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By R. S. Cartwright

Two types of automatic drilling controls, the Halliburton and the Hild, are now available and are coming into more or less general use in deep drilling. The primary function of both is to maintain a safe limit of torque on the drill pipe, this being accomplished by automatically controlling the weight or pressure on the cutting tool. Neither type will necessarily increase drilling speed, but by permitting advantage to be taken of "breaks" in the hole higher average cutting speed may be maintained. The control is essentially a safety device, and should be considered as such. It is not the purpose of this paper to discuss the merits of drilling controls, although the advantages over manual feed at the brake drum are obvious, but rather to point out some of the limitations. The Halliburton Control The Halliburton control is designed to operate during drilling through the agency of the draw works. Automatic and constant control. of the torque on the bit is governed by clutches on the control itself, and the line shaft to drum shaft drives on the draw works. In operations other than drilling the control is simply a jackshaft between prime mover and draw works. It is, of course, adaptable to any type of power. Because control of the torque on the bit is dependent upon the various ratios or clutch combinations available on the Halliburton control and the draw works, it follows that there are certain limitations in points of control. Table 1 shows the possible ratios which can be obtained with the control and a popular type of three-speed draw works, it being assumed that the highest possible gear combination-the combination which when engaged will suspend the least amount of weight-has a value of 1.00.

Jan 1, 1928

By Nils Heinke, Stephen M. Collinsorth

To anyone who is responsible for the production of blast holes, who is looked to on a daily basis for drill maintenance and performance, whose bottom line may depend on the survival of the mine itself.. How much awareness should one have on such things that truly impact production, maintenance and overall job cost? Do you know your drill’s maximum capacity?

Jan 1, 1998

By G. Robert Frey

INTRODUCTION This chapter on underground rotary drills briefly describes the equipment features, selection or applica¬tion criteria, safety features, and relative costs of both face and roof drills. After a brief description of the basic components, the application, safety, and cost con¬siderations will be explored. ROTARY DRILL COMPONENTS As illustrated in Fig. 1, an underground rotary drill consists of five basic components. These components are the energy system, chassis, boom, feed assembly, and operator's station. Energy System The energy system of a typical underground drill con¬sists of an electric motor, driving a hydraulic pump or pumps. Usually, the drill is equipped with a cable reel to store the trailing power cable from the portable power center in the mine. A simple control box is supplied to house electrical switchgear and protective devices. In addition to the pump, the hydraulic portion of the energy system includes the hydraulic cylinders, hydraulic tram motors, relief valves, control valves, etc., necessary to actuate the various machine functions. Chassis The chassis provides the frame or support structure for the other four basic components of the drill. Fre¬quently, it incorporates an oil reservoir for the hydraulic system. The chasis provides the support for the trans¬mission, which drives rubber tires or, in the case of some foreign machines, the crawler tracks. The steering link¬age and steering tires also may be considered as parts of the chassis. Boom The boom is the structure that supports the feed assembly; it is either hinged or pivoted on the front of the chassis. Hydraulic cylinders on the boom are used to lift or swing the boom relative to the chassis and to swivel or "roll" the feed assembly. Feed Assembly The feed assembly is made up of the support struc¬ture with an integral thrust mechanism, a rotation unit, centralizers to stabilize the auger, and a hose handling arrangement. In addition, most drills have an extension frame with a tilt device to aid in positioning the feed. Operator's Station The operator's station is the area from which the miner operates the drill. UNDERGROUND ROTARY DRILL APPLICATIONS Underground Face Drills Underground face drills are used in mining opera¬tions that utilize the conventional mining system. The face drill is used to drill holes in the exposed face of the material, and the face is then "shot" by means of explo¬sives or high pressure air. The loose material then is ready for loading and transporting from the face to the preparation plant. Typical specifications for under¬ground face drills are listed in Table 1. Certain parameters should be established as to where the drill is to be used and what is expected of it. To create an awareness of some of the considerations that too often are overlooked, some questions are listed that should be asked in conjunction with the selection or application of the proposed drills. Energy System: Can the drill be supplied with the proper voltage to match the available or proposed elec¬trical power system of the mine? Is the system 250, 460, 500, 550, or 950 v; dc or ac; 3-phase; 60 or 50 Hz? Is the drill equipped with an adequate electric motor to handle the proposed duty cycle? Typical motor power on a single-boom drill would range from 25 to 40 kW (35 to 50 hp); the nominal power for a dual-boom

