Search Documents

By Bern Klein, Randy Blaskovich, Reem Roufail

"Morphology is a tool that is rarely used for mineral breakage mechanism evaluation. Ground particles are typically assessed for their size distribution. They are also visually analyzed using image analysis. However, image analysis is not a comprehensive evaluation of the particle surface texture. It evaluates particle’s size parameters such as area, diameter, and perimeter amongst other features. On the other hand, morphology analysis takes the particle assessment to another level of detail. Morphology analysis evaluates particles’ roundness, elongation and angularity that would indicate the degree of roughness of the particle. According to Roufail and Klein (2009), rougher surfaces are generated due to breakage along grain boundaries – intergranular breakage. Mill operation, particularly mill speed, dictates the dynamics in the mill. Stirred mills are known to break the particles via abrasion under standard operation. However, if the dynamics of the grinding media in the mill are changed, the particles could be more exposed to impact and compression loading that would lead to a different mode of breakage.In this paper, the effect of material properties and mill operating conditions on particle morphology will be studied. Hard non-sulfide versus soft sulfide minerals are compared, namely quartz and galena, respectively. Extreme mill speeds are tested covering the range of 1000 to 2000 rpm for a 4-litre Netzsch (ISA) mill. In addition to particle size distribution, micro-analysis is executed in the form of morphological analysis using a tested manual roughness point counting technique.INTRODUCTIONGrinding in general and stirred milling in particular are processes that are used to break particles to liberate metal-bearing minerals for further separation downstream. The energy required to achieve the target particle size versus maximum possible liberation has been studied intensively and it is usually the breaking point for the grinding system chosen in a process flowsheet. Operating conditions are dictated by the energy consumption. Becker et al. (2001) related different forms of energy such as input, specific, volume/mass specific energies to stress intensities and final product fineness. Other research studies focused on energy input in a stirred mill (Zheng, Harris and Somasundaran, 1996)."

Jan 1, 2011

By R B. Evans, M G. Townsend

In Northland, New Zealand, localised large deposits of halloysite clay have been produced by in-situ alteration of rhyolite volcanics of Pliocene or Pleistocene age, which were erupted through pre-Pliocene sedimentary strata and locally through Pleistocene basalt; and which were subsequently onlapped by further basalt flows. Alteration to clay has been a result of both hydrothermal and of meteoric processes, and decreases in intensity of alteration with increasing depth. The raw material is crushed and fractionated to produce a product of less than two micron particle size, which is of exceptional whiteness and brightness. The unique properties of the clays render them highly desirable for specialised ceramic purposes.

Jan 1, 1990

By G. Danko, R. Tiwari, J. Knowles

Many excavation and loading tasks require equipment operators to simultaneously coordinate the motion of multiple machine links, in order to achieve complex tool trajectories. Efficiency, ore selectivity, and machine wear, are all affected by the skill level and attentiveness of the operator. A software-based kinematics reconfiguration system designed to assist operators with various tasks has been implemented on a small experimental excavator using our new differential control architecture. Kinematics transformation and feedback control algorithms are being developed and tested using computer simulation, and the results implemented on the experimental excavator. Several task-specific kinematics transformations, including a virtual revolute-to-Cartesian machine reconfiguration and computer-assisted bucket steering and stabilization have been successfully tested. Progress, challenges, results, expected benefits, and planned work are described.

Jan 1, 2006

By I Clark, S C. Dominy

Bulk sampling programs are typically applied in coarse gold mineralised systems to verify resource/reserve grades. In recent years, there have been controversies surrounding some results of underground bulk sampling exercises compared to the predictions using diamond drill data. Just how realistic is it to predict 100 t lots from drilling that was designed to model blocks of several thousand tonnes? This study looks at the variation of relatively small units within larger planned mining units and compares some of the geostatistical techniques which purport to provide tools for such studies. Relative difficulty of application, computer timings and summaries of results will be used to illustrate the likely variation in bulk sampling units as opposed to mining units and large-scale planning units. A case study based on publicly available data from a gold project in North America is presented. A simplistic and unconditional geostatistical simulation model demonstrated that up to 50 per cent of a relatively high-grade mining block could show as uneconomic low-grade subblocks. A subsequent study will consider a similar demonstration using uniform conditioning. Erroneous impressions of early sampling results can lead to unsupported prejudgements of the final results. Bulk sampling programs require detailed planning based on ore characteristics, where protocols must fit the mineralisation type. Any program requires definition of aims and data quality objectives across grade, geological, geotechnical and geometallurgical parameters.CITATION:Clark, I and Dominy, S C, 2017. Underground bulk sampling, uniform conditioning and conditional simulation – unrealistic expectations?, in Proceedings Eighth World Conference on Sampling and Blending , pp 3–20 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2017

