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By B J. Andrew, M R. Daley

Mount Isa Copper Mines is a world-class mining operation producing approximately six million tonnes of ore per annum. With over 50 years of mining history and over 76 million tonnes of underground resource remaining there are many challenges facing the mine technical team today and into the future. The mine consists of nine distinct areas: the Hangingwall Lens, Footwall Lens, 1100, 1900, N1100, N1900, 3000, 3500 and N3500 orebodies. Each of these areas have different characteristics, requiring varying methods of mine design and ground control for safe and efficient orebody extraction. Each of the areas operate with an independent sequence whilst interacting with the entire underground operation. Within the first five years after graduating mining engineers tend to orient their careers in either a technical or operations direction. Engineers working towards a specialised technical career will often be working as mine planning engineers, whilst others more focused in the operations stream occupy roles such as operations or project engineers. At this stage of a mining engineerÆs career they are not yet categorised into one stream or another, but career decisions made now can generally focus their ultimate career path in one direction or the other. Due to the size of the Mount Isa operations there are many opportunities for engineers pursuing both career path and plenty of room for growth forthose as yet unsure.

Jan 1, 2005

By Sara Anderson, Rachel Nicholls, Tim Chapman, Janice Windle

"In city center sites around the world, and in particular in London, foundation reuse is becoming increasingly widespread as the ground is filled with detritus from previous developments. This paper sets out a systematic framework to consider the need for and benefits of foundation reuse and key issues to be resolved for foundation reuse to be successfully adopted on redevelopment projects. Once foundation reuse has been identified as a potential foundation solution there are several key stages in the design and construction process where the decision to reuse foundations needs to be assessed. The paper concludes by emphasising the importance of ensuring that the foundations being installed now can more easily be reused in the future.INTRODUCTIONThe concept of re-using foundations is not new, and has been adopted on an isolated project-byproject basis for many years. However, over the past decade, interest in the potential of reusing existing piles and caissons within Europe has increased significantly, with a growing interest in the United States of America and Japan. The need has been driven by necessity: on many urban sites the space available for new foundations diminishes with each new set of piles, and these problems can only grow in the future.Initiatives such as the European Union's RuFUS (Re-use of Foundations for Urban Sites) research project have resulted in identification of the key issues for technical viability and risk that have previously hampered potential foundation reuse projects.There is a need to define a systematic approach to the reuse of foundations so that the risks associated with reuse can be identified, managed and mitigated. This requires improvements in knowledge to provide confidence in the long term behaviour of the foundation support and address the risks involved in reusing existing foundations to overcome perceived obstacles in making foundation reuse a realistic option for many sites."

Jan 1, 2005

By L E. Krause

This paper discusses the considerations for optimum maintenance of critical ore handling infrastructure in order to minimise the cost to the business of maintenance periods. As maintenance periods are a direct interruption to production, time is of the essence and careful management of shutdown periods is essential. The ore pass systems currently in use at Xstrata Copper û Mount Isa Copper Operations are up to 30 years old and have had significant wear over the years. The maintenance of these passes and their brows and chutes in a production situation is a challenge as it can potentially expose personnel to high risk situations in addition to the production interruptions. Some alternatives for mitigating the risk of working in ore passes including plugging and ballooning are described. Criteria are included for selecting a method for the safe entry into a given ore pass. Experience in adapting the method of ore pass plugs and some lessons learnt in the process are also discussed.

Jan 1, 2005

By Peter Reinders, Dirk Hummel

This paper describes a newly developed Surface Remote Blasting System (SURBS) for electronic detonators, which is currently being introduced into surface blasting applications. The rationale for developing the SURBS was to meet key needs of mine operations, such as minimizing the shutdown time and the capability to conveniently initiate blasts in difficult terrain from a safe distance. Increased distance from the blast site, combined with a good overview of the site enables maximum safety during blasting. The system also removes the inconvenience of running long firing cables. The SURBS consists of the field-proven detonator and equipment technology of an existing electronic detonator system, a Surface Remote Blasting Box and a Surface Remote Blaster. The Surface Remote Blaster is the Master unit and controls the Remote Blasting Box via encrypted radio communication using a sophisticated safety technology, which guarantees that the highest safety standards are maintained.

