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By J. G. Groppo

In 1992, 48 million tons of fly ash (not including bottom ash, boiler slag and FGD material) was produced in the United States, according to the American Coal Ash Association. Of this amount, 27.2% was utilized; although the percentage of fly ash utilized increased from 20% in 1980, there is significant potential to increase utilization. One of the primary driving forces behind increased utilization is increased disposal costs due to more stringent environmental controls and regulation. Fly ash is classified as a natural pozzolan and finds significant use as a cement additive. It has been found to increase the plasticity of the cement mixture while lowering the amount of mix water needed. In addition to improving leveling and finishing properties, fly ash improves pumpability as well as decreases the heat of hydration of the concrete mix which is particularly important in massive concrete structures such as dams where the concrete needs to cool as quickly as possible. The Loss on Ignition (LOI) of fly ash is an important quality when considering utilization. The LOI is primarily due to the presence of unburned carbon and the standard specifications for the use of fly ash as a mineral admixture in Portland cement concrete are given in ASTM C618-89a. which sets an LOI limit of 6%. However, many states have set a more stringent limit of 3%. The primary reason for the lower LOI specification is that carbon adsorbs air entraining agents which limits freeze-thaw resistance. This is particularly important in climates such as the midwestern US where multiple cycles of freezing and thawing are typical in winter.

Jan 1, 1995

By Walmir Pereira de Amorim Junior

Imersas em um mercado em constante mudança, as empresas têm seguido em uma busca contínua pela melhoria de seus processos. Diante disso, nos últimos 2 anos, o segmento de Aços Planos da ArcelorMittal Brasil vem passando por um processo de transformação, revisitando e reestruturando seus processos internos. Na área de planejamento um dos itens avaliados foi o processo de Planejamento de Vendas e Operações – Sales and Operations Planning (S&OP). O objetivo desse trabalho é a apresentação do novo modelo de S&OP da ArcelorMittal Brasil – Aços Planos, seus benefícios, e ferramentas utilizadas para suportar essa evolução: o SAP Integrated Business Planning for S&OP e a plataforma de colaboração SAP Jam, responsável por orquestrar todo fluxo de S&OP e as interações entre as diversas áreas envolvidas. O novo processo foi baseado nos conceitos existentes na literatura e também é objeto desse artigo. Além disso, no projeto de implementação do SAP IBP e SAP Jam foram utilizadas a Metodologia de Gerenciamento de Projetos baseada nas melhores práticas descritas pelo PMBOK (Project Management Body of Knowledge) do PMI (Project Management Institute) e a Metodologia SAP Activate para a implementação dos produtos. Como resultado da implantação desse projeto, foram obtidos vários benefícios, sendo alguns deles já atingidos e outros a serem capturados após o período de adaptação e estabilização dos processos e ferramentas.

Oct 30, 2017

By Scott W. Hazen

This report describes the design, analysis, and results of a special experimental mine-sampling project conducted as part of the Bureau of Mines continuing program on sample-methods research. The experimental project was conducted at the Bureau?s Denver Mining Research Center and at the Climax molybdenum mine within the framework of a cooperative research agreement between the Bureau and Climax Molybdenum Co., Division of American Metals-Climax, Inc. The primary objective of the project was to investigate the interrelation-ship between sample volume, number of samples, the standard deviation of an assay distribution, and the precision required for an estimate of grade of ore, and to develop this interrelationship into a relatively simple method of application for use in mine sampling.

