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By A. T. Sutaone

"In the Dongri Buzurg Manganese Mine of M/s Manganese Ore (India) Ltd., high grade lumpy manganese ore required for iron and steel industries is produced through multi-stage crushing and screening. This has resulted in accumulation of 50,000 tonnes of low grade fines over the years. This production of such fines is still going on. The fines create environmental problems, like air and water pollution and siltation in adjoining fields. Besides containing lot of manganese values, they occupy large space which is very scare in mining area.The Indian Bureau of Mines under one of its statutory functions has suggested the company to explore the possibility of recovery of additional values under conservation and environmental aspects. Hence the company has sponsored a bulk sample for beneficiation studies in the Modern Mineral Processing Laboratory and Pilot Plant of Indian Bureau of Mines at Nagpur, India. The main manganese minerals present in these mine rejects have been identified as pyrolusite and psilomelane. The purpose of this study was to explore the possibility of evolving a suitable beneficiation flowsheet to obtain manganese concentrates assaying over 72% MnO2 to be used as raw material for the manufacture of dry cell batteries.The sample/material was subjected to characterisation studies in terms of chemical analysis, granulometry and mineralogical compositions. Based on these characterisation studies, the beneficiation process developed comprised of desliming, jigging and low intensity magnetic separation mainly to reject quartz, silicates and jacobsite. The manganese concentrate thus produced assayed 70.2% MnO2 with MnO2 recovery of 78% and weight per cent yield of 63.5. This natural concentrate could be mixed with the electrolytic manganese dioxide produced by the company and this blend can thus be used as a raw material for the manufacture of dry cell batteries by the end users. The paper deals with the details of test work carried out in evolving the process flowsheet."

Jan 1, 2003

By S. Jeon, J. Kim, H. Lee

Though the importance of the engineering rock mass properties such as deformation modulus, cohesion and friction angle is emphasized, the researches on the reliability of these values are rarely performed. By using modified Takagi-Sugeno (TS) fuzzy inference system, a fuzzy model was developed based on the data obtained from domestic tunnel construction sites, and the ability of prediction was compared with the empirical equations conveniently used for estimating these values, which finds that fuzzy model is better than empirical equation. Sufficiently large database, however, is required for training the fuzzy model for more accurate prediction. Obwohl die Wichtigkeit der technischen Eigentümer der Felsenmassen wie zum Beispiel Verformungsmodulus, Bindekraft und Reibungswinkel betont werden, wird die Forschung auf der Zuverläßigkeit dieser Werte selten durchgeführt. Mit modifiziertem Takagi Sugenos (TS) Flaumigenschlußsystem wird die Flaumigenmodelle von den Daten, die von inländischen Tunnelbaustellen erhalten werden, entwickelt. Zum Schätzen dieser Werte ist es viel günstig, Flaumigenmodell zu benutzen, als zu adoptieren die empirische Gleichung für die Fähigkeit der Voraussage. Genügende große Datenbank wird aber zum Ausbilden flaumigen Modells für genauere Voraussage erfordert. Quoique l'importance sur la caractéristique d'ingénierie de la masse de roche comme le module de déformation, la cohésion et l'angle de friction, soit soulignée, la recherche sur la confiance de ces valeurs est rarement effectuée. Avec le système modifié de Takagi-Sugeno(TS) fuzzy inférence, le nouveau modèle fuzzy s'est développé. Après avoir estimé sa valeur, nous pouvons savoir que ce modèle fuzzy, basé sur les données venant du chantier de construction de tunnel national, est mieux que l'équaton empirique. Pourtant plus de données de base sont indispensables pour produire le modèle fuzzy plus précis.

