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By M Edwards

The paper outlines the successful application of some of the on-belt technologies available from Scantech International Pty Ltd and how these have provided benefits in a number of mining and mineral processing operations. Effective process control requires real time analysis so quality can be fed back to the previous process and fed forward to a subsequent process. A range of on-belt analysers that allows for full stream, continuous, non-contact analysis of conveyed materials is available to achieve this. Real time results can provide timely information for effective process control. Benefits of on-belt analysis systems become more evident once the true variability of material quality and moisture content in conveyed flows is measured. To obtain economies of scale in mineral processing operations large material flows are achieved using conveyors. The cost and effort to sample representatively increases as conveyor flows increase. One sample may represent a few tonnes or up to 10 000 tonnes of material. The turnaround time between sampling and availability of sample analysis data does not allow real time process control. Tonnage flow rate, moisture content and elemental or mineralogical composition are required to perform effective process control of most conveyed streams. Tonnages can be effectively measured using belt weighers. The analyses derived from small samples supplied by conveyor-based sampling systems contain high variability. On-belt, continuous analysers see all the material and, through short term compositing of analyses, supply less variable results. Real time analysis helps operators develop a better understanding of material variability. Analysers can be effectively utilised to improve the consistency of product quality through bulk sorting and blending control. Many existing users of the technologies have gained competitive advantages through their ability to supply a more consistent quality product to the market.

Jan 1, 2008

This paper describes the MillMapper technology developed for condition monitoring of liners and other operational parameters in grinding mills used for mineral comminution, by presenting a case study of its application. MillMapper provides maintenance engineers, operations managers and process and plant metallurgists with quantitative, accurate and reliable condition monitoring data for informed decision making regarding the maintenance and metallurgical aspects of such mills. MillMapper uses calibrated laser scanners for the capture of three-dimensional surface representations inside a mill during a shutdown so as to determine shell, feed and discharge liner thickness at a resolution of several million data points, a procedure that nominally takes five minutes to complete. Once several data sets over time have been collected inside a mill, MillMapper can be used for liner wear, liner wear zone, liner weight, ball charge volume, ball charge weight and intelligent profile tracking over time. Liner tracking in combination with site defined reline and failure criteria and with throughput tonnage data is utilised for change out prediction of each separate liner segment type.

Jan 1, 2008

By B Bendtsen, L McQueen

The use of shotcrete as an efficient means of both temporary and permanent ground support has continued to grow over the last 30 years, with its use underground now commonplace around the world. However, the development of analytical design methods has lagged advances in material and application technologies. Historically, part of the reason for this was a lack of understanding of how shotcrete linings actually worked. Considerable progress has been made in this area in recent years and this paper attempts to summarise the current state of practice with respect to shotcrete lining design. It then concludes by summarising areas where the authors consider future research and development is still required.

Jan 1, 2008

By Lutz Markworth, Fernando Parra, Wolfram Jaspers

"The worldwide demand of iron ore and the depletion of the high-purity deposits make it necessary to recover ores in increasingly fine size fractions or low Fe content in the feed material. Impurities for Iron ore processing plants are mainly Silica, Al2O3 and Sulfides.There is a copper processing plant in Chile, which has a high content of Fe in its tailings. These tailings will be re-processed to recover the Fe and to produce a pellet feed concentrate. This challenging flotation process was developed by the customer in his own laboratory. Different flotation technologies were tested. The best results were achieved with the PNEUFLOT® (PNEUmatic FLOTation). For a feed capacity of approximately 600 t/h, a flow sheet of two flotation lines with a reverse two-stage Amine-Silica flotation followed by a single stage reverse Xanthate Pyrite flotation was developed.Because of the two impurities the process control is very critical. Not even the reagent dosing has to be flexible for changes in the feed material; also the flotation cell has to be adaptable. Continuous development of the PNEUFLOT® cell with their specific advantages and the elimination of dysfunctions in the PNEUFLOT® cell have led to a growing demand of this type of equipment worldwide for the iron ore industry within the past years.INTRODUCTIONThe worldwide increasing demand of iron ore is mainly caused by China. This has a major impact on all economics worldwide as the metal price indicates. However, not even the iron ore and steel price, but all other commodities prices and the precious metals prices are increasing by a high percentage. Figure 1 shows the iron ore (pellets) price increase for Fe and the import of iron ore by China. Figure 2 shows the imports of iron ore to China."

