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By J. E. Friant

Until 1956, drill and blast was the only way to excavate rock. In that year, a tunneling machine using disc type cutters economically bored a small Toronto tunnel. Its amazing 105 ft/day set a new world record and set the stage for a new industry. The Disc Cutter Role in Excavation Mechanical excavation of hard rock is by now deeply ensconced in the heavy civil construction industry. All over the world, from the Swiss Alp Melange to Hong Kong Granite, to New York Gneiss, huge Tunneling Boring Machines (TBMs) create transportation, water and sewer tunnels. Powerful machines, boasting as much as 6000 hp, bore through rock, excavating in excess of 1400 tons per hour. The tool that makes this tunneling phenomenon possible is the single blade, rolling disc cutter. These hardened steel discs, from 15 1/2 to 19 inches diameter are arranged on a rotating cutterhead, to cut concentric circles in the rock. As the machine is propelled forward under great pressure, rock below each cutter is crushed. But the efficiency of the cutterhead is derived from the science of cutter spacing (distance between cutter paths). The majority of the rock excavated is not crushed, but flakes off in chips and chunks. No pick, tooth, or drag type cutting tool can duplicate the performance of a disc cutter. The economic use of drag type tools is limited to as low as 5,000 psi UCS rock strength in massive formations. In weakly bonded, foliated rock, drag tools do better, but are still limited to rock generally less than 15,000 psi.

Jan 1, 2002

By J. T. Nel

Non-transfer-arc linear plasma systems are highly suited to manufacturing nanoparticles. In this paper, the manufacturing of such particles with specially designed plasma systems is discussed. In general, it entails the volatilization of a metal halide that is injected in the high-temperature region of a plasma flame, where it is reacted with a suitable reagent, for example O2, to produce nanooxide powders. Metal powders can also be introduced directly in the plasma. Due to the very short residence time of only milliseconds in the reaction zone, as well as the fact that the reaction takes place in the gas phase, combined with very rapid quenching in the order of 10 000°C.s-1, nanoparticles are produced. At Necsa the manufacturing of such particles has been demonstrated on various scales. A pilot plant for the production of nano-Al2O3, and two pilot plants, one using SiCl4 and the other one using SiF4 as feed material, were built to produce fumed, pyrogenic, nano-SiO2. The alumina plant had a production rate of 8?10 kg.h-1 and the silica plants had production rates of 2 and 10 kg.h-1 respectively. Perfectly spherical alumina particles with a particle size distribution of between 10 and 200 nm were produced on a continuous system. Particle size analysis for the silica by SEM measurements showed a d50 of 60 nm and a particle size distribution of 30?100 nm. The specific surface area was in the range of 170m2.g-1. Other samples of plasma produced nanoparticles such ZnO and B4C will also be presented.

Jan 1, 2010

This paper describes the economic study of longwall versus bord and pillar mining using all continuous miners for a colliery located at the South Coast district of New South Wales, Australia. In this district longwall mining appears to be a better economic proposition than bord and pillar. The internal rate of return on investment is found to remain approximately constant for each method irrespective of life. The economic importance of percentage extraction of coal is shown to be small for high values of minimum rates of return, becoming more significant as the minimum rate of return decreases.

