Search Documents

Lonmin, earlier than any other primary platinum producer, had to deal with the concentrating and smelting of UG2-rich ores and concentrates respectively. Smelting was performed at a fairly modest scale compared to the company's industry peers in the platinum group metals (PGMs) industry, and was focused on smelting concentrates obtained through low mass pulls while still maintaining high recoveries at its concentrators. Lonmin gradually smelted larger quantities of UG2 concentrates. Initially two 2.3 MW Infurnco furnaces were commissioned in 1982, followed by three 5 MW circular 3-electrode Pyromet furnaces in 1991. Deep electrode immersions and moderately high hearth power densities were used in all the designs. Lonmin decided to continue with circular furnace technology when it planned its new high-intensity No. 1 Furnace. Neither Lonmin nor the technology supplier and EPCM company foresaw the challenges that scale-up would bring when applied to the smelting of UG2-rich concentrate blends. Superimposed on the high chromite content, was the low base-metal loading, mineralogical difficulties, and fine particle size that resulted from milling of all concentrates (especially UG2 and recycle materials within the smelter). Through a process of fundamental diagnoses of furnace run-outs and wear patterns observed during repairs, the main challenges operating this high-intensity furnace were identified as sulphur vapour corrosion of the copper coolers, uneven and unpredicted movements of refractory bricks with associated copper cooler lift and matte tapblock movement, the formation of three-phase 'mushy' zones, high refractory and taphole wear rates, uncertainty in matte level and associated insufficient matte buffer height, and high furnace operating temperatures. These factors seldom worked in isolation and will be explored in more detail in the paper. The variability in furnace feed characteristics led Lonmin to redesign Furnace No. 1, to invest in backup furnace capacity, and to invest in improved monitoring and control. These improvements consisted of online and high-frequency off-line monitoring of feed chemistry and mineralogy, online pressure monitoring of water-cooled circuits, an alternative matte liquid level measurement in the furnace, and electrode immersion estimation. Improvements were also made at the converters by installing and utilizing optical spectral analysis of the converter flame to characterize converter behaviour and achieve the desired iron end-point for white matte. This paper also briefly discusses the current and future expansion plans, as well as ancillary operations at the smelter such as flue-gas handling and materials handling.

Jan 1, 2011

By M. Brnich, S. Kramer, B. McNamara, T. Hethmon, M. Pedersen-Howard, S. Rajapaske, D. Lingenfelder, B. Huber, D. Hebig

"The development of mining safety and health management as a recognized profession has been long in coming. Over the last 150 years, the mining industry has evolved from having individuals randomly involved in safety related work with no specific responsibilities or qualifications, on to the designation of individuals responsible for safety, regardless of knowledge, qualifications and experience and finally to today’s expectation that virtually every mine and mining company has designated individuals operating as safety and health professionals. Further, with the complexity, risk potential and moral expectations surrounding safety, people who address mine safety and health management are justifiably expected to function in a professional capacity including:1. Rendering a specialized service based on advanced knowledge and skill.2. Maintaining a high degree of obligation to those most affected by mine safety outcomes.3. Bound by an ethical code in working with the public, employers and miners.4. Maintaining confidentiality with an employer or client. This historical change parallels thedevelopment of other professions, e.g., attorneys, engineers, physicians, etc., with the exception that those professions require a license granted by a governmental agency, which is justified on the basis of public protection, in order to practice. Likewise, decisions made by today’s mine safety and health professionals, both directly and in association with other managers, clearly have a significant impact on the life and welfare of miners throughout the world.CertificationIn light of this, there is growing need to improve standards of competency and professionalism for those who work in mine safety and health management. An effective mechanism to accomplish this, other than licensure, is the use of accredited professional certification programs. There are many professional certification programs for safety and health throughout the world (Hale & Harvey, 2012). However, there is only one certification specific to mining —the Certified Mine Safety Professional (CMSP). The International Academy of Mine Safety and Health (ISMSH-SME) was formed with the purpose of developing and managing mining safety and health certification programs for the Society for Mining, Metallurgy and Exploration (SME). In 2016, following the discontinuation of the International Society of Mine Safety Professionals (ISMSP), which developed the Certified Mine Safety Professional (CMSP) credential in the 1990s, the IAMSH-SME began the process of updating and relaunching the CMSP program. Among other work required to gain third-party accreditation both domestically and internationally, the IAMSH-SME has developed a new Body of Knowledge associated with mine safety and health management (Table 1)."

