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Allis Mineral Systems' Grate- Kiln system can economically convert low-grade iron ore into high- grade iron-ore pellets suitable as feed material for blast furnaces for making steel. These pellets can also be fed to a direct reduction process for making sponge iron. The Grate- Car system combines the company's [ ] Grate-Kiln system for iron-ore pelletizing and Accar system for iron- ore reduction. The Grate-Car system consists of a traveling grate, a ported rotary kiln and a rotary cooler that are coupled in series. This system eliminates the pelletizing plant's rotary kiln and annular cooler. It reduces the need for some auxiliary equipment. This results in lower capital cost and lower energy consumption. The traveling grate provides that static bed handling necessary for heat hardening pellets before their discharge into the kiln. The ported kiln provides the reducing atmosphere with a more precise means of controlling the kiln axial temperature profile than conventional rotary kilns.

Jan 1, 1997

By C. L. Sarff

[Automation has become a word that means many things. To management it is the end of the rainbow; you push a button and all your problems are solved. To the working man it is a horrible monster that is taking his livelihood away. To the maintenance man it is a complex that overwhelms him when he thinks of trying to find the trouble when the machine is not operating, properly. Automation has been with us in the coal nines for many years. Long before my time you were using float switches on mine sumps to control the level of the water. That?s automation in the truest sense of the word, but we call it automatic and think nothing of it. If we use the word automatic instead of automation your mine electrician and mechanic will take hold of the problems in stride.]

Jan 1, 1962

By Donald L. King, Frank A. Baczek

Sedimentation-based equipment is used in applications where separation of solids from liquid by gravity settling is desired. If a concentrated solids slurry is desired, the equipment is designed to "thicken"; if a clear liquid is desired the equipment is designed to "clarify." Thickeners normally handle higher solids loading rates than clarifiers, which usually process feed slurries containing low concentrations of suspended solids. Thickeners are therefore designed for heavier-duty requirements, and clarifiers have extra features to ensure more complete suspended solids removal. Major components (Figure 1) that are common to all sedimentation-based equipment are: tank, drive-support structure, drive unit and lifting device, rake structure, feed well, and a means of overflow and underflow withdrawal. Specific features are designed interdependently after the overall separation approach is defined conceptually. This conceptual approach is usually based on past experience or evolves from sedimentation studies conducted on samples of the slurry to be handled. Because many variations and combinations of components are possible, the overall conceptual approach has a number of possible designs that will accomplish the desired results. The final choice is based on practicality, potential for minimizing upsets, and cost.

Jan 1, 1986

By D. R. Babich, E. R. Bauer

Noise-Induced Hearing Loss (NIHL) continues to be a concern of the mining industry. A new noise standard (30 CFR, Part 62) is aimed at reducing NIHL in mining through engineering and administrative noise controls. However, the difficulty and expense of implementing engineering controls can make administrative controls an attractive alternative for reducing worker noise exposure. Over the last three years, the National Institute for Occupational Safety and Health (NIOSH) has conducted worker noise exposure surveys in underground and surface coal mines and coal preparation plants. The surveys revealed numerous possible administrative controls and an approach to implementation and analysis. The surveys have shown that worker dosimetry, time-motion studies, and equipment noise profiling are important aspects of effectively utilizing administrative controls. A description of the approach for selecting, implementing, and evaluating administrative controls, and a list of administrative controls, are reported.

