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By Mika Muinonen

"Dewatering of nickel concentrate at the INCO Thompson integrated mine-metallurgical site takes place within the smelter plant. The eight original 60 foot diameter cable torque thickeners of which four were operational and eight Dorrco internal drum filters have been replaced with a single Outokumpu high rate thickener and a single Lasta pressure filter. The modernization has resulted in a filter cake which has a more stable and lower moisture content. Control of the entire dewatering process has been improved and costs have been reduced.Typical filter cake produced from the Dorrco filters during processing of high tonnages of Birchtree mine ore was ~20% moisture vs. ~13% moisture for concentrate produced from the Thompson mine ore. The high moistures were correlated with the amount of fine magnesium silicate gangue in the concentrate. As Birchtree ore processing rates have increased, this filter cake moisture became unacceptable because of material handling problems and the impact on furnace metallurgy. The Dorrco filters were replaced with the Lasta filter in 2003 that has consistently produced filter cake at ~11% moisture.This paper summarizes the piloting, design, installation and commissioning of the modernized dewatering circuit.INTRODUCTIONThe Thompson integrated nickel processing facility was built in 1958 and originally consisted of a mine-mill-smelter and, soon after, a refinery.Nickel concentrate is pumped from the mill as a dilute slurry directly to the smelter facility ~200 meters along an unheated pipe trestle. Originally, nickel concentrate was de-watered using up to 8 conventional 60-foot diameter thickeners and 8 internal vacuum drum filters."

Jan 1, 2006

By Donald A. Bruce

The construction of major structures in karstic limestone terrains poses difficult problems to designer and contractor alike. This reflects the inherent variability of such conditions, and also the significant impacts caused by the construction processes themselves. Three case histories are provided of recent projects in the United States: the sealing of a major inflow into a quarry, the improvement of a highly loaded bridge pier foundation, and the installation of high capacity micropiles. Emphasis is placed on problem assessment and execution verification.

Jan 1, 2002

Experimental investigations were made into the decoppering of lead, tin, and bismuth using a technique which approximates on the small scale to industrial practice.Decoppering lead with sulphur alone in the absence of tin and silver did not proceed to low copper values. With a minimum of 0·02 per cent Ag or 0·10 per cent Sn, lead was decoppered to less than 0·01 per cent Cuby stirring with 0·2 per cent S over 10 min. Decoppering of tin or bismuth proceeded rapidly to very low levels in the absence of any "catalytic" impurities, at any rate in excess of those concentrations normally encountered in commercially pure tin or bismuth.

Jan 1, 1971

By M. H. Rogers

Coal has been at the forefront of mankind?s drive to improve his quality of life and also for sustainable development, from the Industrial Revolution onwards. The international coal industry today is large, with some 3,7 billion tons being produced and consumed in 1997. South Africa is an important participant in the coal industry, selling some 220 million tons in 1997 of which 64 million tons were exported. It is the second-largest thermal coal exporting country in the world. Despite the size of the world coal industry, it is not immune to change. The address examines growth projections for the industry and the change drivers that will impact on it in the future. Environmental pressures, the most important of which being the climate change debate, the Kyoto Protocol arising from this debate and the development of clean coal technologies, to reduce the impact of coal production and usage on the environment are considered. Other major change drivers considered are competition from other sources of energy and that between coal producers, the deregulation of the electric power industry, corporate restructuring and for the South African producer, legislative reform. The declining (real term) coal price, the consequent squeeze on margins and the need for producers to actively contain costs is covered. Technology has, in the past, been the driver behind the growth and change of the South African coal industry and its future role in ensuring that coal is the fuel of choice for continued improvement in standards of living and economic development is addressed.

Jan 1, 1999

Various reagents are added to flotation pulps to manipulate the chemical environment in order to create favourable conditions for the separation of the desired mineral from the unwanted gangue. Interactions occur between these reagents and between the other chemical parameters existing in the flotation pulp which complicate the elucidation of the behaviour of the respective reagents. This paper discusses the roles of the main classes of reagents added viz. collectors, frothers, depressants and activators, as well as the interactions between frothers and collectors. A case study reporting synergistic interactions between thiol collectors in the flotation of pyrite at pH = 4 is included. The use of Potassium n-butyl xanthate (PNBX) and a dithiocarbamate type collector (DTC) were tested both as pure collectors and as components in a collector mixture. In the batch flotation tests sulphur recovery and grade, water recovery, rate of recovery and image analysis of the surface froth were used to evaluate the effect of the mixture on the overall flotation performance. Bubble loading tests showed that the use of the mixture improved the efficiency of the particle collection process by bubbles. Thermochemical measurements of the adsorption of the collectors onto the mineral, indicated the formation of different surface products by the two collectors.