Jan 1, 1962

By J. F. Boux

"The study of the total utilization of fly ash has involved all of the known technology in the processing of this waste material into useful products. In addition, a complete knowledge of all the possible uses of fly ash and its products in the market area was probably the most important factor in evaluating the theory and practical feasibility of the total utilization of fly ash from a single large supplyLaboratory tests carried out on the separation of fly ash into different fractions were shown to improve its value and utilization. Four main fractions were studied: a fine pozzolanic low-carbon fraction; a coarse fraction for light-weight aggregate production by pelletizing and sintering; a high-iron fraction; and a carbon-rich fraction. The term ""beneficiation"" here refers to a process of separating fly ash into more useful components.Laboratory and pilot sinter strand tests were employed to optimize the sintering capability and the quality of the heat-hardened pellets through a study of the agglomeration cycle in four principal heat zones, under controlled conditions of air flow, temperature and atmosphere, and including the controlled sizing of pellets.The suitability of the heat-hardened pellets as light-weight aggregate was evaluated in test batches of concrete, which were compared with concrete containing commercial lightweight aggregate of established quality.A study of beneficiated fly ash pozzolan as a partial cementitious binder component in normal and high-temperature cured concrete was reported in a paper at the re-cent Second International Fly Ash Symposium.Samples of raw and beneficiated Lakeview ash were compared with samples of other established high-quality fly ash pozzolans. The evaluation indicated the usefulness of beneficiated Lakeview ash as a pozzolan. Economic studies indicated that to accomplish the primary objective of total utilization of any single source of fly ash (in this case. fly ash from the Lakeview Generating Station, producing approximately 400,000 tons per year), a broad knowledge of the technology of various mineral processes was essential.The design of the fly ash processing plant had to be based on the disposal of all the raw fly ash produced by the generating station. This is contrary to the normal design of a processing plant in which raw materials are supplied and produced according to product demand. The design, therefore, had to be of such flexibility as to pro-duce as wide a variety of products as possible, and the ability to market them had to be well researched and understood."

Jan 1, 1970

By B. G. Stone

"INTRODUCTION “Sampling is the process of taking a small portion of an article such that the consistency of the portion shall be representative of the whole” (Baxter and Parks, 1939) “An orebody is a mixture of minerals in proportions that vary in different parts of the mass. As a consequence the proportion of contained metals also varies from place to place. Therefore, a single sample taken in any particular place would not contain the same proportion of metals as does the orebody as a whole except by a highly improbable coincidence. The probable error, which would be very large if only one sample were taken, decreases with the number of samples, but it never disappears completely unless the samples are so numerous and so large that their aggregate is equal to the orebody itself, in which case the orebody would be completely used up in the process of sampling. Since carrying sampling to such an extreme would defeat its own purpose, some probable error is always present in actual cases and the practical objective is to reduce this probable error to allowable limits. This means balancing the number of samples against the desired accuracy; if there are not enough samples the result is unreliable; if there are too many, the time and expense of taking them is excessive.” (McKinstry, et al., 1948). In an actual orebody, the accuracy of sampling depends not alone on the number of samples but also on proper distribution of them throughout the orebody, for it would obviously be incorrect to take all of the samples either in a rich part or a lean part. Therefore it is important to select the places in such a way that all parts of the orebody will be represented. “For those who cultivate land which is alike arid, heavy , and barren, and in which they sow seeds, do not make so great a harvest as those who cultivate a fertile and mellow soil and sow their grain in that. And since by far the greater number of miners are unskilled rather than skilled in the art, it follows that mining is a profitable occupation to very few men, and a source of loss to many more.” (Georgius Agricola page 5 Book 1 as translated by H.C. Hoover and Lou Henry Hoover, 1950)“It is evident that mining is very profitable to those who give it care and attention”"

Jan 1, 2015

By Lauro Lacerda

Shotcrete is a highly adaptable and widely used underground construction material at infrastructure and mining projects around the world. In fact, many projects could not have been completed without its utilization. As underground projects became larger the use of mechanized wet-mix spraying gradually replaced manual dry-mix shotcrete applications. This paper details some of the reasons for that and provides information on the equipment and operational factors including safety and productivity required to successfully complete underground shotcrete projects.

