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By R. Carrier

"There has been a continuous evolution with the use of pre-cast concrete elements in the construction of aluminum smelters. In 1990, Phase I of Alouette was built using cast-in-place concrete exclusively. Whereas, other AP 30 technology plants such as Hillside 2 in the mid-1990s used pre-cast concrete beams with cast-in-place floors. Mozal 2, in 2002, used pre-cast concrete beams with pre-cast partial-slab operating floors. Alouette Phase II went further. Not only were the potroom building beams and floors pre-cast, but the entire pot support system, insulating walls and basement jersey walls were pre-cast. Once the techniques for bending and welding the reinforcement bars and the design for attaching electrical insulating plates to the concrete was perfected, the challenge for the project remained only in the logistics of transporting the pieces to site and simple erection. The overall impact on the project was dramatic. Using prefabricated concrete not only allowed advancement of the schedule, but totally eliminated formwork, re-bar installation, and form removal activities along with the handling of all the materials involved with these activities. With the elimination of these labour and material-intensive portions of the job, exposure to work injuries was dramatically reduced. The most prevalent activity for lost time accidents is during the rough work associated with concrete formwork, placing concrete and form removal. Another area where prefabricated elements were successfully used on Alouette Phase II was for the insulating walls enclosing the pot area, known as the ""claustra walls"". Usually these walls are constructed in-situ using mortar and breeze block. Success was also achieved with prefabrication of the perimetric walls that are installed at the lower floor of the potroom. A big advantage of using prefabricated concrete in the electrolysis area is in assuring electrical isolation for the operating floors. Poured concrete requires a meticulous clean-up effort before commissioning to establish the electrically ""floating"" characteristics of the operating floors. Poured concrete results in ""wash"", stray wood,"

Jan 1, 2006

By Francis Vanbellen

Umicore Precious Metals Refining operates an integrated precious metals smelting and refining plant in Hoboken, Belgium. Once a smelter and refiner of complex concentrates, the plant today?s feed consists exclusively of industrial and consumer recycled products, making it the world?s largest recycling facility for precious metals. Unlike the fairy tale of the Frog Prince, it took much more than a princess? kiss to successfully realize this makeover. A completely renewed plant has been built over the past decade. The most visible technological innovation was the commissioning of the Pb-Cu smelter. Its flexibility towards very different types of feed makes it perfectly suited as main entry to the Hoboken flow sheet. A new Cu-leaching & electro winning plant and precious metals refinery make up the Precious Metals Operations (PMO) whose targets are fast throughput and maximized yields for gold, silver and the platinum group metals. The Base Metals Operations (BMO), flexibly process the by-products from the PMO, valorizing ?impurities? like indium, tellurium, selenium and others. Off gas and waste water treatments ensure compliance with strict environmental standards. Precious metals recycling is an art that goes beyond mastering a unique flow sheet. Umicore Precious Metals Refining offers a complete recycling service, taking care of sampling and assaying, metals management and logistics. The quality of this integral service is recognized through the attribution of ISO certifications for our operational activities, sampling and the environmental care. And it?s an art that follows Michelangelo?s experience: ?Art is 5% of inspiration and 95% of transpiration.?

Jan 1, 2006

By R. B. Krog

As part of its mining health and safety research program, the National Institute for Occupational Safety and Health (NIOSH) conducted a longwall methane emission and mining time study at a mine operating in the Pittsburgh Coalbed to access the methane emission consequences of mining a longer face. The methane emission contributors from the mining of a longwall face are: 1) gas released from the coal broken by the shearer, 2) gas emitted from the coal on the face conveyor, 3) gas emitted from the coal transported on the belt, and 4) background gas emitted from the coal face and from the adjoining ribs. Based on the results of the study, a set of site-specific mathematical formulas and constants were developed to characterize each of the four longwall emission contributors. The mathematical formulas were then applied to longer longwall face mining scenarios to predict the methane emissions from these faces.

