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By C. Samuelsson, G. Carlsson

Characterization of dust from Boliden Mineral AB’s copper-plant in Sweden was carried out using chemical analysis, X-ray diffraction analysis, energy dispersive analysis and wave length analysis using electron microprobe equipment. Dust from four different locations was characterized: the electrostatic precipitator (ESP) after the roasting furnace; the ESP after the copper smelting furnace; from the copper converter ventilation bag house filter; and from the bag house filter collecting dust from the settling furnace and tap gas ventilation. The results showed that the dust is composed of small solid and/or liquid particles from the furnace reactor which have been transported with the process gas to the dust collecting devices. This portion of the dust is mechanically formed. It also contains compounds that have been vaporized in the process and then condensed from the process gas at lower temperature, chemically formed dust. The proportion of mechanical and chemical dust varies with the process generating the dust.

Jan 1, 2001

By B. Weyerman

U. S. Steel's Oak Grove Mine experienced several top hinge failures on their caving shields. It was determined that all the caving shields needed to be replaced with new caving shields before more thilures occurred. The cost and amount of time needed for several scenarios of caving shield change outs were compared. This paper discusses how Oak Grove Mine decided to and did change 126 caving shields in six specially designed jig stations underground during a longwall move using their own UMWA employees.

Jan 1, 2001

In exploiting the ultra-deep, narrow reef ore bodies of the Witwatersrand, the ventilation and cooling systems within the stopes play a critical role because of high concentrations of active workers. This paper examines the heat, ventilation and cooling effects of a number of different stoping layouts for narrow reef mining in ultra-deep operations in very hot rock. The stope ventilation and cooling needs are driven primarily by the difference between the air temperature and that of the rock front being excavated. These needs depend on the face utilization, geometry, face advance (rate and direction), layout, backfill, use of water and machinery1,2,3. Detailed studies of different stoping configurations have been undertaken for mining operations extending to depths of 5000m below surface, where virgin rock temperatures approach 70°C. Extensive work has been completed with regard to evaluating ventilation and cooling requirements to maintain air reject temperatures of 28°C wet-bulb and better. This knowledge is being used to determine overall cooling requirements, reduce operational costs and maximize the efficiency of cooling systems. These issues are important when considering both the local and regional air conditioning systems and the most effective application of in-stope chilled water.

Jan 1, 2001

"Many industrial processes involve materials that are subject to temperature change and thermal stress. Examples range from the casting of large metallic products to the cooling and reliability of small electronic components. Thermally induced stress is a major concern as it can lead to material damage and product failure. Material properties, thermal and mechanical, and process conditions such as the size and location of a feeder in metals casting, or the power dissipation in a computer chip, will govern the magnitude of these stresses. Temperature may also be influenced by fluid flow, for example, the airflow over a computer chip in a laptop will govern the rate of heat extraction, hence the temperature gradients in the chip and the evolving thermal stresses.This paper provides details on the governing equations for heat transfer (temperature) and solid mechanics (stress), their degree of coupling, and the numerical techniques used to solve them. Three examples are discussed to illustrate the use thermomechanical modelling. These also provide an insight into the degree of coupling required between the equations. The first example, involves thermal cycling of electronic components where a prescribed temperature field is applied. As temperature is known, this example only requires the solution of the stress equation. The second example also involves the modelling of an electronic component where the temperature field is also calculated. In both of these examples, the stress calculation is dependent on the temperature field, but the temperature calculation is not dependent of the solution of the stress equation (one-way coupling). The final example provides details on modelling the metals casting process. Both the temperature and stress equations are solved but, unlike the previous two examples, in this case the temperature field is dependent on the results from the stress calculation (two-way coupling)."

Jan 1, 2001

By F. W. H. Dean

A very sensitive sensor for the detection and measurement of hydrogen in solid steel is described. This technique is non-invasive and uses a collector to sweep the hydrogen emanating from a steel surface and feed to it sensor. This method is particularly sensitive, resolving fluxes to < 2 pI cm?2 S?I, with a linear measurement up to 1000 pI cm&apos;2 S?I, The collector is held on the steel substrate by magnets and it is shown that emanation of hydrogen from the steel is controlled by bulk diffusion of the hydrogen through the steel. The technique is demonstrated to have an excellent response time and reproducibility.

Jan 1, 2001

By Gordon Revey

The challenge of managing blasting risk, types of risk, public perception, and a system for managing risk were covered in the first part of this article in the May/June 2000 issue of the Journal of Explosives Engineering. This final part of this two-part series provides a method for identifying specific blasting risks and reviews the importance of community relations.