Jun 13, 2021

By R. A. Nemchek

ABSTRACT Concentrator plant design has evolved from large numbers of small grinding mills to small numbers of large mills. Consequently, plant performance often hinges on the productivity of a single large semi-autogenous grinding mill. Industry attempts to address the grinding mills’ critical nature frequently result in specifications that can be made simpler, more economical, and better focused on the project’s goals. This paper surveys current specification writing practices and proposes an improved approach recognizing that product design, procurement, manufacturing, and quality are interrelated in a successful project. The lessons learned here can apply to all types of machinery specifications.

Jan 1, 2014

By J. M. Kuchta

The Bureau of Mines investigated four simulated coal gob fires to obtain a more reliable data base for defining the state of a sealed mine fire and to evaluate the performance of various fire detectors. The fires were conducted in a multiple-entry section of the Bruceton Experimental Mine by heating 4,000 to 21,000 pounds of rubblized bituminous coal to ignition and monitoring the temperature, gas emissions, and smoke under ventilated and sealed combustion conditions. Product gas concentrations depended upon the coal bed size, coal temperature, heating rate, and oxygen concentration or ventilating condition but varied little after the fires were sealed. Expressions are given that define the temporal variation of CO and O2 after sealing when the coal temperature decreased rapidly. The CO/C02 ratio is a more sensitive fire indicator than the CO/?02 ratio, although the latter is universally used for detecting the incipient state of a coal fire. In comparison, the Jones-Trlckett ratio [ CO2 + ¾ CO ? ¼ H2 ?O2] is less reliable for this purpose. The best detector for determining the state of a mine fire after it has been sealed was a prototype submicrometer smoke particulate sensor. Limitations of the various detector systems are also discussed.

Jan 1, 1982

By L. P. James, W. W. Atkinson

Utah has produced about 31.7 kt (1 billion oz) of silver, more than any state in the United States except Idaho. Several high-grade ore systems in Utah, where the mines are now closed, occur within large polymetallic limestone-hosted districts related to plutonic complexes. These mines fed several major lead smelters for nearly a century. Interaction of magmatic chloride-rich fluids with carbonate rocks localized significant bonanzas within these districts. A low sulfidation state was produced in the fluids by their passage through limestones. The Bingham openpit mine has also yielded more byproduct silver than other porphyry copper-molybdenum-gold systems. Away from exposed intrusive rocks, some large silver-only systems occur in Mesozoic sandstone and in caldera-related veins in volcaniclastic rocks. Thick permeable latest-Proterozoic basement metaquartzite sequences present beneath western Utah may have been important, as perhaps they were in the Coeur d'Alene district of Idaho, in providing chloride and silver-rich ore fluids. However, it is clear that specific Tertiary magmatic events played an essential role in the evolution of the Utah silver-rich metallogenic province. The largest silver districts in the state are genetically related to Tertiary porphyritic plutonic rocks.

Jan 1, 2003

Jan 2, 1976

By Dave Deglon

The Western Cape Mineral Processing Facility (WCMPF) is a collaborative educational initiative between the Departments of Chemical Engineering of the University of Cape Town, the University of Stellenbosch and the Cape Technikon. The WCMPF was established in 1989 with the aim of improving mineral processing education in the Western Cape. Since its inception the WCMPF has had a number of successes in this area, especially in improving the quality of mineral processing practical training. In addition, the WCMPF has played an important role in promoting liaison and interaction between tertiary educational institutions teaching mineral processing in the Western Cape. Over the past decade the WCMPF has played a key role in the education of over five hundred mineral processing graduates and diplomates. This paper presents an overview of the activities of the WCMPF and attempts to encapsulate the ‘lessons learned’ from over a decade of successful functioning as a collaborative educational initiative in mineral processing.