Jan 1, 2006

By S M. Stewart

Building and Maintaining Community Relationships   In mining terms, the town of Waihi is distinctive with the Martha mine situated right in the heart of the town. MarthaÆs central location and other mining activity nearby means there is an increased community focus on the happenings at the mine and the effects and impacts of mining. While WaihiÆs proximity to the mine is unique, all mines have a community context that they operate within.   Issues of proximity simply heighten awareness and emphasise the need for building and maintaining good community relationships. In the three years we have been working alongside the Waihi community, we have worked together with concerned and supportive residents, representatives of Newmont Waihi Gold and representatives of Hauraki District Council, to develop a collaborative framework for addressing the economic, social, environmental, cultural and spiritual wellbeing of the people of Waihi. This could not have occurred without the genuine commitment of all participants.   This collaborative focus has resulted in some tangible progress in Waihi which, in part, stems from people taking an interest in the town because the town is taking an interest in itself. As we have worked and learned within the process of building and maintaining a collaborative and sustainable community environment, we have tried to adhere to a philosophy and a set of basic principles. We believe that this approach, combined with a teachable skill set, helped to create the opportunity to develop a truly collaborative community environment which continues to grow. Our paper will describe this philosophy, these principles and the skill set that we have applied.   The application of the process in Waihi has resulted in a series of outcomes unique to Waihi. These outcomes include formation of the Waihi Community Vision committee, the Vision Waihi Trust and the subgroups set up to further the interests of particular groups, for the collective benefit of all the community.   Based on our experience of other situations, and on the way the Waihi process has developed, we believe that the identified principles and skills can be transported and used in other cultures and contexts. While the resultant outcomes may differ, the underlying principles will still apply. Progress will come from creating a sustainable environment within which the community (including residents, industry and regulatory authority) can determine its own internal relationships and the vibrant growing sense it has of itself.

Jan 1, 2006

By A. Basçetin

Equipment selection in mining engineering is one of the most important decisions that affects the mine design, production planning and economic parameters in open pit and underground mining. Mine planning engineers generally use their intuition and experiences in decision making. Mostly, linguistic variables (the weather is raining, soil is wet, etc.) come into question and decision-makers may not know how these variables are computed. Since the advent of the fuzzy set theory, these uncertainties are easily interpreted in the decision-making process. The development of computer technology and programming of colloquial language with expert systems have considerably reduced decision-makers? burden. This paper reviews the development of a computer programme software called EQS (EQuipment Selection) that automates equipment selection in mining engineering using fuzzy set theory. The EQS with an introduction of the concepts and theories of multiple attribute decision-making, the fuzzy set theory, and EQS applications to mining industry problems with case studies are presented

Jan 1, 2006

By Hakan Gurgenli

Many coal seams have weak shale immediate roofs that cause ground control problems. Therefore, it is important to know the properties of these shales so that preventive measures can be developed in advance. However, it is sometimes hard to understand this rock type due to its unpredictable behavior. A good example of this situation is found in two shale coal mine roofs located in the Illinois coal basin (Herrin No. 6 seam). Although, these mines are located very close to each other, one of them has many roof falls, whereas the other has no measurable ground control problems. The aim of this paper is to explain why and how one shale roof behaves worse than the other. Laboratory tests, including point load strength index, slake durability index, moisture activity index, weatherability index, water content determination, swelling strain and x-ray diffraction tests were performed to analyze the shale properties. According to these analyses, some useful correlations were found between the engineering properties, moisture-sensitivity indices, and weathering properties. Finally, mine and support design considerations based on the test results were discussed and recommendations to prevent ground control problems were given.

Jan 1, 2006

By Gabriel S. Esterhuizen

A survey of pillar conditions was carried out at 21 operating limestone mines that use the room-and-pillar method. The surveyed pillars were all located in rock that was classified as ?Good? to ?Very Good? using the RMR rock mass classification system. The average pillar width was 14.5m and the width to height ratio varied between 0.53 and 3.52. Pillar conditions were rated using a visual rating system that accounts for the effect of geological structures as well as stress related fracturing. Nine cases of pillar instability were recorded. Pillar instabilities were typically limited to individual pillars or small groups of pillars within an otherwise stable layout. Local geological structures such as inclined discontinuities or weak bedding planes contributed to instability in seven of nine cases that were observed. Elevated pillar stresses contributed to instability in the two remaining cases. All the unstable pillars observed had width-to-height ratios of less than 1.5. It is concluded that pillar instability is most likely to be caused by unfavorable geological structures in pillars with width to height ratios of less than 1.5. Stress related instability such as rib spalling becomes more prevalent when the average pillar stress approaches approximately 20 MPa.

