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By Donald J. Knight

HEAT Treatment at 1500' F of a mild steel containing 0.1 pct C, in an atmosphere which is oxidizing to both carbon and iron, results in the progressive oxidation of the metal surface with little or no change in the carbon content of the underlying metal. Further heat treatment of the scaled metal in either a neutral atmosphere or in a vacuum may or may not result in the decarburization of the metal depending upon the physical nature of the scale. It is apparent that if a continuous layer of oxide is present on the steel surface, the reaction OScale + Cmetal Cogas cannot progress since the SO formed gas would be unable to leave the oxide/metal interface. Thus, in order for the reaction to progress, the oxide must be cracked or porous. Vacuum heat treatment at 1500" F of samples with a thick continuous oxide scale showed no decarburization of the steel. However, when cracks were introduced mechanically into the scale prior to the vacuum heat treatment notable decarburization of the metal resulted and a structure as shown by Fig. 1 obtained, i.e., reduction of the crack walls to ferrite. With reference to the diagram of Fig. 2, it would appear that a mechanism of the following type takes place. Carbon atoms arriving at an oxide/metal/void interface, such as 'A', Fig. 2(a), can combine with oxygen atoms from the scale and leave the reaction site as Cogas thereby reducing the oxide to metal. On a greatly magnified scale, Fig. 2(b),this will appear as a ferrite projection along the crack wall. Carbon atoms entering this projection can react with oxygen atoms at point 'C', which is a new interface, and so on leading to a progressive growth of the ferrite along the crack wall and to the surface, Figs. 2 (c) and 1. It would appear that the only means by which thickening of the ferrite film can take place is by a diffusion of oxygen through the ferrite film to react with carbon at the newly formed ferrite/ void interface. Since the diffusion rate of carbon is reportedly much greater than that of oxygen, and since there is a low probability factor of oxygen and carbon atoms arriving simultaneously at the same site on the ferritehoid interface, there will be a tendency for more rapid lengthening than thickening of the ferrite layer, as is observed.

Jan 1, 1962

By M Humphreys

Multi-episodic mineralisation is often characterised by different spatial trends exhibited by different generations of the mineralisation. The structural complexity of mineralisation together with the heterogeneous nature of the mineralised zones prevents unambiguous application of the conventional deterministic methodology for 3D constraining of the mineralised domains (ie conventional wireframing is ambiguous).A different approach, discussed in the present paper, includes a probabilistic definition of the domains encompassing one statistical population of the data. The domains are defined geostatistically using the indicator probability model. An indicator threshold is chosen for the definition of the high and low-grade domains. The spatial distribution of this indicator is then modelled by a variogram. The probability of exceeding the given grade threshold is than estimated by ordinary kriging for each modelled block. Blocks are then grouped according to their probability of exceeding the threshold and a continuous closed volume (domain) created from this likely patchy grouping using an appropriate structural model to fill the gaps). Methodology for the geostatistically assisted domaining is discussed in the paper. It is suggested that this technique represents an additional tool facilitating a structural interpretation of the mineralised zones.After the geostatistical domaining of the lode has been completed the grade within each of the domains is modelled using Uniform Conditioning method. Application of Uniform Conditioning for modeling the grade distribution has a significant advantage over linear methods (such as inverse distance or kriging) because Uniform conditioning enables estimation of local recoverable resources at different selective mining unit sizes that can be substantially smaller than the drilling density and are unable to be estimated directly.

Jan 1, 2002

By Joseph L. Ritchey

The Trail Lake RARE II area comprises 1,300 acres (526 ha) in Lassen and Plumas Counties, California, adjacent to the Caribou wilderness. No mining claims, prospects, or quarries are reported within the study areas, and no evidence of potential mineral deposits was found during a field reconnaissance. Quaternary basaltic lava flows uniformly underlie the area. INTRODUCTION The Trail Lake (No. B5-095) RARE II further planning area occupies 1,300 acres (526 ha) adjacent to the Caribou Wilderness in Lassen and Plumas Counties, California. Susanville is about 30 mi (50 km) east and Chester is about 17 mi (27 km) south of the study area. Access from State Highways 44 and 36 is provided by well-maintained gravel roads.