Jan 1, 1998

A South African gold mining rock-related fatal accident database has been analysed in order to determine rock-related fatality trends in the gold mining industry over the period 1990 to 1998. This analysis was extended further to include some of the individual reefs mined and focused particularly on the Carbon Leader Reef, the Ventersdorp Contact Reef, the Vaal Reef and the Basal Reef. Rock-related accident locations are also presented. A stope rock-related risk is proposed, where the fatality rate in terms of rock-related fatalities per million square metres mined for the gold mining industry as a whole is compared to individual reefs, allowing a stope rock-related risk to be attributed to the individual reef. This comparison is extended further by removing the contribution by the reef being evaluated from the industry data, thereby allowing this reef to be directly compared to the rest of the industry with respect to a stope rock-related risk.

Jan 1, 2001

Advances in Thickener Feedwell Design via Computational Fluid Dynamics Modelling

Sep 13, 2010

By A. E. Harak

To determine the retorting characteristics of a column of mine-run, ungraded oil shale ranging in size from fines to 5-ton pieces, a 150-ton batch-type retort was designed and constructed at the Bureau of Mines Laramie Energy Research Center, Laramie, Wyo. The retort vessel is 45 feet high by 11 ½ feet inside diameter, and is supported in a 95-foot-high steel superstructure. Mine-run shale from the Bureau of Mines facility near Rifle, Colo., assaying about 25 gallons of oil per ton, was used as the test shale. To date, 11 runs have been completed, and the results of the last 10 of these are reported. The effects of oxygen content of the retorting gas and the superficial gas velocity of the retorting gas on oil recovery from a column of mine-run oil shale were studied. In one run, the average particle size of the shale was substantially increased to determine its effect on oil yield. Oil recoveries ranged from a low of 39.3 to a high of 65.8 volume-percent of Fischer assay.

Jan 1, 1974

By E. L. Singleton

The Bureau of Mines investigated extraction of aluminum from aluminum-silicon alloys as a means of utilizing domestic aluminum silicate ores for aluminum production. Aluminum was extracted from aluminum-silicon alloys by electrolysis in molten electrolytes of NaCl-KCI-AIC13 and NaCl-KCI-AIF3 in a laboratory-scale cell. Six alloys with aluminum contents ranging from 20 to 87 percent aluminum were tested, and aluminum products of primary grade or better were obtained. More than 80 percent of the aluminum was recovered with current efficiencies as high as 91 percent. Recovery of a metallurgical-grade silicon product from the anode residue by an acid leaching procedure was possible with the 50-50 and 65-35 Al-Si alloys.

Jan 1, 1972

By Pietro Navarra

A great deal of effort has been expended on how to optimize conventional water cooling circuits in furnace cooling elements, and the results have been largely satisfactory. However, there is a general agreement that the proximity of high-pressure water passages to the flow of molten furnace products is a safety concern. Nonetheless there exists little alternative to the formula: increasing furnace integrity implies the incorporation of more extensive forced-convection water cooling systems. Recent developments in evaporative cooling technology have resulted in the development of a high-capacity heat pipe capable of operating under the thermally intense environments of a metallurgical furnace. The system functions using several kg of a working fluid (water) in total, has no moving parts, and allows for a significant reduction in cooling water requirements. Full-scale pilot tests of a copper tap hole and slag launder were done in 2003 and2005, with detailed results given in this paper.

Jan 1, 2006

By Carlos Magno Palacios Arbizu

La calidad total es la estrategia que busca la mejorar la productividad y eficiencia de los productos que ofrece -en tanto sean reconocidos por este valor-, de forma que genera competitividad en las organizaciones peruanas y se presenta como respuesta a nuevos enfoques de gestión surgidos ante el proceso de globalización. En este sentido, el presente trabajo analiza la forma del avance en el nuevo enfoque de gestión de las empresas mineras, para así proponer alternativas de tratamiento e implementación de un modelo basado en la Calidad Total, de manera que esté alineado dentro de un sector que tenga características propias y diferenciadas de organizaciones de otros sectores productivos.

