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By Sven Eck, Andreas Ludwig, Menghuai Wu

"Phase separation is a frequently occurring phenomenon during solidification accompanied by melt convection, sedimentation or, in the case of two unmixable liquids, a Marangoni driven motion. In order to describe these phase separation phenomena a two-phase volume-averaging model was employed for globular equiaxed solidification of binary alloys and decomposition and solidification of hypermonotectic alloys. The model considers nucleation and growth of equiaxed grains or second phase droplets, motion and sedimentation of grains or droplets, feeding flow and solute transport by diffusion and convection. It allows the prediction of macro segregations and the distributions of grain size or droplet size. Evaluations were made by comparing the numerical predictions with experimental results. For example it is shown that the numerically predicted grain size distribution in a plate casting (Al-4wt%Cu) agrees reasonably well with the experimental analyses.IntroductionModeling of metallurgical processes is a rapidly expanding field and the research activities in the last decades cover a wide range of areas including melt pre-treatment, solidification and subsequent manufacturing routes. Among those activities solidification stands in the central position, because the primary structure of the materials, and even many defects such as porosity, (macro or micro) segregation and inclusions form during solidification. Those primarily formed structures or defects once existing are difficult to be removed or modified by the subsequent material processing.Solidification is a multi-disciplinary field involving thermodynamics, fluid dynamics and solid mechanics, heat and mass transfer, and other disciplinesr1 -31• One of the most challenging problems in solidification modeling is the complex interactions between physical phenomena occurring on different length scales ranging from atomic rearrangement over single crystal-melt interactions to heat extraction, momentum and species transport at the system level. Modeling an industry process on atomic scale is umealistic, even on grain scale (e.g. phase field method) it would need another 40 years to be able to model the exact grain morphology in a casting space envelope of 10x10x10 cm3 [ 4]. Therefore, the realistic models for industry process are based on the solution of the macro transport equations (mass, momentum, enthalpy and species) on system scale. The microscopic phenomena such as thermodynamics, nucleation law, crystal growth kinetics and interactions at the liquid-solid interface are considered with simplified models, which are coupled with the macroscopic transport equations."

Jan 1, 2004

By Allan J. Clark

This paper, describing the milling practice of the Homestake Mining Co., is one of a series being prepared by the Bureau of Mines. The author acknowledges the assistance of T. G. Chapman, one of the consulting engineers of the Bureau of Mines, in arranging this paper for publication.

Jan 1, 1931

By C. J. H. Steenkamp

Theoretically, the main driver behind a mining operations? sourcing decision should differ from company to company, and within a company from project to project, but in reality it often relates to cost. Research confirms that there are a number of factors, including cost, to consider when choosing between in-house and outsourced mining. While the literature is rife with factors to consider, little information exists on how to apply these in practice and the relative importance of the different factors to be considered. A study was conducted to determine whether mining is truly a core competency for a mid-tier commodity specialist mining company. Furthermore, a decision-making framework for mining operations sourcing was developed, and the critical success factors that should be adhered to if outsourced mining is chosen were determined. The research showed that owner mining is not a core competency for the mining company investigated. A decision-making framework was developed using the order winner/order qualifier structure, which can be used to facilitate the mining sourcing decision. The most important tools at the disposal of a mine owner?s team to manage a contractor miner are the social and output control mechanisms, according to the critical success factors study.

