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By Volkmar Niemitz

Approximately 30 miles east of Chicago on the southern shores of Lake Michigan stands Bethlehem Steel's newest fully integrated steelmaking facility - the billion dollar Burns Harbor plant. The initial phase of "green field" construction that began in 1963 was directed to the creation of high quality finishing facilities. In late 1964 the 160" plate mill came "on stream" followed closely by Sheet and Tin and Hot Strip facilities. Unit train shipments of slabs primarily from the Lackawanna plant located near Buffalo constituted the input materials for the new mills. In 1967 a hot metal facilities program was announced for Burns Harbor that at its completion would make the plant fully integrated. Incorporated within the program were: 1. A new high performance 50" x 96" slabbing mill complete with a battery of soaking pits. 2. A two vessel Basic Oxygen Furnace Shop. 3. (1) battery of 6 meter high Coke Ovens with attendant coal handling facilities. 4. A 3800 feet long vessel loading & unloading dock. 5. The first conveyor belt fed Blast Furnace in the United States. 6. An extensive materials handling system for receiving, stocking and reclaiming from storage the raw materials for the Blast Furnace and Coke Ovens operation. The intent of this paper is to provide a detailed description of the functions and components of the materials handling system noted above.

Jan 1, 1970

By C. E. Capes

The continuous balling? operation whereby a moist particulate mass is tumbled in a horizontal revolving drum with recirculation of the undersize product can be extremely unstable. Product and recycle rates are subject to wide fluctuations. Although the problem seems to be well-recognized, there is little published information or quantitative data readily available, especially in relation to industrial-scale circuits. Probably the best available published results are in the Russian literature, an illustration of which is given in Figure 1. These data, taken from a study') of some of the factors which influence the stabilization of the pelletizing process, illustrate the wide variations in circulating load and circuit productivity which may be encountered over a period of operation. The problems of balling circuit stability may be traced to random seed or nuclei generation and uncontrolled agglomerate growth. The situation is analogous to that in crystallization processes where (4 considerable attention is given to nucleation control. Traditionally attempts have been made to optimize system and operating variables to stabilize the balling process. A supplemental approach which is taken here is to build on the considerable

Jan 1, 1975

By H. C. Juvkam-Wold

The design of an aquifer depressurization system is discussed. The system uses a number of wells surrounding a mine shaft to reduce the aquifer pressure in the vicinity of the shaft. The effect of various parameters such as number of wells, wellbore diameter, time and well location is discussed. It is concluded that, with a properly designed depressurization system, the aquifer pressure and the water inflow rate to the shaft may be reduced to less than 15X of their potential values in the absence of wells

Jan 1, 1980

By Thomas W. Turk

The water treatment industry has historically been involved with reducing or inhibiting the inherant scale forming or fouling tendencies of natural waters associated with large industrial cooling water systems. Fouling is an extremely complex phenomenon. From a fundamental point of view, it may be characterized as a combined momentum, heat, and mass transfer problem. Chemical reaction kinetics is involved, as well as the solubility characteristics of salts in water and corrosion technology. It is a routine practice to over size pumps, piping and heat exchangers to compensate for fouling.

Jan 1, 1983

By W. W. Kephart

The glass container industry is the largest producer of glass in the United States. As of this writing, there are approximately 89 active domestic production locations. In 1984, the industry shipped 11.8 million tons of glass containers. Approximately 70% of this production was clear or flint glass, 20% amber, 7% green, and the remainder miscellaneous colors. Although the production of nearly 12 million tons of glass is impressive, anyone following the industry over the last five years is aware that the industry has changed from a pattern of growth in the 1970's to one of maturity in the 1980's. Some observers, less generous, perhaps, have described the 1980's as a period of decline. In 1981, there were 119 production facilities which produced 13.2 million tons of glass the previous year. This equates to a 10% reduction in glass container production from 1980 to 1984, with a corresponding impact on the segment of the industrial minerals producers serving the container glass industry, as shown in Figures 1 and 2.

Jan 1, 1986

By Christian F. Baiz

A new agenda has risen. Born out of governments' policies and world economies, the years ahead will carry with them reduced growth. For inflation dependent and capital intensive industries, such as metals and mining, as well as most other natural resource industries, a period of long-term contraction in outmoded and costly capacity will evolve. This will be supplanted by new, lower cost capacity in some cases, but only if the total cost of production, including cash operating and debt service costs comes in at or below current market conditions. The industrial outlook can be characterized as bearish. As one major U.S. bank economist put it, mining companies planning their five-year forecast from 1984 out, should take the current market conditions and straight-line them to the end of the decade. With low growth and low inflation, the real price of metals will remain flat or slightly declining. As a result, capital funding will be problematic. The low cost producer, that is one with low cash costs and low principal and interest costs per unit of production, will succeed.

