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By N. Novikov, M. Jastrzebski, N. Kryzhanovskaya, D. Shevchenko, I. Kapran, N. V. Novikov, T. Koehler, B. Zaporozhets

"The PFK FeNi Smelter was re-commissioned by Solway Resources in 2002, ending a long period of economic decline in the adjacent town. In 2009 Hatch was retained to design, supply and install a custom furnace crucible that would accommodate a capacity increase from 34 MW to 40 MW and increase campaign life through binding and cooling technologies, as part of ongoing improvement efforts. The involvement of PFK personnel was critical to the successful integration of the new furnace technology with the existing process and operational practice. The furnace upgrade project was completed in 18 months during 2010 – 2011. Since start-up, the furnace has exceeded production expectations, operating successfully at 42 MW.INTRODUCTIONAfter ceasing operations in the 1990’s, the Pobuzhsky Ferronickel Combine (PFK), located in central Ukraine, was stripped of useful equipment and deteriorated while dormant. The surrounding town experienced a period of economic decline throughout the 1990’s. Solway Industries purchased the complex in 2002 and began a systematic incremental program to re-commission the smelter using both local expertise and specialists from other parts of the former Soviet Union. This led to the re-birth of PFK as a successful toll-smelting complex, and a renaissance for the surrounding economy.As part of the continuing improvement program, PFK approached Hatch in 2009 to study the possibility of a capacity expansion from 34 MW to 40 MW. It was decided, based on the results of the study, to design and install a custom furnace crucible integrating the unique PFK FeNi process with modern Hatch furnace technology. This novel approach had many benefits, including: maximum re-use of existing furnace components (off-gas, feed equipment and transformers), minimal impact on upstream and downstream equipment and building structure, and the retention of a familiar operating regime. The latter was a key factor in the success of the project, as it allowed the extensive operating expertise of the PFK staff to remain highly relevant to the upgraded furnace. This led to minimized capital investment, a rapid start-up and no significant operational challenges switching over to the new equipment incorporating Hatch furnace technology."

Jan 1, 2012

By Arthur Barnes, Mika Muinonen, M. J. Lavigne

"The carbothermic reduction of chromite ore to produce high carbon ferrochromium is among the most energy intensive metal extraction processes performed, due not only to the highly endothermic nature of the reduction reactions but also the very high operating temperatures required for the smelting operation to separate the chrome-containing alloy from the discard slag.KWG Resources and XPS have collaborated over the last 3 years in developing a patented (Winter) processing alternative to the traditional smelting operation in which all processing takes place in the solid state at temperatures many hundreds of degrees lower than those required for liquid processing. Amongst the attractions of the process are much lower capital costs, as well as reduced operating costs, particularly of energy.A techno-economic study on the new process identifies a reduction in overall energy consumption of 70% against conventional processing and approximately 40% lower than the current best practice. By utilising more natural gas than coal based energy sources, the KWG process is able to show an overall 50% reduction in greenhouse gas emissions compared with the most energy efficient current practice. The impact of the new process on future processing is therefore regarded as highly significant, with global energy reductions equivalent to the effect of completely eliminating energy demand from a country the size of Italy.The study concluded that the potential for this process to completely revolutionise the global ferrochrome industry should not be underestimated. Its impact reaches far beyond exploitation of a regional natural resource."

Jan 1, 2015

By F. Ngoroma

Concentrators processing PGM bearing ores make use of polysaccharide depressants to reduce the recovery of the undesired naturally floatable gangue minerals, mainly silicates, present in the ore. Recent work has shown that high depressant dosages can completely depress naturally floatable gangue and thus prevent it from reporting to the concentrate. These high depressant dosages can, however, have a negative effect on the recovery of valuable minerals present in the ore by reducing the stability of the froth. In order to counterbalance the effects of depressant addition, frothers are added. It is, however, preferable to maintain independent control over bubble size and froth stability which is difficult to achieve with only one frother. An alternative strategy is, to use a blend of frothers, e.g. a weaker frother in combination with a stronger frother. Such a system allows an additional degree of freedom: changing the ratio of the two frothers, that would provide more independent control of bubble size and froth stability. This study demonstrates, through the use of batch flotation tests, how blending low molecular weight alcohols with commercially available frothers impact the solids and water recovery, as well as the valuable mineral recovery and concentrate grade in different PGM ores. Higher water and solids recoveries together with higher valuable mineral recoveries (>90% copper and >70% nickel) were obtained from tests using frother blends.