Jan 1, 2003

By R. W. Bartlett

High salinity geothermal brines typically contain up to several hundred parts per million of valuable heavy metals, and because of the large potential flow of geothermal brines from future power plants, metal production as a by-product could be significant A-planned 55-MW demonstration plant near Niland, California should generate enough spent brine to contain approximately $670,000 per year in gross metal values. Lawrence Livermore Laboratory estimates (1) a Salton Sea Geothermal potential of 1300 to 8700 MW, which would translate to possible yearly heavy metal values between $5,800,000 and .$l05,000,000. Since these estimates were made on a conservative basis, this geothermal reservoir is potentially a large ore deposit. The heavy metals in order of decreasing abundance in high salinity brines from the Salton Sea geothermal field are usually manganese, zinc, iron, lead, and silver. All but manganese and iron are valuable enough to be of commercial interest. Minor amounts of copper and arsenic are also present. Although heavy metal precipitates, particularly lead, have been found in scales within pipelines and obtained from steam flashing, most of the metals remain soluble during steam production; hence removal of the valuable metals from the spent brine before reinjection in ground reservoirs is indicated. Because the heavy metal concentrations are low, a very simple and inexpensive process is required. The heavy metal value in Niland brine is only ' about $1 per 1000 gallons; see Table 1. The brine composition shown in Table 1 was taken from one of the brine samples used in our study. Projected post-flash brine from a steam plant has somewhat higher Zn and Pb values, but the gross heavy metal value is still less than $2 per 1000 gallons.

Jan 1, 1980

By R Blin, R Walde, R Belli, D Inaudi

A fiber optic distributed sensing system allows the monitoring of parameters useful to determine the short- and long-term behaviour of the structure in response to the external actions, including, eg seismic activities as well as long-term phenomena such as seepage, tunneling, sinkholes, and other geo-structural movements. Monitoring of large retaining structures with such a system provides direct strain/deformation and temperature measurements on the broad interior area with an arrangement of several sensing cable lines, enabling early detection, localisation and sizing of subsurface damages. Measurements are provided every meter along the entire sensing cable, this is particularly important in such cases where the location of defects and damages cannot be predicted. Fiber optic distributed sensing cables are generally available for retrofit installation inside the dam structure using trenches on the downstream face or laid during construction below the geomembrane liner within the bedding sand layer. Mapping the cable route enables exact correlation between a linear coordinate on the cable length and a position in the dam. Cable installation is envisaged to be carried out during further raising of the embankment; additional cable sections are plugged to the previously installed cables and measured with the existing measurement system, requiring only an update of the mapping. The measurement system is placed remotely from the sensing area since a section of sensing cable can be used to link to the sensing area at the storage facility several kilometers away. The system is available for on-line, 24/7 real-time operational data management. Such fiber optic distributed sensing systems allow storage facilities to be monitored with long, accurate, continuous and precise data for geotechnical diagnostic purposes. This contribution will introduce the principles, benefits, and limitations of this technology.

Jul 1, 2021

The Florida phosphate industry, which supplies about three-quarters of the domestic phosphate fertilizer, produces tremendous volumes of phosphatic clay wastes (slimes). These clays retain a high percentage of water for extended periods of time. The clays also pose an environmental hazard because the disposal technique involves aboveground storage behind earthen dams. Although much research has been undertaken by numerous organizations to dewater slime, no completely satisfactory solution has been developed. In June 1972, a cooperative effort by the Federal Bureau of Mines and the Florida phosphate mining industry was initiated to develop a solution for dewatering the Florida phosphatic slimes. This report discusses various aspects of the slimes problem, reviews past research, makes recommendations for future research, and includes a bibliography of references and patents dealing with the subject.

Jan 1, 1975

By Pratt V

The economic, social and political environment of the mining and minerals industries is, as we all know, volatile and affected by constantly changing international forces. In addition, the outcome of negotiations with overseas customers is often uncertain for long periods, or even unfavourable. The industries and companies represented at this Conference are in an arena of high competition, risk taking and enormous capital outlay. They are industries which our overseas markets (rightly or wrongly) have criticised for industrial relations problems, unreliable production and uncertain deliveries. They are industries which have an urgent need to be cost effective and competitive at all levels of activity.A critical factor in the mining and metallurgy industries is, therefore, its human resources and its human resource management. It requires the full use of available talent, innovation, skills and qualifications within its workforce, and the appropriate management of these resources.