Jan 1, 1980

By J. A. Jr. Carpenter

Expanding world economic prosperity, probable peaking of conventional petroleum production in the coming decades and environmental concerns require efforts to increase the efficiency of, and the development of alternatives to, petroleum-based fuels used in automotive transportation. In January 2002, the U.S. Department of Energy (USDOE) and the U.S. Council for Automotive Research (USCAR) of the "Big Three" traditionally-USA-based automakers, DaimlerChrysler, Ford and General Motors, formed the Freedom Cooperative Automotive Research (FreedomCAR) Partnership to fund high-risk, high-payoff research into advanced automotive technologies with the potential for eventually lowering the USA's nearly complete (95%) dependence on petroleum, 55% imported, for its transportation fuels. FreedomCAR replaced the Partnership for a New Generation of Vehicles (PNGV) which existed from 1993 to 2001. In January 2003, the energy-supply industry joined with the FreedomCAR Partnership forming the FreedomCAR and Fuel Initiative (FC&FI) to develop the technologies needed for the mass production of fuel-cell vehicles using hydrogen as fuel and the infrastructure needed to deliver the hydrogen to the consumer. The goal is to enable the automotive and energy-supply industries to make commercialization decisions in 2015 on large-scale introduction of such vehicles and on developing the infrastructure beginning in 2020. In addition to work on fuel cells and hydrogen infrastructure, the FC&FI conducts research on technologies with the potential for nearer-term energy efficiency and environmental benefits, such as new engine concepts, lightweight materials, and engine-electric hybrid propulsion systems. Lightweighting is seen as crucial for shorter and for longer term benefits because hybrid and fuel-cell powertrains are expected, at least in the early stages of adoption, to be heavier and more costly per unit of power than the standard internal-combustion, gasoline- or diesel-fueled powertrains they replace. Research and development (R&D) on casting of aluminum automotive components were major parts of the PNGV and R&D on casting of magnesium automotive components have been and are so under FreedomCAR. This presentation will review those efforts.

Jan 1, 2006

Development of New Comminution Testing Methodologies for Geometallurgical Mapping of Ore Hardness and Throughput The emerging discipline of 'geometallurgy' is becoming increasingly recognised as a discrete and high-value activity that reflects an ongoing trend towards more effective mine site integration and optimisation. Constrained sampling that reflects and defines inherent ore body variability is a key geometallurgical requirement. This requires use of larger numbers of low-cost physical testing which can be applied to small sample volumes suitable for defining natural variability. The AMIRA P843 'GeMIII' project (Geometallurgical Mapping and Mine Modelling) is a major industry-supported research initiative designed to develop new tools, methods and protocols to support geometallurgical integration. As part of this integrated research a new more rapid low-cost comminution test (GeM Comminution index) has been developed which can be employed as a front line tool for geometallurgical mapping purposes and predictive throughput modelling. The test has been designed to be inserted into routine assay sample preparation and is based on constrained jaw crushing protocols linked to analysis of resultant size distributions. Extensive validation and modelling has shown the GeM Comminution Index (Ci) is correlated with the Drop Weight index A*b and Bond Mill Work Index (BMWi). Large scale trials have been conducted within a commercial assay laboratory to demonstrate and optimise incorporation of the Ci test into routine sample preparation protocols. While Ci based estimates of A*b and BMWi are not as precise compared to larger volume more expensive test-work, the ability to undertake large numbers of tests typically in a systematic down-hole manner, provides a high level of data support through adjacency. A Ci based approach is highly suitable for variability mapping, domaining and selecting large composite samples for more precise testing. Within the context of the AMIRA P843 project this forms part of an integrated work flow designed to support geometallurgical integration. The development of a comminution test linked to routine assay sample preparation represents significant value adding to a process that in most cases is already going to be carried out. This paper introduces the Ci test concept and application to geometallurgical testing for throughput modelling

Sep 13, 2010

By G B. Gnoinski

The Skorpion Zinc Mine and Refinery is situated approximately 25 km north of Rosh Pinah, south-western Namibia. The supergene zinc oxide deposit at Skorpion is hosted in a volcano-sedimentary succession within the para-autochthonous Port Nolloth Zone of the Gariep Belt. Rock types hosting the ore deposit include altered and metamorphosed volcaniclastic and clastic sediments, limestone and rhyolite. At Skorpion, the metallurgical process is unique and the plant design requires minimal fluctuations within a selected feed grade. In addition, the presence of limestone inter-fingered with ore in some areas of the deposit results in dilution problems which may increase gangue acid consumption and therefore processing costs. Hence, selective mining is necessary to ensure the delivery of suitable ore to the processing plant, in order to keep the overall operating costs at a minimum. A complex control system is in place and is capable of a high degree of selectivity. The paper describes the grade control system in place at Skorpion Mine which ensures that the qualities of the blocks planned for mining and the material being mined meet the stringent process requirements of the refinery, i.e zinc grade, gangue acid consumption and deleterious elements that may impact on the efficiency and costs of the metallurgical process. Keywords: Skorpion zinc, zinc oxide, supergene, volcano-sedimentary, grade control