Jan 1, 1984

By Robert A. Pimentel

Dust is still a major problem in increasing production from longwall faces. Over the last decade, significant improvements have been made in the development of techniques for reducing dust exposure on conventional and continuous sections. But virtually no improvements have been made in dust control on longwall sections. It is true, that there are many more continuous mining sections than longwall sections in the United States and that the number of workers overexposed on continuous miner sections is much larger than the number on longwall sections. However, the problem on continuous miner sections appears much easier to solve and, in fact, we believe that the techniques are available to get virtually all continuous miner sections in compliance. The problems on longwall sections are much more elusive. Also, the number of longwall sections in the United States is expected to increase during the 1980's. Thus, dust control on longwall sections remains a formidable and important problem. Companies operating longwall sections with a dust problem are faced with the tasks of having to quantify the various dust sources, of selecting proper techniques to reduce the problem, of implementing the techniques and of evaluating their effectiveness.

Jan 1, 1983

By B. G. Kelley

The MIDREX® Direct Reduction Process was developed during the 1960s by the Midland-Ross Corporation, which had pioneered shaft furnace technology and stoichiometric gas reforming for use in processing minerals. In 1969, the first MIDREX® Direct Reduction Plant was built in Portland, OR. Since then, 49 additional modules have been sold in 18 countries. For the last ten years, over 60 percent of the world's direct reduced iron has been produced in MIDREX Plants. During the quarter century since commercialization, many technical improvements have been made, including larger shaft furnaces, in-situ reforming, greater heat recovery, improved catalysts, and hot briquetting. Midrex continues to enhance the technology in the areas of economy-of-scale, energy efficiency, alternate fuels, and raw material flexibility.

Jan 1, 1998

By Richard J. Fantel

This paper addresses the impact of declining world rutile resources upon the production of titanium products and their asso¬ciated costs. Titanium is used primarily for the production of pigments; in its metal form it is considered a strategic and critical material to the U.S. defense and aerospace industries. There are two major mineral sources for titanium: ilmenite and rutile. Both these mineral types can be used to produce titanium pigments. Only high grade titanium concentrates, such as rutile, high-grade ilmenite, and synthetic rutile (which is produced through further processing of ilmenite), can be used in the production of titanium metal. This paper draws upon the data and analyses of a recent Bureau of Mines Minerals Availability Program appraisal that evaluated the international availability of titanium from market economy countries. The paper will show that production from economic rutile mines will decline sometime after the turn of the century and that rutile shortages could be alleviated by production from other high-grade titanium resources such as higher cost rutile deposits and anatase deposits, or through an increase in world synthetic rutile capacity.

Jan 1, 1984

By Wayne C. Smith

Both water pollution and proposed solid waste disposal regulations have a definite effect on the copper leaching industry and some of the major factors affecting the industry are discussed in this paper. New developments of the NDPS are discussed with emphasis on the "toxic" or priority pollutants and EPA's philosophy on the control of these pollutants, The protection of groundwater is the prime aim of RCRA through solid/hazardous waste management. Some of the major elements of the RCA regulations that will affect the copper leaching industry are discussed.

Jan 1, 1980

By Madan M. Singh

Although roof bolting has been a major means of strata support for nearly two decades, little attention has been directed towards the design of bolt Installations. The variables involved are interdependent and their study complex. However, some simple tests may be employed to serve as guides to the efficient design of roof bolt systems. Local conditions are continually varying and are important to pattern design. This paper discusses such considerations and suggests techniques which may be employed to effect improved roof control with bolts.

Jan 1, 1967

By Frank H. Buchella

Principal factors influencing equipment selection can be grouped into five basic categories. Tonnage Requirements, Ore and Waste Loading, transporting, and ground preparation equipment are largely determined by tonnage requirements. Generally, the greater the tonnage requirements, the larger the equipment size selected. Large size equipment is appropriate for a production of about six million tons (total) per month, medium size for three mil- lion tons, and small size for one million tons or less.

Jan 1, 1973

By C. H. Cheh

The amount of fines in run-of-mine coal has been increasing and coal quality has been deteriorating as a result of the increased use of mechanized and continuous mining methods. Removing the mineral matter and pyritic sulfur from coal prior to combustion will lower transportation costs, improve power plant performance and reduce sulfur dioxide emissions. Since physical cleaning methods can only remove individual particles of mineral matter and pyrite, it is necessary to crush and grind coal to fine sizes to separate these contaminants so they can be removed by deep cleaning processes. The increased portion of fines in run-of-mine coal together with attempts to increase the mineral matter removal efficiency have stimulated interest in fine coal cleaning technology. However, there are many problems to be solved before fine coal cleaning can be applied to power plant coals. These problems include: 1. coal cleaning plant capacity is reduced when conventional cleaning circuits are modifies to deep clean coals; 2. existing equipment and technology is not suitable for cleaning fine coal; 3. coal recovery is reduced; and 4. fine coal is difficult to dewater, dry, handle, transport and store.