Sep 1, 2012

By C. D. Elifrits

The required reclamation of land disturbed by surface coal mining often results in the creation of some over steepened slopes which are prone to rapid erosion and sediment production. This natural activity on such slopes is not desirable nor allowed under current regulations. Experience has indicated that novel approaches must be devised to address the problem. Research conducted on field sites in Missouri has indicated that construction, during the reclamation and grading processes, of a man-made drainage system will control the erosion. The drainage system must replicate or exceed the natural system in terms of drainage density and channel frequency. Basic design considerations will be summarized in this paper and field results shown.

Jan 1, 1986

By Carl C. Nesbitt

A process has been developed to recover and recycle metals from wastes of brass foundries which contain copper, zinc and lead in various quantities. Tests were conducted to evaluate several leachants, including sulfuric acid, ammonia, hydrochloric acid, cyanide and acetic acid, and to determine the optimum leaching conditions, such as air flow rate, initial copper ion concentration, temperature, and agitation strength. Sulfuric acid containing copper sulfate with dissolved oxygen is the most successful leachant. More than 99% of the copper and zinc originally present in the waste was dissolved, while only 0.5% of the lead entered the solution after 14 hours of leaching. The leaching mechanisms of copper, zinc, and lead are proposed. The copper and zinc can be recovered from the solution by electrolytic processing. The unleached residue may be converted to a lead carbonate which can be converted to litharge at 400-450°C and to massicot at temperature above 500°C by calcination.

Jan 1, 1995

By Marshall D. Himes

The Pima mine, 39,000 ton per day copper mine, is located 17 miles south of Tucson, Arizona. The mine is in a sequence of Paelozoic and Mesozoic sediments striking east-northeast and dipping southeasterly intruded by a Tertiary quartz monzonite porphyry. The Paleozoic Permian(?) dolo¬mites, limestones, and sandstones have been altered to talc-silicate skarn, marble and quartzite. The overlying Mesozoic Triassic(?) clastic sediments have undergone some recrystallization and hydro¬thermal alteration. The clastic metasediments are divided into three distinct lithologic units, lithic arenite, arkose, and inter¬bedded and overlying black argillite. Three types of hydrothermal alteration in the clastic rocks are propylitic alteration (epidote, chlorite and quartz, with or without sericite), quartz-sericite alteration, and potassic alteration (K-feldspar and quartz, with or without sericite and chlorite). The porphyry has undergone potassic alteration. Dominant structures are an east-west post mineral fault in the western part of the pit, and strong low angle faulting and shearing which truncates the ore body at depth. Two joint sets, one parallel to bedding and the other at right angles to bedding are prominent in the mine. Faulting is in two dominant directions, one striking northwest, dipping northeast and the other striking northeast, dipping northwest. Mineralization is predominantly disseminated pyrite and chalcopyrite, and molybdenite-quartz veinlets. There are lens important amounts of magnetite, hematite, sphalerite, galena, tennantite and bornite. Mineralization is believed to be both structurally and chemically controlled.

Jan 1, 1972

By Lucas Kling e Silva

A deformação plástica de aços acompanha mudanças irreversíveis da microestrutura, que podem ser consideradas como o estágio inicial do processo de fratura. No entanto, detectar, monitorar e avaliar previamente, estados de dano e pequenos defeitos, de forma não destrutiva, ainda se mostra desafiador. Foi reportado na literatura o fenômeno do surgimento espontâneo de fracos campos magnéticos em aços estruturais e em oleodutos, que são originados devido a tensões mecânicas heterogêneas ou térmicas. Esta observação não é associada com transformações de fase induzidas por deformação e parece ser uma ferramenta promissora para a caracterização prévia de danos em aços ferromagnéticos. Para proporcionar uma melhor compreensão das bases físicas deste processo, foram observadas as microestruturas magnéticas de tais materiais e as mudanças ocorridas nos domínios magnéticos dos mesmos após sofrerem deformação plástica. Para isto foi utilizado um meio de solução coloidal com partículas superparamagnéticas na escala nanométrica (ferrofluido) que proporcionou, através da técnica Bitter, observar não apenas uma mudança de tamanho dos domínios magnéticos do material, mas também modificações em sua morfologia. Foram estudados neste trabalho aços ferríticos com as respectivas concentrações de carbono em sua composição: 0.08%; 0.22% e 0.45%.

