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By Matthew E. MacGregor, Hugh T. Kelly

I.H. 635 (LBJ Freeway) was constructed as a loop freeway around the city of Dallas in the late 1960s and early 1970s with a design capacity of 160,000 vehicles per day (vpd). Today’s facility is carrying over 270,000 vpd. To help mitigate community concerns with regard to right-of-way issues, noise, safety, and traffic disruption, the Texas Department of Transportation (TxDOT) is planning a number of significant improvements. The West Section improvements include the construction of managed HOV/Toll lanes. Within this 8-mile section, TxDOT is planning two mined tunnels(1.5 and 1.9 miles long) beneath the LBJ Freeway. The mined tunnels will connect to cut-and-cover box sections in both the east and west directions. This paper presents an overview of the project development from the design schematic, through the geotechnical investigations, into the current design stage. The project is being planned for implementation by use of a Comprehensive Development Agreement.

Jan 1, 2005

By Douglas Banks

Construction for the new 2.5 MGPD raw water intake project commenced December 2002. The project, initially designed as a 12' Ø concrete lined intake shaft,145' deep, with two offset 24" lake taps, 520' and 470' long was subsequently “value engineered” running the two lake taps through a single conduit. The offset for summer and winter pools was accomplished via a second shaft located at the lakes edge. Construction involved the use of blind drilling techniques for the shaft development and drill and blast techniques for the tunneling. All works were completed through extremely hard crystallized sandstone. The project came online August 12, 2004.

Jan 1, 2005

By Frank Cappuccitti, James A. Finch, Stéphanie Gélinas

"A colorimetric technique, originally developed for methyl iso butyl carbinol (MIBC) based on the Komarowsky reaction, has been extended to a wide range of common mineral flotation frothers. The procedure, which is briefly described, is shown suited to on-site determinations in a campaign at Kennecott Utah Copper Copperton Concentrator (Rio Tinto). Some observations are described, including: frother (MIBC) concentration evolution down a bank, frother distribution between pulp and froth phases, and loss of frother over time due to adsorption on certain minerals. A possible interference with a fuel oil addition was overcome. MIBC in recycle water was also measured.The ability to monitor frother easily will help interpret gas dispersion behaviour and should permit further optimization of flotation cell hydrodynamics and chemistry. The capability to directly measure should help optimize the type, amount and location of frother addition, and to assess frother recycled with reclaim process water.INTRODUCTIONOwing to the lack of analytical methods, the task of determining frother concentration in plant flotation circuits is not routinely performed. Industrial sites seldom outsource analyses that are both costly and inconvenient, due to the necessity of shipping freeze-dried samples to remote testing facilities. A more direct colorimetric method has recently been demonstrated for the laboratory characterization of common industrial frothers (Gélinas and Finch, 2004). The approach, based on the Komarowsky reaction (Penniman et al., 1936; Coles et al., 1942; Duke, 1947), was previously described by Parkhomovski et al. (1976) for methyl iso butyl carbinol (MIBC). The reaction involves the interaction of the OH group of a higher alcohol, concentrated sulphuric acid, and salicylaldehyde, to yield coloured solutions with intensities that can be analyzed by UV-visible spectrophotometry."

Jan 1, 2005

By R. L. Virta

Six companies mined fire clay in Missouri and Ohio during 2004. Production, based on a preliminary survey of the fire clay industry, was estimated to be 398 kt(438,700 st), valued at $9.81 million. This was slightly less than the production and value figures from 2003. Missouri was the leading producer state. It accounted for more than 70 percent of the U.S. production. Consumption Domestic producers sold or used fire clay primarily for refractory applications. This application accounted for 79 percent of the market. Refractory products made using fire clay include firebrick and block, grogs, high-alumina brick and specialties, refractory mortars and mixes, and saggers.

Jan 1, 2005

Konkola No 3 shaft experienced severe mining-induced stress and time-related deterioration in ground conditions in an area where an over-cut and bench (OCB) mining method was used to extract a shallow dipping wide orebody. This caused an unacceptable risk for safe mining operations to sustain the required levels of production. After a review of the conditions it was decided to change the mining method to CASCADE to recover ore in the affected area and modify the OCB method and use a modified over-cut and bench method (MOCB) for new mining sections. This paper describes the geotechnical criteria included to derive the mining standards for the MOCB. The geotechnical risks are identified and taken into account to develop stope design parameters, stoping sequences and support requirements. A monitoring programme to assess conditions as mining progresses is also discussed.