Jan 1, 1981

By Fidelis T. Suorineni

The Ashanti mine, located in Obusai, Ghana, West Africa, has been in production for over 100 years, and is currently the second largest single gold producer in Africa. The mine covers a concession area of 434 square kilometers with four main ore types: the quartz vein type, disseminated sulphide type, supergene sulphides and transition ore, and granitoids stock works (visible gold and quartz veinlets). Various mining strategies and methods have been employed for the mining of the narrow-vein ore at Ashanti. In recent years, the mine owner: Ashanti Goldfields Company Ltd. has embarked on a mine-wide expansion program to boost production to a target of one million ounces per annum. With the rapid depletion of its high-grade ore, a suitable mining method was required to produce a high tonnage at low cost to meet production objectives. This paper discusses how the Ashanti mine applied Canada experiences in mining technology to boost production, and the impact that the differing geological settings between the two countries had on the stope performance at the Ashanti operations. Experience developed at the Ashanti mine led to innovative modifications for stope layout and design methods in relatively poor ground conditions.

Oct 1, 2001

By S. P. Sandoval

The U.S. Bureau of Mines investigated the separation of aluminum from copper dump leaching liquors using a supported liquid membrane. Aluminum was selectively transported through porous polypropylene impregnated with di (2-ethylhexyl) phosphoric acid in an aliphatic diluent. The effects of variables, such as solution composition, temperature, and extractant concentration, were measured with a three-level fractional factorial experimental design. Experimental results were used to derive equations for predicting transport rates for aluminum, iron, and copper. The major variables influencing aluminum transport were solution temperature, feed solution pH, aluminum concentration in the feed solution, and extractant concentration. Copper and iron transport rates were almost zero when aluminum transport rates were high. Measured aluminum transport rates under the best conditions of 55° C, pH 3.0, 16 g/L A13+, and 65 pct extractant solution confIrmed the predicted value of 210 f.'g/(cm2.h). Transport rates for iron and copper were less than 5 ug/(cm2.h) under these conditions. Aluminum was recovered from the stripping solutions by sparging with gaseous hydrogen chloride to crystallize aluminum chloride hexahydrate, which was calcined to alumina. Sparging crystallization regenerated the stripping acid for recycle.

Jan 1, 1989

By H. E. Elliott, R. S. Busk, A. T. Peters

One of the problems of the fabricator of metals and alloys is the propensity of some composition rarnges toward abnoermal grain growth during certain stages of fabrication. In this respect magnesium alloys are no exception among alloys. Fortunately, convenient foundry control methods have been developed by which the abnormal grain growth possible in certain magnesium-alloy castings can be suppressed. An unusual characteristic of magnesium alloys, however, is that castings of some composition ranges are subject to local grain growth during heat-treatment without the necessity of intentional mechanical stressing of the part prior to heat-treatment. This effect occurs only under certain critical casting conditions, and only in certain alloys of greater than about 8.5 per cent aluminum content, such as C alloy (Mg, 9 per cent A1, 2 Per cent Zn, 0.2 Per cent Mn) and G alloy (Mg, 10 per cent Al, 0.2 per cent Mn). The first observation of this phenomenon in cast magnesium alloys occasioned much surprise, since it is not observed in other meta1s- Jeffries and Archer1 have stated that "the grain size of cast metals, provided they have not been plastically deformed, cannot be changed by heating below the melting point." The study of the conditions leading to abnormal grain growth in cast magnesium alloys, and of the mechanism of this phenomenon, has led to some very interesting observations. Perhaps the most significant of these was the observation that stresses originating from cooling contraction in magnesium-alloy castings are the only stresses necessary, under certain conditions, to cause local recrystallization and subsequent grain growth in the casting during heat-treatment. Before recent developments, this phenomenon of abnormal local grain growth Was a definite problem in the production foundry on C alloy sand castings. Illustrated (Fig. I) is a picture of a casting scrapped because of this defect. A mottled effect is produced in coarse-grained areas by suitable etching solutions. The properties of metal in the affected area are much impaired by such grain coarsening. Ultimate tensile strengths of half the normal value have been measured in metal of this nature. In this paper are described the techniques that have been developed by The DOW Chemical Co. for studying, and in large measure solving, this production problem. Also discussed are studies of the mechanism by which excessive grain coarsening occurs, and the fundamental conditions that produce this effect. The abnormal grain growth discussed in this paper will be referred to as "germinasium since this term has been definedl as any process leading to an abnormally coarse grain size. This paper deals only with abnormal local grain growth that may occur during the solution heat-treatment of certain magnesium-alloy castings, as dis-

Jan 1, 1945

By R. L. Unger

Restricted fields of vision are a common problem with underground mining equipment. Also, when lighting systems are provided, they may be positioned where they cause glare. This restricts the visibility around the machines even further. To help address these problems, the U.S. Bureau of Mines has developed a PC based software package to aid in the analysis of certain human engineering aspects of mining equipment design. The software is available for use by equipment manufacturers and mining companies for design work on new machines, as well as for evaluating proposed modifications to existing machines.

