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By L. R. Verney

A number of interrelated factors influence the economics of the sulphide smelting of copper, lead, zinc and nickel. This paper discusses these factors, mainly from a US point of view, and shows how they affect the cost of construction and operation of new and existing plants. The paper shows how metallurgical plant construction costs and the consumer price index have increased at a much faster rate than metal prices thereby making some metal mining and production operations within the USA, Canada and the EEC less profitable than operations elsewhere. This in turn inhibits new "grass roots" metallurgical developments. It is explained how retrofit of existing pyrometallurgical plants can be a more viable development than the construction of "green field" plants, especially if such retrofit improves, energy efficiencies, overall operating costs and reduces emissions of sulphur and other toxic wastes. Some aspects of metallurgical plant operation are examined, especially for copper and nickel, to show how changes in operating practices may develop in order to improve overall smelting economies, especially when developed in conjunction with objective retrofit. The paper also examines some financial aspects, especially insofar as the disparity between terms for loans offered to third world countries and the USA and the EEC are concerned and also comments upon the need, especially within the USA, for legislation to permit rapid depreciation of capital. Specific comments are made about environmental aspects, including the lack of uniformity of pollution control legislation and how environmental considerations may have some bearing of the location of future smelting operations.

Jan 1, 1983

By R. M. Cooper, H. K. Herbert, D. N. Phillips

A study was carried out to determine the effects of adding CaCO3, Fe, Al and CaSi2 to the ladle, rather than to the raw materials, in order to increase the concentration of Ca, Fe and Al in the final product to meet customer specifications at Simcoa's Kemerton plant in Western Australia. LA-ICP-MS, SEM-EDXRA and ICP-AES analysis of samples and controls showed that the technique is suitable for controlling minor element concentrations. Iron was successfully added, while calcium silicide with aluminium proved better than limestone with aluminium for controlling Ca and Al concentrations in the silicon

Jun 19, 1905

By Paul Staples, Chris Morley

"The development of the Cerro Verde, Amplats Mogalakwena and Boddington projects over the last few years has helped to establish the use of high pressure grinding rolls (HPGR) in comminution circuit designs in large-scale hard-rock applications. The increasing acceptance of this innovative and sometimes controversial technology has had the natural effect of prompting many other new projects to examine HPGR as an alternative to the established, usually SAG-based, comminution circuit design approach.At the current stage of development of the technology, HPGR-based circuit capital costs are generally higher than for the equivalent SAG-based circuit, so that HPGR must offer sufficient operating cost benefits to offset the additional capital costs over an acceptable pay-back period. It is usually necessary to undertake comprehensive project-specific trade-off studies to quantify this effect.This paper describes the processes involved in the execution of a typical SAG-HPGR trade-off study, from the preliminary assessment of ore characteristics and project criteria, through testwork, circuit modelling, equipment selection and cost estimates, to a project-economics comparative assessment of the options. The trade-off study determines both the technical feasibility of the respective technologies and their commercial viability in the given project setting.The paper concludes with a cautionary note to the effect that, while HPGR has many potential benefits, it is not a panacea, and that, for some ore types and project conditions, the more established conventional technologies are often more appropriate."

Jan 1, 2010

By Paul N. Freeman

This paper describes the in-situ performance of two IFS powered support installations at Betws and Penallta Collieries in the South Wales Coalfield, United Kingdom. Intensive monitoring of all powered support functions, strata movement, support/strata interaction and coal seam disturbance permitted an extensive evaluation of powered support performance for all periods of the mining cycle. The influence of support design, support rating, face design, proximate strata and scam section upon support and operating performance are discussed. In-situ performance is compared to design specification and to the requirements of Production Instruction 1982/6. Aspects which show significant variation are highlighted. Particular attention is drawn to the precise analysis of support/strata interaction in the form of canopy and base loading profiles. This illustrates the influence of support rating and configuration in determining the interaction of the canopy and base with the proximate strata. Extensometric monitoring of the coalface highlights the potential zones of disturbance within the seam which allied with support position monitoring provides an accurate basis for theoretical considerations of support loading. Conclusions are drawn, the application of which may enhance the performance and operation of IFS supports in thin to medium sections.

