Search Documents

By A. Peake

Background The CSIR Division of Mining Technology assumed responsibility for the operations of the Hoist Rope and Mechanical Test Laboratories at Cottesloe in April 1999. The laboratories were previously the responsibility of the CSIR’s Division of Manufacturing and Materials Technology, before which they fell under the National Mechanical Engineering Research Institute (also of CSIR). As the focus of this conference is on safety in mines research institutes, it was thought appropriate that this paper should review some of the activities at Cottesloe and its role in supporting mine safety strategies.

Jan 1, 2003

By D. Keech

The Conveyor Equipment Manufacturers Association (CEMA) specification B105.1 “Welded Steel Conveyor Pulleys” adequately defines standard pulleys for most aggregate material handling applications. However, many aggregate applications demand pulleys of higher capacity and reliability than that offered by CEMA pulleys. This paper examines the CEMA Pulley Standard and pulley specifications for aggregate applications requiring greater capacity and reliability than the CEMA Pulley Standard. Higher reliability increases the uptime and has a lower total cost of ownership.

Jan 1, 2003

By R. A. Bergman

"Process descriptions are provided for the following ten plants that treat high-magnesia lateritic nickel ores (saprolite) by pyrometallurgical means: PT Aneka Tambang; Cerro Matoso S.A.; Falconbridge Dominicana C. por A.; Hyuga Smelting Company Ltd.; Larco (Societé Minière & Métallurgique de Larymna); Loma de Niquel; Le Nickel, SLN-Eramet; Nippon Yakin Kogyo Company Ltd.; Pacific Metals Company Ltd.; and PT Inco Indonesia.Flowsheets, equipment information,chemistry and production data have been compiledfor plants based on both information providedby the companies and on calculated massand energy balances.IntroductionNickel is of vital importance to modern society. Without it, we would not be able to enjoy many of the things that we take for granted, such as computers, airplanes and stainless steel appliances in our homes and workplaces, to mention a few.Nickel occurs in nature both as sulphide and oxide ores. Approximately 36% of the nickel reserves in the Western World occur as sulphide and 64% as oxide ores. Sulphide ores respond to concentration processes, whereas, oxide ores do not. Sulphide ores mined at 1% nickel can be readily concentrated to 10% nickel, whereas, oxide ores cannot be concentrated and therefore have to be processed as mined.Laterite ores are normally classified intotwo groups:1. The high-magnesia ores, saprolites or serpentines, are, as a rule, processed by smelting. The main reason for this is that the nickel replaces magnesium in the magnesium-silicate lattice. To be able to recover nickel, the lattice has to be destroyed. This can be achieved by smelting under reducing conditions.Acid leaching is also possible, but in this case, large amounts of MgSO4 or MgCl2 will be produced making it costly to regenerate the acid.2. The high-iron, low-magnesia ores are known as limonite. The nickel is relatively loosely bonded to goethite and hence can be recovered by selective reduction followed by ammonium-ammonium carbonate leaching. In recently developed processes, these ores are also being extracted by acid pressure leaching, with high Ni and Co recoveries.This paper focusses on the production of ferronickel and nickel matte from the highmagnesia ores."

Jan 1, 2003

By C. E. Hales

In an effort to improve efficiencies and reduce costs, AngloGold has embarked on a process to develop and deliver consistent, high quality, tailings based support or construction products to stopes and tunnels on request. A three-phase approach of product conceptualisation, design and delivery has been adopted. To date a substantial amount of laboratory development has taken place with promising results, indicating that the project aims are achievable. Dans un effort pour améliorer le rendement et réduire les coûts, AngloGold s’est embarqué dans une opération qui vise à développer et fournir aux chantiers d’extraction et tunnels, sur demande, des produits de construction ou de support basés sur rejets qui sont réguliers et de haute qualité. Une méthode à trois volets a été adoptée : conception, création et livraison. A ce jour, un développement important en laboratoire s’est produit, avec des résultats pleins de promesses, qui semblent indiquer que les buts du projet peuvent être atteints. In der Bemühung, die Effizienz zu steigern und Kosten zu verringern, hat AngloGold begonnen ein Verfahren zu entwickeln welches auf Anfrage konsistent hochqualitative auf Haufwerk basierender Unterstützung oder Bauprodukte für Abbaustellen und Tunnels entwickelt und liefert Eine Dreiphasenplan zur Produktkonzeptualisierung, Design und Lieferung wurde adoptiert. Bis jetzt hat eine substantielle Anzahl an Laborentwicklung mit vielversprechenden Resultaten stattgefunden und aufgezeigt, daß die Projektziele erreichbar sind.