Jan 1, 2014

By R. L. Grayson, S. S. Eslambolchi

"In making strategic economic decisions, it is important for a mining company to gain insights on the impact of significant political, social and economic issues when planning for present and future mines. The size of any mine, measured by the average number of employees working in the mine, will likely vary according to the pressures generated by the significant issues from one year to another. The objective of this study is to develop a model that represents U.S. underground coal mine size transitions during the period 2002-2012 using data derived from the MSHA databases. Coupled with information on significant issues over the past ten years, this model is used to gain insight on the impact of the issues on mine sizes. Results indicate that the structural impact of the combined driving pressures can be discerned by examining the year-to-year stability of mine-size categories. The effects of The MINER Act, the Obama Administration environmental policies on coal, and the coal market are evident. The lessons learned from these analyses give good insights on what the industry and market responses have been on the structure of the underground coal industry over the period of study. INTRODUCTION It is apparent that key driving issues affect the structure and viability of the coal industry. The driving issues may be political, social, and/or economic in the final analysis, but are generally rooted in reaction to dramatic and publicized events or movements. Mine disasters, an increase in miners’ disease prevalence, strife in the coal fields, and negative environmental impacts on air, land or water can capture the attention of the media and the public. Some of the issues occur over a long period of time, like the current global climate change movement. The coal industry veteran can sense the changes in political and social sentiment, and attempt to react to the economic repercussions; however, the insights from the media and from unique combinations of driving pressures are difficult to fathom. Thus decisions made on inadequate information related to the driving pressures and their likely impacts could lead to missteps in corporate and market restructuring. One way to gain some more insight on the potential impacts is to examine the complicated restructuring of mine operations in reaction to the driving pressures of the recent past. This paper examines an 11-year history of the changes in the underground coal industry structure, as reflected by changes in the numbers of mines in various statuses by mine-size categories. Superimposed on the results of mine-size changes is a mapping of the key driving pressures that occurred over the same period, 2002-2012. It is assumed that using this methodology, some important insights can be gained on the immediate and delayed responses to the driving pressures during that period."

Jan 1, 2015

By Rambabu Pothina, Rajive Ganguli

The economics of a mineral processing circuit is dependent on the numerous sensors that are critical to optimization and control systems. The sheer volume of sensors results in mines not being able to keep the sensors calibrated. When a sensor goes off calibration, it results in errors which can severely impact plant economics. Normally, these errors are not detected until the error grows and becomes a large (“gross”) error. Undetected errors are not remedied until the next calibration, which on average are a year apart Beamex (2019) [1] across all industries. Classical statistical methods that depend on linear relationships between input and response variables are typically used to find gross errors, but are not effective for highly non-linear and non-stationary operations in mining and mineral processing industries. Calibration of sensors is time-consuming and generally requires physical intervention that results in equipment downtimes causing production losses. Therefore, in situ detection methods are warranted that do not require physical removal of sensors to compare with standard measurements or well-calibrated sensors. Data-mining based techniques and algorithms have high success rate in tackling such problems. This paper presents results from a groundbreaking multi-year big data research project whose goal was to develop data-mining-based original techniques in a multi-sensor environment to identify when sensors start to stray, rather than wait for errors to grow. The carbon stripping (gold) circuit in the Pogo Mine of Alaska was selected for this project. Maintaining strip vessel temperatures at optimum levels is crucial for maximizing gold recoveries at Pogo, and hence the focus was on the temperature sensors of the two strip vessels. An automated algorithm to detect errors in strip vessel temperature sensors was developed that exploited data from multiple sensors in the strip circuit. This algorithm was able to detect with a high success rate when bias errors of magnitude as low as ± 2% were artificially induced into strip vessel temperature data streams. The detection times of about 1 month were much less than the industry average calibration frequency of 1 year. Thus, the algorithm helps detect errors early, without stopping the circuit. The algorithm alarms can serve as triggers when calibrations are done. Experimental methodology along with results, limitations of algorithms, and future research are also presented in this paper.