Jan 1, 2008

By Dziurzyn&apos, W. ski

This article outlines the results of a computer simulation reproducing the transport of a mixture of air and methane following the outburst on 25 November, 2005 in transport gallery D-6, bed 409/4, at the ?Zofiówka? hard coal mine. Based on a mathematical model, numerical method and boundary conditions from the disturbance caused by the outburst, the Ventgraph system of computer simulation programs was adopted for the study. We performed a computer simulation of the influence exerted by the outburst on the propagation of the air and methane mixture, and compared the results of this simulation with those of the actual event as registered by sensors of the mine monitoring system. A validation of the model allowed us to present temporal changes in the concentration of methane and air along flow routes. Keywords: mine ventilation, outburst of methane, numerical simulation, monitoring system.

Jan 1, 2008

By Peter Halbach

Cobalt-rich ferromanganese crusts are one type of the two oxidic metallic mineral resources in the deep ocean that incorporate metals supplied and transported from both land (aerosols, continental run-off) and sea sources (oxygen-minimum zone, hydrothermal alteration of the oceanic crust). The substances directly precipitate from cold seawater under more or less oxic conditions and form thin layers (2 up to 25 cm thick) on hard substrate rocks like volcanic hyaloclastites, weathered basaltic rocks and/or carbonate-fluorapatite; in the crusts many metals therefore exist in the highest state of oxidation. Deposits of the Co-rich ferromanganese crusts are found throughout the global oceans on the flanks, terraces and summits of seamounts and submerged volcanic mountain ranges and platforms, where the ocean currents have kept the seafloor more or less free of sediment for millions of years. The process of hydrogenetic precipitation is basically an inorganic colloidal-chemical and surface-chemical mechanism. Elements in seawater may occur as dissolved hydrated ions or as inorganic as well as organic complexes which in general have either a positive or a negative surface charge depending on the pH of the respective aqueous environment. Those complexes may form hydrated colloids that interact with each other and with other dissolved hydrous metal ions. Hydrated cations such as Co, Ni, Zn, Sn are, for example, attracted by the negatively charged surfaces of colloidal hydrous Mn-oxide particles, whereas hydrated anions (e.g. oxyanions) and elements forming larger complexes with low-charge densities (e.g. U, As, Th, Hf, REE) are attracted by the slightly positively charged hydrous Fe oxihydroxide particles.

Jan 1, 2008

By David Sherwood

The paper has been prepared as the basis for the 2008 John Mitchell Memorial Lecture. It reviews major developments in ground engineering over the last 20 years, not from the point of view of technical processes, but from the drivers that have driven these developments and the needs that they have met. It concludes with a glimpse into the future and suggests to where current trends will probably lead us. By its nature such a review is closely aligned with personal experience and it relies heavily on case histories largely from within the writer?s own experience over that period.

Jan 1, 2008

By George A. Mealey

Caving mining methods that are based on a planned caving of rock above and/or at times surrounding the material being mined can be classified in three broad categories: longwall mining, sublevel caving, and block caving. Each of the three methods involves a distinct technology as well as art of operation. Each requires a relatively large, regular, and predictable ore body. As a rule, the effect of mining results in some form of impact or change on the surface. Operationally, underground caving methods are characterized by high productivity as well as a high percentage of extraction of the mineral being mined. A key element for the productivity of this form of mining is the ability to standardize the various elements of work taking place underground. Therefore, work-men may perform a specialized role rather than function as all-around miners. Further, the nature of the mining methods lend them to a high level of mechanization. Operations and manpower can be centralized into a relatively small area where supervision can be concentrated and therefore be more effective. Productivity as well as safety benefits thereby. The caving method is unique in that the exploitation openings are deliberately destroyed by the process of mining. Rock mechanics principles focus on the ensurance and the propagation of the cave as well as the continuance of the mine openings designed to extract the broken ore. As a rule, production operations are designed to maintain a steady, continuous flow of ore from the extraction areas. This steady flow rather than an intermittent flow tends to promote good caving action as well as reduce hangups.