Jan 1, 2003

By George C. Webb

A wide variety and variable depth (up to 40 ft.) of compressible, uncontrolled fill (including construction debris and a perched water condition) was present at a proposed Kroger construction site in Dent, Ohio. An innovative solution using a combination of an ACIP foundation system with a Tensar geogrid reinforced load distribution platform was used to provide a high quality building pad. This system allowed the use of conventional shallow foundations for structure support. This system was used in lieu of more costly solutions, such as complete undercutting of the entire existing fill and replacement with engineered fill or a deep foundation/ structural slab system. The selected ground modification included a system of augercast piles bearing on shale bedrock, which were installed on a grid pattern over the entire building footprint. Then, three layers of Tensar polyproplene biaxial geogrid were used to create a reinforced soil mat, which was supported on the augercast piles. An eight-foot blanket of engineered fill was placed above the geogrid-reinforced mattress fill to establish the building subgrade elevation. Standard shallow footings and slab-on-grade construction methods were then used to support the 26-ft. tall masonry block building. A small-scale instrumentation program included monitoring the geogrid reinforced mat settlement, geogrid strain and earth pressure distribution under the reinforced mat to evaluate design assumptions and theoretical analyses. This case history describes the first application of a pile supported geogrid reinforced mat for structure support which has been documented in the United States.

Jan 1, 2003

By Mitsutaka Hino

The contents of gangue minerals, such as Al2O3. P2O5, crystalline water and so forth in the iron ore imported to Japan tend to increase year by year. Though the increments of such gangue contents arc approximately 0.1-0.2 mass%, some problems for the blast furnace operation in ironmaking process have already been reported, In order to clarify the mechanism of harmful effect caused by the small increment of gangue minerals, mainly Al2O3. on the blast furnace operation, the dripping behavior of Fe,O-CaO-SiO2-Al2O3-MgO slag from the iron funnel, which simulated the micro-porosity in sinter ore, has been observed with the wide range of basicity, Al2O3, Fe2O and MgO contents. The effect of MgO on the dripping behavior of slag has been summarized in this paper. It was found that the addition of 2mass% MgO resulted in large increase of hold-up on the most of the conditions. When Fe2O content was less than 20mass% and the basicity was lower than 0.8, MgO lowered the hold-up even if the slag contained 10mass% Ah03. Every slag hold-up showed the minimum at the basicity of less than unity on the conditions of constant Fe2O and Al2O3 contents, This trend became remarkable when the slag contained 2 mass% MgO.

Jan 1, 2003

By Zdzistaw MiGzkowski

At KGHM Polska Miedi S.A. a direct flash smelting process is used for smelting of chalcocite concentrate for the production of blister copper. The paper presents a model of complex oxidation process of single concentrate grains smelted at KGHM. The description covers main chemical reactions, phenomena of heat and mass ex-change inside the grains and between a grain and the surrounding space. In the model, two zones describing the course of process inside the grain were distinguished: ? The first one, which moves faster towards the centre of a grain, both organic and carbonate carbon are freed. The process takes place without the presence of oxygen and results in an increase of the temperature in the core of the particle. ? The second zone moves slower into the grain and the rate of the movement is deter-mined by the presence of oxygen. In that zone the sulphur is eliminated and the oxidation of the organic compounds vapours moving from deeper layers of a grain takes place. Based on the results of laboratory tests, the coefficients that describe the oxygen transportation into the grain and decide the progress in the chemical reaction were determined. The paper contains the results of model calculations for single grains reacting in environment of various content of oxygen as well as the results of model calculations for the laboratory reactor system.

