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By John G. Whellock

Over the last decade new constraints have emerged in the metallurgical industry which challenge the very basis of design and construction of smelters and refineries. The hackneyed designs of the past will not now serve the revised objectives of: - minimal cost of ownership - improved productivity - reduced energy consumption - greater flexibility in feed or product - minimized recycle loops and by-products - more stringent environmental control The impact of these constraints has been channeled constructively into process intensification - exemplified at the large scale by the introduction of flash smelting technology and at the smaller scale by the application of rotary process vessels and converters for augmented heat and mass transfer. The design of successful process plants depends on the understanding of the unit operations and their interactions which is the discipline of systems engineering. With the advent of increased process intensification the importance of a systems approach to process design and implementation becomes paramount. This paper describes the systems approach with specific reference to medium scale projects in the primary and secondary metallurgical industry.

Jan 1, 1985

By Irwan Halim, Stephane Polycarpe, Brian Hann

The Narragansett Bay Commission Phase III CSO Program includes construction of the 11,600-foot long, 30-foot ID, deep rock Pawtucket Tunnel in Rhode Island. This paper provides an overview of the Design Build Project features and highlight some of the important design considerations, features, and innovations, including geologic conditions and related TBM design, and deep shaft and tunnel segment designs. The paper provides the most recent updates on some of the project construction activities including TBM tunnel progress and retrieval schemes, tunnel pump station and deep vertical shaft liner installations, SEM construction, and microtunneling for the longest adit using Fiberglass Reinforced Polymer Mortar pipes.

Jun 23, 2024

By K. V. Raj, VASU GANGRADE

Airflow in large-opening stone mines is largely dependent on the natural ventilation due to the large cross- section area of the opening. The openings of such stone mines are typically twice or thrice the size of typical underground coal or metal/nonmetal mines. Due to the influence of natural ventilation, air velocities as well as the static pressure drop in the mines are low. Mines rely on auxiliary fans to ventilate active faces to reduce contaminant exposure to mine workers. The National Institute for Occupational Safety and Health (NIOSH) is conducting research on ventilation of large-opening stone mines to reduce worker exposure to dust and other contaminants such as diesel particulate matter (DPM). In order to reduce worker exposure to dust and DPM, an understanding of the airflow pattern due to auxiliary fans in the mine is needed. Under this research, NIOSH researchers are exploring the computational fluid dynamics (CFD) modeling to understand the airflow behavior in large-opening mines. In this paper, the team is presenting the results from three-dimensional CFD modeling of airflow in a large-opening stone mine and investigating the effect of a fan placement with the movement of trucks.

Feb 1, 2025

By Robert W. Greene

Next month, American Commercial Barge Line Company will begin moving coal from mines on the old Camp Breckinridge property in Western Kentucky to TVA's new 2600 MW steam plant at Cumberland City, Tennessee. By April of 1973, this movement will reach a level of 7,000,000 tons per year. TVA bought the coal rights to this property from the General Services Administration in 1965 for approximately $7 million. The reserve contains about 120 million tons of recoverable No.9 coal, and about the same recover-able amount of No. 11 coal. TVA then contracted through competitive bidding with Peabody Coal Company to mine the No.9 seam through two slope shafts. The mines are about 300 feet deep and are separated by the one major fault on this property. The mine portals are approximately 3-1/2 miles apart, with the northern portal being over nine miles distant from the Ohio River (see Figure No.1). In 1969 TV A took bids on alternate methods for transporting 120 million tons of coal to Cumberland City at seven million tons per year. These alter-natives included overland transportation to the Ohio River by rail or conveyor, water transportation from Union County, Kentucky to Cumberland City, and total transportation packages from Camp Breckinridge to Cumberland City. The latter could be a joint land/water package, or all land (rail). Ultimately American Commercial Barge Line was awarded an $88 million package transportation contract to convey the coal from Camp Breckinridge to Uniontown, Kentucky; to store it at Uniontown in a quantity sufficient to allow ratable delivery to the steam plant; and to barge from Uniontown to Cumberland City via the Ohio and Cumberland Rivers.