Jan 1, 2004

By Harold A. Taylor

The first use of graphite is lost in the mists of time. It was used by primitive man to make drawings on the walls of caves and by the Egyptians to decorate pottery. As early as 1400 AD graphite crucibles were being made in the Haffnerzell District of Bavaria. Through the Middle Ages graphite was confused with other minerals, especially galena and molybdenite. Two common names that are still being used for the mineral are plumbago, meaning lead-silver, and black lead. The latter name implied that graphite is either composed of lead or at least contains a large percentage of it. Gessner is credited with having recognized it as a separate mineral in 1565, but its composition was not determined until 1779, when Scheele demonstrated that graphite oxidized to carbon dioxide, thus proving its carbon constitution. In 1789, Werner named it graphite from the Greek word graphein, meaning to write. The United States has long relied on foreign countries for its graphite supplies. This reliance has been due more to the lack of suitable domestic graphites than to any particular preference for buying minerals overseas. Sri Lankan graphites were imported as early as 1820, and Madagascar graphites have been imported since the properties on that island were opened up about a hundred years later. Mexico has long supplied the United States with most of its requirements for amorphous graphite.

Jan 1, 1994

ABB Industrial Systems is one of the largest electrical engineering companies in the world. ABB develops, manufactures and markets electric drives. The company has more than 100 years experience in the application of medium- and high-voltage AC machines. And ABB's continuous research and development program ensures that its machines use the latest technologies and materials. Each motor is custom designed to meet specific applications. The HXR high-efficiency motors (100 to 1,900 kW or 134 to 2,250 hp at 50 Hz) are efficient and have low noise levels. Typical applications are pumps, fans, blowers, compressors and pulverizers. The enclosed units are constructed with external cooling ribs and fans. And the motors are equipped with solid, longlife stators and rigid rotor construction. The patented rotor construction provides for low vibration levels. ABB's large synchronous motors (1 to 50 MW or 1,340 to 70,000 hp up to 900 rpm) are used in the mining industry for crushing, grinding hoisting and conveying systems. These motors are designed to customer's specifications, including existing foundations. They can be equipped with fixed or adjustable speed control.

Jan 1, 1998

By J. Herbst, I. Heber-Panu, Dan G. Cojocariu, E. Ene-Danalache, G. Poling

A general model which represents not only batch but also continuous flotation in multi-cell machines is presented. This model considers both the size distribution and the distribution of flotabilities in a size class for valuable mineral particles in the pulp. The general expression is shown to reduce to several previously reported models. In addition, a number of new models are found to arise for different specific assumptions concerning the flotability distribution and/or the size distribution of the particles undergoing flotation. Several of these new models are tested experimentally using laboratory-scale batch and pilot-scale continuous data. Model parameters are estimated from this data and a comparison of calculated recoveries and those experimentally determined are presented. Finally, the influence of the feed rate, aeration rate and valuable mineral content of the feed on the recovery is examined.

Jan 1, 1976

By Kadri Dagdelen, Thys B. Johnson, Salih Ramazan

Long-term production scheduling design is a very important part of mining because it determines the economic outcome of a project There have been many attempts to solve the optimum pit scheduling problem, but there has been no success in developing a scheduling method to give optimum results in maximizing net present value of a mining project. Open pit production scheduling problem can be formulated as a mathematical programming problem and solved using Mixed Integer Programming technique. However, it is not possible to solve the formulation within a reasonable time since the number of integer variables required for the mathematical model is too great to do that by today's available computer technology. There- fore, a methodology is required to combine, or aggregate, the mining blocks and to decrease the number of integer variables in scheduling without losing the optimality. Therefore, the fundamental tree concept was developed in this paper to combine the blocks. A fundamental tree is defined as any combination of blocks such that: 1. the blocks can be profitably mined, 2. the blocks obey the slope constraints and, 3. there is no subset of the chosen blocks that meets 1 and 2. A Linear Programming (LP) formulation is developed as a mathematical model to find a set of fundamental trees that exist for a deposit. Since the blocks are combined to form the fundamental trees, the number of variables required for the scheduling model is decreased significantly. This decrease in the number of variables makes it possible to mathematically formulate the multi-time period scheduling problem as a Mixed Integer Programming (MIP) model. A case study is performed on a multi-mineral copper deposit in Peru, South America. NPVs of annual after-tax cash flows generated based on the schedule provided by the "Fundamental Tree Algorithm" is compared with NPVs resulted from the schedules coming from three of the computer packages presently available to the mining industry. These are Mintec's M821V, Earth- work's NPV Scheduler, and Whittle's Milava open pit mine schedulers.