Jan 1, 2001

By S. Lähteenmäki, P. Koivistoinen, J. Levanaho

Semi Autogenous Grinding (SAG) circuit is the most common grinding circuit to day. In Europe and South Africa fully autogenous (AG) circuits are also popular. SAG circuit has a lower capital cost and simple operation. SAG circuit requires the use of grinding balls, which increases operating costs and decreases availability. An AG circuit may produce a higher Net Present Value to the investment. The AG circuit is more complex to design and operate. However, operating experience from AG circuits illustrates that an AG circuit can be as trouble free as a SAG circuit with the benefit of lower operating cost.

Jan 1, 2001

By Chris Larsen, Ian Orford, Mike Cooper

"An autogenous grinding circuit was commissioned at the Brunswick concentrator in October 1998. The autogenous grinding circuit replaced existing surface crushing plants, fine ore storage, rod and primary ball mills. The 8.54m diameter x 4.27m long (EGL) AN1 mill is driven by a bidirectional variable speed 6.3MW ABB wound rotor motor with Slip Energy Recovery (SER) drive. The AG mill was subsequently converted to SAG operation in May 1999 for a number of reasons. The mill is operated in closed circuit with horizontally inclined 660mm diameter cyclones to produce a circuit product P80 of 85 microns. Extensive test work and JKSimMet design modeling resulted in a production circuit operating closely within design expectations.The circuit is highly instrumented and controlled via a hybrid Programmable Logic Controller (PLC-5) and Fisher PROVOX Distributed Control System (DCS) that is in communication with the property information highway. An expert control system (Gensym G2) is used for control of the SAG mill load.Engineering and construction were completed in 28 months from the time of management approval for the project. The Brunswick AG/SAG mill circuit was commissioned on schedule at the $M 23.5 forecast budget."

Jan 1, 2001

David Wolach RMCI PRESIDENT 2001-2002 on behalf of the RMCMI Board of Directors and Officers of The Rocky Mountain Coal Mining Institute cordially invites you and your family to attend the 98th Regular Meeting and Convention to be held June 30 thru July 2, 2002 Breckenridge, Colorado

Jan 1, 2001

By Raymond Chenier

British Columbia (BC) is Canada’s most western province. The landscape in BC is amongst the most beautiful and pristine in the world. Along with its beauty come vast mountain ranges, coastal rain forests, swamplands, deep river valleys, and almost every type of landscape imaginable. These all have, or at one time had, logging roads constructed. Some of these areas should never have had roads constructed due to poor drainage and unstable slopes, but some of the roads could be considered engineering masterpieces. To navigate a vehicle the size of an off-road logging truck down the side of a mountain with an 80°h side slope or greater can be a hair-raising experience. Not to mention coastal rains and/or high elevation blizzards. These factors collectively make logging BC’s most hazardous occupation. People are seriously hurt, sometimes even killed everyday.

Jan 1, 2001

By Lindsay Wade, Peter Dare-Bryan

Benches in surface mines often contain known areas of ore and known areas of waste, which must be mined selectively. When rock is blasted it not only fragments but is also physically, and non-uniformly, moved. Risks therefore exist of ore being lost if treated as waste and of mill feed being diluted by waste. Both possibilities carry serious fmancial implications.

Jan 1, 2001

By D N. B Skinner, R L. Brathwaite, M S. Rattenbury

The Institute of Geological and Nuclear Sciences Ltd has carried out a mineral resource assessment of the Coromandel region, one of the most mineral-rich regions of New Zealand. The assessment focussed on metallic minerals and clays, because these are the main commodities that have potential for increased production and export from the region (and from New Zealand). &nbsp; Three steps were used in the assessment: 1) development of mineral deposit models, 2) comparison of the models with regional geology, structure, geochemistry and past mineral production to estimate the number of undiscovered mineral deposits, and 3) application of grade-tonnage models to determine the quantity and value of the known and undiscovered resources. In step 1, descriptive and grade-tonnage mineral deposit models were developed for 11 different types of mineral deposits: ò&nbsp;&nbsp;&nbsp;&nbsp; Low-sulphidation andesite-hosted epithermal Au-Ag ò&nbsp;&nbsp;&nbsp;&nbsp; Low-sulphidation rhyolite-hosted epithermal Au-Ag ò &nbsp;&nbsp;&nbsp; High-sulphidation quartz-alunite epithermal Au ò &nbsp;&nbsp;&nbsp; Porphyry Cu-Au-Mo ò &nbsp;&nbsp;&nbsp; Andesite-hosted polymetallic veins adjacent to mineralised porphyry stocks ò &nbsp;&nbsp;&nbsp; Zn-Pb-Ag skarn ò &nbsp;&nbsp;&nbsp; Cu-Ag skarn ò &nbsp;&nbsp;&nbsp; Hot spring Hg ò &nbsp;&nbsp;&nbsp; Shoreline placer Ti ò &nbsp;&nbsp;&nbsp; Rhyolite-hosted halloysite clay ò &nbsp;&nbsp;&nbsp; Volcanic-related kaolinite clay &nbsp; Step 2 was aided by a geographic information system (GIS) assembled from a number of digital spatial data sets including: a digital elevation model, an aeromagnetic map (from open file mining company data), a geological map (from the GNS QMAP project), location of areas of hydrothermal alteration, locations of mineral deposits (from the GERM database), stream sediment geochemical analyses (from the REGCHEM database), and a lineament map derived from satellite remote sensing data and the digital elevation model. &nbsp; Based on May 2001 commodity prices, potential resources estimated for the 11 mineral deposit and grade-tonnage models total NZ$22 806 million for the metallic minerals, NZ$1000 million for halloysite clay deposits and NZ$57 million for kaolinite clay deposits.