Jan 1, 2005

By R. M. G. Machunter

Computer models of metallurgical circuits are extensively utilised in design, and prediction of overall plant separation performance. As always, in the final optimised flowsheet design there is a compromise between the recovery of values and grade of the circuit output. This paper mathematically examines various circuit options for the generation of a heavy mineral concentrate from a generic mineral sands wet concentrator plant. Based on data derived from testwork, any particular mineral sand has a unique release curve describing the separation performance of the heavy mineral suite. Models are constructed that combine particular stage output streams as feed to other stages in various configurations. The ramifications of each option are discussed and reasons why one particular option is selected over the others examined.

Jan 1, 2005

Nickel WestÆs Kalgoorlie Nickel Smelter operates three Peirce-Smith converters, each processing 110 tonnes of matte per charge. The vessels are lined with chrome-magnesia refractory with a mouth traditionally constructed from steel liner plates, protected with cast refractory. Mouth refractory is damaged by molten material and the action of cleaning solid buildup off the mouth. Once damage has accumulated, the mouth must be frequently maintained with hot refractory gunning or a mouth leak may occur. Such a leak requires a 32 hour repair period. A converter mouth redesign program was undertaken with the aim of reducing the rate of mouth damage during operation, eliminating mouth leaks and shortening mouth replacement times during vessel rebuild periods. An overview of the redesign process and operational performance is contained herein.

Jan 1, 2005

By D. -A Tremblay

Dynamic wetting spread factors and interfacial heat transfer coefficients were determined for aluminum droplets solidifying on copper substrates, The spread factors were determined from the droplet geometries while the heat transfer coefficients were obtained by solving inverse heat conduction problems, 1-D and 2-D heat transfer models are presented and the results they provided are compared, For the latter, a sensitivity analysis was also performed to determine the influence of thermophysical properties and boundary conditions. Experiments were alternatively carried out with three different gaseous atmospheres and the dynamic wetting spread factors were correlated to the interfacial heat transfer coefficients.

Jan 1, 2005

By S. Mohammadnejad, M. Olizadeh, B. Mehrabi

A new method using a combination of comprehensive mineralogical and analytical approach which includes optical and electrical microscopy and several analytical techniques with diagnostic leaching has been used to characterize the associations and distribution of gold in a variety of minerals from the Zarshuran refractory gold ore, NW Iran. Zarshuran ore with an average of 7.9 g/t Au-grade and about 8% arsenic with gold recovery less than 20% in direct cyanidation is considered as high arsenic, high au-grade refractory gold ore. In most of the refractory ores, gold is associated with arsenopyrite and co-para genetic ore minerals, while in Zarshuran ore; gold is associated with orpiment, realgar and arsenian-pyrite. Considering its mineralogy and As content, it can be considered as the most difficult refractory ore for characterization and processing. Results from the mineralogical examination and diagnostic leaches indicate that there is only a small amount of free gold (17-19%) that is present in cyanide-soluble sulfo-arsenides compounds, predominantly orpiment and realgar. Diagnostic leaches also indicate that little gold is occluded within the silicate structure (14%). Overall, the gold is mostly included in sulfides, arsenic sulfides and sulfo-arsenides (50%). The results also have shown how the technique can be used to gain a good initial understanding of potential metallurgical problems for a refractory gold ore.

Jan 1, 2005

By N. Ogbonna, D. G. Dixon

Although heap bioleaching has been recognized as an economic alternative for treating low grade mineral ores, the underlying physical, chemical and biological processes involved are complex. A detailed investigation into the dynamics of heap bioleaching processes has provided much insight into the underlying complexities, and has led to the development of a sophisticated modelling tool - HeapSim. This tool can be of great help in the design and operation of heap bioleaching processes. In this paper, the mathematical model implemented in HeapSim is examined. The model takes into account mineral kinetics, particle level effects, bacterial growth, oxidation and adsorption, gas absorption, pore diffusion, bulk advection, gas balance and heat conservation. Three case studies where the model has been applied are briefly discussed. Computational Analysis in Hydrometallurgy 35th Annual Hydrometallurgy Meeting held in conjunction with the 44th Annual Conference of Metallurgists of CIM Calgary, Alberta, Canada Edited by

Jan 1, 2005

By J. D. Zhu

A numerical model for predicting microporosity formation in aluminum castings has been developed, which describes the redistribution of hydrogen between solid and liquid phases, the transport of hydrogen in liquid by diffusion and Darcy flow in the mushy zone, One of the key features of the model is that it uses a two-stage approach for porosity prediction, In the first stage, the volume fraction of porosity is calculated based on the reduced pressure, whereas, in the second stage, at fractions solid greater than the liquid encapsulation point, the fraction porosity is calculated based on the volume of liquid trapped within the continuous solid network, which is estimated using a correlation based on the Niyama parameter, The porosity model uses thermal data calculated using the commercial finite element package ABAQUSTM. The model has been applied to examine the evolution of porosity in a series of experimental samples cast using unmodified A356 in which the initial hydrogen content was varied from 0,048 to 0.137 [cc/100g], A comparison between the model predictions and the experimental measurements indicates good agreement in terms of the variation in porosity with distance from the chill and the variation resulting from initial hydrogen content.