Jan 1, 2007

By A. P. N. Sutherland

Pipelines for transporting high concentration slurries are often designed using methods applicable to homogeneous non-Newtonian laminar flow. Many industrial slurries though comprise coarse particles in a non-Newtonian carrier fluid, and existing experimental evidence from tests with such slurries demonstrates that they are not homogeneous. Under laminar shear conditions the coarse particles settle, even in statically stable carrier fluids. To understand this better, the Institute of Materials Science and Technology (IMST) at Cape Peninsula University of Technology (CPUT) is conducting ongoing research into the flow of these high concentration non-Newtonian settling slurries. Since pressure gradient and flow rate measurements alone are insufficient to adequately model the flows, an electrical resistance tomography (ERT) instrument developed by the University of Cape Town (UCT)was incorporated into the pipe test loop to determine pipe cross-section concentration and velocity profiles. The software developed to do this is modular and allows different image reconstruction and cross-correlation algorithms to be implemented and tested without significantly changing the rest of the application. At a total frame capture rate of 566 frames/sec a 2.67 GHz Intel Celeron processor with 500 MB of RAM is fast enough to calculate and display velocity profiles in ?real-time? at an update rate of one profile every two seconds. Examples of experimental concentration and velocity profiles obtained using the system are shown and some proposed improvements/extensions to the system are listed.

Jan 1, 2008

By U. B. Kodukula

Attempts are made to evaluate the feasibility of using a water-injection cyclone for the concentration of iron ore fines. The separation characteristics of clay fines, containing large amounts of alumina and silica, from the iron values are discussed. The effects of critical variables, such as injection water rate, truncated cone diameter, spigot opening and vortex finder diameter, on the performance of a water-injection cyclone in terms of iron, alumina and silica grades; iron recoveries; and alumina and silica rejections are discussed. A set of 16 full-factorial experiments (24) was carried out to gain an understanding of the individual and interaction effects of the variables. The results indicate that classifying iron ore fines containing 63.0% iron, 2.5% alumina and 3.5% silica through a water-injection cyclone can produce concentrates with iron grades greater than 66.0% and alumina and silica contents less than 1.5% and 2.0%, respectively, at different study conditions. The achievable iron recovery values are greater than 88%, and alumina and silica rejections are more than 80% and 50%, respectively, within the specific study conditions. While the truncated cone diameter, injection water rate and spigot diameter influences the alumina rejection to a considerable extent, it is mostly influenced by the vortex finder diameter. The iron recovery and silica rejection values are mostly influenced by spigot diameter and truncated cone diameter. The effect of injection water on the concentration characteristics depend on the prevalent truncated cone diameter and spigot diameter conditions.

Jan 1, 2008

Paiam is a new township in the high mountains of Papua New Guinea built in association with the Porgera Joint Venture mine, one of the world's largest and most remote open cut gold mines. The Paiam town project is an interesting and genuine attempt at building sustainability into a community associated with a mine. A result of a tri-party agreement between a resource developer, government and land owners, this town is a good example of appropriate utilisation of benefits, obtained from resource development, directed at achieving a sustainable environment at local and regional levels.   Mining brought technology and income to the region, although as most mine staff fly directly in and out, local landowners considered there was a limited flow of benefits within the nearby townships. An agreement with government and mine was reached that more mine personnel and their families be housed locally. In 1998, we, a firm of Landscape Architects and Heritage Consultants based in Cairns, Queensland, were engaged to assist develop the fledgling town of Paiam into a livable and sustainable town and to produce material that would convey that information to stakeholders.   The design focused on establishing a sustainable town, with livability, urban form, aesthetics and opportunities for economic, social and cultural development. Aiming to be a livable town for locals and mine staff it included a market place designed as a focus for town life, essential for social cohesion and economic opportunities.   Located at 2200 m on steep rainforest clad topography, the town development has been laid out using an appropriate urban form based on organic village layouts. Clusters of houses allow for a common public area so children's play is monitored assisting with a sense of community similar to a traditional defensible village. Aesthetical consideration helps in developing community pride whilst maximising potential for development of a tourist industry.   Opportunities for ongoing economic development were incorporated in the design and construction process. These included developing skills and trades to service the region and to provide skills, development, income opportunities and infrastructure to last beyond mine closure. Administration procedures were set in place to form the basis of good governance.   The shift from traditional subsistence lifestyle to a sustainable community with traditional attributes was the project's goal and is being achieved.