Jan 1, 2003

By Roberto Golchi

This article describes the method used to quantify the Environmental Impact for the mining, by drilling and blasting, of a borrow pit for a gravity-dam. The affected environment was broken down into a number of components, such as public health and safety, social relationship, air and water quality, flora and fauna. The effect of the various impacting factors from the mining activities, both directly and indirectly, was then calculated for each environmental component. To do this, each impacting factor was first given a magnitude, a number based solely on the range of scenarios possible for the impacting factor. A matrix of weighting factors was then derived to systematically quantify, and normalise, the effects of each impacting factor on each environmental component. The overall impact upon each individual environmental component was then calculated by summing the weighted magnitudes for all the impacting factors.

Jan 1, 2003

By Mônica Suede Santos Silva

This work describes characterization of the performance of the tundish of a six strand continuous casting unit of the Companhia Siderúrgica Belgo Mineira, João Monlevade, Brazil using physical modeling. Permanent and transient conditions, due to ladle metal composition changes are considered. Pulse and step tracer addition techniques are employed to assess the control variables. For transient conditions the degree of inter-mixing and the minimum residence time are determined with a view to optimize the process especially during the grade changes of steel.

Jan 1, 2003

By P. H. Oliver

"The current theory of how explosives fracture rock offers no explanation for the improvements in fragmentation and the reduction of fly rock and back break which occurs when an adequate inter-row delay time is used. Nor does it explain why fragmentation improves with rectangular drill patterns where the hole spacing may be as much as four times the hole burden.A new theory of rock fragmentation is proposed which builds on the existing theory. It offers rational explanations for the many blast effects which the current theory does not address and the need for adequate timing delays between rows. It improves on the design of inter-row delay timing by defining the length of free-blasted face needed in front of a hole *Retired from Inco Ltd., Sudbury, Ontario when selecting the delay element which will provide an adequate inter-row delay time."

Jan 1, 2003

By Helmut Antrekowitsch

Nowadays nearly the half of the world zinc production is used for galvanizing. After their life span most of the galvanized products return as scrap to the steel mill During the steel process the zinc is collected in the flue dust It is astonishing to notice that between 40 and 50 % of the zinc produced is brought into the steel processing cycle by the coated scrap while only 3 to 5 % of the zinc production can be covered by the recycling of the zinc-bearing steel mill dusts. Responsible for this worse ratio is the fact that the established recycling technologies suffer from high energy consumption, low zinc yields, halogen problems and hardly any iron recovery. A development of new or an optimization of current recycling procedures for the dusts is unalterable because of increasing zinc amounts in these residues and the rising costs for the disposal. Different pyrometallurgical recycling technologies are tested in rotary kilns and vertical retorts at the Department of Nonferrous Metallurgy, University of Leoben, Austria. Various reducing agents from carbon monoxide to hydrogen and combinations are used. The results should make it possible to draw conclusions that allow an economical and ecological judgement of the different varieties. The goal is to support the affected industry to increase the low recycling rate and prevent a loss of high zinc values in the steel industry filter dusts.

Jan 1, 2003

By S. M. Spottiswoode, J. A. L. Napier, M. Kataka

The move away from the use of strike stabilising pillars at depth and the adoption of the more flexible system of mining towards final dip remnant pillars brings new opportunities for optimising mine design. In the initial planning stage, the size and spacing of the final pillars is designed using classical design criteria, through limiting modelled values of Energy Release Rate (ERR), Average Pillar Stress (APS) and Excess Shear Stress (ESS). In reality, mines often leave pillars that are larger than those originally designed. One of the reasons for leaving more ground is an unexpectedly high rate of seismicity. In this paper, we present developments in integration of modelling and seismicity that are aimed at developing design criteria that are more responsive to local conditions.