Jan 1, 2005

By S. Felderhof, W. S. Vaughan

"Over the years, it has been increasingly difficult for the minerals industry to raise the necessary capital for its activities. To alleviate this phenomenon, complete transparency and capital market efficiency is needed. Since a company’s mineral resources and mineral reserves base is an essential component to obtaining capital, reporting these assets must also be transparent and efficient. This must occur, however, at an international level given that mineral industry operations, and its financing, are international. To achieve this, an international committee (i.e. Australia, Canada, South Africa, the United Kingdom and Europe, and the United States) was formed and has been developing standards for the reporting of mineral resources and mineral reserves.The effectiveness of these standards, however, depends on adoption by the required regulators. Unfortunately, these standards have not been recognized by the U.S. Securities and Exchange Commission (SEC). Instead, the SEC adheres to its old standard (Industry Guide 7), making it increasingly expensive and difficult for international mining companies to obtain capital in the United States. Compounding the problem is the SEC’s influence over the current work of the International Accounting Standards Board and the International Organization Organization of Securities Commissions. These organizations are in the process of standardizing international accounting practices and international securities rules and regulations. Their current position may prevent adoption of the industry-developed mineral resources and mineral reserves standards which are internationally recognized."

Jan 1, 2005

By S W. Robertson, A Vercuil, P Craven

Mintek is currently developing a design approach for the heap leaching of low-grade primary copper sulphide material. Since the leaching of chalcopyrite requires elevated temperatures, the generation and management of heat within the heap is crucial. Furthermore, the precipitation of iron needs to be managed to prevent premature blinding of the heap, and acid consumption needs to be limited to contain cost and limit the dissolution of gangue impurities. Standard column tests using jacketed 1-m and/or 6-m columns do not allow accurate prediction of temperature changes and heat generation in an actual heap. Mintek therefore utilizes a computer model to calculate the energy balance and heat generation with time, based on the measured sulphide oxidation rates in the column. The temperature in the column is then adjusted to reflect the computer-predicted temperature in an actual heap. Using this approach, an overall copper extraction of 70% was achieved in 120 days, using 1-metre columns, when treating an ore blend containing 1.36% chalcopyrite, 0.23% chalcocite, 0.07% covellite, 3.8% pyrite and silicate gangue (92%). The chalcopyrite contribution to the total copper content in the feed was 75%. This was followed by 6-m columns using a similar approach, and the column results will be validated on a 23,000 tonne test heap. Key Words: heap; bioleach; chalcopyrite

Jan 1, 2005

By A. M. Milev

A stand-alone instrument especially designed for recording strong ground motions was used in this study to create a large data base of peak particle velocities measured on stope hangingwalls. A total number of 58 sites located in stopes mining the Carbon Leader Reef, Ventersdorp Contact Reef, Vaal Reef and Basal Reef were monitored. The peak particle velocities were measured at the surface of the excavations to identify the effect of the free surface and the fractures surrounding the underground mining. From the monitoring results obtained, the velocity criterion of 3 m/s will bean adequate value that support systems have to sustain during a rockburst in most cases. However, PPVs in excess of this criterion were recorded, and some PVDs were damaged or irretrieveable, a consequence of which was that possible extreme events were not recorded. The data recorded on the skin of the excavations were compared to the data recorded by the mine seismic networks to determine the site response, defined as the ratio of the measured peak ground velocity to the peak ground velocity inferred from the mine seismic data. The site response measured at all mines studied was found to be 9 ±3 times on average. Values of the site response did not vary significantly with seismological parameters such as peak ground velocity, hypocentral distance and source radius.

Jan 1, 2005

Lime production is the largest single chemical use for limestone and dolomite. The term “lime” in this review refers to high-calcium and dolomitic quicklime, their hydroxide forms and dead-burned dolomite. This review is restricted to a discussion of the U.S. lime industry. Production and consumption In 2004, according to preliminary data, U.S. lime production was about 20.1 Mt (22.1 million st), an increase of 900 kt (990,000 st) compared with 2003. Production in2004 was valued at about $1.4 billion. Commercial sales of lime totaled 18.6 Mt (20.5 million st) and captive production was 1.5 Mt (1.65 million st). Total U.S. consumption was about 20.2 Mt (22.2 million st). The majority of U.S. lime trade was with Canada.