Jan 1, 1982

By Herbert Dlaska

The BBU - rotary hearth treats lead concentrates and battery scrap by the roast-reaction process. It corresponds in principle to the long-known Newnam hearth, however its hearth-basin is not straight but curved to a closed ring. In operation this annular hearth is filled with liquid lead and rotates around a central blast-box. The charge, heated to a glowing-red, floats on top of the lead bath, into which air is blown from the blast-box through a horizontal slot-type tuyere. Ore pellets and brown coal are continuously charged onto the reacting mass from two storage bins. Lead is set free by the roasting reactions and trickles through the charge into the lead bath from where it is tapped from time to time. The reacting mass is continuously stirred by a mechanical agitator and backed, by a mechanical shovel, against the water-jacketed wall of the blast-box. The gangue of the charge forms lumps of scorified character, the so-called hearth slag or grey slag, which are discharged from the hearth. The waste gases are collected in a hood and conducted to a baghouse from where the fumes and dust are automatically transported to the pelletizing installation and are recycled with new material. The daily output of lead bullion depends mainly on the lead content of the charge. With lead concentrates containing 74% lead, about 24 tons of lead bullion per day are produced on the hearth at a direct lead recovery of about 89 per cent. Approximately 10 per cent of the lead content of the new material passes into the hearth slag from where it can be recovered in a blast furnace or in a rotary furnace. For small lead smelters the BBU-process represents the most economical way of melting high-grade lead concentrates. The process requires a relatively small capital investment, consumes little fuel, utilizes cheap fuel and is very flexible. Further, of great importance, is the fact that battery scrap can be treated by the BBU-process with very good results.

Jan 1, 1970

By Samuel Doak

THE utilization of rotary kilns, of the well-known cement type, for the preparation of iron ores, for the blast furnace, has become of considerable economic importance within the past 10 years in certain localities, notably those where the native ores are lean. Such kilns may be used simply for the agglomeration of ores too fine to be charged into the blast furnace (i.e., ores whose loss in the dust catchers is excessive, and whose fineness is detrimental to the working of the furnace), or for the desulphurization of lump and fine ores the sulphur content of which does not exceed 6 or 7 per cent. The desulphurizing action can be combined with that of agglomeration provided the kiln is sufficiently large. Other processes have been developed for the same purpose, but while I am not able to draw a comparison between them by reason of lack of sufficient data, it is safe to say that the kiln, if properly dimensioned for the character of ore to be treated, will compare favorably in its results, both as to economy and quality of product, with any other process. It is not, however, as well adapted for the treatment of flue dust, as is a sintering operation, on account of the large percentage of fine coke contained therein. Any combustible entering the kiln at its feed end renders the process very much more expensive and unsatisfactory on account of the difficulty of controlling the temperature, also because of the rapidity with which long "rings" form, due to the increased heat at the cooler end of the kiln. The greatest value of the kiln at present is in the treatment of pyrites cinder; that is, the residue from pyrites ore after the extraction of the greater part of the sulphur. This cinder, while high in iron content, has too much sulphur remaining in it to be allowed to form a large part of the blast-furnace burden, without further treatment. It will range in metallic iron from 42 per cent., representing a very low-grade cinder, from a domestic pyrites, to 64 per cent. of the residue from the best Spanish ore, and the corresponding silica content will vary from the maximum of about 25 per cent. to 1 ½ per cent. The residual sulphur depends largely on the type of burner used in the original desulphurization. In general, the leanest original ores retain the greatest amounts of sulphur. In