Oct 30, 2017

By C. N. Adams

The purpose of this investigation was to evaluate the physical and mechanical properties of high-purity titanium made by two processes. Sodium-reduced metal with 58 Brinell hardness number (B.h.n.) and electrorefined metal with 60 B.h.n. and 70 B.h.n. were used. Titanium of these hardness levels did not work-harden excessively, and beyond 40 percent cold work the hardening effect was not great. Rapid softening occurred when the metal was annealed at temperature between 300° and 600° C. Full annealing, as determined by property and microstructure studies, was accomplished after 30 minutes at 700° C. A recrystallization diagram is presented which is based on determinations of annealed grain size as a function of rolling reduction and annealing time. For reductions of less than 20 percent, exaggerated grain growth occurred during annealing; for reductions greater than 20 percent, the variation in grain size for each annealing temperature was minor.

Jan 1, 1961

By Raymond B. Ladoo

"The name bentonite has been applied to a group or series of clay-like materials characterized by an alkaline oxide and alkaline earth content of 5 to 10 per cent, fine grain Giza, high absorptive powers, and usually very strong colloidal properties.Bentonite probably represents no mineral of fixed composition, and its physical properties vary considerably. The type material from Wyoming is light yellow or greenish yellow in color, but from other localities it may be cream colored, white, gray, pink, dark brown or even black. It is exceedingly fine grained, very plastic and highly absorbent. The appearance may be dull or powdeay, but a freshly cut surface usually has a waxy luster. Some varieties have the appearance of wax and may be cut into very thin, translucent shavings. The fracture of the type material is roughly conchoidal, that of other varieties is platey and shale-like, while still others have no typical fracture. Bentonite is highly absorbent; .hen wetted it will absorb more than three times its weight or seven times its volume of water. Some varieties when wetted with water expand to more than six times (some experimenters report eight times) their original volume. The wetted material is exceedingly smooth and soft and feels like soft soap. Unlike most clays, bentonite is easily fusible at a comparatively low temperature.Under a high-power microscope bentonite seems to consist of extremely small, more or less rounded, grains of uniform size, but the texture of most varieties is so fine that individual grains can not be distinguished.Some varieties when finely ground and thoroughly agitated with water will stay in suspension indefinitely, forming a translucent gelatinous mass. The addition of small amounts of acids or sodium chloride seems to have little or no tendency to raid coagulation or settling. Other varieties of similar analysis and appearance go into suspension more easily, but settle out again in a comparatively short time. It has been suggested that the material which stays in suspension indefinitely is a true colloid of the emulsion or lyophilic type."

Oct 1, 1921

By John Atkinson, Steve Repola

This paper will describe two blasting plans that have been developed for American Aggregates' Marble Cliff Quarry located near Columbus, Ohio. Two different limestone formations are mined on different levels of the quarry. Each formation requires a different blasting plan which address vibration considerations, crusher productivity, drilling and blasting costs and adjacent neighborhood concerns. Controlled blasting is critical to continued mining operations in this Midwest urban setting.

Jan 1, 1993

By A. R. Rule

A flotation process was developed by the Bureau of Mines for separation of carbonate and phosphate minerals occurring in unaltered phosphate ores of the Phosphoria formation. The process involves depression of phosphate minerals with fluosilicic acid and flotation of carbonate minerals with fatty acid emulsions. In individual laboratory tests, selective removal of carbonates was achieved with phosphate recoveries ranging from 60 to 80 pct P205. In continuous-circuit testing, sizing and separate treatment of coarse and fine fractions was necessary to achieve 65-pct P205 recovery. Concentrate grade ranged from 26 to 33 pct P205. The flotation tailings containing primarily carbonate and phosphate minerals is a potential fertilizer material. When reacted with H3P04, concentrated superphosphate containing approximately 40 pct available P205 was obtained.