Jan 1, 1994

By R. E. Barbosa

Seepage forces generated during tunnel excavation affect the ground response and may cause severe instability problems, including total ground collapse and flooding into the tunnel. This paper presents a new closed-form analytical solution, for stresses and displacements around a cylindrical tunnel excavated in a porous water-bearing elasto-plastic material, which includes the effects of seepage forces. The analysis is carried out in terms of effective stresses and pore water pressures. The solution shows that seepage forces may have a major effect on the effective stresses around the tunnel, on the extent of the plastic zone, on the radial displacements, and on the tunnel support requirements. The conditions for development of a ?flowing ground? condition at the tunnel face have been identified. The paper presents a procedure for the hydromechanical ground-support interaction analysis, to determine the excavation induced inflow and the pressures acting on the lining, throughout the progressive driving of the tunnel, including the effective pressures exerted by the ground and the pressures generated by the water.

May 1, 2009

By Hiroshi Yamazaki

The paper describes prediction, control and validation of face pressures, and special TBM features for the bored tunnels of the New Metro Rail City Project, Perth, Australia. The selected EPB-TBM passed below a heritage bridge and the operational Perth Railway station in ground conditions consisting of fully saturated uniform sand combined with shallow overburden and a horizontal alignment radius of only 135m. Therefore, strict control of volume loss, TBM operations and ground movements was vital requiring continuous evaluation and adjustments to TBM operation parameters. The paper discusses the effectiveness of applied TBM face pressures and the used foam/polymer soil conditioning which was measured against achieved volume loss and the predicted range of ground settlements.

By J. Little

It is common practice for underground mine plans to be created sequentially, where results from one planning process form the input data for another. While this is practical for manual methods, computerized optimization techniques should consider an integrated approach to creating the global mine plan. This is because optimizing an individual mine planning process, such as stope layouts, introduces a likelihood of increasing costs or decreasing revenues associated with other areas, such as production scheduling, as harmful decisions must be balanced. Considering the interaction and influence that individual underground mine planning processes have on each other during optimization will provide more profitable results than if these are ignored. Optimization techniques for stope layouts and production scheduling are reviewed. An integer programming model is proposed that allows for either integrated or isolated optimization. Both approaches are separately applied to a block model. The results demonstrate the model?s ability to produce optimal long-term sublevel stoping mine plans and the benefits of using an integrated approach. Keywords underground mine optimization, stope layouts, underground production scheduling, integer programming, mathematical programming application.

Oct 1, 2013

By J. Shawn Peterson, David S. Yantek, Adam K. Smith

Occupational noise-induced hearing loss continues to be one of the most pervasive health problems in the mining industry, despite over 25 years of regulation. One of the loudest pieces of equipment used in underground mining is the continuous mining machine. Noise sample data collected by the Mine Safety and Health Administration indicate that 42% of noise overexposures between 2000 and 2005 involved continuous mining machine operators. Previously conducted field and laboratory tests have determined that the continuous mining machine conveyor system is a dominant noise source. Loud impacts occur as the conveyor chain flight bars, used to move the mined aggregate, traverse their path from the top to the underside of the conveyor deck. Various noise control treatments have been applied to abate noise caused by the conveyor system. A durable polyurethane coating has been developed for the conveyor flight bars, resulting in a time-weighted average reduction of 3 dB(A) for an eight-hour work shift. In an attempt to further reduce continuous mining machine operator overexposures, a similar urethane coating has been applied to the tail roller component of the conveyor system. Laboratory results showed a 2 dB(A) reduction in sound power levels, but the component failed during underground durability testing. An outer steel sleeve has been added to the urethane coating of the tail roller to enhance wear resistance during mining. The urethane jacketed tail roller is the latest effort, combined with previous noise treatments, to bring the continuous mining machine into compliance with federal noise regulations.

By Michel Ruel

"PID loops – also known as base layers or regulatory controls – form the foundation of any plant’s control layer and it is generally accepted that PID loop health has a direct impact on the plant’s bottom line. Keeping these thousands of control loops in good health has a direct impact on the plant’s bottom line: it reduces variability, improves quality and throughput, and decreases energy costs and raw material usage. This has been well proven and documented in many articles. In the last ten years, technology has evolved: control engineers can now keep track of control loop performance and link it to the root causes of variability. However, they lack industry-wide best practices and criteria for determining what can be considered as excellent, good, fair, or poor performance. To ensure that PID control loops continue to perform well and meet their objectives, control engineers need a combination of (a) an appropriate monitoring technology and (b) best practices for doing the maintenance of base layer controls.Most plants have limited resources and operate with an increasing number of constraints; therefore, using the right tools and including reports in daily workflow is key for success. This paper suggests roles and responsibilities of key players needed to work toward control performance best practices and discuss organisational changes to succeed.INTRODUCTIONAlthough PID controllers are reliable workhorses in the process industry, they are often underrated. Since the 1980’s, computer control has evolved and the control algorithms used by control engineers have become increasingly complex. However, PID controllers still handle over 90% of the control loops in operating plants. Table 1 shows the savings that can be realized by achieving best-practice in several different process control categories (Brisk, 2004). The savings are expressed as a percentage of production costs."