Jan 1, 2003

By M. Pelser, C Aldrich

"The presence of calcium and magnesium in the hydrometallurgical processing of base metals, results in a number of process difficulties. These problems range from the contamination of the final product (where the final product is a precipitate) to high energy consumptions and large bleed streams during electrowinning. Calcium poses an additional problem in sulphate solutions owing to the low solubility of its sulphate salts. This can easily lead to a process stream that is supersaturated with calcium sulphate, resulting in unwanted solids formation within the process equipment.Several processes are reviewed for the control of calcium and magnesium. Of these, fluoride precipitation was selected for experimental investigation. This method involves the addition of a soluble fluoride to precipitate CaF2 and MgF2. The experiments showed high selectivity for calcium and magnesium over the base metals. The experiments also showed magnesium precipitation to dominate for calcium to magnesium molar ratios greater than 1:3.To avoid the domination of magnesium precipitation, a flow sheet is proposed whereby only a portion of the base metal stream is subjected to fluoride precipitation. For the precipitation, a 10% excess of ammonium fluoride is used to remove the maximum amount of calcium and magnesium. After precipitation and solid-liquid separation the split-stream is returned to reduce the overall calcium and magnesium concentration of the base metal stream."

Jan 1, 2003

In the last two decades, equipment used in the coal mining operations has become much more sophisticated. The way that work is organised and performed in the industry has also changed significantly. Changes in equipment specification or procedures inevitably means that the risk associated with that equipment or procedure also changes. In an attempt to address this the Joint Coal Board Occupational Health and Safety Trust (JCB) commissioned the University of New South Wales Mining Research Centre and Mine Site Technologies to perform a feasibility study into the development and deployment of Virtual Reality (VR) based training simulators in the New South Wales coal industry. The main aims of the study were to identify, the key providers of VR Technology, the VR options available to the JCB and the information that would need to be included in any simulator. It was anticipated that a critical assessment of these components would produce a format for a cost effective, state of the art simulator that could be readily accessed by all mines. The expectations of the feasibility study were that VR should offer three-dimensional (3D) simulations that are interactive, high-resolution models of real environments based on best practice Safety Management Plans. It was anticipated that the simulations would allow trainees to experience the consequences of poor decision-making and allow them to learn from their mistakes in a safe and forgiving environment. It was envisaged that such simulators would become an addition to the existing training methods used in the industry.

Jan 1, 2003

By Elvin R. Beach, Jaroslaw Drelich

Pull-off forces were measured for 8-9 pm diameter polystyrene (PSI particles on smooth spin- coated polystyrene films and hexadecanethiol (HDT) self-assemble monolayer surfaces using atomic force microscopy (AFM). Three parameters were controlled during experimentation: (i) the maximum applied load pressing the particle onto the substrate was varied from 50 to 4,000 nN, (ii) loading/unloading rate for the particle to attach and separate from the substrate varied from 0.01 to 9.3 Hz, and (iii) contact time for particle to reside on the substrate surface before retracting the particle to separate it from the surface changed from I µsecond to 200 seconds. the pull-off forces increased with increasing applied loading, increasing loading/unloading rate, and increasing contact time for the PS particle on PS film and on HDT monolayer. The PS particles experience elastic and plastic deformations duringpull-08 force measurements. Plastic deformation is primarily associated with flattening of surface irregularities. The results obtained in this research suggest that the particle-substrate contact areas of the magnitude comparable to those predicted by the JKR contact mechanical model can be reached in the AFM experiments by using high applied loads and long particle-substrate contact times. This result re-opens the prospect of' using AFM for studying surface energies of deformable micro-particles, even if the micro-particles have small irregularities on the surface.

Jan 1, 2003

By Jens Classen, Thomas Kurth, Karl G. Holter

High performance sprayed concrete equipment installed on two 9.4 m diameter hard rock TBMs enabled a continuous sprayed concrete lining for the entire contour in both tunnels to be performed concurrently with the advancing TBMs. Innovative layout of the sprayed concrete arrangements comprised ring beam constructions each with two independent spraying robots. Each of the spraying robots were independently connected to sprayed concrete pumps, as well as a high capacity concrete logistics system on the backup. The mix designs focused on long open-time, excellent pumpability and tough requirements on strength development. The achieved output capacities of the sprayed concrete amounts to an average of 15 m3 per hour. Peak capacities of 24 m3 per hour have been realized.