Jan 1, 1974

By H. R. Manouchehri

"Pyrrhotite (Po) is one of the most abundant sulfide minerals in processing industry and must be rejected in most cases. Particularly, Po rejection and its selectivity against pentlandite (Pn) have long been a challenge due to similarities in the mineral composition of the two minerals and the collectorless flotation characteristics of Po. Xanthates have been widely used to promote sulfide mineral flotation; however, in the presence of xanthates, the redox potential established at the mineral/solution interface is most important, determining the flotation performance. In this paper, the importance of electrochemistry in Po and Pn flotation has been demonstrated and a comprehensive study was conducted on two different feed streams (i.e., magnetic concentrate and scavenger cleaner streams, containing magnetic and nonmagnetic forms of Po, respectively), from Vale’s Clarabelle Mill in Sudbury, Ontario, with an objective to determine if improvements in Po rejection and Pn recovery could be achieved by controlling pulp electrochemistry. By conducting a series of flotation tests under different Eh conditions and reagent usage schemes, it was revealed that higher Po content in the magnetic stream may protect Pn from being oxidized, improving Pn recovery. The results indicated that at low oxidizing pulp chemistry, the rest potential for the Pn is still high enough to allow the formation of dixanthogen to promote its flotation. Using a Pt electrode, it was found that by controlling pulp potential at -50<Eh< +50 mV, the Pn recovery and Po depression would be satisfactory. The results, using mineral electrodes (Outotec Chena analyzer), indicated that selective separation can be achieved if low-to-moderate oxidation potentials (0 to 100 mV) or reduction (0 to -100 mV) potentials are monitored using Pn and Po electrodes. Mixing two streams at 50:50 wt % would be possibly beneficial in selective separation.IntroductionPyrrhotite (Po), Fe1-xS, is one of the most abundant sulfide minerals in the processing industry. It is an iron-deficient sulfide that occurs either in monoclinic or hexagonal form. The monoclinic one is richer in sulfur and is ferromagnetic, whereas the hexagonal Po is poorer in sulfur and has no magnetic properties. In general, the ferromagnetic properties of natural Po increase with increasing sulfur content. Although Po holds significant iron content, it is not used as a feedstock for the iron and steel industry due to the difficulty in achieving complete removal of sulfur. The common availability of iron oxide ores makes the iron sulfides irrelevant for the steel industry."

Jan 1, 2015

By Launa G. Mallett, Charles Vaught, Dana C. Reinke, Lisa J. Steiner, Lynn L. Rethi, Kathleen M. Kowalski-Trakofler, Jr. Brnich, William J. Wiehagen

Safety and health professionals recognize that training is a critical element of any effective safety and health program. An extensive literature survey has led the authors to conclude that we are at the beginning of a revolution in training due to changes in the demographics of the workforce, the rapid growth of technology, and the universal ascendance of the information age. Of present major concern in the mining industry is how to provide appropriate training for an aging workforce and concurrently develop training for the expected influx of new and less experienced miners as older workers retire. This report explores the key issues in the changing safety and health training area as identified by the multidisciplinary team of NIOSH researchers who conducted the literature survey. Issues include generational differences between newer mine workers and the present workforce with respect to their physical, psychological, social, and cultural characteristics; their learning styles and work expectations; and the impact of technology. Some preliminary conclusions are offered for future training needs.

Jul 1, 2004

By Smortchevskyk N. J.

THIS paper describes the electrical features of the locomotive now (August, 1962) under construction for Craigmont Mines. Intended for non-specialists, it avoids details of design and calculations interesting to electricians only. The paper is divided into three sections. The first deals very briefly with the mine layout and with operating conditions -existing and expected. Reference is made to economic considerations leading to the selection of the type and size of locomotive, as well as to traction diagrams and the calculations. This material is not included in the paper because of its length and because it does not represent anything new. The second section deals with engineering and economic considerations and shows, in some detail, why the A.C. system was chosen. The third section describes the basic components of the locomotive, including the voltage regulator, the rectifiers, the control arrangement and the filter, and deals with considerations affecting the selection of their rating and design. A concluding sub-section describes, very briefly, the track and trolley details and the power distribution switchgear.