Sep 12, 2005

By W. G. Pariseau

A crown pillar cave occurred at the Ropes Mine in December, 1987, that resulted in closure of the mine. Production was resumed soon afterwards with the formulation of a rock mechanics plan designed to address several issues of safety and stability. The plan proved to be successful and shows what can be accomplished in the realm of applied rock mechanics where a cooperative atmosphere exists.

Jan 1, 1989

By C. O. Karacan, S. J. Schatzel, W. P. Diamond

In coal mining, longwall mining is a preferred method to maximize production by extracting large blocks of coal that have been outlined with a set of development entries. In U.S. mines, longwall panels are typically 305 m (1,000ft) wide (with a continual trend towards even wider panels), and usually over 3,050 m (10,000ft) in length. The increasing size of longwall panels, while helping to increase coal production, may also increase methane emissions due to the exposure of the mining environment to a larger area of fractured, gas-bearing strata. Thus, understanding the impact of increased panel widths on methane emissions, and designing gob gas ventholes and bleeder systems accordingly, can enhance the safety of the underground workforce by reducing their exposure to potentially explosive accumulations of methane/air mixtures. As part of its mine safety research program, NIOSH’s Pittsburgh Research Laboratory has initiated a reservoir modeling effort to better understand the interaction of the various geotechnical factors influencing gas flow within and to the underground longwall mining environment. A focus of this modeling effort has been 1) the prediction of the incremental amount of methane emissions to be expected due to increasing longwall panel widths, and 2) optimizing gob gas venthole completion practices to capture more of the gas in the subsided strata above longwall panels before it can enter the ventilation system of the underground workplace. The history matching phase of the study has been carried out on a 381-m (1,250ft) wide panel in the Pittsburgh Coalbed. Simulations have also been completed for a 442 m (1,450ft) wide panel to estimate the incremental increase in methane emissions and the performance of current gob gas venthole placement configurations. Additional venthole placement configurations were simulated to investigate options for optimizing methane capture from the subsided strata above the wider longwall panel.

By J. M. Menacho, J. M. Reyes

"Batch and continuous regrind tests were conducted in 3 kW and 15 kW tower mill units, respectively. Single particle size classes of a chilean copper sulphide concentrate were employed in the batch tests, while a fraction of the plant stream was deviated to the continuous unit operated under different conditions.Results are interpreted in terms of the simplified grinding kinetic model energy-based and conveniently adapted to this application. Based on the above figures plus some industrial data supplied by MPSI Inc., a scale-up relationship was developed for the apparent specific rate of breakage siE, as a function of the net power draw P, i.e.siE = siE text (P/P test) 0.089This equation fit very well the available data at the three scales and its application to regrind 4400 t/day of rougher copper concentrate from 70% below 325 Tyler mesh to 95% below same mesh, involves around 30% energy-saving compared to standard ball mill for same grinding task.INTRODUCTIONImpact and abrasion-attrition breakage are two extreme mechanisms present in any grinding system in a proportion defined by specific design and operating conditions. Impact breakage is generally efficient for coarse grinding, while abrasion-attrition is adequate to produce fine particles. Efficiency of conventional tumbling mills decreases as fineness of the product increases, even though distribution of applied stresses is always much stronger than internal force distribution in the particles. On the other hand.in a vertically stirred ball mill like the tower mill, distribution of applied stresses and particle strengths are in the same order of magnitude, making possible nearly ideal abrasion conditions (1).Tower mill configuration includes a cylindrical body vertically mounted and provided with a central screw with flights to produce circulation of balls moved up through the inner region to return down by the external space. Fresh material can be fed into the top , center or bottom in order to assure appropriate agitation of suspended particles. Size reduction and evacuation rates should compensate settling of coarse particles to avoid sanding of the screw. Detailed description of the tower mill and its operation have been given elsewhere (2),(3)."

