bentonite (C-B) slurry walls have been used for ground water cutoff in deep excavations, contamination containment, and other applications. Hydraulic conductivity is of great concern for cement-bentonite slurry walls. The quality control program usually specifies permeability and strength tests to be performed in a laboratory on samples cast in the field and cured for a certain time. Currently there is no widely accepted in-situ test method for the performance of the constructed slurry wall. A recently constructed cement-bentonite slurry wall in South Carolina included a 200-foot-long test section done in advance of the production of an 8,300 foot-long wall. Intensive tests and investigation were conducted during and after the test section construction: Monitoring piezometers were installed using wet insertion method and packer tests were conducted in boreholes drilled in the post-28-day-cure slurry wall. The permeability measured from the packer tests was about two orders of magnitude higher than the design and the laboratory test values. Additional investigation was performed using a video camera to inspect the borehole walls especially the packer test sections. Test pits were excavated to observe both sides of the cement-bentonite slurry wall. A thorough inspection was conducted to evaluate the integrity of the wall. The lessons learned and issues regarding the disturbance effects of in-situ testing of cement bentonite slurry walls is presented and discussed.

Jan 1, 2008

By Gordon Revey

Over ten million pounds of explosives are used daily to blast rock in mines, quarries and construction projects throughout the United States. Despite the immense volume of explosives used, serious incidents involving the legal use of explosive materials are rare. Unfortunately, when incidents arise they are well publicized, whereas the great majority of blasting projects-even the most challenging ones—quietly occur without incident or public recognition. Although unfair, media coverage focuses on incidents and/or accidents, and as a result skews the public’s perceptions of our industry. These negative perceptions about blasting profoundly effect our work. Most apparent are the community groups who organize to fight blasting work. However, other impacts are more insidious and have long-term effects on our industry. For instance, planning engineers or government agencies often prohibit blasting to avoid the public’s adverse reaction or because of general fear of blasting impacts. Ironically, as regulations and specifications continue to curtail our industry, the net effect is an increase in the cost of rock excavation. As taxpayers, we suffer needlessly by paying more for government funded construction projects. As blasting professionals we are additionally penalized through loss of work.

Jan 1, 2001

By M. Magnelöv, Du Sichen, U. Sjöström

An experimental study has been performed to investigate the behaviour and separation of inclusions at the interface between steel and slag. The study has been limited to liquid inclusions because they can be a potential problem in transient situations such as ladle changes in continuous casting of steel. Model experiments with water and silicon oils have been carried out to study the kinetics of separation of simulated inclusions at an interface. The properties of the inclusions and the slags have been varied by using different oils with different viscosities, densities and surface tensions. The effect of temperature of the liquids has also been examined. Measurements of the terminal velocity, rest time and the behaviour of the liquid inclusions at the interface have been recorded using a video camera. It has been found that the inclusions reach their terminal velocity early in the vessel and the experimental velocities differ somewhat from the values evaluated using ?intermediate law?. The results from the experiments have shown that the size of the inclusions has no appreciable influence on the rest time. Droplets of AK50 oil have been found to have considerably long rest time. A water film surrounding the droplet has been expected to be the main reason for the long rest time. The present study has also shown that the viscosity of the oil has certain effect on the rest time, but only to some extent, since viscosity has double functions. A higher viscosity provides higher resistance to the droplet entering the oil phase leading to longer rest time and at the same time damps the lateral movement of the droplet along the interface, leading to easier stabilization and shorter rest time. On the other hand, a high viscosity of the oil phase results in slow dissolution process. It has been concluded that a meaningful model of inclusion separation at the metal-slag interface must take the interfacial phenomena into consideration. Keywords: Inclusions, terminal velocity, rest time, dissolution.