Jan 9, 1915

By E. P. Pfleider, W. D. Lacabanne

Rotary percussive drilling, vibro-drilling, vibro-rotation drilling, rotary pulsating drilling-all names that mean the same thing-are gradually appearing in mining literature. What is rotary percussive drilling? It is a combined system superimposing a rapid percussive impact on a continuous rotary action in an attempt to utilize the most desirable features of both methods. At present single and multiple carriage-mounted rotary percussion units are being used in the European coal mining regions. One well engineered unit is the Hausherr "Albo" rotary percussive drill, utilizing two alternately operating percussion pistons, and another is the multiple-unit, jumbo-mounted Salzgitter machine. Niisse & Grafer also manufacture rotary percussion drills.

Sep 1, 1955

By C. T. Thompson

"Rotary percussion" implies two types of energy, rotary and percussion. Into these categories fall rock' drills of varying sizes. The larger ones drill above 6" diameter holes; the medium size, 2 3/4" to 4 1/2" holes; and the smallest, 1 1/4" to 2" holes. Essentially, the larger holes are drilled with doom-the-hole drills using tri-cone bits. Percussion energy evolves from the drill piston and rotation power from the rotary table or overhead drive, using drill collars or pull down mechanism to preload the bit.

Jan 1, 1963

By Harley G. Pyles

Rotary Percussion drilling has shown great improvement over rotary drilling, when hard roof is encountered. In addition, Rotary Percussion drills have eliminated the need for air drills in many applications. Improved drilling rates have been achieved but roof bolting is still a bottleneck in many operations and the demand for further improvement will continue. Drilling rates beyond current performance is limited by the capabilities of existing drill steels and bits to resist increased horsepower input. The most apparent immediate solution to improved drilling is to increase the strength and rigidity of the drill steels. Drilling experience indicates that a l-1/2" diameter or 1-5/8" diameter hole can be drilled as rapidly or 'more rapidly than the standard 1-3/8" diameter hole. Greater torque and thrust capacities can be achieved through the use of larger O. D. and I. D, steels, however, this is only possible if the larger hole sizes can be made allowable. Large diameter anchorage shells can be made available at a slight extra cost.

Jan 1, 1965

By Natália Cristina Candian Lobato

Questões como a variação no preço dos minérios, a escassez dos minérios de qualidade e a preocupação contínua com a sustentabilidade faz com que a indústria busque matérias-primas alternativas, o que estimula o uso dos resíduos. Dentro da siderurgia, muitos resíduos gerados possuem elevados teores de metais, logo podem retornar ao ciclo produtivo após passar por tratamentos adequados, acarretando, assim, em economia ao processo. A carepa é um resíduo composto de mais de 60% de ferro. Devido à esta característica já é parcialmente reaproveitada pela siderurgia, porém a presença eventual de óleos em sua composição ainda faz com que parte desse resíduo seja destinada a aterros industriais. A carepa também pode ser empregada como matéria-prima em outros processos industriais. Assim, o intuito deste trabalho é apresentar rotas de reaproveitamento da carepa siderúrgica.

Aug 16, 2017

By D. Prince, G. Nollet

"Since 1994, Aur Ressources has operated Louvicourt mine, a zinc and copper mine close to Val d’Or, at a rate of 4300 t/d. Ever since the start-up of the plant, management has encouraged innovative approaches in reliability. The first of three papers will discuss the vibration monitoring program in place. The program will be described and two examples will be given: detection of a rolling bearing defect on a pinion driving the ball mill and identification of wear on the bearings of the flotation cells. Figures on the return on investment and the costs of a monitoring program will also be given.The second article will discuss the lubrication aspect. Since the establishment of a good monitoring and oil analyses, Louvicourt mine decreased its oil consumption by more than 38 000 L/yr. In addition, the company set up an oil regeneration system that restores the original properties of oil.The third article will cover the management aspect. Work organization as well as the management philosophy enabling the employes to push predictive technology to higher levels will be examined in detail. The key elements which made it possible for Louvicourt mine to position itself among world-class companies in the organization of maintenance will be discussed."