Jan 1, 2003

Geological maps, data, and prospectivity analysis relevant to mineral exploration in New Zealand have recently been released. Regional-scale geological mapping is increasingly available for the country through the QMAP 1:250 000 Geological Map of New Zealand programme. Published QMAP sheets Greymouth, Wakatipu, Waitaki and Dunedin cover large areas of interest for mineral exploration companies. The QMAP geological data are also available in digital form for use with other digital datasets using GIS software. Crown Minerals, in cooperation with GNS, have completed two gold prospectivity studies; the first covering mesothermal gold in the South Island, and the second encompassing epithermal gold in northern New Zealand. These studies have defined areas of interest for these two mineralisation types and assembled geological, mineral occurrence and production, geochemical, geophysical, topographic and cultural data into projects for use with GIS software. Included are the results of prospectivity modeling for gold using these data and specific mineralisation models. The prospectivity studies and relevant data are freely available on CD through Crown Minerals and are intended to encourage mineral exploration in New Zealand.

Jan 1, 2003

Council for 2002/2003 President S.J. Ramokgopa President-elect T.R. Stacey Vice-presidents Senior F.M.G. Egerton Junior W.H. van Niekerk Immediate Past-president A.A.B. Douglas Honorary Treasurer J.A. Cruise

Jan 1, 2003

By J Thoma, W Skinner, W Stewart, R Smart

The acid neutralisation capacity (ANC) of rock sample containing significant iron carbonates and/or reactive framboidal pyrite can be a difficult parameter to determine. Results indicated that negative ANC results can occur if reactive sulfide minerals are present; and an over-estimation of ANC will result if significant Fe rich carbonate minerals are present during industry standard ANC tests. In this paper we investigate these problems. Results showed that a significant lag period may be needed (up to 432 hours) after standard Sobek ANC type tests of siderite for the complete hydrolysis of iron released from this mineral. This even occurred with standard industry modifications that included the addition of two drops of hydrogen peroxide. In this work we use a modified Sobek test that included filtering, and thence continued hydrogen peroxide addition until there was no subsequent pH drop, followed by back titration to pH 7.0. Results indicated that the ANC for the siderite (after zero hours) was immediately comparable to the ANC determined after 432 hours lag by standard Sobek type tests; and a calculated theoretical carbonate ANC. Investigations of coal waste samples containing significant framboidal pyrite indicated that standard Sobek ANC type tests can result in negative ANC values due to the oxidation of this reactive pyrite. Because sulfide acidity is already addressed by the MPA calculation, the inclusion of sulfide acidity as part of the ANC determination is effectively biased towards acid generation and thus positive NAPP values. Negative ANC values cannot be ignored or assumed to be zero as this masks any actual ANC available within the sample, which may possibly affect AMD categorisation. This sulfide acidity can be factored out using the quantity of S in the ANC digestion liquor and knowing the non-acid generating sulfate content of the sample prior to ANC testing. Results indicated that incomplete iron hydrolysis at the completion of the Modified Sobek ANC test is not only a function of iron carbonate dissolution, but is also related to the dissolution of Fe-sulfate salts, and the oxidation of reactive sulfides such as framboidal pyrite.