Jan 1, 2002

By Randall E. Hughes, John F. Burst

This chapter describes the nature and occurrence of the principal clay minerals that are used as ceramic raw materials, explains how these raw materials are used to produce finished goods, and summarizes positive and negative trends that will affect future demand for raw materials and products in the ceramic industry. The term ceramics was derived from the ancient Greek keramikos (a clay jar). A ceramic product is a material that has been fired to at least 468.3°C (Mitchell, 1983). In addition to being one of our earliest manufacturing and construction materials, ceramic products are among the earliest records of civilization. The enduring significance of ceramics is shown by the fact that, even today, the manufacture of whitewares, brick and related red-fired wares, refractories, and engineered ceramics continues to be a major sector of the US economy. A wide range of materials can be made into ceramic products, although relatively few earth materials make up most of the ceramics in today's markets (Table 1). Most ceramic products are made from clay or a related material. The long history of clay use in the ceramics industry stems from its variable and sometimes unique physical and chemical properties, as well as its ubiquitous occurrence and relatively low cost. Clay is important to ceramics because of its plasticity, moldability and filterability, chemical content, color. refractoriness, solubility. corrosion resistance, electrical properties, and other properties that result from the essentially two dimensional morphology of the individual clay mineral platelets. Because of their basic relationships to the chemical and physical properties of clays, the chemical and mineralogical content have been the subject of continuous studies over the past few decades. Advances in knowledge about the chemical, mineralogical, and physical properties of clays are responsible for most of the advances in processing. The need to remove off-colored contaminants, minerals with low melting points, and soluble salts has resulted in beneficiation by wet processing methods such as water washing. Water washing is restricted to kaolins, although low cost methods of water washing have been extended more recently to ball clays in Europe. High intensity magnetic filtration and flotation technologies have noticeably improved the quality of kaolins and broadly expanded their use in the ceramics industry. In addition to products for construction (e.g., brick, tile, sewer pipe, field drain pipe, cement, fiberglass, roof granules, and paint) and manufacturing (e.g., refractories, kiln furniture, sanitary ware, pottery, and dinnerware), clays are used in calcined form as ceramic fillers, carriers, extenders, and grogs. Ceramics suppliers are under economic pressure in several of these product areas. Manufacture of refractories in America has declined as steel production has decreased. Similarly, dinnerware and tile production have declined because of foreign competition. Fortunately, new uses for clays,

Jan 1, 1994

By Allan M. Johnson

The Sherwood Mine is being monitored to determine the nature and extent of changes in the mine and its environs which result from the closing and the cessation of pumping. Of particular interest was the possibility of piping-induced subsidence occurring as the mine flooded. Previous experience in the district indicated that this possibility was very real. A monitoring system, including acoustic sensors, extensometers, surface subsidence monuments, and ground water observation wells was installed in July 1978, just prior to the mine closing. Late in 1979, three piping-induced subsidence events occurred. The monitored data, and related laboratory studies are being applied to a quantitative description of piping-induced subsidence.

Jan 1, 1980

By K. C. Nathsarma

An attempt was made to extract niobium oxide from ~98.5% Nb2O5 using solvent extraction processes. Nb2O5 is used as the feed material in carbothermic reduction processes aimed at producing high-homogeneity, super-conductor-grade niobium on a laboratory scale. The Nb metal used for superconductor applications requires a residual resistivity ratio (RRR) > 300, which in turn needs a stringent purity of Nb and allows impurities (substitutional and interstitial) in ppm levels only. In this paper, solvent extraction of niobium was studied under various experimental conditions, such as effect of different extractants, concentration of methyl isobutyl ketone (MIBK) in the organic phase and concentration of various acids. The concentrate was digested with hydrofluoric acid, with ammonium fluoride (NH4F) as a stripping agent. The extraction of niobium from low hydrofluoric- (HF-) bearing solution was found to be low. Thus, various concentrations of hydrofluoric acid and sulfuric acid, as well as hydrofluoric acid and hydrochloric acid, were investigated towards obtaining a maximum amount of niobium in the filtrate and a minimum amount of niobium in the residue. A McCabe - Thiele plot for extraction of niobium from the aqueous phase, HF-bearing solution using HCl with 85% MIBK in kerosene has been constructed to determine the O:A ratio and the number of stages of the process.