Jan 1, 1992

By Raymond J. Pichette

"Aeromagnetic data can be useful in helping to delineate structures and rock types in gold exploration. Magnetic anomalies associated with Archean volcanic belts in northeastern Ontario can be quickly and effectively analyzed in profile form with the use of model curves. The model curves help to locate contacts between strata. They also help to estimate the magnetite content of the rocks and their depth beneath overburden.An aeromagnetic map of part of Catharine Township, Ontario has been analyzed with the aid of model curves. Several magnetic rock types, potential fault zones and areas of relatively thick overburden were delineated.IntroductionIn any exploration program, a good understanding of the stratigraphy, rock types and structure enhances the possibility of success. For example, environments which host gold deposits in the Abitibi Volcanic Belt may be characterized as follows (Jensen, 1980; Pyke, 1980):(I) They have major faults, especially as tectonic boundaries between volcanic piles which include mafic and ultramafic rocks and clastic sedimentary rocks or gneisses.(2) They have subvolcanic felsic intrusions.(3) They have extensive carbonitization, with or without carbonate and sulphide-facies iron formation.In all cases, delineation of structure and rock type should be a major objective in exploration. The analysis of magnetic data can be a useful tool in this task. This paper is presented with the purpose of describing the application of the magnetic method to gold exploration in Archean volcanic terrains.Magnetic AnalysisTotal-intensity magnetic contour maps can be used to discriminate rock units according to differences in magnetization. However, because of smoothing of texture resulting from the compilation procedure and the fact that survey lines are widely spaced, contours should not be directly used for quantitative analysis. A much more definitive means of magnetic analysis is provided by the use of the original profile or chart recordings. Model curves provide a basis for analyzing these profiles both accurately and rapidly."

Jan 1, 1982

By Terry R. Guilinger

A minitest of the new potassium chloride-potassium carbonate two-stage in situ uranium leach process has been carried out at the Intercontinental Energy Corporation (IEC) Zamzow project site in South Texas. Substantial quantities of high concentration uranium were produced indicating the viability of the leach solution. The test results yield information regarding the reservoir dispersivity, the average cation-exchange capacity of the formation, and the distribution coefficients describing carion-exchange reactions. The test a1 so indicates permeability anisotropy and the existence of disturbed flow fields. The research was partially funded by the U.S. Bureau of Mines.

Jan 1, 1984

By M. P. Valoski

Mine fires and/or explosions continue to occur. While these are unusual events, they comprise emergency situations. Whenever one of these events occurs, the Mine Safety and Health Administration (MSHA) responds with specially trained teams, mine fire experts, sophisticated scientific instrumentation, and trained instrument operators. In order to analyze mine air samples on-site, because time is of the essence, MSHA has a Mobile Gas Laboratory. The laboratory, which is stored near Pittsburgh, is totally self-contained. Sending air samples to a laboratory would take too long. Mine fire experts need the results of the latest analyses as soon as they are finished. The mobile laboratory is housed in the box of a diesel truck. Benches line both sides of the laboratory. Gas chromatographs are mounted on the benches. There is sufficient bench space for multiple bench top gas chromatographs. These instruments and their controllers are shock and vibration isolated to protect them during transit. The mobile laboratory can operate using on board diesel generators or line power. An uninterrupted power supply (UPS) supplies power to the instruments while switching from generator to line power or visa versa. Therefore, analysis of samples can proceed without interruption if a power failure would occur. In the rear of the mobile laboratory are racks that hold compressed gas cylinders. These cylinders contain carrier gas and compressed air. An air compressor is housed under the laboratory to operate the gas chromatograph actuators. Within several hours after arriving at a mine the instruments have stabilized and have been calibrated. The mobile laboratory is ready to begin analyzing air samples. The mobile laboratory has proved itself at many mine fires and explosions since its purchase.

