Thursday, 27 August 2015

An update on the Drakelands tungsten-tin mine

Charlie Northfield of Wolf Minerals has emailed to tell me that commissioning of the Drakelands process plant continued throughout July and into August (see also posting of 25th June). The primary, secondary and scavenger DMS circuits were successfully commissioned. The primary and concentrate regrind mills were also started up. Commissioning of the pre-concentrate refinery commenced with tests on the flotation cells, filter, dryer and reduction kiln. The month also saw the successful completion of 200 working days without a lost time incident (LTI). The official opening of the UK's newest metal mine is on September 17th.

Earlier this month Wolf employees and contractors enjoyed another good sundowner in the warm sunny weather at the Miners’ Arms, Hemerdon.




 

Monday, 24 August 2015

New Book- Comminution Handbook

One of the giants of comminution is undoubtedly Prof. Alban Lynch, who I had the honour of interviewing a year ago (posting of 11 August 2014). Amongst his many honours, last year he was inaugurated into International Mining's Hall of Fame.

I last saw him in Brisbane in 2010 where he was presented with the Lifetime Achievement Award at the IMPC (posting of 8th September 2010) and where his latest book, The History of Flotation, co-authored with Greg Harbort and Mike Nelson was launched (posting of 7th September 2010).

Great to hear therefore that a new work, set to become a seminal volume, is to be launched at Metplant '15 in Perth on September 7th. The Comminution Handbook, edited by Alban Lynch, is a new publication from The AusIMM with chapters from experts in all fields of comminution.

Most mineral processors think of grinding as wet grinding of mineral ores. On the first page Alban gently reminds us that more than twice this tonnage of cement and coal is subjected to fine dry grinding. So this text includes contributions on the whole array of crushing, grinding and classification equipment used to comminute the wide range of materials demanded by our communities. Of course, the discussion would not be complete without the explanations of sizing techniques, classification, testing and scale-up methods, mineral liberation, circuit design, process control, circuit practice and recent technology developments.  It should haunt us that more efficient devices such as high-pressure grinding rolls and tower mills were common in dry grinding at least 25 years before they were discovered for ore grinding. This book may help ensure that we don’t let that happen again.

The handbook begins with mineralogy, and reviews mineral liberation theory and quantitative analytical tools before addressing machines and circuits. Chapters 4 – 10 address types of comminution and classification machines including tumbling mills, crushers, stirred mills and HPGR, then chapters 11 – 16 cover circuit design, process control and modelling. Unlike classic mineral processing texts, this handbook gives substantial attention to comminution in the coal and cement industries as well as hard rock mining. The purpose of the book is to present comminution as it is today to those with the responsibility of improving the technology in the future.

The volume should appeal to professionals who are involved in, or have an interest in, comminution, metallurgy and related fields.

Friday, 21 August 2015

Cornish Mining Sundowner- August

A light drizzle drove us indoors for last night's Cornish Mining Sundowner at Falmouth's Chain Locker. Just over 20 people attended, exclusively Camborne School of Mines staff and students past and present. Apart from myself, past lecturers present were Phil Oliver and Tony Batchelor, and it was good to see past-Director Frances Wall, and my old mineral processing colleague Tony Clarke, one of the great driving forces behind the success of the King Edward Mine Museum. Although I did not catch their names there were a few post-graduate students present and I hope we continue to see more in the future, as the sundowner provides an ideal opportunity to network in a very sociable atmosphere, as well as to sample some of Cornwall's finest ales.

It would be good to see more current CSM staff at the sundowners. MEI's Biohydromet '16 consultant Chris Bryan was the only staff member present last night, and good also to see next year's keynote speaker, biohydrometallurgist Dave Dew in attendance. He graduated from CSM way back in 1979, as did Pete Walsh, who has now become a regular at these events.

Hopefully someone can help me out with a few names on the photos below.


Chris Bryan, Dave Dew, Tony Clarke, Phil Oliver, Nick Eastwood and Pete Walsh

Barbara Wills, Joan Oliver, Frances Wall, Barry Wills, ?, Carol Richards, ?