Jun 1, 2010

THE Taranaki oil-field is situated on the western side of the North Island of New Zealand, at about its widest part, and may be said to be the most compact and fertile part of the Dominion, for, with the exception of the upper half of Mount Egmont and of the ranges adjoining, which absorb 36,000 acres, the whole of the area, minus what is taken up by the rivers and streams is suitable for settlement, and certainly two-thirds is good land. The gross area of the district is 2,417,299 acres. The principle rivers are the Wanganui, Mokau, Waitara, Patea and Waiwakaiho. Mount Egmont, which is 8260 ft. high, used to be called Taranaki, and from it the district takes its name (the Maori meaning of which is "sloping peak ").THE OIL-FIELDThe discription of an oil-field now-a-days usually resolves itself into a mass of figures and statistics, of great interest and value to the engineer and commercial man, but practically indigestible to the general public. It is the realm of the financierand the captain of industry.

Jan 1, 1912

By V. N. Cox, C. H. Grant

Both the underwater method and the rock cratering method contribute useful information in evaluating and comparing new explosive compositions. Results indicate that metallized explosive systems which contain no high explosives can be formulated to offer more energy and to do potentially more work than other slurry explosive systems. Commercial field trials are presently being conducted with a metallized explosive that does not contain any high explosive. Although there have been only a few commercial blasts to date, the results are encouraging. The Dow Chemical Co. has been engaged in explosives research since 1953. The incentive for this research was based on the desire to find additional markets and uses for magnesium metal of which DOW is a heavy producer. The thermodynamic calculations for explosives incorporating light metals indicate energies approximately twice that of nonmetallized explosives currently being used. Early in 1960, additional patent rights were acquired from independent inventors and a development station at Virginia, Minn., was set up to conduct a commercial testing and market evaluation program with this new product. The actual manufacturing of the explosive was to take place in the boreholes. Due to the complexities involved in controlling the manufacture of the explosive in the borehole, performance was sometimes in doubt. Furthermore, experience indicated that the metallized explosive systems could not be evaluated by the standard laboratory methods then being used, and it was necessary for us to look for more suitable research methods. Tests were conducted on several known methods for explosive evaluation. The most promising were the Navy underwater method for energy evaluation and a modified Livingston crater method intended to compare explosive performance in rock. After shooting over 2000 charges of 8 to 60 lb under water and in taconites and granites with many types of explosives, a metallized explosive was developed which is now being manufactured at a pilot plant in Virginia, Minn. and is being evaluated commercially. UNDERWATER METHOD An underwater method of evaluating explosives has a number of advantages. A permanent site can be established and operated indefinitely. A large number of charges may be fired in a short length of time. The medium in which the explosive is shot is exactly the same for successive shots. Data are recorded electronically minimizing human judgment. A disadvantage of the underwater method is the lack of confinement provided by the water medium. Many explosive compositions require a greater degree of confinement to develop good energy release. Although the relative significance of the two components of energy release that are usually measured, the shock energy and the bubble energy, and their relationship to breaking rock are not clearly understood, the underwater method is a valuable research tool for screening explosive compositions and gaining an insight into the manner in which explosives release their energy. Fig. 1 shows schematically the underwater apparatus. The piezoelectric gages are calibrated tourmaline crystals which convert the shock wave to an electrical impulse which is transmitted to an oscilloscope and recorded on Polaroid film. The shock traces are picked up by scopes 1 and 2. Scope 1 is timed to pick up the full trace whereas scope 2 is timed to cover the first increment of the shock trace expanded, and therefore allows full inspection of the propagation and peak pressures. Scope 3 records the bubble trace. When the explosion occurs, a bubble of gaseous detonation products is formed. The outward momentum of the water keeps expanding the bubble even after