Jan 1, 2009

By Jesús E. Gómez

This work is a continuation of a paper presented in the 32nd DFI Annual Conference, Colorado 2007, titled ?Hollow Core Bar Micropiles - Design parameters interpreted from 260 load tests.? The first paper presented the results of the verification and proof tests performed for the retrofit of two bridges with hollow core bars that used 260 micropiles. It included an interpretation of the unit bond values in the different soils where micropiles were installed. Recently two additional bridges within the same geological environment were also retrofitted using 144 hollow core micropiles. This paper includes the interpretation of the additional data from the proof tests performed and refines recommended values for design of hollow core bar micropiles in soils similar to those encountered in these two projects. The authors believe that the data collected will significantly add to the relatively small existing database on micropile tests and may also be useful during implementation of the LRFD design methodology.

Jan 1, 2008

The Archaeozoic Willyama Complex at Broken Hill has suffered several periods of deformation and metamorphism. New structural and petrological information together with that available from the literature gives a picture of the metamorphic evolution of the Barrier Ranges. Several epochs of metamorphism are recognized, and potassium-argon dating of minerals has been applied with limited success to the resolution of these epochs.INTRODUCTIONAdvancements in the mineral industry at Broken Hill over the past eighty years have been accompanied by a continual striving towards increased understanding of both the geological history of the Barrier Ranges and the environment of the Broken Hill ore deposits. However, although many detailed studies of selected localities and particular-aspects of Broken Hill geology have been carried out recently, the regional geology of the Barrier Ranges as a whole has received little attention from a petrological viewpoint since the pioneer investigations of Mawson (1912) and Browne (1922). There still remains a great need for regional surveys combining field studies of the habits, structures and outcrop relationships of the various rock types with laboratory investigations of their chemistry, mineralogy and microscopic ,fabrics. Recording observations arising from three brief visits to the Broken Hill area during 1959 and 1963 may stimulate further surveys.During one of these visits, the generosity of the Zinc Corporation Limited in providing field transport and geological guidance enabled the writer to collect material and study field relationships and appearance of the various rock types at numerous localities covering most of the Willyama outcrop. A complete study has not been conducted...

Jan 1, 1963

By François Robichaud

"The Laronde mill has been in operation since 1988. Actual milling rate ranges from 7,000 to 8,500 mtpd. Laronde uses SAG/ball mill grinding followed by copper and zinc flotation circuits. A cyanidation/Merrill-Crowe process recovers the remaining gold and silver in the flotation tails.In 1999, the carbon in pulp circuit was replaced by a Merrill-Crowe circuit in order to cope with a much higher ratio of silver/gold associated with the discovery of the Penna shaft. Marine type diatomaceous earth was used as filter aid in both clarifier pressure leaf filters and recessed pressure filter presses from 1999 to 2005. In 2005, this filter aid was gradually replaced by alpha-cellulose after several laboratory and plant filtration trials. The selected cellulose is considered to be much less sensitive to parameters such as pH and reagent concentration and have increased clarifier and filter press filtration performance. Also, since cellulose is exothermic, replacing diatomaceous earth with cellulose as filter aid in the filter presses has increased calcining and oxidation rates in the calcining ovens since cellulose is exothermic. Finally, better calcining conditions have resulted in energy and reagent savings at the arc furnaces.This paper describes how the filter aid replacement has contributed to increasing productivity and Net Smelter Return of the refinery while reducing worker’s hazards and operating cost.INTRODUCTIONAll Merrill-Crowe circuits in the world are operated with filter aids. For years, the market for precoat filter aid has been dominated by mineral filter aids such as diatomite and perlite. Flowsheet and equipment selection at the Laronde refinery were performed in the late nineties. At that time, some key parameters of the design criteria had clearly identified marine type diatomaceous earth (DE) as the most successful filter aid. Parameters such as reagent cost and availability, clarity of the filtrate solution and good historical filtration performance in other concentrators had designated DE as the best suited filter aid. Pregnant solution processed in the refinery from its start-up through 2001 was fairly stable in flow rate and reasonable in terms of impurity content (cationic and anionic compounds)."