Jan 1, 2002

By D. Prince, G. Nollet

"Since 1994, Aur Ressources has operated Louvicourt mine, a zinc and copper mine close to Val d’Or, at a rate of 4300 t/d. Ever since the start-up of the plant, management has encouraged innovative approaches in reliability.The first of three papers will discuss the vibration monitoring program in place. The program will be described and two examples will be given: detection of a rolling bearing defect on a pinion driving the ball mill and identification of wear on the bearings of the flotation cells. Figures on the return on investment and the costs of a monitoring program will also be given.The second article will discuss the lubrication aspect. Since the establishment of a good monitoring and oil analyses, Louvicourt mine decreased its oil consumption by more than 38 000 L/yr. In addition, the company set up an oil regeneration system that restores the original properties of oil.The third article will cover the management aspect. Work organization as well as the management philosophy enabling the employees to push predictive technology to higher levels will be examined in detail. The key elements which made it possible for Louvicourt mine to position itself among world-class companies in the organization of maintenance will be discussed. IntroductionThis article is the second of three on predictive maintenance at the Louvicourt mine operated by Aur Resources Inc. The first article, published in the October 2002 issue, was about vibration analysis for rotating machines. This article describes how lubrication and oil analysis for stationary machines permitted Louvicourt to save more than $150,000 within two years and presents the evolution of the oil analysis program.Louvicourt mine, located near Val-d’Or, Quebec, is a copper and zinc mining and milling operation that processes 4300 t/d of ore and employs 289 people. Production began in 1994. Louvicourt mine is a partnership between Aur Ressources (30%), Teck Corp. (25%), and Novicourt (45%)."

Jan 1, 2003

By Jacques Bernazeaud

Rouez is a recent discovery of a major low-grade sulfide body (± 100 m, 0,6 % Cu, 0.3 % Pb, 1 ,5 % Zn, 21 g/t Ag, 1.5 g/t Au) in a populated farming area of Brittany, France, some 30 kilometres northwest of Le Mans. The discovery is the result of an airborne electro- magnetic (INPUT) survey. It is the first time that the INPUT method has been used in France. The survey Gas successful in spite of the numerous interferences normally found in populated areas. The lack of a good drainage system would not allow the discovery of Rouez using stream sediment geochemistry alone. Ground geophysical surveys confirmed the airborne work and gave sufficient information to make the first hole a discovery hole. The deposit is Proterozoic in age and sediment-hosted. The metamorphism is low grade.

Jan 1, 1983

By A. D. Thomas, K. C. Wilson

Some years ago, the authors developed an analysis of non-Newtonian pipe flow based on enhanced turbulent microscale and associated sub-layer thickening. This analysis, which can be used for various rheologic modelling equations, has in the past been applied to smooth-walled pipes. The present paper extends the analysis to rough walls, using the popular Bingham plastic equation as a representative rheological behaviour in order to prepare friction-factor plots for comparison with measured results. The conditions for laminar-turbulent transition for both smooth and rough walls are also considered, and comparisons are made with earlier correlations and with experimental data.

Jan 1, 2007

By A. D. Thomas

Some years ago, the authors developed an analysis of non-Newtonian pipe flow based on enhanced turbulent microscale and associated sublayer thickening. This analysis, which can be used for various rheologic modelling equations, has in the past been applied to smooth-walled pipes. The present paper extends the analysis to rough walls, using the popular Bingham plastic equation as a representative rheological behaviour in order to prepare friction-factor plots for comparison with measured results. The conditions for laminar-turbulent transition for both smooth and rough walls are also considered, and comparisons are made with earlier correlations and with experimental data.