Jan 1, 2001

By Richard W. Hanford

The geotechnical construction industry generally considers soil mixing to be defined as an in situ ground improvement or treatment method by which a dry or wet reagent is introduced into the ground and is blended with the soil by mechanical or rotary mixing tools. This results in relatively homogenous mixtures whose engineering properties are improved and are greater than the soil properties before mixing. Reagents usually include cement, but may also include processed clay such as bentonite, when a reduction in hydraulic conductivity is desired, or other proprietary chemicals when chemical stabilization is the objective. Mixing may be either shallow or deep. Shallow Mixing is the term arbitrarily used for treatment of soils within the upper 30 feet; Deep Mixing denotes treatment below 30 feet to the depth limits of the equipment. Mixing equipment may consist of single or multiple-shaft tools having cutting and mixing blades of many different configurations. To avoid using proprietary nomenclature, reference to Shallow Mixing Methods (SMM) and Deep Mixing Methods (DMM) are the preferred terms. Although originally developed and patented in the United States in 1956, in situ construction using various soil mixing methods is more prevalent in Japan and the Scandinavian countries. Reintroduced into the United States from Japan in 1986 for ground improvement and liquefaction mitigation at Jackson Lake Dam, Wyoming, acceptance of soil mixing methods has been gradual but slow. Applications typically include:

Jan 1, 2001

This paper examines the complex interplay of deposit characteristics, mining plans, tailings disposal techniques and rehabilitation requirements on planning for mineral sands operations. All component parts of this mining cycle are interdependent and cannot be evaluated in isolation when optimising a mineral sands operation. This is most evident when projects are large-scale or involve resources that contain complexities such as high slimes content, consolidated hard band materials, acid forming materials and radioactive materials. Projects located in environmentally sensitive areas add further to the need for more stringent planning. This paper describes the analysis techniques adopted by Hatch to evaluate mining and tailings placement options for a dredging and floating concentrator system. The principles and methods used in the analysis are applicable to any mining system involving the complexities listed above. The focus of this paper is on the reconstitution of mined material as tailings and the impact of this process on mining schedules and tailings construction and placement options.

Jan 1, 2001

By Akira Kaneda

Mitsubishi continuous process employs an electric furnace for settling matte from slag. Electrodes are immersed into the slag layer in the slag-cleaning furnace and the temperature of the melt is maintained at a predetermined level by Joule&apos;s heat. Electrodes are immersed to the depth where the current of each electrode is kept at a set value, and they are raised or lowered automatically to compensate for the deviation from it. Because electric resistance of the bath is varied with the matte level in the furnace and the composition and temperature of the slag, the immersion depth of the electrodes is affected by them. Therefore by monitoring the immersion depth and its change with time, abnormal situations in the furnace, such a~ rise of matte level or local abnormal state of melt, can be detected. In this paper, relations between state of the furnace and electrode behavior are discussed based on the plant data, and then a new and simple monitoring method of the condition of the furnace is proposed.

Jan 1, 2001

By M. Irish, M. Jahraus

Accurate prediction of gold (or other metal) production from a heap leach operation is essential to the economic vitality of any such operation. However, this is also one of the most challenging issues facing managers of these facilities. Three approaches to modeling gold production from the Valley Leach Facility (VLF) at Anglogold’s Cripple Creek & Victor Gold Mining Company are presented. Evolution of these modeling methods has been necessary as ore heights and volumes have increased. In addition, the complex geometry of the VLF presents additional complications to production modeling, Comparison of actual and predicted gold production are presented