Jan 1, 2005

By Gregory B. Poole

As part of a $3.5 billion program to improve the antiquated waste water system in the city of Atlanta, the Nancy Creek Tunnel is being constructed across the northwest portion of the city. This tunnel is over eight miles long and is being constructed using Tunnel Boring Machines (TBM) for the majority of the tunnel and conventional drilling and blasting for three shafts, starter and tail tunnels and four connecting tunnels, totaling 2400 feet in length. An extensive public relations program was developed for this project. A group effort by the owner, engineer and contractor produced a public relations program that both informed and educated the public of the anticipated perceptions and effects of the blasting and TBM activities.

Jan 1, 2005

By Phil Pennington, D. Jack Adams, G. Ward Wilson, Virginia T. McLemore, Luiza Aline F Gutierrez, Rodney Shields, Steven Lockwood, Samuel Tachie-Menson

Microorganisms are directly or indirectly involved in many chemical alterations and in the decomposition of minerals required for their growth. Microbial dissolution of sulfide minerals under acidic conditions can produce over 1,000 times more Acid Rock Drainage (ARD) than chemical action alone. Microbial actions can cause precipitation of minerals, adsorption or release of metals, and formation/destruction of organic-metallic complexes. Soluble minerals can serve as oxidizing substrates, electron donors/acceptors in redox reactions, and can be directly involved in cell metabolism. Microorganisms and microbial oxidation-reduction reactions and their contribution to mineral mobilization and stabilization will be discussed.

Jan 1, 2005

By Li Chen

A new process, i.e. Ball milling--Neural leaching--Oxidation calcinations--Chloridizing distillation--Hydrolysis, was designed to recover germanium from the vacuum furnace slag produced in Shaoguan smelter. The suitable process and operational parameters were determined for the practical production.

Jan 1, 2005

By Gungor Tuncer, Ali Kahriman, Abdulkadir Karadogan, Mehmet Aksoy, Kagan Ozdemire

With increasing environmental constraints on the levels of disturbance induced by blasting operations upon nearby residents, there is an increasing need to be able to design cautious blasting with greater precision. Therefore, determination of maximum amount of explosive per delay for a certain distance especially in large blasts is of great importance for the elimination of these environmental problems. Although too many research studies had been carried out in the past in order to eliminate environmental issues produced from blasting unfortunately a general approach or formula has not been established yet because of the complexity of the matter. In addition to the wave and ground motion characteristics, the complexity of blasting parameters and site factors restrict the developing a general criterion. So experimental site-specific studies should be still done in order to predict and control blasting effects. This paper presents the results of ground vibration measurements carried out in Espey Open-Pit Boron (Colemanite) Mine located on the west side of the central Anatolia near Kütahya province in Turkey. Within the scope of this study, ground vibration components were measured for 13 shots during bench blast optimisation studies in order to predict peak particle velocity level for this site. In blasting operations; ANFO and Powergel Magnum 600 (blasting agent), Powergel Magnum (priming) and delay electric detonators (firing) were used as explosives. Parameters of scaled distance (charge quantity per delay and the distance between the source and the station) were recorded carefully and the ground vibration components were measured for all blast events using 4 different types vibration monitors (3 White Mini-Seis and 1 Instantel Minimate Plus Models). Then, the data pairs of scaled distance and particle velocity obtained from the 38 record events were analysed statistically. At the end of statistical evaluation of the data pairs, an empirical relation which gives average line at 95% confidence level and upper bound 95% prediction line with a reasonable correlation coefficient was established between peak particle velocity and scaled distance.

Jan 1, 2005

By B. Anameric, S. K. Kawatra, K. B. Rundman

The iron nugget process is an economical, environmentally friendly, cokeless, single-step pig iron making process. Residence time dependent process requirements for production of pig iron nuggets at a fixed furnace temperature (1425 C) were investigated. Three chemically and physically different products were produced after complete reduction to iron, depending on the residence time in the furnace. These products were direct reduced iron (DRI), transition direct reduced iron (TDRI), and pig iron nuggets (PIN). The increase in the carbon content of the system as a function of residence time was detected by optical microscopy and Microhardness measurements. Sufficient carbon dissolution for the production of pig iron nuggets was obtained after 40 minutes residence time. The pig iron nuggets produced had chemical and physical properties similar to blast furnace pig iron. They were liquid state products and slag was completely separated from the metal.