Dave Chilcott, ?, Malcolm Hooper, ?, Paul Burton, ?, ?, ?, Linda Batchelor, Tony Batchelor

Thursday, 20 August 2015

St. Agnes to Chapel Porth and Wheal Coates

St. Agnes beach, Trevaunance Cove

This is a fairly easy 3.3 mile walk, with an elevation gain of 720 ft, starting from the beach at St. Agnes, and leading to one of Cornwall's most photographed engine houses.

After a short steep hike up the clifftop from St. Agnes' Trevaunance Cove, the next 2 and a half miles is relatively gentle, but uninspiring cliff walking.



Above Trevaunance Cove 

Looking back towards Perranporth


Between St. Agnes and Wheal Coates
The great attraction of this walk is the opportunity of exploring Wheal Coates, the ruins of which tumble down the cliff, with one of Cornwall's most photogenic engine houses, the Towanroath Shaft pumping engine house, adjacent to the coastal path.

Wheal Coates' Towanroath pumping engine house

Looking south-west to distant St. Ives from Wheal Coates
The mine opened in 1802 and was worked until its closure in 1889. It came into full production in 1815. The surviving buildings date from the 1870s when deep underground mining began at the site. There are three engine houses that formerly housed Cornish engines. Towanroath Pumping Engine House (1872) was used to pump water from the adjacent 600 ft Towanroath shaft. Another Engine House was added in 1880 to crush ore for processing. A calciner dating from 1910-1913 roasted the tin to remove impurities such as arsenic.

In 1881 138 people were employed at the site to mine a seam of tin just below sea level but this and a subsequent period of operation from 1911-1913 were not very successful because tin production was sporadic. From 1815-1914 the mine produced 335 tons of copper and 717 tons of tin.


Looking back to the engine houses of Wheal Coates
From Wheal Coates the steep descent offers great views of the beach at Chapel Porth, and for anyone wishing only to visit Wheal Coates a good option might be to park at the National Trust car park at Chapel Porth and walk the half mile to the mine site.

The descent to Chapel Porth


More Cornish Walks

More on Cornwall

More on Cornish Mining
 

Monday, 17 August 2015

In conversation with Richard A. Williams

Professor Richard Williams is a remarkable man. He is currently a Pro Vice Chancellor at the University of Birmingham UK and Head of the College of Engineering and Physical Sciences, holding a Chair in Energy and Mineral Resources Engineering and leading work on large scale energy storage policy and technology.

Next month he will take over as Principal and Vice Chancellor at Heriot Watt University, a large science and engineering university based in Edinburgh, Dubai and Malaysia.

I first met Richard in 1986, when he attended the NATO Advanced Study Institute in Falmouth. He was then a Research Associate with Imperial College, UK, but it was obvious even at that early stage that he was destined for great things. In 1992 I invited him to the Editorial Board of the developing Minerals Engineering journal, a position he has held with enthusiasm and distinction ever since. But he is much more than a mineral processor. He is an academic leader, engineer and innovator, his leadership experience spanning a career developed at five UK Universities (Imperial, UMIST/Manchester, Exeter, Leeds and Birmingham) and he is one of the few engineers in UK to be an Academician of both the UK and Australian Academies of Engineering. He has particular experience at building and inspiring academic teams to develop significant new activities and business partnerships in UK and overseas locations. He has also been successful in the acquisition of global talent to build and focus research capacity and is widely networked in Singapore, Hong Kong, Malaysia and three provinces in China. His direct experience with building businesses and business awareness in UK and internationally has yielded new strong university partnerships in rail, automotive, renewable energy, nuclear, space technology and defence sectors. Some of these are cross-disciplinary reflecting the necessity for future research frontiers to address social, technical, political and economic agendas.

His academic work spans scholarly publications in chemical and mineral engineering sciences, to applied engineering and instrumentation that has created new high throughput manufacturing processes with major environmental and business benefits. He was appointed full professor aged 33 and one of the youngest Academicians and Vice Presidents of the Royal Academy of Engineering in 2000 and again recently in 2015. Amongst his many honours, awards and prizes is the Order of the British Empire (OBE) for services to science and engineering. He is on the technical advisory board of Lloyds Register Foundation.