Jan 1, 1971

By Nikhil Dhawan, Veeranjaneyulu Rayapudi, Singh Rahulkumar Sunil

The ever-increasing demand for steel and the subsequent depletion of high-grade ores requires the massive utilization of low-grade iron ores. In the present study, an iron ore slime sample containing 56.1% Fe was investigated using physical beneficiation, carbothermal reduction, and a microwave-assisted process; however, physical beneficiation and microwave exposure were found to be inefficient as they yielded lower iron recovery. Using coconut shell as an alternative reductant was found to be promising and does not lead to the formation of higher iron oxides, such as fayalite and wustite phases. The microwave-assisted carbothermal reduction was found at par with conventional reduction, saving time and heating. The optimum magnetic concentrate obtained in both carbothermal reduction routes (microwave and muffle furnace: Fe grade, Fe recovery, and yield of 64.3, 97, and 84%, and 67, 99, and 83%, respectively) are suitable for alternative iron-making or blast furnace units.

By F. Varley, J. Whyatt

A variety of dynamic failure cases with regional impact were described at a bump symposium held in 1958. These types of events, while rare, are of particular interest because their ability to impact a large area has disaster potential. These cases can be grouped into two broad classes of events by mechanism. These are (1) a slip along steeply dipping faults and (2) the fracturing of strong strata above or below the coal seam. Both failure modes produce dynamic or “shock” loads on the perimeter (roof, rib and floor) of mine openings. Special consideration should be given to these failure modes in the planning of deep coal mines, since their occurrence is not within the professional experience of many contemporary workers. In addition, their potential is not evaluated by many of the analysis tools commonly used to evaluate hazards in coal mine plans.

Jan 1, 2009

By Rex T. Ellington

The fluidized bed is an effective method for investigating retorting phenomena and possibly a commercial means of retorting oil shale. Both were examined by Sinclair Oil Corp. (now part of Atlantic Richfield Co.) in the period 1.965 to 1968. The results of the work show that presence of an oxidizing environment during retorting results in loss of oil yield which indicates that vapor phase oil burns in preference to combustion of coke on spent shale. This has implications for several types of retorts. Correlation of the results of this work with that of other investigators shows that the partial pressure of retorting products in contact with oil shale during retorting has an effect on yield. Consideration of hardware indicates that there are several possibilities for commercial embodiment. As a companion to shaft-type retorts the fluidized bed could have good potential. Realistic assessment of costs suggests that further development may have to await commercialization of another process. The existence of a plant in which to test prototype size would markedly reduce such development costs. Results Preliminary development work with the apparatus was carried out using a fluidized bed of sand, as explained later, with the entire system brought up to temperature and flows stabilized. The shale was injected rapidly in a slug (batch) which had small mass compared to that of the high temperature system to make the reaction approach isothermality with reasonable approximation of instantaneous preheating. Typically, the temperature in the center of the bed dropped from 900°F to 600°F one minute after batch addition. It returned to 750' within three minutes and 900° within seven minutes. Obviously, the bed was quenched but it recovered rapidly. Average bed temperatures of 700' to 1020°F were examined to compare the effect of temperature with published results. Yields In the 700°F range were only 10 to 15%, of Fischer Assay (FA). Above about 950'F, oil yields decreased and gas yields increased. Nitrogen was used first as the fluidizing gas to provide a chemically inert medium. Incept for an insignificant dip at 895"F, Figure 1, oil yield was not affected by retorting temperature in the 800° to 900' range as long as residence time was adequate (16 minutes). At 925°F, the oil yield was some 103% FA. With further increase in temperature, the yield decreased to 86% FA at 1015°F. There is no increase in carbon on spent shale, the lost oil goes to Increased gas make.