Jan 1, 2004

By Stafford McKnight, Larissa Koroznikova, Steve Hall, Cameron Klutke

This paper outlines a simple methodology for mineral characterisation, developed as part of the Australian Mineral Industry Research Association (AMIRA) managed research project P777 ?The Development of Heavy Suspension Techniques for High Density Separations (Replacement of Clerici?s Solution)?. The project was sponsored by De Beers, Rio Tinto and Iluka Resources. Heavy mineral characterisation of samples arising from exploration, mining or metallurgical processes is frequently conducted using laboratory heavy liquid analysis. Unfortunately, there are only a limited number of high density (?heavy?) liquids and these tend to be more toxic as their density increases. Low-toxicity inorganic solutions, based on tungsten compounds, have been developed that can be utilised at relative densities (RD) up to 3.0. Beyond this value organic liquids can be used, however this presents significant health and safety hazards. Diiodomethane (methylene iodide) having a relative density of 3.31 is commonly used. Mixtures of thallium formate and thallium malonate were found in the early 1900?s by Clerici to provide liquids having specific gravities between 4.0 and 5.0. For the characterisation of the heavy components of mineral sand deposits (e.g. anatase RD 3.9, rutile RD 4.2, ilmenite RD 4.4 ? 4.7 and zircon RD 4.6 ? 4.8) there is currently no heavy liquid alternative to Clerici?s solution. Clerici?s solution is highly toxic and testing is now conducted by few laboratories worldwide with costs reflecting the chemical costs, infrastructure costs and health and safety regimes (e.g. blood testing of exposed staff). A simple laboratory technique of density fractionation has been developed, employing suspensions of fine tungsten carbide particles in lithium heteropolytungstates solutions, that can replace Clerici?s solution in the evaluation of fine mineral sands samples (e.g. -250 +150 microns). The developing methodology that can achieve low-cost, low toxic separations at relative densities above 4.0 is outlined and the comparison of results with Clerici?s solution presented. In addition, preliminary work on density fractionation of zircon samples is presented. Zircon fractionation relates to their inclusion, radionuclide content and metamictization.

Jan 1, 2007

By L J. Ingle, K L. McPhee, A G. Hunt

Iron Road Limited (IRD) is currently developing the Central Eyre Iron Project (CEIP) at Warramboo on the Eyre Peninsula, South Australia. The project consists of a 30 year open pit mine, magnetite processing facilities, standard-gauge railway and deep water, Cape class capable port. Major South Australian government approvals have been received and funding arrangements confirmed.The 4.5 Bt Mineral Resource (3.7 Bt Ore Reserve), the largest in Australia and among the largest globally, is to be mined to produce 24 Mt/a high-grade, 67 per cent Fe, magnetite concentrate. This in-demand, premium product has a P80 of ~100 &#181;m, suitable for both direct sinter feed and an additive in pelletising.The extensively drilled, homogeneous orebody is unique in both geology and mineralogy; only averaging 15 per cent Fe yet coarse-grained with almost negligible phosphorus and sulfur content. This has allowed significant opportunities to tailor the mining method to the orebody, utilising both optimised blasting as first stage comminution, as well as in-pit crushing and conveying (IPCC) to reduce the heavy haulage diesel fleet and optimise the pit shell.Approximately 1 Mt/d of total material, ore and waste, is required to be moved from the pit daily, introducing materials handling challenges, overcome by a flexible IPCC set-up, multiple overland conveyors and an exacting mine plan. Non-conventional waste and tailings storage is utilised to allow for significant water savings, progressive rehabilitation and minimisation of land impact.The processing facilities utilise both the magnetic and density properties of the magnetite to beneficiate the ore. The coarse-grained nature of the ore is exploited to minimise comminution yet still liberate a high quality product. Utilisation of modular construction methods allows risk reduction during construction and reduced pumping requirements during operation.This paper highlights the uniqueness of the CEIP, with focus on the mineralisation of the orebody, and the beneficial impacts this has on both the proposed mining method and processing. Magnetite mining is not new and IRD has used the learnings of others, and input from various vendors and industry experts, utilising knowledge and expertise to engineer an innovative, yet supported, project design.CITATION:McPhee, K L, Hunt, A G and Ingle, L J, 2017. The Central Eyre Iron Project – developing a new iron ore mine in a challenging climate, in Proceedings Iron Ore 2017, pp 613–620 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By Aline Maria dos Santos Teixeira