Jan 1, 2007

By D. F. Cooper, J. G. Paterson, K. H. Pang

"Effective control of metallurgy by manual adjustment of cell levels is common flotation practice. With an on-stream XRF analyzer interfaced to a process control computer it is possible to program the computer to carry out this function automatically. This paper describes the development and implementation of closed loop control of the concentrate and tailing grades at the Clarabelle Mill of the International Nickel Company of Canada, Limited, The XRF analyzer was used as the sensor, cell level as the control and the computer as the controller.IntroductionThe International Nickel Company of Canada, Limited recently brought on-stream Clarabelle Mill having a rated capacity of 35,000 tons per day. The plant was required to increase milling capacity in the Sudbury area by 9,000 tons per day and to improve milling efficiencies by replacing the obsolete crushing and grinding equipment at the Copper Cliff Mill. This represents the fourth mill built since 1959 and incorporates the latest thinking in a continuing evolution of instrumentation and control concepts. Table 1 illustrates control progress at Inco since 1959.In 1967 Frood-Stobie Mill came on-stream incorporating a central control room, an on-stream analyzer, a data gathering computer, and a significant change in instrumentation from direct-contacted pneumatic to miniature electronic. The computer successfully controls the analyzer but has very limited process control capability. Based on this experience a process control computer system was installed at Clarabelle Mill with the objective of carrying out extensive supervisory control and a limited amount of direct digital control."

Jan 1, 1973

By P. A. Cox

The purpose of the initial research performed under this contract was to determine the margins of safety in explosion-proof (XP) enclosures, which were designed and certified according to the current schedule (Schedule 2G). Results from this work provide baseline data on the current schedule, from which a new schedule can be formulated to give equal or greater levels of safety. Results and discoveries in the initial work led to an expansion of the contract to cover, additionally, weld quality in enclosure fabrication, reliability of enclosures with windows and lenses, and performance tests for enclosure qualification. Finite element calculations and hydrostatic tests revealed wide variations in the margins of safety in the enclosures studied; however, only one enclosure had a safety factor which was less than one. Results from a weld quality survey led to the recommendation of AWS Welding Standard D14.4 for the fabrication of XP enclosures. Based on other work, accelerated aging tests were recommended for qualifying plastics and adhesives that are used in some enclosures, and a Structural Performance Test was developed to test enclosure strength for a minimum static pressure of 150 psig.

Jan 1, 1982

By S. H. Ash

THE BARRIER-PILLAR SYSTEM in the Lackawanna Basin consists of 93 barrier pillars between Archbald and Taylor, Pa. These pillars affect 48 mines, have a total length of 87 miles, and confine 21 underground pools, which contain more than 10 billion gallons of water. From an investigation of size, position, and condition of the barrier pillars, it is apparent that those concerned are uncertain, not only as to the method by which the sizes of the barrier pillars were determined but also as to the stability of those that may be expected to act as dams. Where a barrier pillar must act as a dam, its failure may result in loss of life, the mine, or both; it would be far better had it not existed and thereby given a false sense of security.

Jan 1, 1952

By Xiaofei Guan, Adam C. Powell, Uday B. Pal, Srikanth Gopalan

This paper reports a solid oxide membrane (SOM) electrolysis experiment using an LSM– Inconel inert anode current collector for production of Mg and O2 at 1423K. The electrochemical performance of the SOM cell was evaluated by using various electrochemical techniques including electrochemical impedance spectroscopy, potentiodynamic scans, and potentiostatic electrolysis. The effects of Mg solubility in the flux on the current efficiency and the YSZ membrane stability during SOM electrolysis were discussed and examined through experiment and modeling. The electronic transference number of the flux were measured to assess the Mg dissolution in the flux during SOM electrolysis. A negative correlation between the electronic transference number of the flux and the current efficiency of the SOM electrolysis was observed.