Richard graduated from the Royal School of Mines, Imperial College in 1981 with a degree in Mineral Technology, and in 1985 with a PhD in the electrochemistry of ferrosilicon suspensions.

With fellow Imperial College students John Marsden and Cathy Evans, and their
former tutor Prof Tim Napier-Munn at the IMPC in Brisbane
After a brief period as a Research Associate, he took up a lecturing appointment at the University of Manchester Institute of Science and Technology (UMIST) and became Honorary Professor of Chemical Engineering in 1993. In 1998 he became Royal Academy of Engineering – Rio Tinto, Professor of Minerals Engineering at Camborne School of Mines, which had recently been incorporated into the University of Exeter. In 1999 he left Cornwall to take up a position as Anglo American Professor of Mineral and Process Engineering at the University of Leeds, where in 2001 he became head of the Department of Mining and Mineral Engineering. In 2005 he was appointed Pro-Vice Chancellor for Enterprise and Knowledge Transfer and International Strategy and in 2010 for International Partnerships, before taking up the role in 2011 of Head of College of Engineering and Physical Sciences, and Pro-Vice Chancellor at the University of Birmingham.

At Birmingham he continued research in minerals systems with a focus on particle adhesion and wider systems energy. He was a Director of the Manufacturing Technology Centre in Coventry and of the development of a new metallurgical activity in the form of a £60M High Temperature Research Centre in collaboration with Rolls Royce. These activities have developed the Coventry site as a major industrial campus for the University of Birmingham. In 2013 he became Professor of Energy and Minerals Resource Engineering at Birmingham, and in 2014 Honorary Professor at Taylors University, Kula Lumpur, Malaysia as part of the Grand Challenge Alliance. He is a visiting professor at Southeast University in Nanjing and at Chinese Academy of Sciences.

A characteristic of his fundamental work in particle, surface science and processing systems has been the way it has transferred to industrial practice. His early work on packing of ‘arbitrary shaped particles’ is widely cited and used in particle packing and waste management. The frustrations of visualising the invisible particle behaviour in opaque mineral slurries led to the creations and commercialisation of industrial electrical tomography, now used worldwide in minerals separation and audit, hydraulic conveying and food sectors. He was amongst the first to demonstrate desk-top use of x-ray tomography in mineralogical assessment of complex ores and multi-scale modelling of filter cakes. 
Richard with other UK Pioneers of Process Tomography, Ken Primrose, Prof Brian Hoyle,
Prof Lynn Gladden, Prof J Seville, Prof H McCann and Prof D Parker

Richard (right) and his wife Jane (left) and collaborators from the nuclear industry
receiving the Institute of Chemical Engineering prize for best innovation based company
(Industrial Tomography Systems plc) from Mr Boris Johnson


On Sky TV discussing the energy storage
and transport using cryogenic liquids
In the last ten years his interest in heat and cold transfer in nanofluids and process scale energy utilisation has contributed to new work in using cryogenic fluids to store energy, provide zero-emission transport, resulting in a National Centre for Cryogenic Energy Storage. Related commercial equipment is now being developed. In conversation recently he said “As an academic your latest research is often your best! For me this involves two topics. First, new fundamental measurements on the origin of stickiness in industrial powders. Secondly, and at a completely different scale, the adoption and wider understanding of what is now termed ‘the cold economy’ - as industries see how they can store power and create cold resource using cryogenic liquids. This has opportunity to transform energy utilisation in mining and other sectors. A story that we hope may unfold in coming years.”

As I said earlier, he is a remarkable man, and the above brief outline of his achievements only scratches the surface of his many achievements in what has been a relatively brief career to date. The wonderful thing, however, is that his many accomplishments has not changed the man within. He is still the friendly, unassuming man that I met all those years ago at the NATO conference in Falmouth, so it was a pleasure to talk to him about his life and his thoughts on the future of science and engineering.