Jan 1, 2011

By Robert Walker

The win theme of this session is Unique Material Handing Systems. The theme was selected because of two major factors. 1. Accomplishments of unique character manage to attract interest regardless of their age. 2. There is much to be learned from pioneering efforts of the past as they are the stepping stones to technological development. Thus, 2-1/2 years after completion, the engineering feat of Oroville Dam still looms large let us take a close look at this project to see what made it unique. To begin with, it established a number of firsts: At 770 feet it was the highest earth fill dam in the world. At $121 million dollars, it was the largest ever United States construction project (Civil). At 80 million cubic yards it had the largest earth volume of any dam in the world. The extensive use of belt conveyors for this application had never before been tried. The use of a high capacity bucket wheel-excavator with shiftable belt conveyors had never before been utilized as a con¬tractor's tool. The principal of the "integral train" was applied most effectively whereby up to 220,000 tons of material-was transported daily some 14 miles. To achieve optimum economics a number of technical breakthroughs were necessary. The suppliers of major commercial components worked hand-in-hand with system engineers to develop new machinery necessary for the highly mobile characteristics of the systems, viz., single pulley drives delivering 2000 horsepower, 1000 horsepower right-angle shaft-mounted reducers, across the line starting of 1000 horsepower squirrel cage motors, 10 miles of steel chord conveyor belts with belt tensions up to 150,000 pounds, aircraft-type disc brakes, hydraulic take-ups, train loading at a rate of 25,000 tons per hour, automatic train indexing for rotary dumping at 10,000 tons per hour, roll-over car dumping without uncoupling cars, shifting 7500 ft. long conveyors up to 300 feet laterally without disassembly. These are some of the superlatives that have made the Oroville Dam project unique. The measure of its success is demonstrated by the results.

Jan 1, 1970

By E. W. Lindroos, Fred D. DeVaney, R. L. Bennett, R. W. Hernlund, W. R. van Slyke, W. F. McDermott, C. U. Keranen

INTRODUCTION Iron is the world's most widely used metal and constitutes about 5% of the earth's crust. Iron ores are found widely distributed throughout the world. Because of its wide occurrence and relatively low value, an iron ore to be merchantable must contain a relatively high percentage of the metal to be considered as a source of iron. Few ores containing less than 25% iron would be considered as ore unless they existed in large amounts and could be concentrated very cheaply. The grade of the ore, the ease of concentration, and the transportation cost to market are fundamental considerations deter- mining its worth. Iron never occurs as a natural metal except in meteorites. Most iron ores occur as oxides, and to a lesser degree as carbonates. A small amount is recovered as a byproduct from iron sulfides. Iron ore must be reduced (oxygen removed) to metal for use. Iron is marketed in many forms and combinations, such as pig iron and a great variety of steels. Iron is practically never pure as marketed but contains varying amounts of carbon, phosphorus, sulfur, and alloying elements such as nickel, chromium, etc., all of which affect the physical proper- ties of the end product. Please note that in this section all analyses ore on a dry basis and all tonnage figures are on a long-ton basis of 2,240 lb unless otherwise noted.