Jan 6, 2018

By Zhouhua Jinag

The attempt has been made to manufacture high nitrogen austenitic stainless steels by pressurized electro-slag remelting furnace with maximum nitrogen pressure of 7MPa. To obtain high nitrogen content in steels, the compound electrodes with different nitrogen sources (FeCrN, Si3N4) were prepared. Using the Si3N4 as the nitrogen alloying source, the silicon contents in ingots were prone to be out of the specification range, and the electric current fluctuated greatly and the surface qualities of the ingots were poor. The surface qualities of the ingots were improved using FeCrN as nitrogen alloying source. The sound and compact macrostructure ingot with the maximum nitrogen above 1.0wt% could be obtained. A series of high nitrogen austenitic stainless steels have been successfully developed by this method. The mechanical and pitting corrosion resistance properties of high nitrogen austenitic stainless steels were investigated. The results show that the steels exhibit excellent mechanical and pitting corrosion resistance properties.

Jan 1, 2009

By Bryan de Barros Soares

O aço carbono é um material amplamente empregado na indústria petrolífera devido sua elevada resistência mecânica e baixo custo. Entretanto, este material não possui boa resistência à corrosão. Neste contexto a predição da taxa de corrosão é de extrema importância para estimar a durabilidade desses materiais. Atualmente isto é feito com base em dados de ensaios de perda de massa em um único tempo de imersão, estimando-se a taxa de corrosão. Contudo, para converter os dados de perda de massa em taxas de corrosão é imprescindível que os ensaios sejam conduzidos em diferentes tempos de imersão e que haja linearidade entre perda de massa e tempo. Neste trabalho a corrosão do aço carbono em meios saturados com CO2 foi investigada através de ensaios de perda de massa em três tempos de imersão diferentes, com o objetivo de avaliar essa linearidade. Dos quatro meios corrosivos estudados, um não apresentou linearidade entre PM e tempo de imersão, sendo portanto incorreto extrapolar os dados para taxa de corrosão. Os resultados comprovaram que a extrapolação de dados de PM para taxas de corrosão não pode ser aplicada sem uma prévia verificação da linearidade entre perda de massa e tempo de imersão.

Aug 16, 2017

By Leonardo Massone

The p-y method is one of the most popular methods in pile design and has been calibrated for various boundary conditions using numerical and experimental studies during recent years. Most studies on reinforced concrete (RC) piles have included the impact of flexural nonlinearity, (e.g. nonlinear moment?curvature relations) but not considered associated pile shear deformations when deriving p-y curves from field data. Common p-y curves may be better applicable for piles with flexure dominated failures (e.g. piles with free- head boundary conditions). For piles with fixed head boundaries (i.e. rotation restrained piles) shear deformations could be of significant influence. To study this problem, a coupled shear flexure interaction model for axial-bending-shear behavior coded in OpenSees was applied to a 0.61 m (2 ft) diameter flagpole and a 0.61m (2 ft) diameter fixed head pile specimen to investigate the possible influence of shear deformations to the overall pile responses. The surrounding soil was represented by p-y curves derived from prior large scale testing on piles with similar boundary conditions. Analysis results show that for flagpole piles, shear forces and shear deformations were insignificant. Considerable contributions of pile shear displacements and forces were observed for the fixed head pile, with shear displacements contributing up to 40% of the total pile displacement. Results suggest that nonlinear shear deformations for reinforced concrete piles should be considered for fixed-head or similar conditions, and that currently used p-y curves may underestimate the actual lateral pile displacement and possibly lead to unsafe design for the particular boundary condition.