By R. Dippenaar

Traditionally, iron ore has been reduced with coke in a blast furnace and the hot-metal product of the blast furnace containing carbon, manganese, silicon, sulphur and phosphorous, was subsequently refined in a steelmaking furnace. During iron making as well as during steelmaking, significant amounts of slag are produced. Two decades ago, more than 13 m tonne of blast furnace slag and 4 m tonne of steelmaking slag per annum were produced in the USA alone. It is, therefore, not surprising that many attempts have been made to re-use iron and steelmaking slags. However, these slags are not merely metallurgical waste products but, on the contrary, their compositions and physical properties are judiciously designed to optimize the operations in the respective metallurgical reactors. The variation in composition and properties of blast furnaces lags are largely determined by the gangue in the ore and ash in the coke and much progress has been made in the re-use of such slag. With respect to steelmaking slag, emphasis has in recent years been placed on hot-metal treatment before refining and ladle treatment after decarburization. The bulk removal of silicon, phosphorous and sulphur from the hot-metal product of the blast furnace by specially designed slags prior to refining in a basic oxygen furnace, has reduced tap-to-tap time, lowered cost and produced steel of much higher quality. The use of synthetic slags in ladle refining techniques subsequent to decarburization in the basic oxygen furnace has resulted in reduced hydrogen and nitrogen contents and reduced solute impurities. Moreover, inclusion shape and composition control, again by the use of specially designed slags has led to the achievement of much improved mechanical properties of the steel. In these revised process routes, slag of different compositions are produced in the variety of unit processes and hence the re-use of steelmaking slags has become much more complex. Clearly, a thorough understanding of the design and use of these different slags is a pre-requisite to the development of re-use strategies. Japanese steelmakers have spearheaded attempts to reduce slag volumes in the individual unit processes and to strive towards ‘slagless steelmaking’ by recycling slags internally. Steelmaking slag volumes have been reduced on commercial scale from about 140 kg/tonne steel to 60kg/tonne steel. Moreover, model predictions have shown that, in principle, all slag can be recycled and the phosphorous extracted to produce fertilizer. This development is of particular significance since the supply of low-phosphorous iron ores is diminishing at an ever increasing rate. Keywords: slag, environment, iron, steel,

Jan 1, 2004

A unique sluicing process for recovering tailing impounded in a valley was developed by Electrolytic Zinc Company of Australasia Ltd., West Coast Mines, Rosebery, Tasmania.Earthmoving equipment could not be used as most of the material to be recovered was semi-fluid. A conventional sluking method was also impracticable as there was no suitable working face from which the process could be commenced.Operations started from a flat surface, using special techniques for sinking through the tailing and establishing producing working faces as the sinking process continued.After about 2 years the bottom of the dam was reached and conventional sluicing methods could be used.

Jan 1, 1973

By J. G. van der Watt

Due to increasing concerns of global rare earth element shortfalls in the near future, possible alternative sources of rare earth elements have recently become of economic interest. One such alternative is decanting acid mine water originating primarily from abandoned old mines in the Witwatersrand region of the Republic of South Africa. In this study, a novel way of rare earth element removal from the acid mine drainage was employed, making use of bentonite clay, which has very good adsorbent properties, as a rare earth element carrier material. The process can be economically viable only, if the elements can be selectively removed from the bentonite clay carrier material so as to yield reusable clay. Acid leaching was proposed to liberate the adsorbed rare earth elements from the bentonite clay. Accordingly, acid leaching experiments were performed to study the desorption of three commonly-found rare earth elements, namely neodymium, samarium, and dysprosium, from bentonite clay in the presence of sulphuric and hydrochloric acid. It was established that the three rare earth element species could be selectively removed as a group from iron, magnesium, and manganese metals through the careful manipulation of the pH. An investigation into the kinetic aspects of the rare earth element desorption process from the bentonite clay was also undertaken. The applicability of various kinetic models such as zero-order, pseudo first-order, pseudo second-order, elovich, parabolic diffusion, and power function were tested to describe the time-dependent desorption of rare earth elements from bentonite clay. It was determined that the pseudo second-order kinetic model represented the dissolution processes for neodymium, samarium, and dysprosium from bentonite clay the most accurately.