Jan 1, 2003

By Cheong-Kee Park

Since 1983, Korea Ocean Research and Development Institute (KORDI) have performed surveys on deep-sea mineral deposits in various areas with respects to their occurrences in Pacific ocean including manganese nodules in the C-C area of Northeast Pacific, Co-rich manganese crusts in various seamounts of West Pacific and hydrothermal sulfide deposits in back arc basins of Southwest Pacific. Among the results of these activities of KORDI, remarkable things were the registration as a pioneer investor in 1994 through the Government of Korea and the accomplishment of relinquishment on the allocated area in 2002 according to the relevant regulations. KORDI is faced to handle detailed surveys to select the optimum mining sites in the allocated area of 75,000 km2 and environmental studies to meet the requirements of the regulations or recommendations of the ISA. In respects of future exploration strategies, it is considered that methods and tools of previous exploration activities should be changed to the highly advanced technology. Establishment of an advanced exploration system and actual practice in appropriate areas become one of important tasks of KORDI in exploring deep-sea minerals, particularly manganese nodules. A technical strategy for future detailed surveys in the allocated area is realization of simultaneous and precise data acquisition on bottom information, such as variations of microtopography, nodule distribution, and transparent layer thickness of sediments in relatively small area (10 km x 10 km) representing certain specific regions, by high resolution survey technology. It would be not only a challenge for new exploration system in deep-sea environment, but also a mission for deep seabed mining venture.

Jan 1, 2003

By D R. Carr

The installation of the Flotation Capacity Project flow sheet in the copper concentrator at Mount Isa Mines Limited has recently been completed. The project involved increasing the flotation capacity with Wemco tank cells and Jameson cells as well as changing the copper cleaner circuit layout. The engineering design and construction for the brownfield expansion had significant involvement from operational, maintenance and technical personnel adopting the same approach as the highly successful George Fisher project in the Lead/Zinc Concentrator at MIM. The involvement of people familiar with the concentrator allowed for smooth integration of the changes into an operating concentrator with minimal downtime. Detailed circuit analysis over many years identified opportunities for improvements in the flotation circuit for both grade and recovery. This paper describes the program of work that led to the Copper Concentrator Flotation Capacity Project, and the implementation of the circuit expansion and flow sheet changes that resulted in an overall improvement in the circuit recovery.

Jan 1, 2003

By J G. Webster-Brown, K L. Brown

The Waihi Region is host to many low sulphidation epithermal Au-Ag deposits. The Golden Cross mine located at the head of the Waitekauri River, eight kilometres NW of Waihi, was a gold mining operation that placed significant emphasis on environmental management. An assessment of the influence of this mining project on stream sediment geochemistry (Fe, Mn, As, Cu, Pb, Zn, Cr, Cd, Ni, Ag and Se) in the Waitekauri Catchment has been made. Effective waste management during the mine operation appears to have prevented contamination of stream sediment. Trace metal concentrations in the Waitekauri Catchment sediment have generally decreased since 1987, and are currently mainly below the ANZECC (2000) sediment quality guidelines. However, elevated As levels were recorded in the Upper Waitekauri River and Battery Stream, exceeding guideline values. Elevated levels of Cu, Pb, Zn and Cd were found in the Huanui Stream, a tributary of the lower Waitekauri River. This reflects the influence of past mining operations in the valley, as well as natural weathering of hydrothermally altered Coromandel Group andesite. At a number of sites, Mn concentrations also exceeded sediment quality guidelines, and this may be derived from the remediated Golden Cross mine site.

Jan 1, 2003

By L M. Foster, J R. Kellett, G A. McMah

The Great Artesian Basin (GAB) contains one of the largest reserves of fresh water in the world. The volume in storage is enormous, being estimated at nearly 65 000 million megalitres (ML). Development of this resource, dominantly for the pastoral industry, began in the late-1800s and quickly accelerated. With exploitation of the resource, artesian pressures declined almost as rapidly. This loss of head is a result of the total discharge from the basin and much of this discharge is waste of water. The waste through uncontrolled bores and inefficient distribution systems still amounts to about 75 per cent of all discharge. However, the volume in storage has hardly been depleted. The major concern is the effect of withdrawal on artesian pressures. Due to the size of the Basin, the relatively flat gradients and low permeability, the movement of water through the aquifers is extremely slow and independent of recharge. Hence, the normal concepts of sustainable yield (ie discharge should equal recharge) cannot be applied to the Basin as a whole as travel times do not allow for the effect of recharge to be seen away from the outcrop areas within management timeframes. The large volume in storage, though, can provide an extensive buffer to the impacts of temporary water needs. This effect should be considered when assessing the acceptability of fixed life projects such as mines and the extracted volumes from their operations. Identifying a sustainable yield involves balancing the acceptability of the economic, environmental and social costs with the associated discharge and fall in head, to arrive at an acceptable balance.