Jan 1, 1985

By Joseph R. Hatch

Previous studies of the Thompson and Temperly ore bodies show alteration aureoles in the Middle Ordovician host-rock limestones, dolomites and shales extending laterally as much as 60m from the ore. Thickness, texture, carbonate and clay mineralogy, major-, minor-, and trace-element contents; and carbonate carbon and carbonate oxygen Isotope compositions of the host rocks all have been significantly altered by hydrothermal processes. Organic geochemical analyses of samples from the basal 8-cm-thick carbonaceous shale bed and immediately overlying limestone bed of the Quimbys Mill Member of the Platteville Formation, collected from within the ore, the alteration aureole, and the unaltered country rock show: 1) solution of carbonates and residual concentration of organic matter, 2) decreases in the volatile (Si) and pyrolytic (S2) hydrocarbon yields In samples of the basal shale from within the ore, 3) decreases in the relative amounts of the lower molecular weight (<nC25) saturated hydrocarbons in samples from the ore, and 4) no changes in either the organic carbon isotope composition or the Rock-Eval or biomarker thermal maturation Indicators. In light of the 125-170°C depositional temperatures documented for the early marmatitic sphalerltes in these deposits by fluid Inclusion studies, the lack of thermal alteration of the organic matter suggests a relatively short mineralization episode, a conclusion supported by the relatively simple sphalerite band stratigraphy. The decreases in the volatile and pyrolytic hydrocarbon yields for shale samples from the ore supports a model for mineral deposition which obtains sulfide through reaction of brine sulfate and indigenous organic matter.

Jan 1, 2013

By William C. Ellis

Underground water is part of a continuing hydrologic cycle, which involves all elements of water occurrence. All groundwater of economic importance is in process of movement through a porous rock stratum from a place of intake or recharge to a place of disposal. Groundwater moves and is contained in fractures in the rock and/or in intergranular spaces of porous formations. Where there have been no water developments by man, groundwater is in a state of approximate equilibrium and the forces of replenishment and discharge are in balance. Thus, groundwater, unlike other mineral resources, is constantly being replenished in most areas at a rate which is measurable and which is important in the planning of its utilization. As illustrated by Figure 1, replenishment of groundwater supplies results from the direct penetration of rainfall through the soil to the water table, by seepage from surface streams or ponds, and/or by subsurface movement from an adjacent groundwater body. Under natural discharge conditions, water is commonly consumed by transpiration of trees and other types of vegetation, by flows from springs, by evaporation from shallow depths below the surface, and seepage into streams that traverse the area.

Jan 1, 1964

Giant gold deposits are considered products of crustal-scale systems. Reduced fluids stored in mid to lower crustal reservoirs were discharged into mid to upper crustal sites of deposition. Elements of the architecture include crustal-scale structures, reduced packages of rock and regional seals. Gas-rich aqueous fluids were common but non-aqueous fluids may have been significant in the deeper parts of the systems. Fluid fluxes in over pressured domains were maintained by porosity waves. Abnormal heat input from the mantle may not be required once the systems were perturbed. Fluid-mixing and hypogene enrichment were probably the most significant precipitation processes.