More conversations

Thursday, 13 August 2015

Descent into a Cornish submarine mine in 1850

The remarkable photos taken by JC Burrow in the late 19th century and his accompanying notes on descending the mines with his equipment bear testimony to the hardships faced by miners working in the deep mines of Cornwall (postings of 25th May and 2nd July).
But there are few contemporary accounts of what it was like in those mines near Land's End, which worked rich copper lodes far out to sea- Cornwall's submarine mines (posting of 2nd October 2014).
A fascinating book was published in 1851 "Rambles beyond railways or notes in Cornwall taken a-foot" in which the author, W. Wilkie Collins, describes a walking tour of Cornwall with a companion in 1850, shortly before Brunel's railway line crossed the River Tamar and opened up Cornwall for mass tourism (posting of 10 December 2012).
On leaving Land's End the author describes how, walking northwards, after about 5 miles they reached the Botallack copper mine where, armed with a letter of introduction, they were escorted underground.
Botallack
Approaching Botallack mines from Land's End, 2015
These were the days before portable cameras, so we must rely on Collins' vivid descriptions of Botallack, both on the surface and underground:
"We were told to go to the counting-house to present our credentials; and on our road thither, we beheld the buildings and machinery of the mine, literally stretching down the precipitous face of the cliff, from the land at the top, to the sea at the bottom. Here, we beheld a scaffolding perched on a rock that rose out of the waves—there, a steam-pump was at work raising gallons of water from the mine every minute, on a mere ledge of land half way down the steep cliff side".
The steam pump he refers to is the lower pumping engine of the famous Crowns Engine Houses. This was built in 1835 and in 1842 a discovery of rich copper ore was made in the 85 fathom (510 ft) level on Crowns Lode, extending out under the sea. This lode was the principal copper producing lode of the mine, and 7,200 tons of copper ore were produced in 1842-1845. By the time that Collins visited the mine the price of copper had fallen rapidly and tin soon became the profitable metal, the upper winding engine opening in 1862.
Botallack mines in the late 19th century......
 