Jan 1, 2003

By Freddie Hunter

An underground mining method for extracting an eight metre (26') coal horizon, containing a sandstone layer. A decrease in the thickness of the rock strata between the number two and number three seams of the Sasolburg Coal Field, has resulted in a total mining horizon approximately eight metres (26') thick. This parting varies in thickness and competency and in some areas is impractical to cut with a continuous miner. In addition, the general mining area is highly jointed. The top seam is first mined to a normal bord and pillar plan with a continuous miner. The bottom seam is then mined by selectively undercutting the stone parting constituting the floor of the top seam. In areas where this parting is between 0.75 - 2.50 metres (29.5" - 98") thick, it is suspended from the primary roof support installed when mining the top seam. Secondary, high extraction retreat mining is then undertaken in the coal pillars adjacent to the suspension supported headings in the bottom seam. Left in-situ, the parting provides lateral support to the pillar sidewalls in both the top and bottom seams, enabling high percentage extraction rates in what was previously thought an uneconomically mineable area. The paper proposed, presents the challenges and practical implications of executing the mining method, including the primary roof control of the top seam and the stone parting between scams.

Jan 1, 2003

By J. S. Gardner, R. Woolacott, P. D. Robinson

In 1917, U.S. Coal and Coke Company, a subsidiary of U.S. Steel, opened Mine 31 and built the community of Lynch, Kentucky. For the time this was truly a major engineering accomplishment. It was documented in Howard N. Eavenson’s 1939 AIME paper, “Coal Through the Ages.” In 1996, Arch Coal donated the Portal 31 property to Harlan County for public use. In 2003 the Southeast Education Foundation, Inc. and the Kentucky Coal Museum plan to open the Portal 31 Exhibition Mine to the public to tell the story of Kentucky coalmining through the decades. This presentation will summarize the history of the project, efforts to bring it to reality, the engineering problems, and the challenges of providing a safe environment for visitors.

Jan 1, 2003

By Mary Stewart, Jim G. Petrie, Geoff Brent

"Life Cycle Assessment (LCA) is gaining increasing acceptance as a decision-support tool by which to evaluate the environmental performance of a product, process or service. This is evidenced by its inclusion in international policy documents (for example in the European Union’s Integrated Product Policy) and in environmental management standards (the ISO 14 040 series of environmental management codes relate to LCA). In response to this, the minerals industry has conducted a number of commodity-specific LCAs. These include studies for global production of a number of commodities including copper, nickel, aluminium and steel. In addition, a number of minerals companies profess to use LCA as part of their suite of project and technology assessment tools. Often, this collected use represents more a situation of “we do this because we’re told it’s good for business” rather than from any demonstrable evidence of this fact. This has led to a situation of much confusion and disillusionment within the industry, exacerbated by the obvious current limitations of LCA to accurately reflect the environmental performance of minerals and metals.Our point of departure here is that LCA, conforming as it does to the tenets of environmental systems analysis, is a valuable starting point, and that there is merit in exploring to what extent the methodology can be enhanced to better reflect the environmental performance of minerals and metals. Specifically, we explore here the further development of LCA to address the following:• Land Use issues• Consumption of Abiotic Resources including metallic and non-metallic minerals, water and soil)• Human and Eco-toxicity issues relating to mobility and bio-availability of metals• Salinityand address these through selected experimental and simulation case studies relating to energy- and base minerals production. Advances resulting from the United Nations Environment Programme/Society for Environmental Toxicology and Chemistry Life Cycle Initiative are presented in that they directly affect the application of LCA to mining, minerals and metals. Comments are offered on how best the mining and minerals industry might interface with future developments resulting from this Initiative in order that the Initiative can deliver outcomes which render LCA a useful tool for decision making in mining and minerals processing."