Jan 1, 1972

By Timothy C. Richmond

The Stillwater District is located in south central Montana approximately 75 miles southwest of Billings, the state's largest city. It lies along the northeast front of the Beartooth Mountains and is within the boundaries of the Custer and Gelatin National Forests. The district contains some of the nation's most spectacular mountain scenery. Montana's highest peaks, including 12,799 foot Granite Peak, rise a few miles south of the area. Much of the district is located on a gently undulating plateau which averages 8500 ft. above sea level, broken by hills up to 10,000 feet and slashed by glacially carved canyons, some of which are more than 3,000 feet deep.(Fig. 1) Immediately to the north and east, the land falls away to the Great Plains, stretching unbroken to the Mississippi River. Two major tributaries of the Yellowstone River, the Stillwater and Boulder Rivers, traverse the area and several large streams originate in the district itself. Access to the high mountain country and the adjoining Beartooth Primitive Area is restricted to a few horse and jeep trails continuing from the terminus of improved roads in the bottom of the Stillwater and Boulder Valleys. Hunters, fishermen and cabin owners make intensive use of the area along its improved transportation routes, but hikers seldom venture more than three miles beyond the end of the roads. People from the Billings area are the most frequent visitors.

Jan 1, 1974

Up to the middle of 19 14, when I had reached what seemed like the advanced age of 30, I had enjoyed far more than my share of success and a lot of minor adventure. But the exciting experiences in distant lands that Soldiers of Fortune had made me long for had not yet materialized. And I had not accomplished the two goals that Mrs. Hughes' geography class at Belmont had set up for me. They were to see In its tropical home the enormous yellow bill of the toucan bird and to ride on a straw "bolsa" on Lake Titicaca. These aims were gratified In the next five years that were the epitome of "romance" in its German connotation of facts seen through the rosy glasses of imagination. Dr. Louis Ricketts was to a large extent responsible for my opportunity. I had been lucky enough to do a lot of work for and with the Doctor, as he was affectionately called by the mining men of the southwest. My association was in connection with his work with John Greenway on the complex metallurgical problems at Ajo. Soon after the Ajo investigation Ricketts had been made chief consultant for the Anaconda Copper Co. When Anaconda decided to undertake a cam- paign of exploration of the west coast of South America Dr. Ricketts thought of me and arranged with Greenway to give me a leave of absence from my Calumet and Arizona job. It took three days in New York in June 1914 to arrange the expedition. Ben Thayer, executive vice president of Anaconda, did most of the planning and I was to report to him. T.H. France, a 45-year-old mining engineer who had been driven out of Mexico by the Madera Revolution, was to accompany and help me. He spoke excellent Spanish and his years of Mexican experience had taught him how to get along with Latin Americans. He went ahead to Bolivia, our first target, to get an idea of the country and the problems. This was lucky as I hardly knew where Bolivia was.

Jan 1, 1976

By Karoly (Charles) Kocsis, Jeff Johnson, Felipe Calizaya, Tulio Dias, Natanna Nunes

Two pressure balancing chambers were constructed at a Colorado coal mine to reduce the risk of spontaneous combustion. Each chamber was established by installing a Kennedy stopping at about 10 ft (3 m) in front of an isolation seal, and equipped with two safety doors, a nitrogen injection system, and a set of environmental monitors. Several pressure balancing tests for different ventilation conditions were conducted in these chambers. During each test, pressurized nitrogen was injected into the chamber and the pressure differentials across the stoppings and seals monitored. This study presents a summary of the results achieved, lessons learned, and the basic requirements to operate a pressure chamber effectively.