Jan 1, 2008

By I. Pordea

The materials used for the construction of buildings contain natural radionuclides of the U238 and Th232 series and are ? 50% due to land radioactivity. Another component of natural radioactivity is K40, with ? 40%. The presence of these radiopollutants in the final products (i.e. bricks, concrete) due to body irradiation is by two pathways: external irradiation and internal irradiation. External irradiation is due to gamma radiations emitted by Pb214 (RaB) + Bi214 (RaC) from the U238 series, by Ra228 (Mezothoriu I) + Ac228 (Mezothoriu II) + Tl208 (ThC??) from the Th232 series and by the K40 radionuclide. Internal irradiation is due to inhalation of radon (Rn222) and Rn220 (Tn) plus short life descendents (Po, Pb, Bi), radionuclides which are present in concrete. A fraction from radon present in concrete enters into a house leading to internal irradiation by inhalation. In Romania, the maximum concentration of radon allowed for new buildings is 200 Bq/m3.

Jan 1, 2008

By Michael S. Moats, Jan D. Miller, Wlodzimierz W. Zmierczak

"For many, hydrogen in a pure hydrogen economy would be like natural gas in today’s energy economy. Unfortunately, hydrogen’s physical properties are unsuited to the energy market’s requirements in terms of packaging, storage, transfer, and delivery. In this paper, a hybrid energy economy that packages hydrogen chemically on carbon atoms from various sources including recycled carbon dioxide is introduced and discussed. For this new hybrid energy economy to become a sustainable reality, the ability to recycle carbon dioxide and use hydrogen to create an appropriate energy product, such as dimethyl ether (DME), is needed. DME is recognized as a potential next generation, “beyond-petroleum”, environmentally benign commodity for energy storage and distribution. It is expected that to maximize the sustainability of the proposed hybrid energy economy, “green” hydrogen will be utilized. The “green” hydrogen would be created by the electrolysis of water powered by renewable energy sources, such as solar, wind or geothermal heat.IntroductionWith the growing concerns surrounding trends in global warming and increasing concentrations of “greenhouse” gases, such as CO2 and CH4, efforts to mitigate the emission of these gases from industrial sources are growing. With respect to CO2, the demonstrations of various capture and sequestration methods are underway around the world.The sequestration of CO2 is mainly focused on storing the gas underground or deep in the ocean. The Intergovernmental Panel on Climate Change (IPCC) estimates that 2000 Gtonnes of CO2 can be stored underground in depleted oilfields, un-minable coal beds and other geologic features [1]. Additionally CO2 may be stored at the bottom of the ocean. The lure of storing carbon dioxide in depleted oilfields or un-mineable coal seams is that an economic benefit (enhanced oil or methane recovery) can offset the costs of gas capture, transportation and storage. Unfortunately, all of these storage methods have potential for the release of CO2 or CH4 back into atmosphere or creating environmental damage (mobilizing heavy metals, disrupting deep sea ecology)."