Jan 1, 2007

By S. Kittel, P. Galleguillos, H. E. Urtubia

The rougher flotation at Escondida consists of 80 cells of 100 m3 each, with injected air. Escondida has developed a system of automatic control of the rougher flotation using video cameras, which have been operating since 1997 for remote monitoring and manual control. Since 1999, an image processing software and a group of rules have allowed implementation of an expert system. To date, the expert system controls the superficial speed of each cell by adjusting the air flow and the froth depth of the flotation bank. Preliminary tests of the expert control on two of the eight rows gave 1.2% higher rougher recovery at a 92% degree of confidence. The proven benefits are already sufficient to move towards a complete plant implementation.

Jan 1, 2001

By J. T. Furey

"A pilot plant study was conducted to evaluate the performance of column flotation in the recovery of gold from a gold/tellurides bearing sulphide ore, and to compare the performance of column flotation to conventional ""mechanically agitated"" flotation.Tests were conducted in a 60 liter glass column with ground flotation feed split from a concurrently operating conventional pilot plant, thus permitting direct comparison between the two processes. During the test program, the effects of wash water rate, gas holdup, froth depth, residence time and flow bias were examined in detail.The ore had an average ""as tested"" feed grade of about 5 g/t gold and 1 % sulphur, with the gold occurring primarily as inclusions of montbragite (Au2Te3) in pyrite, with minor amounts of native gold. Conventional flotation using 60 minutes residence time across four roughing stages recovered about 97% of the gold into concentrates grading about 50 g/t Au. A single stage of column flotation roughing using 25 minutes residence time matched the conventional circuit recovery of 97%, but produced grades of+ 150 g/t Au. INTRODUCTIONColumn flotation is the most significant innovation that has occurred in the mineral processing industry in recent years and has become an important alternative to mechanical flotation. Column flotation has been most widely accepted and applied in cleaning service where it has frequently proven to be superior to mechanically agitated flotation. Roughing in columns has not been ignored, but early testing indicated that columns may not be capable of achieving adequate recovery and, to date, columns have not been seen as serious competitors for mechanical roughers."

Jan 1, 1990

By James T. Furey, Laurence D. Hartzog, Graham A. Karklin

A pilot plant study was conducted to evaluate the performance of column flotation in the recovery of gold from the gold/tellurides bearing sulphide ore of the Kensington deposit (Echo Bay Mines and Coeur d'Alene Mines), and to compare the performance of column flotation to conventional "mechanically agitated" flotation, Tests were conducted in a 150 mm diameter, 60 liter glass column with ground flotation feed split from a concurrently operating conventional pilot plant, thus permitting direct comparison between the two processes. During the test program, the effects of wash water rate, gas holdup, froth depth, residence time and flow bias were examined in detail. The bulk metallurgical ore sample had an average "as tested" feed grade of about 5 git gold and 1 % sulphur, with the gold occurring primarily as inclusions of montbrayite (Au2Te3) in pyrite, with minor amounts of native gold. Conventional flotation using 60 minutes residence time across four roughing stages recovered about 97% of the gold into concentrates grading about 50 g/t Au. A single stage of column flotation roughing using 25 minutes residence time matched the conventional circuit recovery of97%, but produced grades of +150 git Au.

Jan 1, 1992

By Mark Ferra

Flotation is used in mining to produce concentrates of copper, gold and several other valuable ores. In 2017, a copper mine near Globe, Arizona improved their rougher cells productivity using technically advanced electro-hydraulic actuators in the flotation process by enabling excellent tank pulp level process stability. The new actuators controlled the dart valve position to allow pulp to leave the cell. Tank cell pulp level can change due to feed and discharge fluctuations from neighboring tanks. When traditional pneumatic actuators are used, they have sluggish response times and overshoot due to the inherent physical property of air being compressible. Electro-hydraulic actuators have the benefit of hydraulic stiffness to deliver accurate and repeatable (0.1%) dart valve positioning. The froth layer has more opportunity time to maximize mass transfer into the launderer. The results are an increase in copper recovery by 2-4%. INTRODUCTION In 2013 there was an international flotation technical conference well attended by respected flotation specialists for both mining companies and academia. During the technical session a leading metallurgist was discussing pulp level measurement and said that when he was on the cell deck he stated, pneumatic actuators air cylinders stroking up and down. The presenter then claimed with confidence that "I listened to actuator move so the pulp level in the tank was being controlled!" No one questioned his assumption and I can assert that the audience was quite technical and not shy in their critiques of speakers. The flotation community simply believed that the existing pneumatic technology was enough with no alternative. Having a stable flotation cell pulp level is critical to effective copper recovery. Controlling pulp levels in flotation cells is a complex task that includes modulating dart valves in each cell. The use of REXA Electraulic actuators will decrease the process dead time and maintain froth height in a controlled manner, especially from pulp slurry volume fluctuations from neighboring cells. By reducing flotation cell pulp level tank height variation, a copper mine in Arizona has realized a 2-4% recovery improvement by increasing the froth transfer to the launderers in the rougher cell circuits compared to pneumatic actuators. This paper examines the benefits of using an electro-hydraulic actuator to ensure proper pulp level control and reduce the process operational cost. It will focus on actuator positioning the dart valves to maintain pulp level setpoint at a copper mine in Arizona.