By Rambabu Pothina, Rajive Ganguli

The economics of a mineral processing circuit is dependent on the numerous sensors that are critical to optimization and control systems. The sheer volume of sensors results in mines not being able to keep the sensors calibrated. When a sensor goes off calibration, it results in errors which can severely impact plant economics. Normally, these errors are not detected until the error grows and becomes a large (“gross”) error. Undetected errors are not remedied until the next calibration, which on average are a year apart Beamex (2019) [1] across all industries. Classical statistical methods that depend on linear relationships between input and response variables are typically used to find gross errors, but are not effective for highly non-linear and non-stationary operations in mining and mineral processing industries. Calibration of sensors is time-consuming and generally requires physical intervention that results in equipment downtimes causing production losses. Therefore, in situ detection methods are warranted that do not require physical removal of sensors to compare with standard measurements or well-calibrated sensors. Data-mining based techniques and algorithms have high success rate in tackling such problems. This paper presents results from a groundbreaking multi-year big data research project whose goal was to develop data-mining-based original techniques in a multi-sensor environment to identify when sensors start to stray, rather than wait for errors to grow. The carbon stripping (gold) circuit in the Pogo Mine of Alaska was selected for this project. Maintaining strip vessel temperatures at optimum levels is crucial for maximizing gold recoveries at Pogo, and hence the focus was on the temperature sensors of the two strip vessels. An automated algorithm to detect errors in strip vessel temperature sensors was developed that exploited data from multiple sensors in the strip circuit. This algorithm was able to detect with a high success rate when bias errors of magnitude as low as ± 2% were artificially induced into strip vessel temperature data streams. The detection times of about 1 month were much less than the industry average calibration frequency of 1 year. Thus, the algorithm helps detect errors early, without stopping the circuit. The algorithm alarms can serve as triggers when calibrations are done. Experimental methodology along with results, limitations of algorithms, and future research are also presented in this paper.

By Frank W. Dickson, George Tunell

Five hot spring areas of the western United States show evidences of present day deposition of HgS; two also show evidences of accompanying Sb2S3 deposition. Sulfide minerals are depositing at or near the surface from hot waters that differ for each spring ai:ea in amount and kinds of dissolved matter. All the springs contain dissolved substances that act as buffering agents and that cause increased alkalinity with increasing temperature. Transport of Sb2S3 is possible in H2O and in boron and sulfide solutions. Increasing alkalinity and temperature enhance stibnite solubility. Quantitatively important transport of HgS appears restricted to alkaline sulfide solutions that contain HgS2=. Elemental mercury probably forms in deep hot waters because HgS breaks down into mercury and sulfur above 200°C, and free S is removed by reaction with water. Elemental mercury should accompany HgS2= in solutions that were at 200°C or higher. Cinnabar deposits from saturated alkaline sulfide solutions because of combinations of temperature decrease, dilution, oxidation, and reactions with wall rock: Amedee Hot Springs, Boiling Springs, and Coso Hot Springs are areas in which HgS is the only sulfide deposited. Hot waters at Amedee and Boiling Springs are supersaturated with HgS or transport colloidal HgS. Steamboat Springs waters deposit mainly silica and stibnite, but they have deposited HgS recently. Sulphur Bank waters deposit mostly stibnite and some HgS. The hot-spring waters of all springs represent highly modified deep water. Field and laboratory studies support the concept of transport of HgS in moderately alkaline sulfide solutions as HgS2=. Fluctuating deposition of stibnite and cinnabar reflects availability of sulfide or variations in deep-source HgS and Sb,S,. Silica and HgS dissolve mutually in alkaline sulfide solutions, and cinnabar and quartz would be expected to deposit simultaneously. Free mercury given off by hot-spring waters would impregnate country rocks.

Jan 1, 1968

By Seth C. Schaefer

The Bureau of Mines investigated the thermodynamic properties of Bi203 (bismuth sesquioxide) and Sn02 (stannic oxide). Standard Gibbs energies of formation (AGfO) of these compounds were determined with high-temperature electromotive force (emf) cells using stabilized Zr02 (zirconia) as the electrolyte. Potential measurements were obtained from the cell

Jan 1, 1984

By K. E. Stanfield

[Asphalt and road oil are the principal products manufactured from Wyoming ?clack oils? which, because of their high asphalt an high sulfur content, are difficult and costly to refine into high-grade motor fuels, burning oils, and lubricants by pre sent methods. Accordingly, the remand for these asphaltic residuums for the construction of roads and other uses is a controlling- factor in the quantity of crude oil produced. The increasing utilization of special asphalts as inexpensive bonding, insulating, and waterproofing materials indicates the desirability of obtaining information on the yield and properties, of asphalts from Wyoming black oil to promote a wider and more stable caret for these asphaltic materials.]