Jan 1, 2012

By J. A. Meech, R. J. Tucker

"A dynamic computer model has been developed to simulate the operation of ore crushing plants. The model was created in a general form to allow imitation of a wide variety of secondary crushing circuits with only minor program modifications. The system can be run on either a microcomputer or a large time-sharing main frame computer as required.The size reduction and separation characteristics of crushers and screens are based on standard manufacturers' design and performance data. These calculations are isolated within various subroutines to facilitate tailoring of the model to emulate any particular plant of interest. Input and output data are presented in a variety of formats. Crusher, screen and conveyor amperages and surge bin levels can be presented in a tabular form along with appropriate alarms arising from improper circuit operation or process interruptions. Graphical representation of the circuit together with strip chart data output are features of the system when operated in a microcomputer environment.The program is currently being used at Queen's University as a teaching aid to demonstrate plant operating characteristics, control strategies and design concepts. The acceptance of, and reaction to the program at this level indicates a good potential for it to provide a valuable tool for operator training."

Jan 1, 1985

By J. Wiese

Recently the operating philosophy at concentrators processing platinum bearing ores has started to move from a recovery dominated system to one in which the production of high grade concentrates at the expense of some recovery would provide greater benefits in the further upgrading of the platinum group minerals (PGM). The low grades usually obtained are associated with the presence of naturally floatable talcaceous gangue minerals in all PGM ores. Polysaccharide depressants such as guar gum and carboxymethyl cellulose (CMC) are used to improve the grades of the concentrates. Recent testwork has shown that the use of high depressant concentrations can prevent any naturally floatable gangue from reporting to the concentrate. The only gangue present in the concentrates would be due to its entrainment in the froth. Under these conditions much higher grades can be achieved. The sulphide minerals themselves, however, become susceptible to depression at high depressant concentrations. This work examines how the recovery of sulphide minerals in two Merensky ores was affected by the type and concentration of the collector in the presence of high depressant concentration (500 g/t) and that the response of the sulphide minerals was also dependent on the type of depressant used (guar or CMC).

Jan 1, 2009

This paper describes the back analysis of the Pavoncelli tunnel, an hydraulic tunnel which was excavated between 1904 and 1915 in South of Italy and experienced severe damages during the 1980 Irpino-Lucano earthquake. A numerical simulation which is intended to study the behaviour of the tunnel during this seismic event is presented, also accounting for the swelling phenomenon that took place during and after construction.

May 1, 2009

Some 50 miles of tunnel have been driven in the Snowy Mountains Area since tunnelling commenced in 1951. Hates have improved progressively due to the know-how of American supervision and use of large matched equipment of modern design.The work has been carried out by contractors, working almost exclusively under schedule of rates contracts. The Authority has maintained active research into tunnelling problems, especially that of support, and this has resulted in considerable economies and improved rates of progress. The contractors also have sought economies both by management and equipment techniques. Ammonium nitrate came into favour as an explosive essentially because of its lower cost, and handling techniques have improved progressively. Rock conditions preclude use of the "Mole" type equipment in its present stage of development, but one contractor introduced the "sliding floor" and this could exert a great influence on future tunnelling methods.Examination of tunnels that have been in service for some time confirmed the quality of the work and endorsed the policy of continued research and development.GENEHALThe Snowy Mountains Scheme provides for the diversion of the Snowy and Eucumbene waters through two transmountain tunnels to the western river systems. These diversions, together with additional regulations provided for waters already flowing inland, will provide an average additional discharge of 1,818,000 ac it per year for irrigation.Furthermore, approximately 6,000 million kWh of electrical energy will be generated annually in power stations with a total installed capacity of some 3,000,000 kW (Fig. 1.).INVESTIGATIONThe aim of investigation work is firstly to collect sufficient information to allow the overall scheme to be planned and then to follow up with detailed information on eachproject. The correct balance for all aspects of this work is a matter for keen judgment, as the tunnels must be planned...