Jan 1, 2012

By Seppo Haapamaki

"Since it started production in 1970, Anderson Lake Mine has experienced several radical changes in mining methods as a result of the physical characteristics of the ore zone along with the need for improved productivity. This paper examines the transition from longhole open stoping to mechanized cut-and fill then to vertical crater retreat at Anderson Lake Mine. The reasons for the need to change mining methods is analyzed taking into consideration the impact of such criteria as improved productivity and ground conditions and how these criteria affected the over-all economic viability of the mine. IntroductionAnderson Lake Mine is one of five producing copper mines in the Snow Lake area and is situated approximately 3 km southeast of the townsite of Snow Lake (Fig. I).The mine production rate at Anderson Lake is 700 tpd and all ore is trucked from the mine to the mill located approximately 2.5 km from the mine site . The mine is serviced by a three-compartment shaft sunk to a depth of 3300 ft with level spacings at 175 ft and 150 ft intervals from the 600 ft level to the 3000 ft level. .The shaft was collared in 1965 and, a year later, the hoist and compressors were installed. By 1969, a crusher system had been built and actual production began in 1970. During 1978, production was suspended for the year to allow for 430 ft of shaft deepening."

Jan 1, 1988

By L. Xinghua

Limonite is a general term for a group of amorphous iron oxide and iron hydroxide materials. It is considered as one of the very refractory iron ore types due to its wide variation in chemical composition, iron content, moisture content and easily sliming in the course of comminution. Iron grade of test sample is 25.48%, the iron minerals are mainly limonite; and the gangue minerals consist of quartz and feldspar in majority, secondarily silicate minerals. In this test work, high intensity magnetic separation (HIMS)-cationic reverse flotation and magnetic roasting-low intensity magnetic separation (LIMS) tests were conducted on limonite ore. The test results show that the concentrate with iron grade of 50.97% and recovery of 68.50% can be obtained by HIMS-cationic reverse flotation technique; while using magnetic roasting-LIMS technique, the better concentrate indexes of iron grade of 60.36% and recovery of 89.71% are achieved, and the iron grade of tailing is only 4.42%. Therefore, the magnetic roasting-LIMS technique is a better suitable method for beneficiation of low-grade limonite ore. Keywords: Low-grade limonite; Mineralogy; HIMS; Cationic reverse flotation; Magnetic roasting; LIMS

Feb 27, 2013

By R. Horn

The financial performance of the mining industry, measured by return on equity and capital employed, has been inadequate for many years. Consequently, mining companies are not valued highly by stock markets. Among the more important causes for the decline in the sector are the conservative working practices and reluctance to adapt to change or to develop new technology, although some relatively recent developments such as SX-EW copper and heap leach gold have made a significant impact on the cost base of these metals. The subsidiary business of metals exploration suffers from the same problems as the rest of the industry. The rate of discovery of ore deposits has been falling over many years and since the late 1990s, there has been a sharp reduction in global exploration activity that, if it continues, will further reduce the global supply of new ore reserves. New technological developments, particularly in geophysics and different operational practices may help reverse this trend. Statistical methods for evaluating the risk of ore reserve estimates will also improve the economic return on new mining ventures. The science of ore geology has potential to reduce exploration risk, but modern ore genetic theory has not contributed greatly to recent discoveries. The junior exploration market has almost ceased, but a new style of technically specialized efficient small exploration company has emerged which, in alliances with major companies, may be the vehicle for future global exploration. Exploration in virgin terrains has a higher risk discounted potential for the discovery of very large orebodies than that in known mining districts but mining companies have little financial incentive for this high risk exploration because of the very long lead time to production. Alliances of two or more companies reduce the risk in both the exploration for and development of major new mining projects. If new orebodies are not found, then metal prices will inevitably rise in the long term. Governments of industrial countries, particularly those with a significant mining industry such as Canada, should therefore provide assistance to exploration in order to maintain their existing industry and prevent a metals shortage from developing in the future with its consequent impact on the world economy and increased environmental damage as large lowgrade orebodies are developed to supply an expanding market.

Jan 1, 2002

By John R. McWilliams

This report is one of a series published by the Bureau of Mines describing methods and practices at various mines throughout the United States. A previous program, conducted from 1928 to 1939, was well received by the mining industry and technical institutions and provided much source material for engineering textbooks and technical handbooks. The stringent wartime demands on the mining industry, the rapidly changing postwar economic situation, and greatly accelerated technologic growth have combined to render many of the previous data obsolete. The objective of the present program is to assemble reliable technical information on mining methods and practices throughout the country and present it for the use of the mining industry, technical schools, textbook authors, and other interested persons. This report deals with the design and development of the Berkeley open- pit mine at Butte, Mont., owned and operated by The Anaconda Company. The Berkeley pit is but one facet of a well-organized and integrated copper-mining operation involving the entire Butte district. Vein-type mining, important for 75 years, is still in progress at depths from 600 feet to nearly 1 mile; on intermediate levels, low-grade ore left untouched by earlier vein-type mines is being extracted by block caving entire ore zones,3/ and secondarily enriched but lower grade near-surface portions of the same ore zones are being mined by open-pit operations (fig. 1). The Berkeley pit itself is named for the Berkeley mine, one of the old mines that extracted copper ore from high-grade veins in the area that now will be mined by open-pit methods.