Jan 1, 2011

Optimisation of the Performance of Flotation Circuits Using a Genetic Algorithm Oriented by Process-Based Rules

Sep 13, 2010

By Ron J. Elliott, Dylan Wedgewood

A series of five signature holes were blasted at the Highvale Mine and the resultant seismic data was analyzed to make recommendations on how best to address neighbour complaints regarding blast vibrations. From an analysis of peak vibration levels measured at the closest neighbour for blasting during 2016, it was determined that the blast vibration intensity varied between 1.4 to 4.3 mm/sec (0.06-0.17 ins./sec.), well below the level of concern for the onset of minor damage to residential structures, however, the frequency of the blast vibrations was between 2.2 and 9.7 Hz, which is within the range of the natural resonant frequency for a single story home. This was determined to be the cause of the neighbour complaints, as the home would be responding to the blast vibrations.

Jan 1, 2018

By Baojie Zhang

The main goal of this study was not only to investigate the effectiveness of the FGX Dry Separator for removing pure rock from run-of-mine coal producing a better feed stock for conventional coal preparation plants but also to optimize the FGX Dry Separator performance for producing a salable clean coal product without using the conventional wet coal preparation processes. A Model FGX-1 Dry Separator with feed throughput capacity of 10 tph was extensively tested at the Illinois Coal Development Park using two coal samples having distinctly different cleaning characteristics. Statistically designed experimental programs were conducted to indentify critical process variables and optimize FGX Dry Separator performance by systematic adjustments of critical process variable parameters. The coal cleaning performance of the FGX Dry Separator was evaluated for the particle size range of 63.5 x 4.76 mm in most cases, although FGX Dry Separator feed consisted of nominal -63.5 mm run-of-mine coals. The best cleaning performance obtained from the FGX Dry Separator is described by specific gravity of separation (SG50) and probable error (Ep) values of 1.98 and 0.17, respectively. The SG50 and Ep values for individual size fractions were as follow: 1.90 and 0.12 for the +50.8 mm size fraction, 1.95 and 0.18 for the 50.8 x 25.4 mm size fraction, 2.01 and 0.19 for the 25.4 x 12.7 mm size fraction, and 2.03 and 0.23 for the 12.7 x 4.76 mm size fraction. These process efficiency measures produced a clean coal with ash content of 13.38% from a feed coal with ash content of 34.45%. Ash content of tailings and middlings streams were 85.09% and 39.57%, respectively. Total sulfur contents of corresponding streams were 3.87%, 4.68%, 6.87%, and 4.62%. For a relatively easy to clean Illinois No 6 seam coal (Cleaning Index: 0.72), only about 0.42% of the clean coal (i.e., 1.6 float fraction) present in the feed was lost to the tailings stream. For a relatively difficult to clean coal (Cleaning Index: 0.53), about 0.98% of the clean coal present in the feed was lost to the tailings stream.

Jan 1, 2012

By T. E. W. Nind

"A short description of the chamber lift method for producing oil wells is followed by some comments on compressor requirements and gas utilization. A quantitative analysis of the process is presented and, based on this analysis, criteria are suggested for selecting wells for which this type of lift might be suitable. The analysis leads to the conclusions that chamber lift is an efficient producing mechanism for wells having very low productivity indices (say about 0.05 bbl/d/ p.s.i. or less), but that for such wells optimum utilization of injection gas cannot be attained. It is suggested that the gas injection time per cycle should be kept as low as possible, compatible with a small oil fallback volume, and that the cycle frequency should be in the range of 20-40 cycles/ day. For wells with productivity indices of 0.2 bbl/d/p.s.i. or higher, chamber lift is relatively inefficient; how-ever, if well allowables are low it may offer an attractive, low cost, alternative to gas lift or pumping."