Jan 1, 1963

By J. D. Steenkamp

"In July of 2016 and June 2017, major tap-hole repairs were carried out during the annual shutdown of two 63 MVA submerged arc furnaces producing ferrochromium in South Africa. The hot excavations of the tap-holes allowed for a study of the wear profiles. Subsequent thermodynamic calculations allowed for the quantification of the potential for chemical reaction between refractory and slag or alloy contributing to wear in the tap-hole area. Results from both wear profiling and thermodynamic calculations are reported here. IntroductionFerrochrome (FeCr) is an essential alloy in the production of stainless steel (Gasik, 2013). In 2017, 11.7 Mt of FeCr was produced (Pariser et al., 2018.). The main producers were China (39%), South Africa (29%), Kazakstan (12%), and India (8%).A number of grades of FeCr are available to producers of stainless steel, including high-carbon ferrochrome (HCFeCr) (Gasik, 2013). HCFeCr typically contains 60–70% Cr and 4–6% C (Basson and Daavittila, 2013). When the chromium content is lower (50–55% Cr) and the carbon content higher (6–8% C), it is referred to as charge chrome. Charge chrome is typically produced in South Africa due to the grades of ore available.FeCr is produced in submerged arc furnaces (SAFs) and in open arc furnaces (Mc Dougall, 2013) by carbothermic reduction of oxide raw materials. In a SAF the electrode tips are submerged in a porous charge mix. In FeCr production, the electrical energy is mainly liberated by resistive heating of the wet coke bed (Barker et al., 2007; Steenkamp et al., 2017). Thermally conductive lining design philosophies are typically applied in SAFs producing FeCr (Steenkamp, Denton, and Hayman, 2017; Coetzee, Duncanson, and Sylven, 2010; Coetzee et al., 2010).In July of 2016 and June of 2017, major tap-hole repairs were carried out during the annual shutdown of two 63 MVA SAFs producing FeCr in South Africa. The hot excavations of the tap-holes allowed for a study of the wear profiles. Both SAFs were operated on the same site, by two different operating crews, using the same raw materials. The major difference between them was that the SAF excavated in 2016 was an open SAF (referred to as Furnace A) and the one excavated in 2017 was a closed SAF (referred to as Furnace B). In an open SAF, a gap exists between the top of the steel shell and the roof, with the top of the burden being open to the atmosphere and the CO-rich off-gas being combusted as it escapes. In a closed SAF, the roof is attached to the steel shell and the CO-rich off-gas is collected from an offtake on the roof for further treatment and used in downstream processes.The paper presented here reports the macro-scale observations on refractory wear for the two SAFs, and studies the potential for chemical wear of refractory by slag and alloy as a potential contributing factor to the tap-hole wear observed."

Jun 1, 2019

By Philip E. Niebuhr

A procedure, which can be performed in the field by nonanalytical personnel, is given for sensitive spot tests for detecting tellurium or selenium. The expressed need of a field test for detecting small amounts of tellurium, which may be accompanied by relatively large amounts of selenium, has led to the development of this method. Tellurium search has been impeded by the lack of a satisfactory test from the standpoint of sensitivity and specificity. A quantitative laboratory method exists, but it is expensive and relatively laborious. Several other qualitative tests are known, but they require unstable solutions, which must be freshly prepared for use, and a greater variety of laboratory equipment. The particular advantages of the test described are its simplicity and the stability of the reagents required, there-fore is is well adapted for field use. Also, this test was found to be of practical use in the analytical laboratory when screening samples, thereby reducing analytical costs. The roughly quantitative interpretation of the results can save time by indicating the approximate size of the sample taken for a quantitative determination.