Jan 1, 2005

By A. H. Swart

Rock engineering is concerned with the design of rock structures generated by mining activities. Therefore, rock engineering designs have major implications for the safe recovery of mineral deposits and operating costs. The paper deals with a few challenges facing rock mechanics engineers operating in the hard rock underground mining environment in South Africa. Finally, examples are included, which may assist rock mechanics engineers in providing better designs, which could ultimately lead to further improvement in safety and lower operating costs.

Jan 1, 2005

By T C. Westerfield, G, M J. Mankosa

An innovative separator known as the HydroFloat cell has been developed specifically for the upgrading of coarse particles that are difficult to recover using conventional flotation cells. The novel characteristic of this separator is the formation of a hindered teeter-bed of fluidised solids into which small air bubbles are injected. The air bubbles selectively attach to hydrophobic particles and form particle/bubble agglomerates that segregate atop the teeter-bed due to their lower apparent specific gravity. The low-density agglomerates are eventually carried into the product overflow launder by the rising current of teeter water. Hydrophilic particles remain in the teeter-bed and are discharged to underflow as a high solids content tailing. Benefits of this hybrid flotation-density separator include enhanced bubble-particle contacting, increased particle residence time, and very low air demand. Test data indicate that significant improvements in the recovery of coarse particles can be achieved using this innovative technology. This article describes the theoretical basis for the development of the HydroFloat cell and provides an overview of recent pilot-scale tests conducted for the phosphate industry.

Jan 1, 2005

By Zhan Jing

Keywords: thermodynamic, Ni-Co alloy powders, composition, fibrous The mathematics model of Ni(II)-Co(II)-C2O42?-NH3?H2O-H2O of thermodynamic equilibrium system has been developed theoretically according to the law of conservation of mass and the law of simultaneous equilibrium, and the logarithm concentration-pH (log[Me2+]T-pH) diagrams of this system have been made. The effect of ligand and pH value was studied. Two issues in coprecipitation route to synthesize fibrous nickel-cobalt alloy precursor powder, com-position and morphology which are a first priority, are addressed based on thermodynamic analysis and experiments. The results show that suitable pH value range of coprecipitation of nickel ions and cobalt ions in theory can be obtained to maintain fibrous, excellent compositonal homogeneity and stoichiometry in coprecipitation products. Experimental demonstration is also carried out.

Jan 1, 2005

By K. B. Hodgins, P. Ouellette

"The North American mining industry faces challenging emissions regulations in the coming years with the introduction of new standards for off-road diesel engines. In order to remain competitive, industry stakeholders must invest in new technologies that are economically and environmentally sustainable.Westport Innovations Inc., Vancouver,British Columbia, has developed high-pressure direct injection (HPDI) technology that allows diesel engines to run primarily on natural gas with no intrusive engine modifications while reducing emissions of nitrous oxides (NOx), particulate matter (PM), and CO2 with no loss in performance. This is accomplished through late-cycle, high-pressure direct injection of natural gas into a diesel engine combustion chamber at the end of the compression stroke. A small amount of diesel fuel is injected first to initiate combustion, followed by the natural gas fuel main injection. The diesel cycle and its operating characteristics are fully retained including high combustion efficiency, lowspeed torque, high-power output, no engine knock, and fast response to load changes. Natural gas has not been an attractive fuel alternative in mining operations due to the reduced performance associated with spark ignition engines and the added weight and space required for compressed natural gas tanks. However, liquefied natural gas (LNG) can be stored with less impact on weight and space than compressed natural gas (CNG) by virtue of its increased energy density over CNG.Westport has applied HPDI technology to the Cummins QSK series engines for high horsepower applications such as power generation and mine haul trucking. HPDI can also be applied to other engine manufacturer platforms and market applications. Westport is interested in demonstrating the unique characteristics of HPDI in mine haul trucks to show diesel performance with low emissions levels using low-cost LNG fuel.Retrofitting a Tier 1 engine with HPDI would provide emissions reductions below the EPA 2006 Tier 2 standards while maintaining the performance and efficiency of the Tier 1 platform. The longer-term target is the Blue Sky voluntary standards of 3.8 g/kW-hr (2.8 g/bhphr) of NOx + non-methane hydrocarbons (NMHC), and 0.12 g/kW-hr (0.09 g/bhp-hr) of particulate matter (PM) and future standards. Typically, an HPDI engine is capable of reducing NOx emissions by 40% over diesel operation at the same efficiency. On a mining truck meeting Tier 2 standards, this NOx reduction would translate into NOx emissions approximately 14 t per year lower than under diesel operation. PM emissions are typically reduced by some 60% with HPDI fueling, which would translate into a yearly reduction of 650 kg. Similarly, engine-out greenhouse gas (GHG) emissions are reduced by 21%, resulting in a yearly reduction of approximately 950 t per vehicle.Above those of emissions reduction, efficient natural gas usage in mine haul operations would offer significant benefits in terms of fuel cost savings, which may be further combined with monetary emission credits. HPDI technology would enable operators to exercise environmental stewardship while gaining a competitive advantage in advance of new Tier 2 and Tier 3 emissions regulations. The advantages of natural gas use among mine haul truck operations can be replicated across a broad range of engines and applications."