Jan 1, 2003

By G W. Wilson, P Ritchie, N A. Currey

The design and rehabilitation of potentially acid forming (PAF) waste rock dumps is site specific, being a function, among other factors, of the rock types, the dumping and storage method employed, and the climatic setting. The æstore and releaseÆ cover system developed to manage acid rock drainage (ARD) from mineralised waste rock dumps at Kidston Gold MinesÆ open pit operations in the semi-arid climate of North Queensland, Australia, has been monitored for seven years. The paper describes the philosophy behind the design of the PAF dump and æstore and releaseÆ cover system and the adaptation of the cover system over time to suit KidstonÆs conditions. The results of monitoring over the seven years since the first cover was constructed are presented, and the approach being taken at Kidston to ensure that the risk of impacts from any residual ARD is accommodated and to facilitate lease surrender are described. The Kidston story is a valuable case study of a successful approach to remediating an identified source of ARD in a semi-arid climate, which has actively engaged all Stakeholders.

Jan 1, 2003

This paper characterizes the copper cycle, that is, the flows of copper entering and leaving the African economy over a one-year period (1994). The major flows over the entire life-cycle of copper are examined; these include production (mining, milling and refining), fabrication of semi-products and manufacturing of finished products, use, and the waste management system. The results reveal that substantial amounts of copper (of order705 Gg/yr) are mined in Africa; of that amount, about 70 per cent is exported following processing, 18 per cent is utilized by African fabricators, and 12 per cent is discarded. The flows of copper products from African fabricators and product imports from other continents exceed product discards by large amounts. This difference, about 0.25 kg Cu/capita/yr on average, is added to in-use stock, largely as wire, plumbing tube, and in electronics. Some 65 per cent of the copper in discard flows is contained in electrical and electronic products, where it is relatively easy to collect and process for reuse. About a third of the copper discard flows known is recycled. The actual percentage is almost certainly higher because of informal (and unrecorded) recycling. Much of the remaining discarded copper is diluted into the municipal waste stream, where recovery and recycling are probably not economically justified. Keywords: material flow analysis, resource management, material budgets, copper, stocks and flows, systems analysis, Africa, developing country

Jan 1, 2003

By M. C. Bétournay

Strainbursts are common in overstressed brittle rock around deep mine openings. Such failures are characterized by a biaxial state of stress in the plane of the opening boundary. A zone of compressive stresses imposes initial failures near or at the surface of the opening that results in spalling of thin slabs of rock roughly parallel to the free face. While the failure of rock under biaxial loading conditions is increasingly common in deep underground mines, only a few representative laboratory studies have been reported in the literature, without emphasis on rockbursting aspects, and none in the last decade. This paper presents the results of a testing program on a granite rock type. Biaxial testing, conducted on 100 mm cubic samples, was carried out to examine the influence of lateral confinement and loading rate on the rock’s ultimate strength. The paper reports the test results in terms of normalized biaxial failure envelope s1/sc-s2/sc. A discussion of the failure mechanisms observed is presented. Les coups de toits de déformations sont choses communes dans le rock cassant surcontraint en place autour des ouvertures minières profondes. De telles ruptures sont caractérisées par un état de contraintes biaxiales dans le plan de la périphérie de l’ouverture. Une zone de contraintes compressives impose des ruptures initiales à ou près de la surface de l’ouverture, qui produit des relâchements de minces plaques de roc plus ou moins parallel à la surface. Bien que les ruptures de roc sous des conditions biaxiales sont de plus en plus communes dans les mines à grandes profondeurs, il n’y a eu que quelques études représentatives en laboratoire de publiées, sans emphase sur des aspects de coups de terrains, et aucunes publiées depuis la dernière décennie. L’article présente les résultats d’une campagne d’essais appliquée à un type de granit. La campagne d’essais biaxiaux, sur des échantillons cubiques de 100 mm, avait pour objectif d’examiner l’influence du confinement latéral et le taux de chargement sur la résistance ultime du roc. Cet article fait part des résultats en terme de l’enveloppe de rupture biaxiale normalisée s1/sc-s2/sc. Une discussion sur les mécanismes de ruptures observés est présentée. Dehnungsbrüche findet man häufig in übergespannten spröden Felsen um die Öffnung von tiefen Minen. Solche Brüche sind von einer zweiachsigen Spannung in der Ebene der Grenze der Öffnung charakterisiert. Eine Zone von Druckspannungen verursacht initiale Brüche, entweder an der Öberflache der Öffnung oder in der Nähe. Davon scheiden sich dünne Felsplatten mehr oder weniger parallele mit der freien Wand. Obwohl Felsbrüche unter zweiachsiger Beanspruchung immer mehr häufig in tiefen Minen beobachtet sind, hat man über nur einige repräsentative Laborversuche in der Literatur berichtet. Diese Studien diskutieren das Thema ohne Betonung auf Felsbrüchen, und keine sind in den letzten zehn Jahren erschienen. Die vorliegene Arbeit gibt die Ergebnisse eines Testprogramms auf einem Typ von Granitfels. Durch zweiachsige Prüfungen von kubischen Proben mit Seitenlangen von 100 mm sollte man den Einfluss von seitlicher Ermittlung und der Beanspruchungsrate auf die Bruchfestigkeit des Felsen studieren. Man findet auch die Prüfergebnisse in bezug auf das normalisierte, zweiachsige Bruchkriterium s1/sc-s2/sc. Die beobachteten Bruchmechanismen sind auch diskutiert.