Feb 1, 2024

By C. D. Mann

INTRODUCTION The sublevel stoping mining method is usually applied to a relatively steeply dipping, competent ore body, surrounded by competent wall rock. Ore is produced by drilling and blasting longholes, which can range from 50 mm (2 in.) to 200 mm (7% in.) diam, with lengths up to 90 m (300 ft). Longholes can be inclined in any direction, but the ring or pattern usually forms a plane, and the holes are blasted as a unit. Recently developed mobile drilling and loading machinery, as well as new explosives products, blasting techniques, and cemented sand and rock fill have made sublevel stoping a highly efficient and versatile mining method. When designing a sublevel stoping production sys- tem, it should be kept in mind that production rates from conventional sublevel stopes vary widely through- out the life of the stope. Early production is at a low rate, coming only from the drawpoints near the slot, but increases as new drawpoints are reached by the stope face. As the stope nears completion, again, fewer drawpoints are productive. Enough drawpoints must be available at any time to provide required production. Drawpoint availability should be compared to equipment availability; plan for more drawpoints than are needed at any one time. Accurate, realistic scheduling is essential to smooth production rates. Also, initial recovery of ore in a stope/pillar block is normally from 35% to 50% in sublevel stoping. Planning of pillar recovery, representing the majority of ore tonnage in a production block, must be done during early mine planning. Since much of the development already done for primary stoping (access for drilling, drawpoints, and haulageways), can be used for pillar recovery, early production from pillars is highly desirable. The following description of components of the system is an attempt to highlight some of the most important features and requirements of mechanized sublevel stoping methods. Similar comments would apply to the use of older equipment (column-and-arm drill setups, slushers, etc.) in similar methods. As in any good mining system, maximum economic recovery of the resource in the ground is the primary consideration. STOPE DESIGN CHARACTERISTICS Length and Width The following are some of the factors which affect sublevel open stope length and width dimensions: ore body geometry, principal stress directions, competence of stope back, optimum drill pattern, and drilling drift layout. In new mines initial stope layout design may occur before the ore body is actually intersected by mine workings. Stope dimensioning is a critical decision, and assistance from as many knowledgeable people as possible at this stage is essential. Operators with past experience in similar ore bodies, rock mechanics experts, and others with mine design experience should participate at this stage of stope planning. Height The following are some of the factors which must be considered in determining stope height: competence of stope pillar and stope/fill walls; slenderness ratio of adjacent pillars; ore body dip; ore body thickness; hole depth capability of the drilling machine; fragmentation characteristics of the ore; and level intervals in existing mines. In competent ground, drill-hole length and accuracy are the most important determinants of stoping height. Frequently entire drilling sublevels can be eliminated because of the depth capability of sophisticated drilling equipment, resulting in significant development cost savings. Drawpoint Location and Design Some of the most important considerations of a good drawpoint system are optimum spacing of draw- points, within the constraints of stope dimensions, for uniform drawdown and maximum recovery; excavations designed for stability for the life of the ore block to be drawn-primary stope ore as well as subsequent pillar ore; floor or roadway design including type of surface, reinforcing, grade for water runoff; orientation with respect to the main haulageway, for optimum loader maneuverability and ground stability at the inter- section; and length, to allow articulated front-end loaders to work in a straight configuration. Careful drawpoint design and construction are keys to successful production. Extra care in development, such as smooth wall blasting, rockbolts or grouted rebar, wire mesh, and shotcrete usually will ensure long draw- point life. Human exposure during production loading is of longer duration than during development or production drilling, and consequently preparation of draw- points is easily justified, particularly when pillar ore can be drawn through the same drawpoints. Secondary blasting of boulders can weaken drawpoints, also justifying good ground control techniques. A smooth draw- point floor of poured, reinforced concrete, on a grade of +3% or +4% toward the ore pile facilitates water flow out of the drawpoint, and ease of loader bucket penetration into the muck pile. Slot Raising, Slotting A slot or other space for rock expansion is necessary in conventional sublevel stoping where vertical rings or rows of holes are blasted. The slot can be started at a slot raise driven by conventional raising methods, raise boring, drop raising (predrilling and blasting a raise from the top, using small diameter-less than 200-mm (7%-in.)-holes for relief), or crater blasting (similar to drop raising, but without relief holes). The slot usually extends from the extraction level to the back of the stope. It is normally expanded to full stope width by

Jan 1, 1982

By Garland R. Dever

Limestone resources for industrial, constructional, and agricultural uses occur on the surface and at minable depths in several areas along the Ohio River and its navigable tributaries in Kentucky. Operable thicknesses of high-calcium and high-carbonate limestones suitable for use in cement and lime production, steel manufacture, environmental-control measures, and other special uses are documented in Ordovician and Mississippian formations by analysis of 0.3-meter (foot-by-foot) samples. Active and potential mine and quarry sites afford access to water transportation and proximity to a number of industrial and metropolitan centers. Geologic factors affecting the distribution of deposits include the Cincinnati arch, regional dip into the Appalachian and Eastern Interior basins, complex faulting in and near the Western Kentucky fluorspar mining district, and late Paleozoic erosional unconformities in northeastern Kentucky.