Jan 1, 2014

By H. Demirel

This paper deals with concentration of hematitic-limonitic iron ores. The ore sample obtained from Karakuz (Turkey) contain:. about 40-46 I Fe. First, a low intensity magnetic separation process was employed to separate the strongly magnetic particles cf "-10+2 mm" and "-2+0.075 mm" size fractions and magnetic concentrates with 59.1 % Fe aid % 58.0 Fe were obtained respectively. The non-magnetics of both fractions were then fed to a nigh intensity permanent magnetic separator. The Fe contents of "-10+2 nun" and "2+0.075 mm" size fractions were increased from 28.2 to 51.13 and from 35.4 7. to 43.25 respectively after single pass. Easing on these results, it was concluded that the high intensity permanent magnetic separator could he used as a pre-concentrator f.7.1- hematitic-limonitic Karakuz iron ore.

Jan 1, 1991

By Others, C. M. Weld

During the past two years the Bureau of Mines has issued a series of mimeographed reports giving the results of research work and experiments conducted as part of its war minerals investigations. In this bulletin the reports on manganese are presented, which range in scope from the beneficiation of the ore to the utilization of the metal. The bulletin is in eleven chapters, each comprising a separate report, arranged in the order given below. 1. General information regarding manganese, by C. M. Weld. 2. Uses of manganese other than in steel making, by W. C. Phalen. 3. Problems involved in the concentration and utilization of domestic low-grade manganese ores, by Edmund Newton. 4. Preparation of manganese ore, by W. R. Crane. 5. Leaching of manganese ores with sulphur dioxide, by C. E. Van Barneveld. 6. The Jones process for concentrating manganese ores; results of laboratory investigations, by Peter Christianson and W. H. Hunter. 7. Cost of producing ferromanganese ores, by C. M. Weld and W. R. Crane. 8. Production of manganese alloys in the blast furnace, by P. H. Royster. 9. National importance of allocating low-ash coke to the man- ganese-alloy furnaces, by P. H. Royster. 10. Electric smelting of domestic manganese ores, by H. W. Gillett and C. E. Williams. 11. Use of manganese alloys in open-hearth steel practice, by Samuel L. Hoyt. As each chapter was originally prepared as a unit, there is neces- sarily some duplication and overlapping. With certain exceptions, however, each paper is reproduced in practically its original form. In chapter 1, covering certain general phases of the industry, such as uses, specifications, prices, and statistics, the subject matter has been somewhat modified in view of changes in conditions.About 95 per cent of the manganese consumed in the United States goes into the manufacture of steel. The remaining 5 per cent is used in a number of minor industries, the chief of which is the manufacture of dry cells. These minor uses are described in chapter 2. No discussion of the geology of manganese eres is presented, but a short bibliography on the subject is appended. With few excep- tions the manganese deposits of the United States are irregular, pockety, and uncertain. Largely for this reason, mining methods are crude and hardly warrant descriptions. The concentration of manganese ores, however, is an important problem and involves some details not common to other ores. Chapter 3 discusses the concentration and utilization of low-grade ones, notes the relationship of concentration to metallurgical prao- tices, outlines concentrating processes, and treats of commercial problems. In general, as regards concentration methods, manganese ores may be divided into two groups, as follows: (1) Ores permitting mechanical separation of the manganese minerals and the gangue, and (2) ores in which the manganese minerals and the gangues are so intimately associated that separation requires some hydrometal- lurgical or pyrometallurgical process. Heretofore, attention has been confined almost wholly to mechanical separation, chiefly by gravity. In fact, so far as known, all production of concentrates has been by wet gravity methods, although during the war some companies investigated the commercial pessibilities of magnetic separation and reported favorable results, the construction of one magnetic con- centration mill being started. The usual wet gravity methods are described in chapter 4. During the war, the Bureau of Mines undertook investigations of methods applicable to ores of group 2. A hydrometallurgical process involving leaching with sulphur dioxide was studied at the mining experiment station of the bureau at Tucson, Ariz. The results of this work, presented in chapter 5, indicate that the process is metallurgically feasible but the cost makes it unattractive. The results of an investigation of a pyrometallurgical process known as the Jones process are presented in chapter 6. The process, which is still in the experimental stage, was found to be metal- lurgically sound. The manganese product is not a concentrate but an alloy, made directly from a lean unconcentrated ore. The custom- ary method is to manufacture alloys from high-grade ores or from concentrates of leaner ores. A discussion of the costs of ferro-grade manganese ores is pre- sented in chapter 7. This discussion is in general terms only, but should be of use in so far as it relates to competitive conditions.