Jan 1, 1962

By C. M. Harrer

The location, features, quality, and extent of iron ore deposits are evaluated in this Bureau of Mines report. The results of pioneer beneficiation on Wyoming taconites and their success are discussed along with developments in the iron-ore mining industry, markets, and economics. Market potential, transportation, resource developments, taxation, cost of iron ore enterprises, and the future of Wyoming iron resources are evaluated. Although occurrences of iron ores in Wyoming were known prior to 1870, early production to 1900 was as a nonferrous metallurgical flux and as mineral pigment for paints. In 1901, the Hartville-Sunrise hematite deposits were available to the Western iron and steel industry and in 1962, the first western taconite operation was placed in production at Atlantic City, Wyo. This investigation disclosed the probability of other large iron deposits in Wyoming. Taconite in the Bradley Peak area of the Seminoe Mountains has a potentiality of 100 million tons; that in the Owl Creek Mountains may prove very large also. Pioneer beneficiation testing has been included, and results have been generally encouraging. Research continues on the large titaniferous magnetite deposits of Albany County, Wyo. At present high-density titaniferous magnetite is being mined and processed at Iron Mountain for heavy-aggregate and as a sized coating for underwater pipelines. Ample mineral raw materials needed for mining and processing Wyoming iron ores are available. Investments for iron-ore processing plants will generally be large, particularly for taconite and titaniferous magnetite.

Jan 1, 1966

By Brian Heer, David Young, Randall Essex

The Manapouri Power Station is New Zealand’s largest hydroelectric facility located on the South Island of New Zealand. Constructed in the 1960’s, it includes a 700 MW under-ground power station and a 9.8 km (6.1 mile), 9.2 m (30 ft) diameter tailrace tunnel. The output of the power station is currently limited due to excessive head losses in the tailrace tunnel. To remedy this situation, the Electricity Corporation of New Zealand (ECNZ) retained Woodward-Clyde to design a second tailrace tunnel and appurtenant facilities and prepare Contract Documents for construction. The Project will involve the construction of a 9.8 km(6.1 miles), 10 m (33 ft) diameter, TBM-mined tunnel, hydraulic control structures at the upstream and downstream ends of the tunnel, an underground dewatering shaft and station, and tailrace channel improvements. This paper summarizes the key design and construction issues addressed during the planning and design phases, outlines the risk management provisions incorporated in the Contract, and overviews the Interactive Tender Process (ITP)that was implemented during the pre-tendering and tendering periods.

Jan 1, 1997

By Julio Villon

Actualmente en las técnicas de trabajo de minería es frecuente el uso de tecnologías como la teleoperación, telecomunicación, capacidad computacional masiva, redes de información, bases de datos más poderosas, etc. Por ello, es necesario considerar que el éxito en la implementación está relacionado al proceso de adopción, los requerimientos de capacitación y el manejo del cambio. En ese sentido, el presente texto señala la importancia de la integración tecnológica en la minería para mejorar la productividad y la gestión de los activos. La actividad minera debe ser enfocada como una cadena de valor que tiene diferentes procesos alineados con la estrategia y los objetivos de la empresa. Dichas definiciones van a reflejar la manera cómo la empresa decide relacionarse con su entorno: accionistas, clientes, proveedores, trabajadores, estado, comunidad. Los procesos se traducen a nivel de secuencias de actividades y de ejecución de estas definiciones.

Sep 19, 2006

By C. M. Harrer

The location, features, quality, and extent of iron ore deposits are evaluated in this Bureau of Mines report. The results of pioneer beneficiation on Wyoming taconites and their success are discussed along with developments in the iron-ore mining industry, markets, and economics. Market potential, transportation, resource developments, taxation, cost of iron ore enterprises, and the future of Wyoming iron resources are evaluated. Although occurrences of iron ores in Wyoming were known prior to 1870, early production to 1900 was as a nonferrous metallurgical flux and as mineral pigment for paints. In 1901, the Hartville-Sunrise hematite deposits were available to the Western iron and steel industry and in 1962, the first western taconite operation was placed in production at Atlantic City, Wyo. This investigation disclosed the probability of other large iron deposits in Wyoming. Taconite in the Bradley Peak area of the Seminoe Mountains has a potentiality of 100 million tons; that in the Owl Creek Mountains may prove very large also. Pioneer beneficiation testing has been included, and results have been generally encouraging. Research continues on the large titaniferous magnetite deposits of Albany County, Wyo. At present high-density titaniferous magnetite is being mined and processed at Iron Mountain for heavy-aggregate and as a sized coating for underwater pipelines. Ample mineral raw materials needed for mining and processing Wyoming iron ores are available. Investments for iron-ore processing plants will generally be large, particularly for taconite and titaniferous magnetite.