Jan 1, 2006

By M. J. Papo, A. Muwila

Hercules? is a low nickel austenitic stainless steel developed at Mintek that has a typical composition of 9 wt% Mn, 0.05 wt% C, 2 wt% Ni, 0.25 wt% N and 16.5 wt% Cr. A more corrosion resistant version of Hercules? (Hercules? B) with 0.5 wt% Mo has also been developed. Potentiodynamic tests performed on Hercules? B in a 5 wt% sulphuric acid solution showed it to have improved corrosion resistance comparable to that of AISI 304. The effect of a varying Mn content on the corrosion resistance of Hercules? B has also been investigated and the results discussed in this paper. From the corrosion test results, it is clear that decreasing the Mn content of Hercules? B increased the corrosion rate while increasing it decreased the corrosion rate. KEYWORDS Austenitic stainless steel, %ferrite, molybdenum, manganese, nitrogen, electrochemical corrosion tests, potentiodynamic scans, microstructure, chemical analysis.

Jan 1, 2006

By Francis Vanbellen

Umicore Precious Metals Refining operates an integrated precious metals smelting and refining plant in Hoboken, Belgium. Once a smelter and refiner of complex concentrates, the plant today?s feed consists exclusively of industrial and consumer recycled products, making it the world?s largest recycling facility for precious metals. Unlike the fairy tale of the Frog Prince, it took much more than a princess? kiss to successfully realize this makeover. A completely renewed plant has been built over the past decade.

Jan 1, 2006

By F. Freme

Coal production in the United States reached a record level in 2005, ending the year at 1.03 Gt (1,133.3 million st) according to preliminary data from the U.S. Energy Information Administration (Table 1). Production in 2005 was 19.2 Mt (21.2 million st) higher than the 2004 level of 1 Gt (1,112.1 million st) and surpassed the prior record set in 2001 by 5.1 Mt (5.6 million st). Although total U.S. coal consumption rose in 2005, not all coal-consuming sectors had increased consumption for the year. Coal consumption increased in the electric power sector by 2.2 percent and declined in the other industrial sector, while coking coal consumption decreased slightly.

Jan 1, 2006

By V. V. Geikhman

The paper updates the Plant experience in the development and implementation of an advanced environmentally friendly zinc production technology complying with the technological and economic level of producers in the world and the standards of maximum permissible gas emissions stipulated by the Russian legislation. General water recycling engineering allowed to ensure 95.6% water rotation level. All solid wastes formed during treating zinc concentrate are processed into marketable products or semiproducts and sold. As a result of implementing innovation techniques production at the Chelyabinsk Zinc Plant is non-waste.

Jan 1, 2006

By Jacques J. Eksteen

Metallurgical accounting around toll treatment smelters pose a number of challenges. This paper reviews the requirements for good sampling practice, and how conflicting requirements for good furnace operation and design often makes reliable closure of the metallurgical balance tenuous at best. Typical physical causes of variance and bias will be identified. The propagation of error (in the form of variance) will be discussed for a copper smelter.

Jan 1, 2006

By Francis Vanbellen

Umicore Precious Metals Refining operates an integrated precious metals smelting and refining plant in Hoboken, Belgium. Once a smelter and refiner of complex concentrates, the plant today?s feed consists exclusively of industrial and consumer recycled products, making it the world?s largest recycling facility for precious metals. Unlike the fairy tale of the Frog Prince, it took much more than a princess? kiss to successfully realize this makeover. A completely renewed plant has been built over the past decade. The most visible technological innovation was the commissioning of the Pb-Cu smelter. Its flexibility towards very different types of feed makes it perfectly suited as main entry to the Hoboken flow sheet. A new Cu-leaching & electro winning plant and precious metals refinery make up the Precious Metals Operations (PMO) whose targets are fast throughput and maximized yields for gold, silver and the platinum group metals. The Base Metals Operations (BMO), flexibly process the by-products from the PMO, valorizing ?impurities? like indium, tellurium, selenium and others. Off gas and waste water treatments ensure compliance with strict environmental standards. Precious metals recycling is an art that goes beyond mastering a unique flow sheet. Umicore Precious Metals Refining offers a complete recycling service, taking care of sampling and assaying, metals management and logistics. The quality of this integral service is recognized through the attribution of ISO certifications for our operational activities, sampling and the environmental care. And it?s an art that follows Michelangelo?s experience: ?Art is 5% of inspiration and 95% of transpiration.?