Serpentinite is an ultra basic and metamorphic rock consisting mainly of magnesium, calcium and silicon oxides. The rock under study is a host rock of chromite mine located in Andorinha, BA. The objective of this paper is to evaluate the rock&apos;s physical and chemical characteristics to be used as an additional fertilizer of acid soils. After comminution, rock samples were submitted to chemical analysis, XRD, SEM-EDS and TGA. Afterwards, particle size distribution was determined. Result analysis confirms that our rock consists mainly of dolomite, calcite and diopside. According to the result obtained, it can be said that the serpentinite rock has promising applications in agriculture for the correction and additional fertilization of acid soils. However, it is necessary to study the characteristics of the rock such as its dangers and toxicity as well as evaluate them according to the legislation for corrective acidity.

Jan 1, 2010

By Douglas Bartley, Brian Wingfield, Robert McClure

Recent studies and limited tests indicate favorable results utilizing high accuracy electronic detonator technology over conventional non-electric pyrotechnic systems. This study discusses the application of this technology using the Daveytronic programmable system in an on-going production basis. The study quantifies the performance as it relates to fragmentation, excavation, vibration and productivity in an eastern U.S. aggregate mining operation. In order to insure accurate data, tight field controls were adhered to during the drilling and blasting process as they related to blast design, bench preparation, pattern layout, drilling and blasthole loading. Following the blast the excavation and crushing procedures were studied to quantify any down stream advantages due to improvements in fragmentation. This study will help provide the industry with information as to the advantages of high accuracy electronic blasting systems over conventional pyrotechnic systems and show the results of an operation utilizing electronic detonator technology through their production season.

Jan 1, 2000

By L. Alan Weakly

Global warming is a political reality in the United States today. The actual impact of the continued utilization of fossil fuels is not known and is open to debate. However, the growing concern about the continued use of these fuels is problematic. There are technologies available to us today that would permit America to meet its future energy demand and not contribute to global warming. The inconvenient reality is that fossil fuels cannot completely be replaced with energy conservation and the use of wind, solar, hydroelectric, geothermal and nuclear energy. The connection between the greenhouse effect and global climate change was first identified by physicist John Tyndall in the 1860s. To prove the greenhouse hypothesis, Roger Revelle and his research team started measuring carbon dioxide concentrations in the earth?s atmosphere in the early 1960s (Becker, 2007). With the rising concern about global warming, scientists throughout the world have been obtaining surface and air temperature data. Scientists have also been comparing CO2 concentrations found in glaciers throughout the world with theorized annual temperatures. Data for both dates back 1,000 years. Armed with this data, many nations of the world and the United Nations Intergovernmental Panel on Climate Change (IPCC) have concluded that climate change is a reality. The IPCC also concluded that this climate change is the result of mankind?s consumption of fossil fuels and that catastrophic consequences will occur on a

Jan 1, 2008

By David J. Hoadley

This report describes the development and underground operation of a semi-automatic, raise climber, Man and Supply Hoist System designed for stope access in underground metal and nonmetal mines. Demonstrated capabilities of the system include a 4000-lb payload capacity, control from the traveling cage and from up to five remote stations, operating in vertical or inclined raises 5 ft in diameter and up to 300 ft in length and a travel speed of 50 ft/min. The &apos;system has the capability of operating in crooked raises because the conveyance climbs two stationary wire ropes suspended down the raise. The drive unit is electrically powered with power and control signals supplied to the drive unit through an armored cable also suspended down the raise. The system has been designed for portability, ease of installation and minimum raise development. The system can be installed by two men in five shifts. The hoist has been demonstrated successfully in two underground applications. The first demonstration was in a 5-ft diam, 60 deg inclined raise over a 2-month period. The second demonstration utilized a vertical 5-ft diam borehole to access a blast-hole stoping area. The system successfully provided two shift-a-day service over a 7-month duration demonstration. This report provides a detailed description of the hoist design and its demonstrated performance in two mine applications.

Jan 1, 1981