Jan 1, 2003

Remnants of Plio-Pleistocene hot spring systems in Northland, New Zealand contain sulfide minerals, principally pyrite, marcasite and cinnabar. The climate is warm temperate to subtropical, with up to 3 m of rainfall per annum, and rocks are deeply weathered. Decomposition of the iron sulfides in natural outcrops and human excavations results in acid rock drainage with pH typically between 2 and 5, and locally down to pH 1. Deeply weathered basement greywacke is clay-rich and has negligible neutralisation capacity. Some overlying volcanic flows have resisted weathering, and pH is kept near neutral by relict secondary calcite in small areas. Natural rainforest soils commonly have pH between 4 and 5 over mineralised and unmineralised greywacke. Mineralised zones are enriched in arsenic, which occurs in solid solution (up to 1 wt per cent) in sulfides and phosphate minerals. Mercury also occurs in solid solution in some of these minerals, as well as in cinnabar. Base metals are present in low (background) concentrations only. Decomposition of the iron sulfides and phosphates releases the solid solution arsenic and mercury into the acid rock drainage solutions. Arsenic is readily adsorbed on to iron oxyhydroxides formed in acid rock drainage situations, and can be effectively removed from the biosphere. However, this arsenic is released back into the environment if the pH rises, as adsorbed oxyanions become less strongly bound and are displaced by hydroxyl ions. Behaviour of dissolved mercury is similar to that of arsenic but less well understood in these settings. Both arsenic and mercury are readily leached into pH 6 solutions from solid material collected from acid rock drainage sites. These observations suggest that neutralisation of acid rock drainage sites is undesirable in this setting, as arsenic and mercury will become more mobile in the environment. The naturally low pH of 4 to 5 of the forest floor, or even lower pH of natural acid rock drainage, is a preferable management option.

Jan 1, 2003

By J. Broadhurst

"A number of metal supplying industries have in recent years seen the compilation of life cycle inventories (LCIs) and life cycle assessments (LCAs). The activity has largely been driven by the interest of ultimate metal users, such as the automotive industry, in the interest of designing more sustainable products. Often, the compilation of such inventories has been little more than an auditing exercise. However, the process of conducting an LCA can have more value, guiding designers and operators to points within the technology train where significant emissions and impacts originate. The LCA product can thus be used to inform on-site environmental management, and, where process data is used to construct dynamic operational models, to support strategic decision making in the realm of project planning and technology selection. LCA thus serves as a valuable tool to support the industry’s drive to support the sustainable development of the societies in which it operates.This paper reviews and compares the priorities of environmental and closure planning in the design phase, with environmental management and auditing during operation, and with green procurement of minerals and metals products. It shows how life cycle assessments of various complexities can be used to reconcile these various objectives, ensuring that the latter, critical to business success, can be addressed from the outset in a new project. The paper then reviews a case study of the use of LCA in the base & precious metals industry, where the complexity of the operation disallowed the simpler auditing process so that a detailed process understanding had to be built up in order to compile a meaningful life cycle inventory."

Jan 1, 2003