Jan 1, 1959

By J. Kulas, J. Weaver, K. Hagley

An assessment of potential groundwater movement beneath the tailing impoundment at the Red Dog Mine was performed, and has indicated a unique aquifer situation within sub-permafrost groundwater at the site. The aquifer was shown to be isolated from both vertical recharge and a real discharge, and is characterized as a virtually no-flow system. The permafrost resulted in a deep aquifer with high tidal efficiency, meaning that variable surface loads are easily transmitted to the fluid. The tidal efficiency has been characterized through analysis of water level fluctuations that respond to earth tides, barometric pressure loads, and loading from the pond.

Jan 1, 2002

By J. Hansen

This paper has been written for presentation during the Open Pit Mining Session at the SME Annual Meeting and Exhibit, Denver, Colorado, February 26 to 28, 2001. The paper addresses the application of automated monitoring of electric rope shovels to improve performance and blasting technique.

Jan 1, 2001

By Mike Ounpuu

"Locked cycle testing has become more common practice in the last 10 years. Reasons vary from a desire to avoid pilot plant testing, demand for more variability testing within deposits, and perhaps most importantly, a request from the financial institutions who invariably finance many of the projects. Surprisingly, many people don’t understand locked cycle testing, analysis and balancing. This paper provides a brief overview of locked cycle testing, and then progresses into a more detailed discussion on the analysis and balancing of locked cycle test data. The paper endeavors to educate CMP personnel on how to determine if the test was good and if a reasonable metallurgical projection was made. The paper uses case studies to illustrate the key points.INTRODUCTIONA locked cycle test is a repetitive batch used to simulate a continuous circuit. The basic procedure has a complete batch test performed in the first cycle which is then followed by similar batch tests which have “intermediate” material from the previous cycle added to the appropriate location in the current cycle. These batch tests, or cycles, are continued in this iterative manner for an arbitrary number of cycles. The final products from each cycle, i.e. final concentrate and final tailings, are filtered and thus removed from further processing. At the end of the test, all the products, final and intermediate, are dried, weighed and subjected to chemical analysis. The test is balanced and a metallurgical projection is made.This description can be found in many of our classical textbooks for the mineral engineer 1, 2, 3,4. Unfortunately, none of these textbooks provide any discussion beyond the basic procedure. Often, they provide comments such as in Taggart’ where he states; “It is questionable whether in any case it approximates mill results any more closely than the standard batch test”. It is truly surprising that our classic textbooks promote that locked cycle tests are more art than science, and suggest that they can be of dubious value. None of the textbooks provide meaningful insight or discussion in how to assess:"

Jan 1, 2001

By Guo H. Lei

Over the last four decades, barrettes have been ever-increasingly adopted as the foundations for tall buildings and heavy infrastructure projects all over the world. Many findings have been gained from practical applications and theoretical researches. In this article, a collection of literature is reviewed on the installation effects and load-carrying behaviour of barrettes derived from field and laboratory tests and theoretical studies. It covers many aspects, such as the ground deformations and stress changes caused by the installation of barrettes, the shaft resistance mobilisation behaviour, the construction effects on the shaft resistance, and the effects of pile spacing, pile shape and pile group layout on the load-carrying behaviour of barrettes.