Jan 1, 2003

By P. A. Riveros, W. D. Gould, R. Molnar, D. W. Koren, P. Bédard

This paper reports the results of the field demonstration campaign of a new process for removing and destroying ammonia from mining/ metallurgical effluent solutions. The 50-day campaign was carried out at a uranium plant in Saskatchewan, Canada. The process was developed by adapting and integrating two well established technologies: zeolite adsorption/ elution to extract the ammonia from the effluent stream and to produce a concentrated ammonia eluate; and conversion of the ammonia in the eluate to innocuous nitrogen by applying bacterial nitrification-denitrification (NH3 = > NO3 - => N2). The data show that reasonable target criteria were met, under very challenging operating conditions. Problem areas and possible causes for poor performance are identified. Preliminary and generic cost estimates of the process are also presented.

Jan 1, 2003

By C. P. Manning

This paper reports recent progress in the development of a unique metal extraction technology utilizing zirconia-based inert anodes for the electrolytic reduction of metals from their oxides. In this process, the target metal oxide is dissolved in an ionically conducting liquid solvent phase. An extended anode consisting of an oxygen-ion-conducting stabilized zirconia membrane in intimate contact with a catalytically active electronic phase and an inert electronically conducting cathode are inserted into the molten flux containing the oxide. When the appropriate electric potential is applied between the electrodes the target metal is reduced at the cathode and oxygen ions are selectively transported across the stabilized zirconia membrane and oxidized at the anode. When the process is conducted at temperatures between 1200-1400°C, the ohmic resistance drop across the stabilized zirconia membrane is low, and high current densities on the order of I A/cm2 or greater can be obtained. In addition, the process efficiency can be increased further by directly reforming hydrocarbon fuel over the anode. Laboratory experiments at Boston University have demonstrated the technical viability of employing zirconia-based inert anodes for environmentally sound production of metals such as magnesium, tantalum, aluminum, etc., directly from their oxides. Significant progress has been made in the application of this concept to the electrolytic reduction of magnesium at 1300°C. The research topics covered include stability of the zirconia membrane in the selected molten solvent (flux), volatility of the flux, electrochemical characterization of the electrolytic cell, and analysis of the metals produced.

Jan 1, 2003

Investment decisions in the Australian mining industry are often made without awareness of the impact of risk on project outcomes. A fundamental change in thinking is required to move away from the traditional attitude of æcushioning the blowÆ towards a measured approach to project risk. Such an approach involves quantifying and understanding project uncertainty so that investments may be shielded from downside risk while at the same time exposed to upside potential. Communication and collaboration between study teams and corporate financial managers must be improved before the industry can improve its project investment record. Monte-Carlo simulation provides a way to quantify and understand investment risk, but its accuracy depends on how well the variability of input parameters is estimated. Research in this area is currently centred on quantifying uncertainty in mineral resource estimation using new conditional simulation techniques, but a less-rigorous method can be applied in practice to begin the education process and develop the required awareness at board level.

Jan 1, 2003

By I Testrow, M Wiggin

Scrutiny of the whole explosives industry has increased as a result of the terrorist attacks on the World Trade Centre and the Pentagon on 11 September 2001 and the bombings in Indonesia, including the Bali bombings last year. This has been highlighted in specific press releases from governing bodies, like the Department of Mineral and Petroleum Resources û Western Australia, on the necessity of being in compliance with regulations for storage of explosives. As a result, audits by inspectors to assess compliance are to be expected. In a proactive move, DynoConsult has assisted several customers through benchmarking current practices, in order to identify any areas of non-compliance to the statutory requirements for explosive storage and security. This paper discusses the outcomes of supplier discussions and customer audits and highlights the implications for the industry.