Jan 1, 1963

By Wolfgang Gütter

India is targeting to boost its electrical capacity from 100 GW to 200 GW within the next 10 years. The National Hydroelectric Power Corporation (NHPC) has decided in2001 to take execution of the 800 MW Stage-II of the prestigious 2,051 MW Parbatihydrol electric project in Kulu district of the northern province Himachal Pradesh. Two parallel 30° inclined underground pressure shafts of 1.542m in length each will be excavated in different geological formations and lined with hexagonal concrete segments by a hard rock double shield TBM. That kind of heading will be a novelty to India and an innovative method for inclined pressure shafts. The 4.88m Mitsubishi DSTBM will be assembled underground on a swivelling steel platform especially designed for the launching as well as for the acceptance of the TBM in the upper cavern of each shaft. The hexagonal segmental lining system causes a significant higher job safety than an open TBM with conventional support. Each ring consists of four honeycomb segments with 20 cm thickness. After finalisation of the excavation a steel liner will be installed and concreted. The Joint Venture Jäger-Seli will perform the two pressure shafts as a sub-contractor for the Indian company Gammon India Ltd.

Jan 1, 2005

By A. G. Mayton

Vehicle vibration exposure has been linked to chronic back pain and low back symptoms among agricultural tractor drivers. The objectives of this study by the National Institute for Occupational Safety and Health (NIOSH) were to assess driver whole body vibration (WBV) exposures and recommend interventions to reduce the risk of back related injuries, particularly relative to vehicle jarring/jolting (the transient mechanical shock components of WBV). The methodology included collecting, from two independent samples, ?eld data and health and work history data of farm equipment operators. Data were collected during mowing, raking, baling, chiseling, tilling, and road travel for different model tractors. Spraying using a sprayer and shrub removal with a skid steer loader were also included. Based on ISO 2631 (1985), the American Conference of Governmental Industrial Hygienists, threshold limit values, presents 0.5 m/s2 as the action level recommended by the Commission of European Communities for overall weighted total RMS acceleration (vector sum for axes x, y, and z) [ACGIH, 2006. Threshold limit values and biological exposure indices. Cincinnati, OH]. WBV measured at the operator/seat interface exceeded this action level. The roughest rides and highest vector sum accelerations occurred with small utility tractor mowers (3.3 and 2.8 m/s2) and a skid steer loader (1.7 m/s2). Major ?ndings from health and work history data showed 96% of participants reported having to bend or twist their necks, although 24% reported neck symptoms. Sixty four percent of participating operators reported experiencing back symptoms (e.g., pain, aching, stiffness, etc.). Recommendations included: specifying a seat that ??better?? isolates operators from jars/jolts with new tractor purchases; maintaining the seat/seat suspension and replacing worn or damaged cushions with NIOSH tested viscoelastic foam padding; using larger diameter tires with radial ply instead of bias ply construction, particularly on small utility tractor mowers, to aid in attenuating ride ??roughness??; using a swivel seat to reduce the stress on the neck from bending or twisting; and improving efforts to educate owner/operators of the adverse effects of WBV exposures. Since the data presented in this paper were collected from two independent samples, the authors were unable to draw any correlations or etiological inferences from the study. However, results were compared and contrasted with other studies which included similar vibration measurements in agriculture.

Jan 1, 2008

By M. Olper

The change in regulations and the strong attention to the environment have suggested some changes in the traditional processes for the recycling of lead acid batteries. Engitec Technologies, marketing the Integrated CX® System, is continuously updating and improving its technology to fulfil the technical, economical and ecological requirements coming from the market and from the environmental authorities. In this paper Engitec Technologies will present the latest technical innovations introduced in the Integrated CX® System.

Jan 1, 2008

By Gordon R. Sima

This contract is concerned with the construction of a Time Resolved Audio Dosimeter System consisting of one readout unit and several dosimeter units. The Time Resolved Audio Dosimeter System was designed and developed by the Bureau of Mines with the purpose of this contract aimed at obtaining additional units for further field testing and evaluation. All construction was in accordance with the Bureau of Mines design and/or Bureau approved drawings produced during the course of this contract. This report contains a summary of the construction efforts, problems encountered, recommendations and all drawings produced under this contract.