Jan 1, 1941

Filtration of pulps of varying densities is an essential operation in the hydro-metallurgical production of zinc. The use of filters naturally applies only to the "wet" plants, and in these varying types and sizes are in commission. At Risdon, the Moore suction filter is used for the heavier pulps, except in one instance, where a modification of the Butters-Cassell filter is installed.Filter presses are in general use, and of these, one is a washing unit; the plates, and frames are of cast iron or mild steel, except in one case which is a centre feed press having wooden frames.FILTER DESIGNThe problem of filtration presented itself very early in the history of Risdon and the first developments occurred in what was termed the 250 -lb. plant. Here experiments were made with many types of filters, and as this was the pilot plant on which the design of the 10 ton plant (10 tons of zinc per day) was based, quick decisions were necessary.An Oliver type filter was chosen for the heavier pulp or residue, and a Shriver wooden frame filter press for the lighter pulps.To this day, but with a number of variations, filter presses continue to function unopposed in their particular field; however, the Oliver filter was soon superseded because it was found impossible to wash the filter cake efficiently without repulping; consequently its use was abandoned and the Moore filter adopted.Both- these filters have been modified and developed in many ways to meet the requirements of a zinc plant, but they retain their original basic features.

Jan 1, 1949

A genesis based on new developments in the physical chemistry and flow properties of colloidal substances is proposed for the pipe-like Peko orebody. The rheological behaviour of sediments is governed by the contained colloids. Remobilization of thick pasty sediment during diagenesis is regarded as an essential step in the concentration of metal dispersed in sediments. At a high concentration the sediment pore fluid is a dense gelloid such that van der Waals attractive forces between the colloidal particles exceeds the coulombic repulsion. This permits accretion of the colloids into globular clots and their fracture fragments. These have a uniform size distribution dependent upon the rate of shear, and the sediment lithifies to clotted, porphyry-like, "gritty", dolomitic or igneous-looking intrusions and flows. The physical chemical properties of natural sediment colloids appear adequate to account for ore formation.Adsorption accounts for the dispersion and retention of metal in sediments. Accretion accounts for the segregation of the colloidal materials to give the various types of clotted igneous-looking intrusive source rocks. Syneresis enables the colloids to spontaneously draw together and to dehydrate. Formation of an ordered lattice achieves a lower energy state and desorbs metals and insoluble metal compounds "particle by particle" into the escaping water of hydration and pore water. Peptization enables migration of the metal hydrosols as stable dispersions until they merge for outflow through seepage zones or water extrusion channels. Nucleation and concretion precipitate the metal dispersoids from pore waters seeping through hydrous parts of the source rock, porous beds, faults, and zones of weakness by which the connate waters leave the lithifying sediments. Gelatinous precipitated mineral matter in the ore channels is capable of thixotropic reliquefaction when disturbed by shock or movement. Local reintrusion, flowage, interveinings,brecciation, and intermixing of the materials is the result.The principles of the suggested genesis are applicable to both syngenetic and epigenetic mineral accumulations.

Jan 1, 1966

By Yuting Xue, Gamal Rashed, Zoheir Khademian, Connor Brown, Khaled Mohamed

Ground falls in U.S. underground coal mines can lead to significant consequences, including loss of life, injuries, damaged equipment, and production stoppage. Improving the safety of the workplace is of utmost importance for mine workers and the U.S. economy. The Mine Safety and Health Administration (MSHA) accident/injury/illness dataset provides short narratives for reported incidents, including ground-falls. The main objective of this study is to develop a framework that includes: 1) utilizing machine learning algorithms to categorize ground-fall incidents from narratives based on the main cause of the occurrence and 2) demonstrating an example of a user-friendly visualization to display injury/fatality trends from narratives in U.S. coal mines between 1983 and 2021. The developed framework was tested on a subset of the data and achieved an average F1-score of 96% in categorizing the incidents. The outcome will help identify areas requiring additional research and innovative solutions to reduce severe occupational hazards.