Jan 1, 2003

By J. N. Van der Merwe

The data base of failed coal pillars in South Africa was analysed with regard to the time of failure in an effort to develop a method to predict how long after their formation coal pillars will fail. It was found that meaningful results could only be obtained by splitting the data base up into groups that displayed similar behaviour. It was postulated, based on observation and experience, that coal pillars fail by a process of progressive weakening progressing into the pillar from the edges. Minimum pillar dimensions to ensure failure were calculated?these were the dimensions that corresponded to a minimum ?real? factor of safety. From the scaling distance required to reach the minimum safety factor, rates of scaling for the failed pillars were calculated based on the observed real lives of the pillars. It was found that the rates of scaling were unique for different mining areas and that they correlated directly with mining height and inversely with time. Using the derived scaling rates, the predicted pillar lives were back calculated for the pillars in the data base of failed pillars. In two of the three groups, the predicted lives correlated well with the observed lives on a one-to-one comparison. In all cases, the predicted lives were in the same time range as the observed lives. Overall, the frequency of predicted lives closely replicated the observed frequency of observed lives of the pillars in the data base of failed pillars. The method was successful in distinguishing between the data base of failed and a representative sample of intact pillars. While the predictions matched the observed lives of failed pillars, the predictions of expected lives for intact (hitherto unfailed) pillars were orders of magnitude greater. It is now possible to estimate the frequencies of future pillar failures for the purposes of mine closure and undermining of surface structures within broad bands.

Jan 1, 2003

By B Clemen, D Gordon, F Cesnik, P Griffin

In March 2002 Newcrest Mining Ltd commissioned a 4 Mtpa gold-copper concentrator at its Cadia Valley Operations in New South Wales. This paper presents the design and construction considerations, commissioning and ramp up issues related to start up of the concentrator as well as current performance and future expansion plans. Commissioning of the plant was the culmination of six years of project planning, from discovery of the resource during the Cadia Hill drill out campaign in November 1996 to project implementation and plant operation. Current resource estimates stand at around 50 Mt with an average grade of 2.4 g/t gold and 0.8 per cent copper. At current processing rates the project life is expected to exceed ten years. The processing plant comprises a 9.75 m (32 ft) diameter Fully Autogenous (AG) mill, a single 6.7 m (22 ft) diameter ball mill, pebble crushers, gravity gold recovery circuit and flotation plant. Upgrades to the existing infrastructure and manning requirements at Cadia will be discussed as well as the resultant impacts on operating costs for the operation. The processing plant was expected to deliver 290 000 ounces of gold and 30 000 tonnes of copper in concentrate in its first full year of operation and progress against that goal will be presented.

Jan 1, 2003

By Michael Zinigrad

The quality of metallic materials depends on their composition and structure and these are determined by various physico-chemical and technological factors. To effectively prepare materials with required composition, structure and properties it is necessary to carry out a research in two parallel directions: Comprehensive analysis of thennodynamics, kineties and mechanisms of the processes taking place at the solid-liquid-gaseous phase interface during welding processes and development of mathematical models of the specific welding technologies. We have developed unique method of mathematical modeling of phase interaction at high temperatures. This method allows us to build models taking into account the thennodynamic characteristics of the processes, the influence of the initial composition and temperature on the equilibrium state of the reactions, the kinetics of heterogeneous processes, the influence of the temperature, composition, hydrodynamic and thennal factors on the velocity of the chemical and diffusion processes. The model can be implemented in the optimization of various technological processes in welding, surfacing, casting as well as in manufacturing of steels and non-ferrous alloys, materials refining, alloying with special additives, removing of non-metallic inclusions.

Jan 1, 2003