Jan 1, 2005

By Bruce Hebblewhite

This paper focuses on the recent achievements and practices developed through the Minerals Tertiary Education Council (MTEC) initiative of the Minerals Council of Australia (MCA), in conjunction with the three partner universities involved in mining engineering education – University of New South Wales (UNSW), West Australian School of Mines, Curtin University (WASM), and University of Queensland (UQ). The collaboration between these partner universities and industry has led to the development of shared course material, cross-institutional teaching arrangements, and development of a number of flexible, distance-based delivery programs. The paper will then move on to future initiatives. Importantly, the exciting challenge is the future initiative planned to cement this collaboration by the formation of a “virtual” national school of mining engineering – Mining Education Australia (MEA). This will provide a common 3rd and 4th year program to all three universities from 2007, involving innovative teaching and learning arrangements, greater student exchange potential and a more significant input by industry into the education process. Such an initiative is not without its challenges, and has a long way to go, before becoming a reality. However, it offers greater attractiveness and marketing potential to prospective students, as well as economic efficiencies, whilst delivering a better quality, and hopefully greater quantity of graduates to industry. It can also form a launching platform for a much greater level of international collaboration, through a proposed International Mining Education Network (IMEN) which is currently being floated amongst a number of international educators.

Jan 1, 2005

By C. S. Kucukkaragoz

An ilmenite concentrate was reduced in the solid state with carbon under argon atmosphere at temperatures between 1000oC and 1400oC. The ilmenite concentrate and 50% excess carbon were reacted to achieve the highest attainable degree of reduction at each temperature and the reaction products were subjected to a series of analytical work by optical microscopy, X-ray diffraction analysis and SEM ( EDS) analysis. The ilmenite remained unaltered at 1000oC and had a slight change in its composition at 1050oC. A secondary oxide phase containing metallic nuclei was detectable at 12% reduction at 1100oC. The reduction of TixOy took place in a sequence changing the y/x ratio from 2.0 to a value less than 1.0 at 84% reduction at 1400oC. Metallic phase consisted of Fe and C initially and started to include Ti at the later stages. Complete reduction of TixOy to metallic Ti was not possible at these temperatures.

Jan 1, 2005

By Randall M. Wheeler, Kenneth K. Eltschlager

Blasting Seismographs use microphones to measure air overpressure from blasting. The microphone height above the ground has been the object of some controversy. The current ISEE “Field Practice Guidelines for Blasting Seismographs” specify microphone placement within 1.2 inches of the ground or over 3 feet above the ground. In this study, air overpressure measurements were taken at different height intervals and compared. Blasting seismographs constructed to the ISEE “Performance Standards for Blasting Seismographs” were used to monitor construction, quarry, and coal mine blasting. Near and far field measurements were taken to obtain representative spectral and amplitude ranges. The comparative analysis shows that microphone height has negligible impact on air overpressure measurements.1

Jan 1, 2005

By O. Hyvärinen

Outokumpu has developed a new chloride leaching process called HydroCopper®. In this process copper sulfide concentrates are leached at atmospheric pressure in concentrated sodium chloride solution using cupric ions as the oxidant. Copper is recovered from the purified leach solution by precipitating cuprous oxide, which is then reduced to pure copper and further melted and cast directly into copper products. The key reactants: sodium hydroxide, hydrogen and chlorine are generated from the spent sodium chloride using chlor-alkali technology. An important feature in the HydroCopperTM process is that the gold contained in copper concentrates is leached as chloride complexes and recovered from solution by activated carbon. Conditions for the leaching of gold-bearing pyrite can also be achieved in the chloride system by optimizing the redox conditions. This paper deals with the basic factors affecting gold leaching from copper sulfide concentrates. Opportunities for the recovery of refractory gold associated with arsenopyrite and pyrite will also be discussed.

Jan 1, 2005

By Clyde Sitterud

Presentation Agenda ?Global Mining Tire Demand ?What is driving it? ?Latest Situation ?How long it will last? ?Michelin?s Response to Increase Supply ?New plant ?Additional presses ?Recommendations for Mining Users ?Treat tires as your major assets ?Areas of attention that will produce immediate results

Jan 1, 2005