Jan 1, 1963

By Lane White

In mid-April 1992, MINING ENGINEERING mailed a survey questionnaire relating to mining shovels and hydraulic excavators to 125 SME members working at surface mines or at the headquarters of companies that operate surface mines. The mailing was directed to individuals whose titles indicate that they have management or mine planning responsibilities for surface mining operations. A total of 56 usable surveys returned by June 17 are the basis of this report. Precious metals mines Eighteen precious metals mines or mining companies returned completed surveys in time to be included in this report. Of these, 14 use hydraulic shovels only for both ore and waste, I uses both hydraulic and rope shovels, and 2 use Caterpillar 988 front-end loaders for both ore and waste. (Of the latter 2, neither expects to be in the market for a shovel in the next three years. I of these 2 placed Harnischfeger P&H number one and O&K number two in response to the question, "Based on your current knowledge of their machines, which manufacturer would you likely chose to supply new shovels or excavators to a mine or mines operating under your responsibility, if you were in the market?") Another uses front-end loaders, make not designated. The latter does not expect to be in the market for mining shovels or excavators within the next three years. Of the final total of 14 precious metals mines using only hydraulic excavators to load ore and waste, 8 use Hitachi excavators only, 1 uses Demag excavators only, 1 uses Liebherr excavators only, 1 uses O&K excavators only, 1 uses Harnischfeger P&H and O&K excavators, 1 uses Harnischfeger P&H and Hitachi excavators, and 1 uses Hitachi and Demag excavators. Of the 14 precious metals mines using only hydraulic excavators, 7 use excavators in the 7.6 to 11.5 m; (10 to 15 cu yd) size range. Of these 7, 5 use only excavators in this size range, and they are used to load both ore and waste. 1 of the 7 also uses 11.5 to 17 m&apos; (15 to 22 cu yd) excavators, and I also uses a 17 to 23 m3 (22 to 30 cu yd) excavator. Of the 7 remaining of these 14 precious metals mines that use only hydraulic excavators, 3 use 11.5 to 17 m&apos; (15 to 22 cu yd), 2 use 17 to 23 m3 (22 to 30 cu yd), and 2 use less than 7.6 m&apos; (10 cu yd) units.

Jan 1, 1992

By T. M. Chagwedera, A. E. Lewis, J. Chivavava

Eutectic freeze crystallisation is a novel separation technique that can be applied to treat brine solutions such as reverse osmosis retentates, which are often a mixture of different inorganic salts. The treatment of calcium sulphate-rich brine solutions through eutectic freeze crystallisation has resulted in gypsum scale formation on the walls of the crystallisers and ancillary equipment. In order to prevent gypsum scaling on equipment surfaces, it is essential to understand the mechanism of gypsum scaling on cold surfaces. This paper focused on the interaction between gypsum crystallisation in the bulk solution and scaling on the crystalliser walls in the presence of gypsum seeds. A cooled, U-shaped stainless-steel tube suspended in the saturated solution was employed as the scaling surface. Preliminary results showed that the scale layer was predominantly composed of needle-type and hexagonal prismatic crystals. The rate of scale deposition was highest during the first 24 hours, thereafter it decreased. A thin scale layer was observed to have coated the tube within the first hour of the experiment. Seeding, using reagent grade gypsum crystals, was effective in reducing scale layer formation through providing a surface for growth. The highest scale reduction, 81%, was realised at a seed loading of 0.50 g/L. At a high seed loading of 4.01 g/L, the seed material adhered to the tube. Keywords: Gypsum, eutectic freeze crystallization, seeding, scaling, cooling crystallisation

Jan 1, 2020

The Beginning ! The status quo simply isn?t sustainable ! Our social license is at risk ! The bar keeps rising ? We must improve our performance, both operational and social ? We must improve stakeholder judgement of our industry by taking action collectively Implementing TSM " TSM Guiding Principles " Performance Indicators " Crisis communications " External Outreach " Tailings management " Energy management " Performance manuals, guides " Reporting " Communities of Interest Advisory Panel