Jan 1, 1977

By L. U. Spellman

Atlantic Cement Company's new multimillion dollar, 10,000,000 barrel per year cement plant went into full operation in February, 1962, bringing into reality a new concept in the distribution of Portland cement. The Cerro and Newmont Mining Corporations, well established in the mineral extraction and dressing industry, backed the venture. To take advantage of the, economics inherent in single production units of large capacity, it was necessary to first find a market' capable of absorbing such large quantities. Cement can be economically shipped by rail and truck about 200 miles. Beyond' that radius from the producing facility the freight costs become prohibitive. No single marker area within that radius exists which could absorb such a large volume of cement. However, water transportation provides a relatively inexpensive method of transporting bulk products many times over such a distance. Thus, it was decided to locate the producing facility near a deep water port which had ready access both to the Atlantic Ocean and, just as important, a good source of raw material. An extensive feasibility study was made and the site at Ravena, New York on the Hudson River near Albany was chosen. Here, vast quantities of limestone in the foothills of the Catskill Mountains are found within a short distance of-the deep-water Hudson River.

Jan 1, 1964

By Camillo Premoli

Namibia is one of Africa's newest nations. A German colony until 1915, it then became a South African protectorate until 1990, when it gained independence after an armed struggle that lasted more than two decades. However, no trace of past bitterness can be found today in the capital, Windhoek, or in the countryside. Namibia is now one of the safest parts of Africa. Namibia's industrial base and infrastructure have been untouched by war. Swapo, the ruling party, has embarked on a successful policy of reconciliation and economic development. The GNP per capita is a surprising $1500 (from the World Bank), one of the highest in Africa. Namibia's population stands at 1.3 million, including about 100,000 whites. Namibia is a very sparsely populated country (1.7 inhabitants per km2). About 70% of the people are farmers. Namibia has a surface area of 824,232 km2 (318,261 sq miles), about the size of France and Germany combined. The semi-arid climate and generally flat morphology make the country well suited to mineral exploration. About 40% of the country presents abundant rock outcrops. The rest is buried under the Kalahari sands. However, this cover in most of the country hardly exceeds 200 m (655 ft), and Australian technology has shown that large mineral deposits (Roxby Downs) can nowadays be found at even greater depths. Mining is Namibia's largest industry. In 1991, it accounted for 22% of the country's GDP, about 70% to 80% of its exports by value and 25% of internally generated government revenues. The Ministry of Mines and Energy (MME) is responsible for formulating and implementing national mineral policies. This agency has recently introduced legislation aimed at encouraging new and long-term investment in the mineral sector. The variety of Namibian mineral resources, both metallic and nonmetallic, is rivaled by few countries worldwide.

Jan 1, 1994

By Lennart Malmqvist

Decision-making in exploration deals with experience, knowledge, and sometimes faith, but very often financing and profit, mineral resource aspects, employment, and general political ambitions are parts of the scene. At one end of this spectrum, there is the prospector and his decision on the actual project. The exploration business now expands from its pioneering phase for the benefit of a single company to a wider spectrum which includes the benefit of the large mining consortium and a national development program. Its objectives are also to maintain employment and to favor long-term stability in a mining district or a mining company. The prospector then has new aspects and questions to consider such as, what to do in mining districts where there is a shortage of ore resources but there are still useful investments in mines, processing plants, etc. To analyze the exploration process, therefore, seems to be of great importance in a time of rapidly changing conditions. As in other areas of complex decision-making, for example, in the fields of investments, of production, and of the armed forces, computers most certainly have an important role to play in future exploration decision-making systems. However, we must first analyze our own business as closely as possible to find out what kind of information we need, i.e., why we recommend an exploration program as a good or a poor one. An important part of the debate about exploration is the case study. Case studies on exploration are few and most of those written are only about successful exploration programs. Where are the case studies of the failures and the not so successful programs? Every prospector knows that the majority of exploration projects fail. Consequently, the most important experience seems to be hidden in the failures.