Jan 1, 1985

By R. M. Powers

The Florida Institute of Phosphate Research (FIPR) has funded a four-year research project to develop a computer model 'which will predict the hydrologic impacts of phosphate mining on surface and groundwater systems. The core of the model is an analytical geographic information system (SPANS) which integrates EPA's Hydrology Simulation Program Fortran (HSPF) surface water model with the McDonald-Harbaugh groundwater model (MODFLOW). The hydrologic model conducts both event and continuous annual Simulations driven by variable precipitation and temperature data. The model is currently being calibrated and will be ready for distribution to the user community in mid-1991.

Jan 1, 1990

By T. Gonzales

Magma Metals Company operates an Outokumpu Flash Furnace, four Peirce-Smith Converters and two Anode Casting Wheels supported by six Anode Vessels. Process gasses from the Flash Furnace and Converters are treated in a two train/double contact sulfuric acid plant. Sulfur capture for the smelter is +98%. The new flash furnace was commissioned on July 7, 1988 and has processed over three million tons of sulfide concentrate without a major rebuild. Magma has gained unique experience in the operation of the flash furnace at high oxygen enrichments with low off-gas dust loadings. New procedures have been developed to maintain secondary material generation at equilibrium and for maintaining metallurgical control of operating parameters. This paper describes all the procedures, operation control parameters and operating philosophy that has allowed Magma to achieve superior performance.

Jan 1, 1992

By Peter Zhang, Mark Van Dyke, Ted Klemetti, Morgan Sears

Room-and-pillar mining is a mining method used in the United States to extract coal from underground, and pillar recovery is widely practiced for maximizing coal recovery and mining economics. Under certain conditions, room-and-pillar mining can create high stresses in coal pillars resulting in a coal outburst. These outbursts represent one of the more severe safety hazards in underground coal mines, potentially causing injuries and fatalities. Over the past ten years, coal outbursts have resulted in three fatalities in U.S. room-and-pillar mines. Though coal outbursts generally occur under deep cover, they are more likely to occur during pillar recovery and under multiple-seam mining conditions. Coal outbursts are generally associated with strong roof and floor and heavy loading of coal pillars, but it is difficult to predict whether, where, and when they will occur. In this respect, risk management provides a proactive tool to prevent coal outbursts in room-and-pillar mining by identifying mining areas with high risk of outburst and mitigating the risk accordingly.