Jan 1, 1977

Jan 1, 2004

By S. Fuentes, J. Cáceres

"During the past fifteen years, mines utilizing the block caving method have improved performance and systematically reduced total mining costs.This paper describes improvements in mine design, mine planning, and mine management, including methods enabling the Chilean and international mining industry to ensure cost savings and productivity growth while using the block caving method. These improvements have encouraged the re-evaluation of underground operations at operating and closed open pits, and challenge surface mining applications as the only low-cost mining method. This paper describes a strategy to estimate the optimum open pit to underground transition time during the life of a mine. IntroductionDuring the last fifteen years, block caving mines have experienced huge changes in designs, planning and administration. These changes have permitted operators to drastically reduce costs, improve equipment productivity, and improve overall business performance. As a consequence of this situation, the block/panel caving mining system is challenging actual open pit operations to maximize the net present value (NPV)."

Jan 1, 2004

By David Norval

Ni, Co, Cu and Pt, mattes are common materials that require granulating and milling of the resultant granules for further processing. This route is acceptable if the material is brittle (friable) which is a property associated with the higher sulphur mattes. For lower sulphur levels, where the matte is less amenable to milling, the costs of the milling increases. This paper will compare water granulation with certain dry granulation processes and the downstream processes required for Hydrometallurgy. It will further introduce and expand on atomisation which offers a further safety benefit in the control of the metal flow into the 'wet zone' with the use of a tundish flow control also reducing the conversion from the matte to powder in one fairly straightforward operation.

Jan 1, 2006

Delivered at the University of Sydney, on June 4th, 1954.THE TORCH WE HOLDLast year Our Institute celebrated its Diamond Jubilee, coincident with the holding of the Fifth Empire Mining and Metallurigcal Congress in Australia and New Zealand. We can be proud of our growth over the 61 years since the inaugural meeting in Adelaide in April, 1893, which followed suggestions from a provisional committee of mining men, formed in 1892 in Broken Hill.We can also be proud of our technical achievements in the fields of economic geology, mining and metallurgy.Should we be content with the growth of our mining and metallurgical industries over these years? My answer is in the negative. The discovery of new mineral deposits is essential for the continuance and development of the industries we represent.Let me review the background and trends of our industry in an attempt to emphasise the changing factors influencing the search for minerals and their exploitation.Australia was blessed with the discovery of coal in New South Wales in 1796; copper in South Australia at Kapunda, Burra, Wallaroo and Moonta in the eighteen-forties; gold in Victoria and Eastern Australia in the 'fifties; tin at Mount Bischoff, Tasmania, and gold at Charters Towers, Queensland, in the 'seventies; lead-silver at Broken Hill, New South Wales; gold and copper at Mount Morgan, Queensland, and copper at Mount Lyell, Tasmania, in the 'eighties; and gold at Kalgoorlie, Western Australia, and zinc-lead atRosebery, Tasmania, in the 'nineties. As well, the iron ore deposits of the Middleback Ranges, South Australia, and Yampi Sound, Western Australia, were known before...

Jan 1, 1954

By D. J. Fourie

During the production of pure TiO2for the pigment industry, ilmenite, containing 35?60% TiO2, is reduced to high titania slag, containing 70?95% ?TiO2? and pig iron. The high titania slag produced, consists mainly of titanium in different oxidation states and FeO in equilibrium with liquid iron. To predict the phase and chemical reaction equilibria in a furnace, a suitable solution model is required with accurately determined binary interaction parameters, as slag melts tend to behave very non-ideally. This paper investigates two popular slag models, namely, modified quasi-Chemical (MQC) model and the cell model and provides the binary interaction parameters based on recently published data of the ternary system and critically assessed published unary and binary data. Very few modelling results have been published on the ternary Ti-Fe-O system pertaining to high titanium slags. The solution models, with their regressed interaction parameters, can subsequently be implemented in commercial software of the slag-metal phase equilibria to predict how much and which type of solids will precipitate for a given bulk slag chemistry and operating temperature or, alternatively, above which temperature should a furnace be operated to avoid excessive solids precipitation.

Jan 1, 2005