Jan 1, 2006

By A. M. Keenan, R. H. Carpenter

Geologic faults have always been a plague to the mining industry, and have often reduced a mining venture from a profitable to a marginal operation, and even at times have forced companies to liquidation or bankruptcy. The use of geology as an economic tool in coal mining is not generally recognized, particularly in coal deposits which are horizontal or essentially flat-lying, in which faulting might not be prevalent. However in pitching coal seams, the existence of faults is considered an inherent challenge, as the inclination of the seam or seams per se, is a product of geologic disturbance. The problems of faults are a constant challenge to the management of the Thompson Creek Coal and Coke Corp. in their operations in Pitkin County, Colorado, where high grade medium volatile coking coal is mined. The background for this paper has been provided by the experiences of these operations, in overcoming the effects of faults in mining, and resolving the fault structures. The properties of the Thompson Creek Coal and Coke Corp. are located in central Colorado, 13 miles southwest of Carbondale, Colorado, a tow] on the main highway between Glenwood Springs and Aspen, Fig. 1. The elevation at the mine portals is approximately 8000 feet: there is a relief of some 2.000 feet to the adjacent ridges rising away from the [nine portals. 'The entire present production of these properties totaling 180.000 tons of clean coal per year is trucked to the railhead at Carbondale, Colorado, from whence it is shipped to the Geneva Steel Plant at Provo, Utah. The properties were initially opened in September 1952. A total of 125 men are currently employed with the production conting from the Number 1 and 3 Mines, and development workings of the Number 2 and 5 Mines respectively. While the No. 2 Vine was opened in 1953 prior to No, 3 Mine, the encountering of faults without sufficient development work accomplished to sustain production, necessitated the diversion of manpower to the other [nines for economic considerations. GEOLOGY '1-he productive coal seams occur in the Mesaverde formation of Late Cretaceous age which outcrop along the eastern edge of the Piance Creek Basin from the Grand Hogback, a part of the southwestern flank of the White River Uplift north of Glenwood Springs, southward through the 'Thompson Creek area and the

Jan 1, 1961

GENERAL CONTRACTOR: ALEXANDER CONSTRUCTORS, INC. STRUCTURAL ENGINEER: CAGLEY & ASSOCIATES, INC. GEOTECHNICAL ENGINEER: F.T. KITLINSKI & ASSOCIATES, INC. PILE FOUNDATION CONTRACTOR: L.G. BARCUS AND SONS, INC. PROJECT PROFILE: 108-10 in. diameter AugerPiles installed to an approximate depth of 32 ft. Piles were installed through Stiff Clayey Fill and Medium-Dense Sands to Decomposed Shale. Piles were drilled to a refusal criteria of 1 ft. / 3 min. Piles were installed using a Barcus Mantis AugerPile rig which is large enough to install piles 25 to 50 ft. long outdoors. The Mantis is also ideal for indoor and low overhead installations. On top of being extremely versatile, the Mantis is also very economical to mobilize. The existing structure is supported on H-Piles. The AugerPiles were furnished and installed for less than the material price of the H-Piles. Design loads were under 40 tons which eliminated the need for a load test. AugerPiles were selected for minimal vibration, limited noise, and economy.

Jan 1, 2001

By Bruno Gemmi

A new warehouse built with prefabricated components over an area underlined by soft marine soil deposits started showing differential settlements well before its completion. Its 103 spread footings carrying up to 4,000kN (450t) axial loads had been cast on jet-grouted columns extending and penetrating a layer of sand at a depth of 10m (33ft). Investigations performed to assess the wholeness and consistency of the jet-grouted columns revealed a state of loose jet-grouted masses and uncontrolled, off target migrations of the jet-grouting. Most of the jet-grouting itself was settling. The following remedial solutions were suggested: 1. Construction of new and better controlled jet-grouted columns. 2. Cement-based soil grouting. 3. Expanding resin injections. 4. Minipiles drilled-through the existing footings and reaching into a denser layer of sand existing at 23m below grade. Remedial solution 1. was immediately discarded due to cost and the possibility of a repeating failure in this non-granular and highly compressible soil. Tests of remedial solutions 2. and 3. were carried out. The outcome of the grouting was monitored by Electro Resistivity Tomography (ERT) (Bares et al., 2003), an innovative 3D electro tomography procedure showing where grout had been actually placed and its migrations off target. A successful 4,000kN (450t) load tests confirmed the validity of the solution. Finally, upon the completion of a successful load test, solution 4. was chosen. It supplied the highest degree of reliability thanks to the ease of controlling the final and actual location of the minipiles and to the higher safety factor provided. All remedial work to install the minipiles was eventually performed inside the building. Additional load tests and settlement measurements confirmed the adequacy and success of the chosen solution.