Jan 1, 2008

By Kiseong Hyeong

Geochemical characteristics, shapes and surface textures of manganese nodules from two blocks located in the southern (9°N~11°N) (KR5) and northern parts (16°N~17°N) (KR2) of the Clarion-Clipperton fracture zone between 130°W and 133°W were investigated in terms of sediment distribution and metal contents for better understanding of controlling factors of seabed manganese nodule genesis. Two blocks, ~700 km away, are dominated by the nodules with different origins, each of which has distinctive chemical compositions and shapes. KR2 block is dominated by irregular and poly-type nodules of hydrogenetic origin with low Mn/Fe, Cu, and Ni contents and high Fe and Co contents, while KR5 block is dominated by discoidal and ellipsoidal nodules of diagenetic origin with high Mn/Fe, Cu, and Ni contents and low Fe and Co contents. In addition, nodules from two blocks show different surface textures: smooth and transitional in KR2 and dimorphic and rough in KR5. Sediment distribution is also distinctly different in two blocks. The study area consists of three sediment types: Unit 1 ? dark brown mud with an intermediate metal content, Unit 2 - yellowish brown mud with poor metal content, and Unit 3 ? black metalliferous mud. KR2 is characterized by the thick occurrences (<250 cm) of Unit 1 at the surface while Unit 1 distributes thin (<12 cm) in KR5. Higher primary production rate in the southern block proximal to equator and resulting high supply rate of metals to the sediment might be the cause for the dominance of diagenetic nodules in the southern block, but potential controls of different sediment distribution on the nodule genesis can not be excluded. If it is the case, Unit 1 with an intermediate metal content likely has been acting as a sink for metals by precipitating micro-nodules within the sediment column. Within the KR5, the hydrogenetic nodules occur preferentially on the seabed where Unit 3 distributes at shallower depth (<50 cm). Unit 3 has 2 or 3 times higher metal contents than other types of sediments. It might play the same role as Unit 1 in the northern block that prevents the supply of metals to the sediment surface. It also supports the potential effect of sediment distribution on nodule genesis. Keywords: Nodules genesis, Sediment distribution, Supply rate of metals

Jan 1, 2008

By Michael L. Jones

Outline ?Background ?Identify and quantify CO2 sources ?Consider options for CO2 separation and capture ?Review options for sequestration/reuse ?Determine best option for managing CO2

Jan 1, 2008

By S Pollak, A Amon

This paper describes the current and finished design work which has been performed for shallow rock station caverns for New York CityÆs first new subway construction in 60 years. A new robust, sophisticated, design procedure has been developed for two up to 30 m wide caverns, with overburden of less then 12 m, and rock cover to span ratios (C/S) in the order of 0.25. The design is based on empirical input parameters like the Q-value, rock mass rating (RMR) values, rock mass class after Cording (1984), cover to span ratios, which have been validated by the use of structural computer models as well as two- and three-dimensional numerical discontinuum models. The design approach is a staged approach using first principles, empirical models and non-linear FEM and DEM models. In addition, the paper describes the factors and circumstances why shallow caverns have been selected instead of cut-and-cover structures and why all the underground station structures have been developed as drained structures.

Jan 1, 2008

By Flavio Rojos-Tapia, Oscar Pereira-Cerda, Samuel Sánchez-Pino, Samuel Sánchez-Baquedano

"Pneumatic flotation was introduced to the Chilean Copper Mining Industry in 1993 by Ingeniería de Minerales S.A. (IDM). The technology is based on the designs of Dr. Rainer Imhof from Germany, who is the designer of several different types of pneumatic flotation cells, already sold through his Company Maelgwyn Mineral Service Limited (MMH). The company is represented by Ingenieria de Minerales S.A. (IDM) in South America.Pneumatic flotation, has been used in tough industrial applications .It has been successfully used for metallic ores such as copper sulphide and oxide minerals, copper slag, silica and silicates from iron magnetic preconcentrate (reverse flotation) and gold. It has also provided promising results when applied to molybdenum flotation. The latest applications, with ultrafine molybdenum particles in operating plants, is showing the V and G Cell (end model designed) as a real technological alternative to conventional flotation., The G Cell is an extremely high speed flotation machine with high selectivity which introduces the possibility of producing a final molybdenum concentrate with only one stage of cleaning. This is a completely new development in molybdenum flotation in the industrial circuit which has the potential to dramatically reduce the circulating load in the cleaning circuit. As a consequence the capital costs of future Molybdenum plants may also be reduced. The suitability of the G Cell will have to be determined on a case by case basis but it provides the metallurgist with an alternate flowsheet for consideration.The good performance of the G Cell can be explained by the high gas hold-up and very effective micro-turbulence which helps improve the attachment of solid particles to the bubbles. This technology may change our traditional concept of residence time in flotation. Additionally, the rotation phenomena introduced in the vessel of the G Cell ,creates radial separation forces which are critical to achieving a more rapid separation of the target minerals from the tailing. This results in a much reduced residence time requirement in the flotation machine. Some benefits associated with the use of the new G Cell are: less energy consumption, less maintenance costs, simple and reliable circuit to operate and a small area required for installing the circuits.As a result of the industrial experience in the Chile, the pneumatic flotation type G Cell can be regarded as a technology which must be considered as a replacement technology for the rougher and cleaner stages for fine particle flotation."