Jan 1, 2006

By T O&apos, Sullivan

Reconciliation of metal production from a sublevel cave (SLC) mining operation is a complicated process. SLC reconciliation is unlike reconciliation for open stope operations, where a tonnage of extracted ore can be assigned to an exact volume of in situ ore, and a direct comparison made between the estimation of contained metal and actual metal production. In SLC operations the ore extracted from a particular SLC drawpoint will be composed in part from the parcel of freshly blasted in situ material, in part from varying components of ore material (from cave stocks) flowing down from other previously mined areas vertically above the current draw position and in part from external dilution. This leads to difficulties in reconciling production grades against estimated grades. The problem is that we know how much metal we have produced but we can not precisely say where it has come from. Metal production reconciliation is fundamental in assessing ore reserve estimation accuracy and performance and in determining a draw management strategy for SLC mining. In terms of contained metal, differences in extracted metal compared to in situ metal represent changes to cave stocks. To generate local estimates of the cave stocks, differences in metal for each ring are treated as additions to or subtractions from a series of vertical columns of stocks extending throughout the height of the cave. The sum of metal differences (extracted versus in situ) for each vertical column results in a residual metal map at any particular mining level. The metal maps show areas where the metal production has been greater than or less than expected. The maps also highlight areas in the cave where residual metal is located, areas where targeted overdraw can reduce cave stocks.

Jan 1, 2006

By T Niitti, J Turunen, P B, A Rinne

In todayÆs marketplace, with high metals prices, many operations are faced with the challenge of improving recovery in the particle size ranges which are normally difficult to recover. This presentation focuses on the various methods used to alter the flow dynamics in a mechanical flotation cell, thereby improving metallurgical results. Modern computational fluid dynamics (CFD) tools have been used in the design phase, with subsequent validation at the plant. Some of the validated variables include mixing profile, power draw and local air hold-up. This presentation underlines how modern CFD analysis can be used to screen and select different approaches before commencing costly trial-and-error experiments at plant scale. Two methods of affecting flow dynamics are discussed û firstly, by altering the geometry of the rotor-stator area and, secondly, by fitting additional features in the tank. The rotor-stator area can be modified to provide more concentrated turbulent kinetic energy or, respectively, to provide more pumping efficiency with less attrition. The tank can be fitted with various additional features, aimed to create different particle suspension profiles. The benefit of both methods is that they can be applied not only to newly installed flotation technology, but also to existing plant cells, thus enabling potential improvement in the mixing profiles, solids suspension, tank sanding and metallurgical performance. Results of several sitesÆ tests are discussed in terms of flow variables measurement as well as metallurgy. This paper demonstrates the effects of different flow dynamics on the mixing profiles and metallurgical results of existing mechanical flotation cells.

Jan 1, 2006

By Andreas Hucke

For the roadway design in the German hard coal mining industry, an advanced combined planning system has been applied during the past 20 years. The German mining industry is working with single entry roadways system. After first longwall passage the roadways will be stabilised with side wall building material packages. Later this roadway will be used again for the second retreating longwall. The intention of the implementation of several different design methods for the planning of the roadways is to enhance the reliability of the results. On one hand the planning system uses numerical simulation and physical modelling in addition to analytical and empirical methods. On the other hand in-situ monitoring and analysis during the roadway development will be used to verify and calibrate the numerical and physical models. Especially before the implementation of new support elements in underground, this system is suitable and reasonable because the new support elements will be tested in the physical and numerical simulation prior to cost intensive underground tests. The interaction between the numerical and physical modelling in comparison with underground monitoring and analysis during development and the later use of roadways will be shown with some examples. The first example shows a rock bolted rectangular roadway which will be mined at both sides of the roadway. Different support and roadway building material package systems are investigated under various stress conditions. The results are utilised to optimise the roadway support and the roadway side package systems. The influence of different points in time of the installation of several support elements in a combined arch and bolted roadway is shown as another example. Two different types of support systems are compared within the physical models. These models are used as a base for ongoing numerical analysis and simulation to find out the ideal point of time to assemble the different support elements. The last example handles the influence of slickensides in the roof of arch shaped roadway on their stability. Different slickenside positions and densities are investigated and classified.

Jan 1, 2006

By V. L. Mitsopoulos

This paper provides a summary of tailings disposal techniques and the improvements that have been made through the introduction of thickened tailings disposal. The general properties and characteristics of thickened tailings are described, as is a design process for selecting appropriate technologies for thickening, pumping, transporting and storing tailings. The factors affecting the selection of an appropriate disposal site and operational considerations for the effective utilisation of tailings storage areas are also documented.