Jan 1, 2011

By J. Drelich, J. Pletka

Lost foam casting patterns are foamed polystyrene shapes glued together into the shape of the part to be cast and are coated with a refractory material consisting of a mineral mixture and binders. Prior to casting, a significant number of the patterns are damaged and inevitably land-filled. In this study, a process is developed for the recovery of foamed polystyrene from the coating and glue contaminants. The process consists of shredding, impact comminution, size classification and density separation. It is successful in separating up to 97% of the contaminants, while recovering 95% of the polystyrene.

Jan 1, 2001

By Matters, R T, Coldham, Slee, J C, R J, Wallman

The Committee desires to thank the managers of the various mines along the line of lode for their hearty co-operation in its labours. It would also extend thanks to Messrs J C Moulden, Howchin, Twelvetrees, and the West Australian Geological Surveyfor various information; to Messrs J G Dreyer, S Pope, T Read, P Moncrieff, R Williams, and W J Rose for analyses; and to a number of local gentlemen for advice and help. Professor Skeats, of Melbourne University, gave much valued assistance in petrology, and Mr Herbert Lavers kindly undertook the study of the garnets.INTRODUCTIONThe famous Broken Hill lode is situated in a low range of hills, the Barrier Ranges, near the western border of New South Wales. It has been worked since 1884-fust for silver, then for silver and lead, and at present for lead, silver, and zinc...

Jan 1, 1910

Fragmentation Characteristics of Iron Ores from Anshan, China

Sep 13, 2010

By J. D. Allen

In the coal preparation plant at U.S. Steel Corp.'s Concord mine in Alabama, the product moisture was reduced from about 20% to 9% through the development of a workable flowsheet for dying the clean coal. Some of the high points of the conversion of the Concord washer from vibrating screen dewatering to centrifuge drying are presented in this article. The coal preparation plant at the United States Steel Corp.'s Concord mine near Bessemer, Ala., began operations in June, 1950. The basic cleaning circuit consisted of a Chance cone for cleaning the 2-in. x 3/8-in. fraction and concentrating tables for cleaning the -3/8-in. coal fraction. Dewatering of the final product was accomplished with 35-mesh vibrating screens. However, because Concord coal is very friable with 85% passing 3 mesh and 25% passing 28 mesh (Fig. I), a considerable quantity of fines passed through the dewatering screens. To recover these fines, the dewatering screen effluent was sent to two 70-ft-diam hyd rose para tors from which the underflow returned to the dewatering screens and the overflow went to a 175-ft-diam thickener for water clarification, as illustrated in Fig. 2. As might be expected, there was considerable recirculation of the -35-mesh coal in this system. This degraded the coal and led to higher moistures. It also resulted in a fines bleed-off of plant water and thickener underflow to a fine-coal settling pond. In 1961, vacuum filters were installed to supplement the screens and to recover the fine coal lost in the bleed-off. The above system resulted in a product moisture of about 20%. Further reduction to approximately 11% was accomplished by drainage from railroad cars during transit to the coke plant. Control of the moisture at unloading was poor because of variations in operating levels and railroad car availability, but since the Concord coal constituted a relatively small percentage of the over-all coal mix at the coke plant, its high moisture and fluctuations did not seriously hamper coking operations. Early in 1964, however, the proportion of Concord coal was increased with a resulting increase in the moisture of the total coal mix, and this caused difficulties in the coke plant. The increased participation of Concord coal also brought about a shortage of railroad cars which raised the moisture content to a point where the coal became almost impossible to handle. In an effort to alleviate this problem, U.S. Steel initiated a research program to develop a flowsheet for reducing the moisture to approximately 10% and to determine whether the resulting product would be satisfactory for the coke plant. Under this program, an experimental flowsheet for evaluating both a vibratory centrifuge system and a solid bowl centrifuge system was drawn up as shown in Fig. 3. A horizontal vibratory centrifuge was installed to reduce the moisture in the dewatered coarse coal, and a four-cell, flotation machine was installed to clean the -65-mesh portion of the 3/8-in. x 0 table raw coal feed. Several shortcomings in the above circuits were apparent. For one thing, large quantities of repulping water were required. Furthermore, since about half of the flotation feed was of a size consist that could have been cleaned on the tables, these circuits would result in an unnecessary increase in reagent costs and facilities. Maintenance of the hydro separators and pumps for pumping the underflow to the filters,

Jan 1, 1969