Jan 1, 1999

By C. O. Brawner

INTRODUCTION My first major involvement on a rock mine slope stability project was in 1966 after I had become a principal of Golder Brawner & Associates in Vancouver, Canada. I received a request from Kennecott to evaluate two serious rock slope failures adjacent to the concentrator on their British Columbia molybdenum property near Alice Arm, BC, which was under construction. A rock slope up to 200 ft* high had been excavated at a design angle of 700. The inspection indicated that several large blocks of about 1000 cu yd each had failed on steeply inclined joint surfaces. Stability was reduced by extensive seepage caused by heavy rainfall. In addition, considerable overbreak had occurred, indicating excessive blasting had been used to excavate the slope. A program was developed to rock bolt potentially unstable blocks that could slide on dipping discontinuities. Some rock was scaled back to the inclined joints, and drain holes were drilled to reduce water pressures. The project was completed successfully and within reasonable economics. As a result of this success, enquiries were received regarding other mining projects. This indicated the potential demand for rock slope engineering. As a result, I took one month off to meet and discuss rock mechanics and slope stability with various people internationally. These included D. Coates in Canada, E. Hoek in England, K. John and L. Mueller in Germany, M. Rocha in Portugal, and the US Bureau of Mines in Denver, CO. Early misconceptions Based on involvement in projects during the next few years, it was concluded that there were a considerable number of misconceptions that existed among some geologists and mining engineers dealing with surface rock mechanics. Some of these included: • Water is a lubricant. This is incorrect. Water reduces the shear strength along discontinuities due to buoyancy, which reduces frictional strength. It also reduces the cohesion of clayey-type rocks. • The optimum pit slope angle in rock is 45°. The optimum slope angle for safety and economics is variable and is influenced particularly by structural geology, water pressures, mine blasting practices, and the depth and degree of weathering. • The flattest angle for slope stability is dictated by the angle of repose of broken rock, about 370. Where clayey-type rocks or clayey infill in discontinuities exists, failure can occur at much flatter angles, requiring flatter slopes or artificial stabilization. • Uniaxial and triaxial tests provide the necessary shear strength parameters to design rock slopes. Most failures in rock slopes are controlled by directional discontinuities. Therefore, the direct shear test is the correct test to evaluate strength parameters for most problems.

Jan 1, 1987

By William W. Kephart

Brockway Glass Company, Inc., manufactures glass containers at fourteen plants located in nine states. The relatively high place value of the major glass batch components dictates that raw material supplies be obtained from numerous sources in the United States and Canada. One objective of our central composition control program is to arrive at a glass composition with similar physical properties at each of our plant locations. This requires that adjustments be made in the batch compositions to compensate for chemical variations from one raw material source to another. Minor chemical variations will occur in sand, limestone, and dolomite from one source to another. Major variations are present in the alumina sources because of the diverse rock types utilized.

Jan 1, 1973

By Ted Klemetti

Roof deterioration in weak moisture-sensitive rock leads to roof falls in coal mines. An observation site was set up in intake air at an underground coal mine in central Ohio to evaluate the time-dependent deterioration of moisture-sensitive roof rock. By periodically collecting and weighing the rock falling from the roof, the National Institute for Occupational Safety and Health (NIOSH) was able to quantify the deterioration of the moisture-sensitive shale roof. The measurements showed that more roof rock is falling in the dry winter months. Movements in an intersection were monitored in order to determine if deformation correlated with seasonal changes in temperature and humidity. The rate of intersection roof-to-floor convergence was found to be cyclical and related to seasonal changes, with more convergence during the months of April through September. At the study site intersection, the roof beam did not show deflection indicating movement most likely due to mine floor deformation. The bolt load also increased in the warmer months before shedding load, possibly due to rock failure. Temperature and relative humidity sensors, placed in holes in the roof show that mine air does not mix with the air in the holes. Consistent saturation levels of relative humidity were measured in the holes and it appears that high levels of moisture may have migrated into the bolt holes from roof shales. A roof sealant applied to a portion of the test roof appears to be preserving the roof and reducing the amount of rock fall into the entry, while the screened area virtually eliminated rock falling from the roof.

Jan 1, 2009

By K. J. Reid

With the current trends of increasing costs and decreasing head grades the mineral industry is no longer operating in very high profit areas and has been forced to pay greater attention to the application of modern technology. Although here are many technological advances to the credit of the industry in recent years there are still many processes being operated in the traditional manner and still many areas awaiting the application of methods which have been proven in other industries. Compared with the chemical industry the mineral industry is seriously ageing in the general areas of process analysis and process control, more so than can be justified by the complications arising from having to deal with particulate systems with properties far different from ideal, or even non-ideal, liquid systems. One area in which there has been a remarkable lack of application in the Mineral industry is that of analog computation and the authors feel that there is considerable scope for the use of the analog computer in studying mineral industry processes. The paper outlines the basic principles and features of the analog computer and describes its role as a simulation tool in some engineering and mineral processing systems.

Jan 1, 1972