Jan 1, 2005

By Mikko Ruonala, Pertti Lamberg, Olli Hyvärinen

The smelting of copper sulphide concentrate is the dominant route in copper production (Figure 1). Heap leaching of oxidized copper ores with weak sulphuric acid together with copper solvent extraction and electrowinning has gained popularity during recent decades, and it accounts for close to 20 % of primary copper production. Heap leaching offers advantages such as lower costs and consequently the construction of a production plant at a mine site is made possible. Limited resources of oxidized copper ores, the long leaching time of chalcopyrite and inability to recover gold inhibit this growth. The HydroCopperTM process developed by Outokumpu Technology at the laboratories of Outokumpu Research, Pori, Finland, is a new chloride leaching technology /1,2/, which offers an alternative to smelting and heap leaching (Figure 1). In the HydroCopperTM process sulphidic concentrates with various mineralogy and grade can be treated at the mine site to produce high-quality copper. Instead of copper cathodes the HydroCopperTM end products are copper wire rod, copper bars or copper billets. One of the advantages of HydroCopperTM technology is that gold can also be recovered in the process simultaneously /3/. To confirm the functioning of the new process and to dimension equipment Outokumpu Technology built the HydroCopperTM demonstration plant in Pori, Finland /4/. It has a capacity of 1 metric ton of copper per day. After testing with Pyhäsalmi copper concentrate in 2003, the first commercial demonstration run with Erdenet copper concentrate took place in 2004.

Jan 1, 2005

By T. Rasmussen, T. G. Jørgensen, T. Fischer, R. K. McLimans, C. Knudsen, D. Frei

Ilmenite-bearing paleo-beach deposits were discovered in Jylland, Denmark using a combination of Ground Penetrating Radar (GPR), portable X-ray fluorescence (XMET), bulk XRF analyses, Computer Controlled Scanning Electron Microscopy (CCSEM), and wire line logging. The Miocene-age paleo-beach deposits are located below a thin Quaternary cover in a region of very moderate relief and essentially no outcrop demanding unique approaches in exploration. Initially, an isopach map of the Quaternary is prepared from existing water well data. A geological model for likely occurrence of Miocene paleo-beach deposits is generated and the coincidence of thin Quaternary cover and potential paleo-beach deposits define targets for detailed exploration. The defined targets are traversed with GPR to identify paleo-beach structures which are then used to define a drilling program. This methodology located a paleo-barrier island at the Vorslunde location with more than 10% ilmenite in the sand. During the drilling process, the TiO2 and heavy mineral contents of the sand were logged every meter with a portable XRF unit (XMET) and subsequently calibrated more accurately by comparison to bulk XRF and CCSEM analyses for selected samples. The bulk XRF data also provided more complete compositional information. Insitu determination of geology, heavy mineral abundance, and corroboration of the XRF logging was done using wire line logs, a combination of spectral gamma and induction conductivity logs. Detailed characteristics (abundance, grain size, shape) and chemical composition of minerals was determined by the GEUS CCSEM methodology (Frei et al, this vol.). The average weight percent TiO2 for all Ti-minerals is 62%, 60% excluding rutile. That elevated TiO2 content (>> ilmenite stoichiometric value, ca. 50 %) indicates that ilmenite experienced an iron-leaching environment. The source of the sand deposit was investigated by dating contained zircon. The results show that the likely sources of zircon are in southern Norway and southwestern Sweden with common zircon ages of ca 1100 Ma. and 1500 Ma.