Jan 1, 1989

By P. C. Schutte

Ergonomics is the scientific discipline concerned with the understanding of interactions among humans and other elements of a system, and the profession that applies theory, principles, data and methods to design in order to optimize human well-being and overall system performance. Despite the fact that the application of ergonomics principles can make a major contribution to the management of significant occupational safety and health risks, ergonomics is currently applied on a limited scale in the South African mining industry. The objective of this paper is to provide a perspective of ergonomics, the main aim being to create a point of departure for the development of strategic objectives to enhance existing health and safety initiatives through the application of sound ergonomics principles. Two of the major consequences of poor ergonomics, namely work-related musculoskeletal disorders and worker fatigue, and possible means of introducing ergonomics into the South African mining industry, are discussed.

Jan 1, 2005

By Michael Allen, Paul Worsey

In underground blasting, the pull of the initial cut is the limiting factor for the success of the rest of the round. By improving the pull of the first cut, a critical step is made towards improving the entire round. This project attempted to optimize a burn cut’s effective pull by varying the depths of the relief holes in the burn. The effect of varying the depths of the relief holes was investigated, including depths longer than that of the cut’s charged holes. The overall objective was to consistently achieve greater pull than in a standard burn, using an identical amount of explosives. Increased pull results in savings of both time and cost in underground heading advance.

Jan 1, 2015

By Peter Ryan

A patented process for agglomeration of Smelter ESP dusts is described. Addition of suitable binders followed by compaction, transforms fine, difficult to handle material into a dry, flowable agglomerate suitable for plant reentry. Details for the agglomeration process metallurgy and laboratory pilot plant testing are discussed. An example of full scale plant operations is described.

Jan 1, 1999

By Ivor Hawkes

This report describes the results of a study to evaluate new design concepts for percussive rock drills that will result in quieter machines. It is shown that by incorporating such features as an efficient muffler, a plenum chamber integral with the machine body, and shroud tubes around the drill rods, etc., noise levels are reduced from about 114 dBA to about 95 dBA with very little change in drilling performance.

Jan 1, 1977

By R. Shen

This paper presents results of a feasibility study of recycling manganese furnace dust generated in production of ferromanganese and silicomanganese at Tasmanian Electrometallurgical Company, Australia. Dried manganese furnace dust contains about 20 wt% of carbon, in average 33.4 wt% of manganese and 1.3 wt% of zinc. Manganese in the dust is in the form of MnO, Mn3O4 and MnCO3; zinc is mainly in the form of ZnO andZnSO4. Analysis of the zinc balance with dust recycling showed that to keep zinc intake at the acceptable level, it should be partly removed from the dust. In the reduction laboratory experiments, zinc oxide was reduced to zinc vapour by tar of the dust. Reduction of zinc oxide started at 800°C and zinc removal rate increased with increasing temperature; removal of zinc was close to completion at 1100oC. Optimal conditions for removing zinc from the dust include temperature in the range 1000-1150°C, inert gas atmosphere and furnace dust fraction in the furnace dust-manganese ore mixture above 60%. In the sintering of manganese ore with addition of manganese dust in the sintering pot, zinc was reoxidised and deposited in the sinter bed. Removal of zinc in the sintering pot tests was in the range 4-17%. Up to 30% zinc removal was achieved from the bottom layer of the sinter bed. It can be concluded that zinc removal will be low during the processing of manganese furnace dust in the sinter plant. The zinc removal rate will be the highest when pelletised manganese furnace dust is added to the bottom layer of the sintering bed.

Jan 1, 2007

THE transformation, in a sample of levitation melted iodide titanium, has been studied with a Leitz hot-stage microscope. The specimen was etched in HF:HNO3: glycerine, (1:1:2) giving a structure shown in Fig. 1, and was then heated at approximately 5OC per min. At 870°C (±5OC) the etching product disappeared, the a-grain boundaries showed in relief, and some new grain boundaries (presumably of ß) appeared (Fig. 2, see arrow). Some evidence of ß-grain growth is indicated by the apparent longitudinal movement of a ß-grain boundary shown in Figs. 2 and 3 (see arrows). The specimen was later heated to 1000°C and then cooled at 2°C per min. At 845°C rumpling of the surface was first noticed, Fig. 4, and continued at constant temperature. The photomicrograph reproduced in Fig. 5 was taken 6 sec after Fig. 4, at 845°C. Fig. 6 shows the structure after cooling to room temperature. The room-temperature structure, showing a rumpled surface has been observed by previous investigators.' These structures presumably indicate a sheer transformation ß - a, athermally nucleated, but capable of isothermal progression.

Jan 1, 1960