Jan 1, 1982

By Robert M. Abrams

The passage of an ore pulp through the froth flotation process results in the production, after dewatering, of a finely divided concentrate. This intermediate product Trust be handled to the subsequent process facilities via belt or other types of conveyors, hoppers, bins, chutes and feeders, and the like, Flotation concentrate has some difficult handling properties such as abrasiveness, sluggishness when moist, or fluidity when dry, These characteristics require the judicious selection or design of handling, equipment and the careful engineering of transfer chutes. It is to the special problems which are encountered in this in-plant handling procedure that this paper is addressed. The methods which will be discussed have beer. developed primarily for the handling of the froth flotation concentrates of copper, leap, and taconite iron ores, but may be generalized, with appropriate modifications, to apply to other similar metallic concentrate&. The controlled feeding of concentrates frog: bins and hoppers is covered alone with some of the techniques used to transfer concentrates from ore belt conveyor to another. Methods are described for unloading belt conveyors into bins or storage tiles, The reclamation from storage piles is also treated.

Jan 1, 1976

By Yoginder P. Chugh

Effects of moisture absorption on the behavior of the Dykersburg shale overlying Harrisburg coal seam in Southern Illinois are presented in this paper. Cylindrical samples of the shale 2.5 cm in diameter and 5.0 cm long were studied for weight gain and swelling strains at 90, 95, and 100 percent relative humidity and under immersed water conditions. After attaining equilibrium conditions, the samples were studied for changes in the strength and deformation behavior. The depth of moisture penetration was measured using the Vickers microhardness measurements. Using the basic mass transfer concepts, effective diffusion coefficients were computed for the shale.

Jan 1, 1980

By D. L. Leach

This report covers laboratory experiments simulating in situ copper recovery from primary sulfide ores in sulfuric acid systems pressurized with oxygen. Copper extraction and acid consumption data are correlated with temperature in the range 50-150°C and quenched pH in the range 0.25-2. Adverse changes in the chemical composition of the leach solution and the formation of gangue-mineral alteration products and secondary sulfides can severely limit the extraction of copper above 90°C. Keeping the pH below the self-buffered value of about 2 and the temperature below about 110°C produces the maximum extraction rates. Forcing the pH too low not only results in excessively high acid consumption but may also limit the extraction of copper at temperatures above 100°C.

Jan 1, 1975

By Milton F. Searl

Introduction The urgency of further development of our domestic energy resources becomes more apparent every day. The production capability of existing facilities, taken in the aggregate, declines perhaps 10% per year; imported energy is expensive if available at all; conservation helps reduce demand but eventually will reach a point of diminishing return; new energy sources are promising but past experience, as with nuclear power, teaches us lead times are long and success is not assured. To approach the energy future rationally, it is essential to have some idea of the size of the nation's remaining energy resources, their characteristics, and the degree of uncertainty involved in their estimates. Resources are, of course, only one end of a long chain leading to energy supply to the ultimate consumer. They are an essential element, however, and the only one not under society's control. Given that the resources and a national will to produce the energy exist, it is possible to convert the resources to supply in, generally, an environmentally reasonable manner. However, the process of developing supply takes time. Government must permit access to the resource, and remunerative prices and further evolution of technlogy are required. This paper does not deal with these essentials, but they must not be forgotten. This discussion is limited to coal, oil, natural gas and gas liquids, uranium, and oil shale. Other energy sources are discussed elsewhere in this issue. Crude Oil Conventional crude oil resources are of greatest concern today, given our dependence on imported oil and its rapidly rising price. Estimates of oil originally in place (OOIP) range from 619 billion bbl to 1,094 billion bbl, differing by almost a factor of two (Table 1). This is surprising because the U.S. is a mature petroleum province with over 120 billion bbl produced and over 400 billion bbl OOIP discovered. Differences in the estimates involve differences in the experience of the various estimators, the interpretation of present geologic information and historical statistics, the methodology, and probably the extent (i.e., water depths) for which offshore resources are included. The range shown for the estimate of a given estimator appears to be primarily due to geologic uncertainty. This uncertainty can be measured by taking the ratio of the low and of the high estimate to the expected estimate for that information source. The low estimates range from 0.85 to 0.87 of their respective values. The high estimates range from 1.18 to 1.27 of the expected values. In all cases the high estimate is further from the expected value than the low,

Jan 1, 1980

By Searl. Milton F.