Jan 1, 1920

By Franklin M. Grynkewicz

The subject of bearing pile performance installed by vibratory hammers has been a matter of increasing study and continued controversy. A recent case study from a major bridge replacement project is discussed which provides encouraging data on the use of vibratory pile hammers as a primary means of pile installation and also presents the problems associated with its general acceptance. The bridge project case study foundations consisted of HP 14 x 89 pile sections, designed to develop capacity primarily in friction. Preliminary tip elevations were determined by traditional static analyses. Production pile installation was performed using an IHC S-70 Hydro-Hammer. Driving criteria and final production pile tip elevations were determined after preliminary indicator pile drive tests and static load test results at bridge pier cofferdam locations. Based on impact driven production pile performance, the Contractor wished to investigate vibratory driven piles as a means to accelerate construction schedule. Dynamic pile testing procedures were used as the primary measurement tool and test results were compared to the production pile drive records and prior static load tests. Field testing consisted of driving and monitoring with the PDA impact driven piles to the design tip elevation. Three vibratory driven piles were installed to the same tip elevation and immediately subjected to impact driving and dynamic testing to compare dynamic pile resistance. The results indicated that the site soil conditions were favorable for vibratory pile hammer installation. Recommendations and procedures for proceeding with vibratory hammer pile installation were presented to the Owner. These procedures included quality control in conformance with latest AASHTO recommendations. The Owner, in spite of the site specific data base and QA/QC procedures, would not accept vibratory pile hammer installation, due to the absence of precedence. It is concluded that for vibratory methods to become accepted a rational method of analysis, design and field QA/QC procedures requires development. In addition, the engineering community and Owners/Agencies must be more open to alternate methods of foundation construction. The continued development of dynamic methods of monitoring vibratory pile installation is considered to be key to the general acceptance of this installation procedure.

Jan 1, 1991

By Lennart Mukka

The Kiruna Mine in Sweden currently has three ventilation systems. The first two (a new and old system) serve the production areas. The third system is used for the facilities on the former main haulage level 775. That area includes offices and workshops for load haul dumpers (LHD) and drill rigs. The third ventilation system also covers the crushing and haulage on level 1045. At the present time, the total airflow for the mine is 1,600 m3/sec(3.4 million cfm). The current system serves the levels above the 775 level. The new one is for the levels between 775 and 1,085 m (2,540 and 3,560 ft), which are needed for the new ore body. When all of the production is below level 775, the old ventilation system will be closed down.

Jan 1, 2002

Mine waste and mine reclamation are topics of major interest to the mining industry, the government and the general public. This publication and its companion volume are the proceedings of a conference held in Pittsburgh, April 19-21, 1988. There were nine sessions (50 papers) that dealt with the geochemistry, hydrology and problems of mine waste and mine water, especially acid mine drainage. These comprise Volume 1. The nine sessions (43 papers) that dealt with reclamation and restoration of disturbed lands, as well as related policy issues, are included in volume 2. Volume 2 also contains the ten papers that pertained to control of subsidence and mine fires at abandoned mines. Poster session presentations are, in general, represented by abstracts; these have been placed in the back of both volumes.

Jan 1, 1988

By C. A. Johnson, K. F. Unrug

The identification of the major subsidence areas in the Eastern Kentucky Coal Field has been made to distinguish the subsidence phenomena on the basis of geographical location. Further, this identification process is based upon selected critical geological, topographical, and mining features in the coal fields. The proposed identification of the regions is derived from a comparison of the subsidence potential in a particular area. The most likely severe subsidence areas are compared to those with the probable low subsidence severity. The combination of certain geological and mining parameters involved allows for the derivation of a classification of the subsidence potential.

Jan 1, 1986