Jan 1, 2008

By Jim Hall, Denis Rickman, Jon Windham, John Ehrgott, Stephen Akers, Byron Armstrong

With the growing concerns about terrorism world-wide, numerous agencies conduct experiments to investigate the effects of terrorist vehicle bombs. In many cases, the vehicle bomb of interest utilizes some form of ammonium nitrate/fuel oil (ANFO) as the explosive source. Due to the high cost of fullscale testing, it is advantageous to conduct at least some vehicle bomb experiments at reduced scale. Extensive testing has shown that ANFO is a non-ideal explosive, and its explosive output does not scale reliably at explosive masses below approximately 400 lb (182 kg). Most scale-model testing requires explosive masses 1 to 5 orders of magnitude smaller. Thus, scale-model testing is typically conducted with “ideal” explosives, such as composition C-4, which perform in a scalable manner at virtually any charge mass. The utilization of an ideal explosive to model ANFO requires the existence of an accurate means of equating the performance of the two explosives. The airblast equivalence of C-4 and ANFO has been well established. However, the cratering equivalence of these explosives is not thoroughly quantified. This is especially true for the case of an above-ground detonation, which is precisely the scenario of interest in vehicle bomb studies. A study has been conducted to better define the cratering equivalence of C-4 and ANFO for above-ground detonations. This paper presents a discussion of results from this research.

Jan 1, 2008

By R. E. Mclvor

This is an update of an original dissertation on this topic by Lavallee, McIvor and Stolovitch (1992). A step-by-step, technical procedure used to measure and improve the performance of plant grinding circuits was adapted into a training program. ?Systematic Design of Instruction? was applied to: ? Determine if training was a suitable way to deliver this new technology; ? Define the technical content of the program; ? Select program specifications based on learner and context characteristics; ? Design, create and test prototypes of the training modules; and, ? Establish a process for plant implementation. The training program covers numerous skills that are extremely valuable for plant personnel, not only in the grinding area, but also for many other parts of the plant. This paper describes how new skills are brought into the workplace through designed instruction can be an effective alternative to hiring during severe skilled labor shortages.

Jan 1, 2008

By S. Al-Thyabat

Conditioning of flotation feed is an important prerequisite for efficient flotation. This process depends on parameters such as conditioning time, slurry concentration and slurry pH. The objective of this paper is to optimize the conditioning process for the flotation feed. This was achieved by first conducting preliminary experiments at constant slurry pH to determine the significant ranges of slurry concentration and conditioning time. Then, factorial experimental design (32 experiments) was used to investigate the significance of the above parameters and their interactions on flotation recovery and grade. Statistical analyses using ANOVA approach showed that flotation recovery (R) and concentrate grade (g) were affected by feed conditioning. It was found that concentrate grade was linearly proportional to the slurry concentration and conditioning time, while flotation recovery was exponentially proportional to the conditioning parameters. A contour plot of the flotation response (recovery and grade) against conditioning parameters showed that the optimum operating parameters for flotation feed conditioning was a conditioning time of 1.5 to 2 minutes and a slurry conentration of 55% to 60%.