Jan 1, 1966

By Michael B. Cortie

Mesoporous gold sponge has the unique property of being both metallic and highly resistant to oxidation. It has potential application in catalysis, in bio-sensors, in optical coatings, in analytical chemistry and, as we show here, as the basis for a new kind of ultra-capacitor. Due to the cost of gold, the most probable niche for a gold-based ultra-capacitor would be in the high-power/high-energy regime, a region where gold would compete with devices based on RuO2. A high internal resistance limits the power that can be usefully drawn from existing carbon-based ultra-capacitors, and that this problem can potentially be overcome by gold-based devices. A simple proof-of-concept ultra-capacitor based on mesoporous gold is described and its behaviour during charge and discharge cycles examined. In this work a step change in the input or output voltage of the device was used as the controlling parameter. There was also a residual faradaic current resulting from traces of undissolved aluminium left over from the AuAl2 precursor used to make the sponge, and some charge storage due to polarization of the solution. Deconvolution of these three effects was not entirely accomplished, but an ostensible capacitance of about 7 to 14 mF/g Au was demonstrated. Further improvement from these early results seems likely.

Oct 1, 2003

By Warren M. Mahan

A rotary kiln process was developed by the Federal Bureau of Mines to produce consistently an iron product containing 3 to 7 percent nickel. Cuban laterite and serpentine ores were smelted in a gas-fired batch-rotary kiln) 5 feet in diameter and 9 feet long. The metal contained 2 to 4 percent carbon, with little or no silicon, and could be produced on a large scale with modest capital investment. A total of 121 tests was run using this procedure. The tests were conducted with a maximum temperature of 2,625° F., using linings of firebrick containing 40 to 70 percent alumina. Slags in the kiln were acid to neutral. The material in each batch passed through three stages: (1) Sponge metal, (2) carburization, and (3) balling and meltdown. Half the tests were made while firing the kiln with atmospheric-temperature air; the remainder were fired with preheated air. Tests showed that preheated air decreased fuel requirements, dust losses, and reducing agent, and increased the capacity of the kiln.

Jan 1, 1960

By C. A. Rowland Jr

"I. INTRODUCTIONFred C. Bond's ""Third Theory of Comminution"" (1) was published in 1952. The mathematical statement of the Third Theory is the well-known Bond Formula:where W - Kw H per short tonWl - Work IndexP - Product size in microns which 80% passesF .. Product size in microns which 80% passesWork Index, as defined by Fred Bond, "" ... is the comminution parameter which expresses the resistance of the material to crushing and grinding. Numerically, the Work Index is the KwHrs per short ton required to reduce the material from theoretically infinite feed size to 80% passing 100 microns."" (2)Work indices for grinding can be obtained tram Bond grindability tests and can be calculated from plant grinding mill operating data when power consumed per ton of ore ground, the feed size analysis and the product size analysis are known.Work indices obtained tram Bond grindability tests, having been obtained from standard and controlled laboratory procedures, are reproducible and for the sample tested are accurate. The degree of accuracy relative to plant mill operation depends upon how representative the sample is of the total mill feed.The results of the Bond closed circuit rod and ball mill grindability tests (3) are given in grams of product sized material produced per revolution of the test mill. In developing a method to evaluate plant operating data and results from his grindability test, Fred Bond developed the ""Third Theory of Comminution."" In the process formulae were developed for converting grams per revolutionobtained from grindability tests to work index.The standard feed sizes for the Bond grindability tests are:Rod Mill Test ore crushed to minus 1ll inchBall Mill Test ore crushed to minus 6 mesh (Tyler)The formulae for converting grams per revolution to work index incorporate the 80% passing sizes for the feed to and the product produced in the specific test. Therefore, accurate work indices can be obtained from Bond grindability tests when the feed size is finer than standard. To obtain accurate test results, the ratio of reduction should be greater than 6 to 1."

Jan 1, 1972