Feb 1, 2024

By Jerry Ran

Stope back caving in a mine using open stope mining interrupts the planned mining sequence and causes oversize muck and dilution with adverse economic implications. As many underground mines are mining or have plans to mine at depth, stope back caving could have significant impact on the mine sustainability. Therefore understanding the caving mechanism is important in preventing future occurrence and improving the mine economic performance. Falconbridge Ltd Kidd Mine is an underground mine using open stope method producing more than 2 million tonnes per year. Its current lowest mining level is approximately 2070m below surface and the lower portion of the orebody is being developed. In years of 2002 and 2003 the back of three stopes of approximately 1900m and 2040m below surface caved and caused substantial mining difficulties at the mine. As these caved stopes are subject to stress concentration, seismic activities and near major geological structures, the caving mechanism is much more complex than that of stopes near surface. In addition to the recorded caving history by site observations, the mine carried out cavity surveys and test drilling to define the caved profiles. The mine seismic monitoring database provided information at these stopes. Stress modeling work conducted by an external consultant provided the stress patterns at the caved stopes. Based on the field collected data and stress and seismic information, this paper presents details of the stope caving process and cavity surveyed profiles, reviews the predictability of the stability graph approach for these cases, discusses the caving mechanism and proposes preventive measures to stabilize the stope back.

May 1, 2004

The project to reopen the Tasmania Mine has centred around efforts to reopen the Hart Shaft to access the high grade reef remaining below the old workings, which extend down to 457 in. Efforts in 1982 and 1987 were frustrated by unstable clay ground around the shaft, which resulted in significant subsidence of the shaft collar and lining. A successful program has since been implemented to solve the problems, stabilize the collar and recover the upper shaft which had collapsed down to 90 m.

Jan 1, 1989

The phenomena of nature cannot present themselves to any thinking wild without claiming from it some solution. The earth, as it has often been observed, is laid out like a well ordered cabinet, presenting to us, in measure, some means of judging how the laws of nature and the essential properties of matter have worked out all we see before us. "That there have been depositions of strata gradually laid down aud stocked with the remains of the living objects, vegetable and animal, that flourished when they were being imposed, is an universally acknowledged fact. It speaks of a constantly maintained series of operations whereby the globe has been brought to its present condition, and which are ever advancing it to stages that are still before it. That immeasurable ages have been consumed in effecting these developments is also conceded. We witness the very graduated rate of the existing advances and can see that the past action must have been conducted in the same slow deliberate manner. There are many questions, however, upon which inquirers are not agreed, hence they are still within the domains of fair discussion.What has led to those great climatic changes whereby the same portions of the earth have had at various times climates that were glacial, temperate, and tropical? What causes the constant contortions and dislocations of strata and the upheaval and depression of land levels, and that there is a tendency to alternation in the parallel areas undergoing opposite kinds of movement as if the sinking of one area balanced the rIsing of another? What is the reason that the centres of volcanic action are continually shifting, and that the line of greatest activity is always upon the rising areas? That portions of the earth have been subjected to intense alid long continued volcanic action, and again to long periods of repose, and that the periods of activity and repose are·recurrent at long intervals of time? What the mountain chains of the world are in broadly parallel bands? What has caused the stratified rocks to be tilted from their original?

Industrial minerals and rocks are those which are economically important because of desirable physical and/or chemical properties rather than metal or energy content. The evaluation of these resources for investment purposes in general follows established procedures after due consideration of well documented input data. However, in view of the sensitivity of many industrial mineral projects to specific inputs they require very careful analysis. The characteristics of the industrial minerals and the industrial minerals industry are reviewed and the significance of logistics, customer requirements, technology and marketing are discussed. Implications in relation to resources/reserves terminology are considered with phosphate rock used as an example. It is concluded that industrial mineral projects as a consequence of technology and market dependence in particular can give a high level of investment risk. The industry, however, offers most interesting and challenging employment opportunities for geologists, mineral engineers and economists.