Introduction The urgency of further development of our domestic energy resources becomes more apparent every day. The production capability of existing facilities, taken in the aggregate, declines perhaps 10% per year; imported energy is expensive if available at all; conservation helps reduce demand but eventually will reach a point of diminishing return; new energy sources are promising but past experience, as with nuclear power, teaches us lead times are long and success is not assured. To approach the energy future rationally, it is essential to have some idea of the size of the nation's remaining energy resources, their characteristics, and the degree of uncertainty involved in their estimates. Resources are, of course, only one end of a long chain leading to energy supply to the ultimate consumer. They are an essential element, however, and the only one not under society's control. Given that the resources and a national will to produce the energy exist, it is possible to convert the resources to supply in, generally, an environmentally reasonable manner. However, the process of developing supply takes time. Government must permit access to the resource, and remunerative prices and further evolution of technology are required. This paper does not deal with these essentials, but they must not be forgotten. This discussion is limited to coal, oil, natural gas and gas liquids, uranium, and oil shale. Other energy sources are discussed elsewhere in this issue. Crude Oil Conventional crude oil resources are of greatest concern today, given our dependence on imported oil and its rapidly rising price. Estimates of oil originally in place (OOIP) range from 619 billion bbl to 1,094 billion bbl, differing by almost a factor of two (Table 1). This is surprising because the U.S. is a mature petroleum province with over 120 billion bbl produced and over 400 billion bbl OOIP discovered. Differences in the estimates involve differences in the experience of the various estimators, the interpretation of present geologic information and historical statistics, the methodology, and probably the extent (i.e., water depths) for which offshore resources are included. The range shown for the estimate of a given estimator appears to be primarily due to geologic uncertainty. This uncertainty can be measured by taking the ratio of the low and of the high estimate to the expected estimate for that information source. The low estimates range from 0.85 to 0.87 of their respective values. The high estimates range from 1.18 to 1.27 of the expected values. In all cases the high estimate is further from the expected value than the low,

Jan 9, 1980

By E. M. - Technical Papers Spokes

A.B. Rushton The work and resulting publications of the Committee on Underground Coal Mine Safety and The President's Commission on Coal were appropriate at the time of publication. The statistics cited in the publications appeared to be valid, and the actions proposed by the committee had merit. Although the actions proposed to achieve further improvements in safety may have been worthy of repeating, to associate statistics (Table 1) that are seven to eight years old with company names is bad. Statistics are readily available from the Mine Safety and Health Administration (MSHA) and are usually within three months of being up to date. A review of the most recent Coal Controlling Co. Report will reveal significant changes in the rankings. The more recent statistics should have been cited, or at least compared with those used in the article. Westmoreland Coal Co. is listed as having a 21.1 disabling injury rate for the period (1/78-12/80). The disabling injury rate for the Company for the year ending 1985 was 7.4 for the underground mines and 6.25 for the total facilities. Through March 1986, the dis- abling rate for the underground mines was 2.86. The management and employees of Westmoreland Coal Co. are committed to safety. The improvements achieved over the past five years attest to that commitment. We are justifiably proud of the achievement and dislike being misrepresented as in the April 1986 article Reply by E.M. Spokes I regret that the lapse of time since the original work gives a picture of safety practice that is no longer true today. That Westmoreland has reduced its disabling injury rate by 65% to 7.4 in 1985 is most commendable, and I congratulate you for this accomplishment. It is typical of the progress sought by the National Academy of Science and National Research Council when they funded the original study and published "Toward Safer Underground Coal Mines" in 1982. If a significant number of companies do as well as Westmoreland, the report will have served its purpose. Since the paper was primarily a condensation of the original report, it would not have been appropriate to seek access to later statistics. The purpose in seeking its publication at the time of presentation was to reach those who might have missed the original report. The fact that publication was delayed has not voided that purpose and may have reminded some who were aware of the original that its recommendations still apply to improvement of underground coal mine safety

Jan 1, 1987

By Madeline Mello, Michael Low, Nick Karlin, Bryce Scofield

The LA Effluent Outfall Tunnel is the first tunnel in the United States to incorporate post- tensioning into the precast segmental lining. Several unique components were integrated to ensure that the post tensioning could be carried out successfully in the tunnel, even concurrently with the TBM excavation. This also required the development of new processes both in the casting facility and in the TBM to ensure that the almost 3,700 rings could be successfully manufactured, threaded, stressed, and grouted. This paper will discuss the material selection, fabrication, and installation of, as well as lessons learned from, this first in country tunnel lining.

Jun 23, 2024