Jan 1, 2006

By R. C. Bratton, R. Q. Honaker

Hindered-bed separators are recognized as low-cost, high-capacity devices for both classification and density separation; however, since their inception, there have been few significant advances in the fundamental technology. Recently, Eriez has shown through modeling and pilot-scale testing that the innovative approach to feed presentation offered in the CrossFlow teeter-bed separator provides improved metallurgy when compared to traditional hindered-bed classifiers or single-stage coal spirals. This design feature prevents excess water from entering the separation chamber and disrupting the overall fluidization flow rate within the teeter zone. Most recently, a side-by-side industrial scale evaluation has verified that this technology improves overall efficiency and simultaneously reduces the separation cut-point. With regards to coal processing, data from full-scale units indicate that the CrossFlow offers good separation efficiency, high unit capacity, and metallurgical results consistent with laboratory- and pilot-scale separators.

Jan 1, 2006

By E Hondros

Innovation and Business Skills Australia (IBSA) commissioned The Boston Consulting Group (BCG) to undertake a study into how the role of AustraliaÆs senior managers is likely to change between now and 2020 and to identify the skills and attributes that will be needed to respond to those changes. This report builds on a previous study prepared by BCG in the early 1990s for the Industry Taskforce on Leadership and Management Skills (Karpin Committee), which provided a snapshot of the Senior Manager in 2010. The following powerpoint slides summarise the 2020 Vision û The Manager of the 21st Century û outlining how the role of AustraliaÆs senior managers is likely to change between now and 2020 and to identify the skills and attributes that will be needed to respond to those changes. The presentation is summed up in the following quote from Jon Nicholson û Senior Vice President of BCG: We believe that to succeed in the years up to 2020, executives will need to master a range of hard and soft skills. Amongst other things, they will require to manage multi-generaional teams, the creativity to measure staff performance on outputs rather than inputs, and a high degree of technical and functional expertise in addition to their general management credentials. This paper is available as a PowerPoint presentation only.

Jan 1, 2006

By M. Jacobs

Keywords: Smelting, converting, sulphide, sulphide smelting, platinum, platinum group metals, PGM, base metals, nickel, copper, matte, slag, furnace, electric furnace, Söderberg, electrode, granulation, converter, flash drier, sulphuric acid, acid plant, Ausmelt, Sirosmelt, pyrometallurgy, metallurgy, Anglo Platinum, South Africa Waterval Smelter complex is situated in Rustenburg, in South Africa?s North West Province. The smelter objective is to process wet concentrate to produce crushed, slow-cooled, sulphur-deficient nickel-copper matte rich in platinum group metals (PGMs), gold, and base metals for despatch to the Magnetic Concentration Plant at the Base Metals Refinery. Throughout its history, the smelter complex has been continuously upgraded in line with increasing production demand, changing feeds, environmental initiatives, and advances in available technology. The smelter receives filter cake and slurry from Anglo Platinum concentrators and joint ventures. Wet concentrate is fed through a flash drying process utilising coal-fired, fluidised bed hot-gas generators, to produce dry feed material for the electric furnaces and slag-cleaning furnace. For primary smelting, two electric furnaces are used, each with a rated capacity of 34MW. Furnace matte, containing the bulk of the base metal sulphides and PGMs, is tapped periodically into refractory-lined ladles and granulated using high-pressure water jets, then dried through electrically powered pneumo-driers to become the main feed to the Anglo platinum Converting Process (ACP). Slag is tapped semi-continuously, granulated, and treated through the slag mill. The ACP treats the combined matte output of Waterval, Polokwane, and Mortimer smelters. It is a top-blown furnace, with furnace matte, air, and oxygen being injected into the converter via a lance submerged in the slag. Converter matte is tapped and bottom cast into moulds, slow-cooled, crushed, and despatched to the refineries. Slag is granulated and dried for recycling to the slag-cleaning furnace. ACP slag is fed to the slag-cleaning furnace along with a reductant and a sulphur source. Slag-cleaning-furnace matte is granulated for processing by the ACP, while slag is granulated and processed in the slag mill. The slag mill and flotation circuit treats granulated slag from the electric furnaces and slag-cleaning furnace to recover entrained matte containing valuable PGMs and base metal sulphides.

Jan 1, 2006