Jan 1, 2019

By Harry Siewert

"The commissioning of the 4th concentrator (C4) at Freeport Indonesia in early 1998 increased total mill throughput from 130k to 230k tonnes per day. The C4 flowsheet consists of a single 38 ft diameter SAG mill, four 24 ft diameter ball mills followed by four banks of 4,500 ft3 WEMCO flotation cells.The design of the C4 rougher flotation circuit was based on the expectation that the copper and gold recoveries achieved with the 4500 ft3 flotation cells would be equivalent to or better than that achieved with the 3,000 ft3 flotation cells in the 3rd concentrator (C3) rougher circuit. This assumption was due to the fact that the C4 flotation feed size would be less than 15% +212 microns compared to the C3 rougher flotation feed size of less than 23% +212 microns. By mid 1998 it had become apparent that the C4 rougher flotation copper and gold recoveries were below those predicted.In order to determine the cause of the lower recoveries, stage by stage rougher flotation surveys were performed in all four concentrators. The results of the surveys showed that the C4 rougher flotation circuit had a lower recovery of +200 micron material than that achieved in the C 1, C2 and C3 concentrators. Through mineralogical analysis, it was determined that a majority of the copper contained in the +200 micron fractions was liberated and recoverable. This paper describes the steps taken to increase coarse particle recovery, overall plant recovery and the results achieved."

Jan 1, 2001

By Nelson SOUTO, Nicolas LEGRAND, Christian COUNHAYE, Don EARLEY

The work is motivated by the automotive customer requirements for a roughness with high peak density (RPc > 75 peaks/cm) on steel sheet surfaces to maintain a good strip surface finish after painting. For that purpose, a new approach is utilized to compute roughness transfer and predict final roughness on uncoated steel sheets (average roughness, skewness, peak density) as a function of temper rolling conditions. The approach is based on the Monte Carlo method combined with the Abott curves and an auto-correlation function to numerically generate roughness profiles for roll and strip respectively. To compute the roughness transfer due to the interaction between roll and strip surfaces during rolling, a composite Abott curve that combines roll and strip Abott curves is used with an asperity crushing model integrated with a rolling model. This enables simulating two roughness transfer mechanisms in the roll bite: the strip asperity crushing mechanism by roll roughness and the strip asperity ploughing mechanism due to roll-strip interfacial sliding speed. The model shows the importance of considering the two mechanisms to predict roughness transfer correctly when strip elongation is high, typically a few percent, and roll bite friction is low. In these conditions, the forward slip at the exit of the roll bite tends to erode strip roughness significantly and decrease considerably the peak density on the strip. For lower elongation levels (~1%) and high roll bite friction, the ploughing mechanism becomes negligible and roughness transfer is controlled by the crushing mechanism only. With these two mechanisms, the model reasonably predicts the evolution of average roughness and peak density over a wide range of temper rolling conditions (new/worn work rolls, hard/soft grades, various elongations), but skewness is more difficult to predict for some trials.

Oct 1, 2019