Jan 1, 2001

By Donald Leroux, Ralph Dahlke, Dave Scott, Finch. James A., Cesar O. Gomez

"The efficiency of the flotation process depends on how effectively air is dispersed into small bubbles. Bubble surface area flux - the surface area of bubbles per unit time per unit cross-section area of a cell - is emerging as the parameter to characterize gas dispersion. One of the approaches proposed to measure bubble surface area flux in industrial cells is based on the measurement of two variables: gas velocity and gas holdup, using separate sensors. Plant testing of the gas velocity sensor gave evidence of a series of operational problems which may be necessary to correct before attempting to characterize gas dispersion. Problems such as uneven air distribution within a cell and along a bank, faulty air and slurry valves detected during attempts to redistribute air, and poor control of pulp level and gas flow became evident. Detection of these problems from gas velocity measurements is illustrated.INTRODUCTIONBubble surface area flux is considered a key variable in the optimization of flotation circuit performance (Gorain et al., 1997; 1998). The Mineral Processing Group at McGill University has devised and developed a method for estimating bubble surface area flux in industrial flotation cells (Finch et al., 1999). The method is based on measuring gas holdup and superficial gas velocity using two separate sensors and applying drift flux analysis to estimate bubble size (Dobby et al., 1988; Banisi and Finch, 1994). With bubble size and superficial gas velocity known bubble surface area flux can be calculated.This method was selected by Noranda to characterize gas dispersion in cells as part of a program to model and optimize flotation circuit performance. However, initial testing at Brunswick Mine with the gas velocity sensor provided some unexpected results indicating operational problems and equipment malfunctions that needed to be addressed before systematic measurement of gas dispersion could be initiated.The subject of this communication is to illustrate the detection of these problems from gas velocity measurements. The line 3 Zn Cleaner circuit comprising four stages of Denver DR cells was the main subject of analysis, including the effect of correcting these problems on the metallurgical performance of the Zn 3rd cleaner bank of ten DRl 00 cells."

Jan 1, 2001

By M. El Ganaoui, P. Bontoux

"A computational model to investigate solid/liquid phase change transitions for binary alloy under directional solidification is presented. Conservation equations are developed by using an homogeneous formulation. A second order accuracy method of time and space based on finite volume approximation has been evaluated by comparing results to spectral solution for time-dependent solutal convection developping in a melted alloy. For extended model to solid/liquid interface effects time amplification of solutal perturbation injected near the interface is described before considering solutal convection is melt.IntroductionThe enthalpy method gives a front fixing approach for energy equation without introducing coordinate transformation. The interfare position is recovered a posteriori [1]. A number of authors have extended this approach so as to include the convection phenomena within the two phase 'mushy region' [2, 3, 4, 5, 6].We have developed a time-dependent enthalpy-porosity formulation for directional solidification [4, 6, 8]. The interaction between solid and liquid phases is modelised by a Darcien type force in the phase change area. The behaviour of the melt is similar with the flow of an incompressible fluid in a porous medium. This force is proportional to the relative phase velocity. It corresponds to a damping force depending on the anisotropic permeability of the 'mushy zone'. The permeability depends on the liquid fraction and on the size of·solidification microstructures. An informative discussion of a new slant on the general approach of continuum mechanics needed to analyze the formation of mushy zone is given in [12]. The method is extended to the presence of species diffusion: the solutal Stefan condition which expresses the solute incorporation or rejection across the interface is accounted implicitly in a species equation valid in all the domain [14, 15]."

Jan 1, 2001

By Vaughan R. Voller

"Numerical methods for dealing with a temperature dependent conductivity are discussed. An approach based on a local application of a Kirchhoff transformation at the discrete level is presented. The application of this transformation - that does not require any inversion- is demonstrated on solving a two-dimensional test problem.IntroductionMuch is said in the recent literature on the modeling necessity of obtaining appropriate thermo-physical properties; in particular the requirement to account for properties that are ""strong"" functions of the depended variables, e.g., Temperature. Of course obtaining appropriate thermo-physical properties serves no purpose unless they can be accurately integrated into a discrete numerical calculation. The purpose of this paper is to examine how temperature dependent conductivities that exhibit discontinuities or rapid changes can be handled in a numerical code.The discussion will be made in the context of a control volume finite element method [1]. After a brief outline of control volume finite element fundamentals basic methods of dealing with discontinuous or rapidly changing thermal conductivity are discussed. This is followed by the presentation of the recently proposed local Kirchhoff method [2,3], The paper concludes with an investigation of the performance of the various conductivity schemes in solving two dimensional problems. This testing clearly shows the advantages (accuracy and implementation) in using the local Kirchhoff method."

Jan 1, 2001

By Lawrie Logan, Mike Wiggin

This paper will be in two parts, a discussion of the benefits available from benefit sharing as a concept followed by an examination of how this approach was applied at Mesa J Mine and what improvements were made. The first part is an outline of the ways that both parties in a benefit sharing agreement can uncover additional wealth by bringing a new approach to the relationships between mine and supplier. The paper describes a partnering agreement recently established between Robe River Iron Associates (RRIA) and Dyno Nobel Asia Pacific Ltd (DNAP) to access the wealth locked up by the usual explosives supply contracts in Australia and elsewhere. The partners are acting cooperatively to maximise the benefits to both parties from optimising blasting practices at the Mesa J Iron Ore Mine in the Pilbara region of Western Australia.

Jan 1, 2001