Jan 1, 1988

By Danton L. Paulson

Elevated temperature electrical resistivity measurements were made by the Bureau of Mines on arc-melted, spin-cast, and hot-pressed columbium carbide¬carbon (CbC-C) and zirconium carbide-carbon (ZrC-C) materials up to 2,000° C. The CbC-C materials displayed electrical resistivity values ranging from 35.20 microhm cm at 23° C for hot-pressed material containing 12 wt pct carbon to 242.64 microhm cm at 1,622° C for arc-cast material containing 17.0 wt pct carbon. Electrical resistivity values ranged from 29 microhm cm at 20° C for arc-cast ZrC-C containing 16 wt pct carbon to 279 microhm cm at 1,951° C for hot-pressed ZrC-C containing 21 wt pct carbon. Data from a previous report were included to establish comparison between the electrical resistivities of the CbC-C, ZrC-C, and HfC-C systems.

Jan 1, 1969

A process was developed to produce electrolytic manganese dioxide, suitable for use in high quality dry cells, from Risdon anode mud. ImpurItIes present In the anode mud were removed prior to the electrolysis which was performed from a manganese sulphate bath using the following conditions.Temp. 95°CH2S04 50-55 g/l.Mn2+ 55-60 g/l.Anode c.d. 10·0 A/sq. ft.Operation under these conditions yielded current efficiency and power consumption figures of 95 per cent and 0·8 kWh/lb respectively. The product conformed to battery manufacturers' specifications as regards physical and chemical properties and performed satisfactorily in a battery testing programme.

Jan 1, 1968

By Chulgi Suk, Hoon Park, Hyonsoo Kim, Hakman Kim, Sangho Cho

Dust emission from blast demolition and other construction activities can be a nuisance; it is widely recognized that fine particles less than 10 µm in equivalent diameter (called PM10) may cause health problems. Mist spray systems, such as rain guns, sprinklers, water/surfactant sprays (or foams) etc., are some of the most effective dust suppression methods. A large amount of research has showed that when water droplets are produced in an equal amount to that of dust particles, the airborne dust is suppressed by the agglomeration of dust and mist particles. A method for generating micro-sized mist from water, achieved by the detonation of explosives in the water tube, was suggested and is called the ‘detonationdriven water bag burst system’. There are many experimentally observed limitations of the explosioninduced water break-up process. The water bag explosion tests were simulated using the AUTODYN software, in order to investigate the aerosolization mechanisms of the detonation-driven water and water break-up process into micron-sized droplets. As a result of the numerical analyses, the diffusion direction of water when detonating in the central interior part of water tube was radioactive and significantly stronger than when detonating in the bottom exterior part; this is due to the compressive flow of the volume change inside of the water tube, which resulted from the blasting wave inside of the tube, as well as the reflected pressure on the ground. Blast tests of full-scaled reinforced concrete columns were conducted to verify the effectiveness of the suggested detonation-driven water bag burst system. The water breakdown and dispersion that occurred while blasting the reinforced concrete columns were observed using a high-speed camera, and dust generation was monitored using four density detectors. The suggested detonation-driven water bag burst system showed that the average dust density decreased by up to 7 mg/m3.

Jan 1, 2016

By David Cole

THE appearance of the Wilfley table in 1897 marked an epoch in the art of concentration of ores. The table has merited and received an almost unprecedented measure of public approval, lasting through its whole patent life. It has been very little improved in itself, or improved upon by competitors. The new machines bidding for popular favor have been of the Wilfley family, but without ability to do markedly better work than the parent m:-chine, or to (to more work except by the use of superimposed decks, the latter having obvious disadvantages. FIG. 1.-The- Butchart RIFFLE System. During the past three years there has been developed at Morenci a new type or arrangement of riffles applicable to the Wilfley type of concentrating table which corrects many of the objectionable features or limitations of the older system and obviates most of the difficulties encountered with it, particularly when handling ores having a low ratio of concentration. The new type is known as the Butchart1 riffle system, and its general arrangement is shown in Figs. 1 and 2.

Jan 2, 1915