Jan 1, 1979

By L. H. Pye

For large mining sites in the west, the traditional method for performing an ecological risk assessment (ERA) provides little useful information for risk managers faced with selecting and designing sound remedial options. Current U.S. Environmental Protection Agency (EPA) risk assessment guidance largely supports quantitative risk characterization of individual species as surrogates for population and ecosystem-level effects. Developing a work plan for investigating and remediating ecosystem-level changes potentially caused by large-scale historic mining/smelting contaminant release requires a decision process that incorporates a more holistic ecosystem management approach. Some of the most wasteful efforts associated with mine site ecological risk assessments arise when the risk analysis and data collection programs are not specifically linked up-front to the risk manager's decision needs. The following paper discusses the importance of employing a decision-based, ecosystem management framework when conducting ecological risk assessments at large mining sites. A case study of an ecological risk assessment currently being performed at a large New Mexico copper mine site is presented.

Jan 1, 1999

By Paul G. Schmidt

The Crandon massive sulfide deposit Forest County, Wisconsin, was discovered by Exxon Minerals Company, U.S.A., in July 1975. Announced estimated in-place reserves are 62 M metric tons (70 million short tons), grading about 5% zinc and 1% copper. The reserves are evenly divided between massive sulfide are and stringer sulfide ore. The sulfide body is associated with Precambrian felsic pyroclastic rocks, and it is overlain by intermediate volcanic rocks and their derived sedimentary rocks. These rocks were subjected to greenschist facies metamorphism and were tilted to a near-vertical attitude. Geologic observations indicate a submarine-volcanic-exhalative origin for this deposit.

Jan 1, 1978

By John A. Folinsbee

Placer Dome Canada owns and operates the Campbell mine and mill at Balmertown, in the north western corner of Ontario. The mine operates at 1.3 kt/d (1,500 stpd). It produced more than 9.3 t/a (300,000 oz/year) of gold during the last three years. Changes to the gravity concentration circuit have resulted in a 10% to 15% increase in gravity recovery. The mill head grade at the Campbell Mill is relatively high, averaging 18.5 g/t (0.54 oz/st) over the total reserve tonnage. During the past several years, the head grade was averaging close to 20 g/t (0.6 oz/st). Before 1994, gravity concentration was achieved by using a combination of conventional mineral jigs and tables. Jig concentrates were upgraded on shaking tables to produce a concentrate, which was refined to bullion. In May 1994, management decided to buy two Knelson CD 760-mm (30-in.) concentrators. The objective was to replace the existing jigs and increase gravity gold recovery by up to 15%. Gravity recovery with jigs averaged between 30% to 35%. Gravity recovery was anticipated to increase to about 50% with the Knelsons.

Jan 1, 1997

By Herbert Pöllmann

The mineralogical and chemical compositions of various waste materials undergo different reactions when treated thermally The heavy metal contents can be bound to stable phases. These minerals are called reservoir minerals. The main property of these minerals is the stability in their geochemical surrounding containing the heavy metal cations and anions. Examples for these minerals are apatites, spinels, garnets, perovskites and also water containing minerals like ettringites, metal-metal-hydroxi salts, jarosites and zeolites. When the chemical compositions of different wastes are mixed according to the compositions of the new formed minerals, a probable reuse of these wastes can be obtained. The use of waste incineration ashes for the production of cementitious binders and the use of flue gas desulfurization products for cement additives are shown. Also the transformation of highly contaminated materials into stable reservoir mineral assemblages are shown including the study of stabilization and immobilization techniques.

Jan 1, 1998

By Richard A. Thomas, Liming Yuan, Wei Tang, JOHN SOLES

Lithium-ion battery applications are increasing for battery-powered vehicles because of their high energy density and expected long cycle life. With the development of battery-powered vehicles, fire and explosion hazards associated with lithium-ion batteries are a safety issue that needs to be addressed. Lithium-ion batteries can go through a thermal runaway under different abuse conditions including thermal abuse, mechanical abuse, and electrical abuse, leading to a fire or explosion. The NIOSH Mining program is conducting research to prevent and respond to lithium-ion battery fires for battery electric vehicles in the mining industry. In this study, experiments were conducted to investigate the effectiveness of different suppression systems including dry chemical, class D powder, and water mist for lithium iron phosphate battery pack fires. The effects of activation time and release time of the water mist system on the suppression of lithium-ion battery fires were studied. The results of this study may be helpful for developing strategic firefighting and response plans for battery-powered vehicles used in mining.

Feb 17, 2024