May 1, 2004

By Enrique Rubio Esquivel, Matías Fuentes Bustamante

The transition from open pit to underground mining represents a key strategic challenge in modern mine planning. This paper presents a multicriteria and multivariable methodology to plan such a transition, integrating technical, economic, environmental, and social considerations. The proposed framework focuses on risk reduction (de-risking) through the identification of alternative development paths, the use of stochastic simulation to model geological and technical uncertainty, and different mining strategies such as methods, production rates, sequence, etc. for ultimate underground implementation. The study summarizes the limitations of traditional planning methods—which usually treat the open pit and underground mine designs as independent processes—, also often it considers a single mining method and production rate for the underground option. Instead it is proposed an integrated approach that leverages synergies between both mining methods and scalable production rates. Also the proposed methodology incorporates the definition of critical variables (geotechnical, economic, and social, among others), the construction of multiple operational and technological transition paths, and the evaluation of each path under criteria of economic attractiveness and practical do-ability (capacity to be executed). Using simulation tools (SIMPLAN for operational performance and SIMVAL for economic evaluation), probabilistic distributions of the different path are obtained, enabling the quantification of the project’s Value at Risk (VaR). A subsequent multicriteria analysis weights the expected profitability against the feasibility of execution of each alternative, producing a decision matrix that provides a framework for evaluating the different project path. As a result, the proposed approach identifies OP→UG transition strategies that maximize business value by capturing remaining resources while minimizing financial and operational risks. Finally, strategic conclusions and recommendations for the industry are provided, emphasizing the importance of early transition planning even challenging the open pit sequencing of the latest push backs by introducing early underground operations. Future work includes strengthening the methodology—such as integrating real-time analysis and adaptive decision-making—and providing recommendations for its application in various mining operations. In summary, this paper delivers a technical and professional framework to guide mining companies on when and how to carry out a successful transition from open pit to underground mining, balancing resource recovery with financial, operational, and social security.

Feb 22, 2026

By S. M. Shelton, M. M. Fine, T. L. Johnston

"INTRODUCTION The Bynum property is about 15 miles west of Gadsden and 1 mile north of Walnut Grove, Etowah County, Ala. The ore lies in layers and as irregular masses and pockets in the clay residue from decomposed quartzite and limestone formations to the district.The property has been developed by means of numerous shallow shafts sunk to water level - about 25 foot. Operations are confined to small-scale, selective mining of pockets of high-grade ore. The ore is marketed directly, without beneficiation. The property does not yield a large amount of manganese ores. No estimates of reserve ore tonnages are available.A 206-pound sample was furnished for test. It was taken at random from a stock rile estimated to contain 130 tons of ore. The sample con¬sisted of a mixture of manganese oxides, iron oxides, and siliceous fragments in clay. The manganese occurred largely as soft, unconsolidated pyrolusite and wad. Some hard, crystalline pieces of psilomelane were distributed through the soft material. Small amounts of iron oxides were associated with the manganese oxides. Chert, quartzite, and clay comprised the gangue minerals.Dry analysis of the sample was as follows: 36.0 percent manganese, 6.1 percent iron, 2: .0 percent silica, 1.5 percent calcium carbonate, 0.36 percent phosphorus, 3.0 percent alumina, 2.2 percent barium, and 0.31 percent zinc."

May 1, 1942

By Ernest Y. Baafi

The technique of linear kriging as a grade estimation method of mining blocks is reasonably established in the mining industry. Because of the nonbias condition imposed in kriging which requires that the kriging weights (?i) add up to one, negative weights are sometimes used in kriging. The use of negative weights is not justifiable from the practical standpoint. Also, negative block grades can be obtained in some extreme situations which makes no practical sense. To guarantee non-negative weights an additional constraint is required in the kriging system of equations. Unfortunately, the nonnegative weight constraint results in a set of non- linear system of equations. In this paper, a derivation of the resulting set of nonlinear equations is presented and a numerical algorithm is developed for the solution of the equations. Because the algorithm developed does not remove negative weights arbitrarily, optimal nonnegative weights are always guaranteed. Results obtained using the developed algorithm were compared with those using the standard linear kriging, in terms of computer time and the estimation results. Both the computer time and the kriging variance were found to be higher with nonnegative constraint, as expected. However, some systematic pattern was observed in the kriged values (i.e., over or under estimation) with or without the nonnegative constraint. The study also demonstrated when one should generally expect negative kriging weights in practice, and what practical impact the negative weights can have on the kriging estimates.

Jan 1, 1984