Apr 26, 2022

By J. E. Burke, C. W. Mason

In attempting to study precipitation from a tetragonal lattice, using solid solutione of bismuth in tin, it was found that although a Widmanstätten pattern is observed1,4 only a qualitative analysis of the orientation relationships is possible, because of the unusual structural changes that accompany the precipitation process. Microscopical Studies Alloys were made from Chempur tin (Standard samples 42b and 426, National Bureau of Standards), and bismuth (Kahl-baum C.P.) by melting weighed quantities together under palm oil, stirring well, and castilig in a heated graphite mold. The polishing and etching techniques employed largely govern the visibility of the structural changes. The preliminary surfacing operations were similar to those recommended by Villela and Bergekoff,5 through Behr-Manning 3/0 abrasive papers, lubricated by a solution of paraffin in kerosene. A rough metallographic polish was next given, using a thin cotton cloth charged with relevigated alumina (maximum particle size of about 4µ) and soap solution; repeated etching and polishing served to remove disturbed metal. For high-power examination better preparation was necessary. It was found that on such soft metals the threads of the fabric, rather than the abrasive, cause most of the scratching. Cotton outing flannel, which had been brushed so that the nap lay down, was fairly satisfactory, but a heavy grade of silk velvet (not the noncrushable kind) was found to be better, especially after some use. A better procedure was as follows: The metal lap was warmed slightly, and a 4-in. circle of woolen broadcloth was cemented to its center by a thin film of melted paraffin. The broadcloth was then moistened with water, and a 30 to 40 per cent solution of sodium hydroxide heated to about 50°C. was poured over it, allowed to stand for I to 2 min. and then washed off. It was neither necessary nor desirable to remove all the sodium hydroxide from the cloth, since its etching action aided in the removal of the flowed layer from the sample. The cloth was then charged with a paste of the relevigated alumina in water. Since this lap did not remove deep scratches, it was necessary previously to polish the specimen on some material such as the silk velvet. The sodium hydroxide softens and partly gelatinizes the woolen lap covering, permitting a scratch-free polish, but its action continues, and the cloth deterioratcs after about 24 hr. This is not serious, because a new lap can be prepared in about 5 min., and only small pieces of cloth are used. Etching with a strongly acid solution of ferric chloride was found satisfactory for removing the flowed layer. For the final etching, the most satisfactory reagent was that of Tafls,7 the formula for which is: FeC13.6H2O, 2 grams; HC1, 5 c.c.; H2O, 30 c.c.; C2H5OH (95 per cent), 60 C.C. This etchant reveals differences in com-

Jan 1, 1942

By J. E. Burke, C. W. Mason

In attempting to study precipitation from a tetragonal lattice, using solid solutione of bismuth in tin, it was found that although a Widmanstätten pattern is observed1,4 only a qualitative analysis of the orientation relationships is possible, because of the unusual structural changes that accompany the precipitation process. Microscopical Studies Alloys were made from Chempur tin (Standard samples 42b and 426, National Bureau of Standards), and bismuth (Kahl-baum C.P.) by melting weighed quantities together under palm oil, stirring well, and castilig in a heated graphite mold. The polishing and etching techniques employed largely govern the visibility of the structural changes. The preliminary surfacing operations were similar to those recommended by Villela and Bergekoff,5 through Behr-Manning 3/0 abrasive papers, lubricated by a solution of paraffin in kerosene. A rough metallographic polish was next given, using a thin cotton cloth charged with relevigated alumina (maximum particle size of about 4µ) and soap solution; repeated etching and polishing served to remove disturbed metal. For high-power examination better preparation was necessary. It was found that on such soft metals the threads of the fabric, rather than the abrasive, cause most of the scratching. Cotton outing flannel, which had been brushed so that the nap lay down, was fairly satisfactory, but a heavy grade of silk velvet (not the noncrushable kind) was found to be better, especially after some use. A better procedure was as follows: The metal lap was warmed slightly, and a 4-in. circle of woolen broadcloth was cemented to its center by a thin film of melted paraffin. The broadcloth was then moistened with water, and a 30 to 40 per cent solution of sodium hydroxide heated to about 50°C. was poured over it, allowed to stand for I to 2 min. and then washed off. It was neither necessary nor desirable to remove all the sodium hydroxide from the cloth, since its etching action aided in the removal of the flowed layer from the sample. The cloth was then charged with a paste of the relevigated alumina in water. Since this lap did not remove deep scratches, it was necessary previously to polish the specimen on some material such as the silk velvet. The sodium hydroxide softens and partly gelatinizes the woolen lap covering, permitting a scratch-free polish, but its action continues, and the cloth deterioratcs after about 24 hr. This is not serious, because a new lap can be prepared in about 5 min., and only small pieces of cloth are used. Etching with a strongly acid solution of ferric chloride was found satisfactory for removing the flowed layer. For the final etching, the most satisfactory reagent was that of Tafls,7 the formula for which is: FeC13.6H2O, 2 grams; HC1, 5 c.c.; H2O, 30 c.c.; C2H5OH (95 per cent), 60 C.C. This etchant reveals differences in com-

Jan 1, 1942