Jan 1, 1960

By Luthie Els, Chris Coetzee, Roedolf Koekemoer, Casper Els, Olof Vorster, Frank Fereday

Three electric arc furnaces (EAFs) were constructed by Union Carbide at Tubatse Ferrochrome (TFC) in1975. This plant was expanded to four furnaces at the East Plant in 1985 and the gas cleaning system was enlarged without taking flow dynamics into consideration. In order to improve competitiveness, TFC has increased furnace capacity, partially substituted coal for coke, and changed the charge mix. These changes increase the heat and dust load into the air pollution control (APC) system. TFC embarked on a project to improve the APC capacity by: ?Quantifying the required off-gas capacity ?Optimising the aerodynamic flow through the system by means of Computational Fluid Dynamics (CFD) ?Converting the old Brandt Koyo top entry baghouses to bottom entry ?Upgrading the cleaning system ?Installing Gore-tex® ePTFE membrane filter bags The estimation of required off-gas capacity is traditionally done by rule-of-thumb methods such as specific extraction. A more elegant evaluation method was developed for simulating the effects of changes in charge mix on the furnace reaction gas volume and the APC system. Reaction gases are calculated by modelling the reactions taking place in the furnace and off-gas volumes are compared to both fan and baghouse capacity. This enables identification of bottle-necks in the off-gas system. CFD techniques were utilized to evaluate geometric imbalances and propose solutions to ensure optimal use of off-gas capacity. The system modifications were completed over several months and the modified equipment went into service in May2006.

Jan 1, 2007

By T. Hudaverdi

Several studies have been conducted on blastability and prediction of fragmentation. The term blastability is used to refer the susceptibility of the rock to blasting and is closely related to fragmentation. Parameters that determine fragmentation by blasting may be divided into two groups. The first group consists of blasting design parameters. The blast design parameters are controllable parameters and determined by the explosive engineers. The burden, spacing between holes, bench height, drillhole diameter, stemming height and explosive density are all design parameters. The second group consists of rock mass parameters that are referred to as uncontrollable parameters. The uncontrollable parameters are physical and mechanical properties of rock and rock mass structure. The strength, modulus of elasticity, density of rock, number of joint sets, joint orientation and joint spacing are among uncontrollable parameters. The rock mass parameters and blast design parameters should be considered together to explain fragmentation process. In this study, a blast database was accumulated to use for multivariate analysis. The blast database contains the blasts performed near Istanbul region quarries and the blasts that were preformed in various mines in the world by the blasting researchers. The cluster analysis was used to separate the blast data into different similarity groups. Group memberships were analyzed and checked by the discriminant analysis. Then, the multivariate regression analysis was used to develop a prediction equation for blast fragmentation for each group. Finally, a validation of the suggested models was performed for various mines. The model comprises blast design parameters, mechanical properties of rock and rock mass structure.

Jan 1, 2011

The 105th Annual General Meeting of The South African Institute of Mining and Metallurgy was held in the J.C. Lemmer Auditorium, SA National Museum of Military History, 22Erlswold Way, Saxonwold, Johannesburg on Thursday, 8thAugust, 2002. Welcome The President extended a special welcome to the guests and representatives of our sister institutes and other associations. Also to recipients of awards, senior members of industry, Honorary Life Fellows, Past-presidents, our Members and other guests, among them the following: Mzolisi Diliza, Chief Executive, Chamber of Mines of South Africa Dawie van Wyk and Rod Tucker, Vice-presidents, The Geological Society of South Africa Vaughan Townsend, President, Institute of Certificated Mechanical and Electrical Engineers, South Africa Karel Landman, President, Institute of Mine Surveyors of South Africa Frik Grobbelaar, South African Colliery Managers? Association Pierre Ballot, President, South African Institute of Electrical Engineers Trueman Goba, President, South African Institution of Civil Engineers

Jan 1, 2002

By John J. Deutsch

"1T is a great pleasure for me to be present at the Annual Dinner of the C.I.M.; a pleasure which is combined with a mutual opportunity that I value highly. First of all, this occasion gives me a chance to meet again many Members of your Institute and to become more fully informed of the special problems of the mining industry. This alone is ample reason for me to welcome the invitation to join you tonight. In addition, this occasion provides me with an opportunity to tell you something about the work of the Economic Council which might be of particular interest to your industry.In the mining industry, keen competition and constant change are basic facts of life. The continuing prosperity of the Canadian mining industry depends fundamentally on how successfully it is able to adapt both to the changing conditions within the industry and to major trends which operate throughout the world.First of all, the scale and organization of the industry are evolving to new and different dimensions. As one authority has put it, ""The cream of the small high-grade, easy-to-mine ore deposits of this world have been consumed and mining is becoming more and more an industry of very large scale, complex operations. It has already become in most countries a capital intensive industry and its problems, scientific, technical and economic, are growing in difficulty."""

Jan 1, 1966