Jan 1, 2005

By Ji-He Wei

Keywords: stainless steel, AOD refining, side and top combined blowing, mixing characteristics, water modeling The fluid mixing characteristics in the bath during the side and top combined blowing AOD (argon-oxygen decarburization) refining process of stainless steel have preliminarily been studied on a water model unit of a 120 t AOD converter. The geometric similarity ratio between the model and its prototype (including the side tuyeres and the top lances) was 1:4. On the basis of the theoretical calculations for the parameters of the gas streams in the side tuyeres and the top lances, the gas blowing rates used for the model have more reasonably been determined. The influence of the tuyere number and position arrangement, and the gas flow rates for side and top blowing on the characteristics has been examined. The results demonstrated that the liquid in the bath underwent vigorous circulatory motion during gas blowing, without obvious dead zone in the bath, resulting in a well mixing effectiveness. The gas flow rate of the main tuyere had a governing role on the characteristics, a suitable increase in the gas flow rate of the subtuyere could improve mixing efficiency, and the gas jet from top lance could make the mixing time prolong. Corresponding to the oxygen top blowing rate specified by the technology, a roughly equivalent and good mixing effectiveness could be reached by using six side tuyeres with an angle of 27° between each tuyere, and five side tuyeres with an angular separation of 22.5° or 27° between each tuyere. The relationships of the mixing time with the gas blowing rates of main-tuyeres and sub-tuyeres and top lance, the angle between each tuyere, and the tuyere number have been obtained.

Jan 1, 2005

By Bob King

Jan 1, 2005

By A. Nivala, S. Ulgiati, M. Canino

Mining and processing of bastnaesite ore, (Ln)CO3F, for lanthanides extraction is investigated in this paper. This series of elements proved to be applicable for a wide range of high-tech uses. In spite of the strategic importance of lanthanides, no LCA and energy analyses of their extraction have ever been published. We perform in this paper a Life Cycle Assessment of the Lanthanide production cycle, based on available database and literature data from Mountain Pass mine (USA) and other worldwide mining and processing sites, most of which in China. We investigated three main steps: mining, milling (including transport, grinding and drying), and flotation (for lanthanide chloride extraction). We do not investigate here the separation of pure oxides from lanthanide chloride, a compound which is also marketed as such. The conventional LCA was integrated by means of energy and emergy evaluations, aimed at investigating respectively the global energy cost and the environmental sustainability of the process. Indicators of material intensity, thermodynamic efficiency, and environmental impact (including LCA and ecological footprint impact categories) are calculated and discussed.

Jan 1, 2005

By P. M. Soupios

A near geophysical surface investigation of a landfill area close to the Hania city, in Crete Island, Greece, was conducted as inextricable phase of a preliminary geotechnical, geological and hydrogeological study of the area under investigation. Electrical Resistivity Tomography (ERT), one of the most promising prospecting techniques mainly concerning its effective contribution to resolve several environmental problems, was applied for the geophysical modelling. ERT is a robust imaging method the theory and implementation of which are well documented in geophysical research literature. The survey site is located in Akrotirion Peninsula, about 7km east of Hania city in Crete I. The geological setting comprises Trypalion limestones, marly limestones and a clayed weathered layer. Cavities are also identified at various scales which are recent tectono-karstic voids resulted from the combined actions of karstic erosion and tectonic stress on the Trypalion limestones where they are located. Due to the above-mentioned geological singularity and in the light of the requirement for an environmentally safe construction of the landfill, an ERT survey was carried out by deploying the dipole?dipole electrode configuration. Specifically, seven geoelectrical tomographies were conducted reaching the prospecting depth of 36m. The resulted images conduced, a) to overcome geotechnical problems, b) to plan the future sites for waste disposal and c) to reliably estimate the thickness of the already deposited wastes.

Jan 1, 2005

By Peter Shuttleworth, Chris Fesq, Eddie Woods

Precast concrete segmental linings for tunnels have traditionally been designed with conventional steel bar reinforcement. In many cases, this has been satisfactory in service, but in others, major problems have occurred with the durability of the linings. Commonly this has resulted from corrosion of the reinforcement, mainly from chloridesin ground water, causing spalling of the concrete and leading to very expensive and disruptive repair programs. This paper discusses the relative merits of designing tunnel linings with steel fiber reinforcement to provide long-term durability, improved impact resistance and toughness for greater load capacity across joints, enhanced robustness during transportation and erection, plus improved fire resistance with the addition of polypropylene fibers. Guidance is also given in the selection of the correct fiber type, mix design and testing methods to establish the optimum dosage required and production techniques to ensure even distribution and compaction.

Jan 1, 2005