..... and today
Collins describes the clothes that he was given for the mine tour:
"The clothing consisted of a flannel shirt, flannel drawers, canvas trousers, and a canvas jacket—all stained of a tawny copper colour; but all quite clean. A white night-cap and a round hat, composed of some iron-hard substance, well calculated to protect the head from any loose stones that might fall on it, completed the equipment; to which, three tallow-candles were afterwards added, two to hang at the buttonhole, one to carry in the hand."
As the winding engine was 12 years away, descent of the mine was by ladders, the dangers of doing this being described in the posting of 2nd July.
"We left the counting-house, and ascended the face of the cliff—then, walked a short distance along the edge, descended a little again, and stopped at a wooden platform built across a deep gully. Here, the miner pulled up a trap-door, and disclosed a perpendicular ladder leading down to a black hole, like the opening of a chimney....just as we seemed to be lowering ourselves into total darkness, we were desired to stand on a narrow landing-place opposite the ladder, and wait there while the miner went below for a light. He soon reascended to us, bringing, not only the light he had promised, but a large lump of damp clay with it. Having lighted our candles he stuck them against the front of our hats with the clay—in order, as he said, to leave both our hands free to us to use as we liked.
The process of getting down the ladders was not very pleasant. They were all quite perpendicular, the rounds were placed at irregular distances, were many of them much worn away, and were slippery with water and copper-ooze. Add to this, the narrowness of the shaft, the dripping wet rock shutting you in, as it were, all round your back and sides against the ladder - the fathomless darkness beneath—the light flaring immediately above you, as if your head was on fire—the voice of the miner below, rumbling away in dull echoes lower and lower into the bowels of the earth—the consciousness that if the rounds of the ladder broke, you might fall down a thousand feet or so of narrow tunnel in a moment—imagine all this, and you may easily realize what are the first impressions produced by a descent into a Cornish mine.
By the time we had got down seventy fathoms, or four hundred and twenty feet of perpendicular ladders, we stopped at another landing-place, just broad enough to afford standing room for us three. Here, the miner, pointing to an opening yawning horizontally in the rock at one side of us, said that this was the first gallery from the surface; that we had done with the ladders for the present; and that a little climbing and crawling were now to begin. Our path was a strange one, as we advanced through the rift. Rough stones of all sizes, holes here, and eminences there, impeded us at every yard. Sometimes, we could walk on in a stooping position—sometimes, we were obliged to crawl on our hands and knees. Occasionally, greater difficulties than these presented themselves. Certain parts of the gallery dipped into black, ugly-looking pits, crossed by thin planks, over which we walked dizzily, a little bewildered by the violent contrast between the flaring light that we carried above us, and the pitch darkness beneath and before us.
After we have walked a little farther in a crouching position, he calls a halt, makes a seat for us by sticking a piece of old board between the rocky walls of the gallery, and then proceeds to explain the exact subterranean position which we actually occupy. We are now four hundred yards out, under the bottom of the sea; and twenty fathoms or a hundred and twenty feet below the sea level. Coast-trade vessels are sailing over our heads.
One hundred and forty feet beneath us men are at work, and there are galleries deeper yet, even below that! The extraordinary position down the face of the cliff, of the engines and other works on the surface, at Botallack, is now explained. The mine is not excavated like other mines under the land, but under the sea! Having communicated these particulars, the miner next tells us to keep strict silence and listen. After listening for a few moments, a distant, unearthly noise becomes faintly audible—a long, low, mysterious moaning, which never changes, which is felt on the ear as well as heard by it—a sound that might proceed from some incalculable distance, from some far invisible height—a sound so unlike anything that is heard on the upper ground, in the free air of heaven; so sublimely mournful and still; so ghostly and impressive when listened to in the subterranean recesses of the earth, that we continue instinctively to hold our peace, as if enchanted by it, and think not of communicating to each other the awe and astonishment which it has inspired in us from the very first.
At last, the miner speaks again, and tells us that what we hear is the sound of the surf, lashing the rocks a hundred and twenty feet above us, and of the waves that are breaking on the beach beyond. The tide is now at the flow, and the sea is in no extraordinary state of agitation: so the sound is low and distant just at this period. But, when storms are at their height, when the ocean hurls mountain after mountain of water on the cliffs, then the noise is terrific; the roaring heard down here in the mine is so inexpressibly fierce and awful, that the boldest men at work are afraid to continue their labour. All ascend to the surface, to breathe the upper air and stand on the firm earth: dreading, though no such catastrophe has ever happened yet, that the sea will break in on them if they remain in the caverns below.
Hearing this, we get up to look at the rock above us. We are able to stand upright in the position we now occupy; and flaring our candles hither and thither in the darkness, can see the bright pure copper streaking the dark ceiling of the gallery in every direction. Lumps of ooze, of the most lustrous green colour, traversed by a natural network of thin red veins of iron, appear here and there in large irregular patches, over which water is dripping slowly and incessantly in certain places. This is the salt water percolating through invisible crannies in the rock. On stormy days it spirts out furiously in thin, continuous streams. Just over our heads we observe a wooden plug of the thickness of a man's leg; there is a hole here, and the plug is all that we have to keep out the sea."
And a reminder that rich seams of copper still lie below the Atlantic Ocean sea-floor:
"Immense wealth of metal is contained in the roof of this gallery, throughout its whole length; but it remains, and will always remain, untouched. The miners dare not take it, for it is part, and a great part, of the rock which forms their only protection against the sea; and which has been so far worked away here, that its thickness is limited to an average of three feet only between the water and the gallery in which we now stand. No one knows what might be the consequence of another day's labour with the pickaxe on any part of it."
And the retreat to the surface, or 'to grass':
"We next proceed to discuss the propriety of descending two hundred and forty feet more of ladders, for the sake of visiting that part of the mine where the men are at work. Two or three causes concur to make us doubt the wisdom of going lower. There is a hot, moist, sickly vapour floating about us, which becomes more oppressive every moment; we are already perspiring at every pore, as we were told we should; and our hands, faces, jackets, and trousers are all more or less covered with a mixture of mud, tallow, and iron-drippings, which we can feel and smell much more acutely than is exactly desirable. We ask the miner what there is to see lower down. He replies, nothing but men breaking ore with pickaxes; the galleries of the mine are alike, however deep they may go; when you have seen one you have seen all. The answer decides us—we determine to get back to the surface."
 
The 2nd edition of Rambles Beyond Railways..." is available from Amazon.