Jan 1, 2008

By Dan Alexander, Ivan Crnkovic, Sarah Schwarz

"Several plant studies have been conducted at the Zinifex Century Mine over the past 5 years. For each of the plant studies, surveys of the zinc primary circuit were conducted, characterisation measurements for each operating cell taken, and the floatability components of the ore mapped to develop a model of the circuit. The floatability components and machine parameters were then used to simulate changes in circuit configuration and operating conditions, enabling further potential improvements in circuit performance to be identified.This paper reviews the current flotation practice at the mine, as well as various circuit changes and developments implemented by site. The application of the methodology and the evolution of the standard procedure are also discussed.INTRODUCTIONBase metals were first discovered in the Lawn Hill region of Queensland’s North West in 1869 and the first mining lease in this area was pegged in 1887 over what is now known as the Silver King vein deposit. The area encompassing these veins, which includes the Century deposit, was proclaimed the Burketown Mining Field in 1899. Exploration titles were granted to CRA in 1987, precisely 100 years after the initial discovery at Silver King, hence the name ‘Century’.Century was commissioned by Pasminco in late 1999, with the mine becoming fully operational on 1 March 2000 and the official opening taking place in April. Pasminco had bought the Century and Dugald River deposits from CRA in 1997 for A$345 million, and invested some A$710 million in bringing Century into production. Today, Century is the world’s second-largest zinc mine in terms of its output, having reached full capacity in 2003.The Zinifex Century Limited (“ZCL”) lead-zinc-silver deposit is located approximately 250 kms north-north west of Mt Isa in north-western Queensland. The deposit is a large flat-lying ore body covering an area of some 1.2 by 1.4 km, the 45 m-thick stratabound sulphide orebody is hosted within an 850 m-thick sequence of Proterozoic siltstone, shales and sandstone, amenable to open-cut mining methods. The mine has ramped up to full production delivering five and a half million tonnes of ore per annum, yielding approximately 900,000 tonnes of zinc concentrate and 90,000 tonnes of lead concentrate. Mine life is expected to be about 8 years"

Jan 1, 2008

The sampling of a run-of-mine (ROM) ore with the objective of controlling the fundamental variance associated with the sampling step is a poorly understood subject. Finding the effective sampling constant by repetitive sampling to establish the variance between nominally identical subsamples of a given mass of the ore is a laborious, time-consuming and very expensive exercise. In this paper, the run-of-mine ore is modelled using three components: ore, waste, and relatively fine material which shows significant liberation of the mineral phase(s) carrying the target analyte. The expression for the sampling constant of the mixture is developed from first principles. The form of the equation provides insight into the factors that are important in controlling the magnitude of the sampling constant and hence the fundamental uncertainty associated with a given mass of sample. The controlling factors are shown to be the size distribution of the ore/waste mixture, the proportion of waste mixed with the ore and the extent of liberation and the size distribution of the liberated material in the finer fractions.

Jan 1, 2008

By H W. Scriba

The development and improvement of computer-based process simulation packages over the past 20 years has provided process engineers with a powerful tool to use in the design of complex metallurgical plants. The use of such modelling tools has enabled the design of process plants that minimise operating and capital costs whilst optimising plant efficiency and recovery. Almost every new project developed in the current market is underpinned by a simulation of the process. In line with engineering best practice this simulation should be based on laboratory/pilot plant test work results and sound assumptions. Any errors that are not identified in the development of the process simulation may have significant effects on the final design and operation of the processing plant. Developing a simulation of the process in a comprehensive, logical and auditable manner is thus essential in ensuring the simulation accurately represents the expected process plant behaviour. A methodology that ensures these requirements are met has been developed by SNC-Lavalin Australia and is described in this paper. The methodology includes the major review stages of data collection, model planning, model building and optimisation, model review, scenario testing and options development, and model reporting. All of these stages should incorporate comprehensive client interaction and review by a suitably qualified representative. In applying these methodologies SNC-Lavalin Australia ensures that the process simulation model developed can be confidently utilised in the design of the process plant, and in the estimation of operating and capital costs, whilst ensuring that engineering best practices are met.

Jan 1, 2008