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By Donald Leroux, Lori Lynn Smith, Robert Hutchison

"The grinding circuit of the Heath Steele concentrator was sampled under five different sets of operating conditions. The balanced results of the sampling campaigns were used to calibrate steady-state rod mill, ball mill and cyclone models using a commercial simulation software package (JKSimMet® ). Thirteen process variables had the potential to affect significantly the performance of the grinding circuit. Statistical-Design-of- Experiments techniques were applied to plan the suite of simulations in order to improve the quality of and minimize the time to find the optimal solution. The effect of each factor on three performance indices (the cyclone overflow size distribution, the circulating load and the cyclone underflow density) was modeled with empirical polynomial relationships using another software package (Design-Expert@)T. he conditions under which the cyclone overflow size distribution was maximized while respecting circulating load and cyclone density constraints were identified using these relationships. Among the most interesting results is the prediction of a set of conditions where the circuit target size distribution is achieved with only three ball mills instead of four.IntroductionProduction at the Heath Steele concentrator (near Miramichi, New Brunswick) started some 43 years ago at a rate of 750 t/d. The plant capacity was increased to 4000 t/d through successive expansion phases in the seventies (Sapiro, 1977; Johnston, 1978). However, as a result of depleting ore reserves, the plant throughput had to be gradually reduced to the current production rate of 2700 t/d. Heath Steele Mines currently have proven and probable reserves which would see it producing until the end of 1999 (Noranda Inc., 1997).An analysis of the grinding circuit of the Heath Steele concentrator was recently commissioned to identify opportunities for reducing operating costs while maintaining budgeted mill throughput and metallurgical performance. Since the plant will likely be operated below nominal capacity for the rest of its lifetime, the possibility of improving grinding efficiency by operating with fewer ball mills and/or crushers was contemplated."

Jan 1, 1999

By R. Parada

A real-time dynamic simulation model has been developed to characterise the flash furnace operation at the Chagres smelter. This model permits the operators to plan the process to meet the Peirce Smith converters' schedules and feed the acid plant with gases that satisfy its best operating efficiency range. Essential control parameters for the furnace (process air enrichment, oxygen coefficient and supplementary heat) are calculated to satisfy process targets such as matte grade, slag silica and matte/slag temperatures. These calculations are carried out with a real-time simulation. Flash furnace control and operational stability permits setting up control strategies that streamline the flow of copper to converters and of sulphur to the acid plant.

Jan 1, 1999

By Dippenaar R, Evans T

Twin-roll continuous casting technology is rapidly approaching commercialisation. Fundamentally different than conventional continuous casting, heat transfer and hence solidification during twin-roll casting are governed by the interfacial melt/mould thermal resistance, as opposed to the resistance of the solidifying shell. Under these conditions the interface resistance is predominantly controlled by the melt/substrate wetting behaviour. The very early stages of melt/mould contact are characterised by highly transient heat transfer conditions. The overall melt cooling rates prior to the formation of the first solid are reported to be in the range of 1000 - 50000 K/s with melt undercoolings of up to 300 K. At the points of intimate melt/mould contact the thermal resistance is approaching zero, where cooling rates and undercooling much larger than those reported in the literature are probably occurring. Improved wetting will reduce the energy barrier for nucleation while at the same time increasing the cooling rate of the liquid. Since the overall nucleation rate is controlled both by the rate of cluster formation and the rate of atom transfer to the nucleus, a critical cooling rate will exist above which the nucleation rate is expected to be reduced. Under these conditions, it is possible that the first solid phase to form is a metastable glass which subsequently transforms into a crystalline phase. The implications on nucleation and early growth are also discussed.

Jan 1, 1999

By S. Brummelkamp, G. Van Weert

Separation of minerals by shape has received little attention, since minerals normally do not break into different shapes during crushing and grinding. However, comminution of consumer wastes generates opportunities for novel separations based on particle shape. For instance, ductile plastics are broken into longer curved shapes, whereas brittle plastics yield angular particles. Using spouting beds for particle separation in water requires controlling the spout's instability. The preferred geometry for such redesigned spouting beds is reported. Plastic cylinders, discs and spheres were separated as a function of rising water velocity and amount of particles in the system. By using 5 mm particles, differences in settling behavior could be video recorded.

Jan 1, 1999

By R Harding, T Hunt

For the past 120 years, Portland cement manufacture has been undertaken on the shores of the Whangarei Harbour in northern New Zealand. Through a serendipitous conjunction of geo-chemistry, the argillaceous marl found on Limestone Island in the harbour and Tikorangi Hill provides a perfect mix of the various elements required for strong and durable cement. Golden Bay Cement, and its predecessors, have been the guardians and managers of the use of these minerals. As the demands of the concrete industry have increased, so have the needs of the manufacturing process. Careful mapping of the resource at both Portland and Wilsonville Quarries has been undertaken. This has allowed the Company to change the Quarry operation from a purely volume basis to one of selection and blending of constituent minerals. Within the manufacturing process, change has also been introduced. Analytical techniques, using x-ray fluorescence spectrometry, microscopy and the application of modem data collation, has allowed fine tuning of the process. The Company now produces an increasing diverse range of products for both the domestic New Zealand market and exports to various South Pacific countries. This paper discusses the processing of limestone and æcement rockÆ into cement clinker, an intermediate synthetic mineral ground into cement. It examines control and blending regimes, and some methods used in determining process efficiency. An important technique ærediscoveredÆ has been the application of microscopy to clinker.  Examination of the major silicate minerals enables interpretation of the kiln processing and feedback to process operators. It also enables a prediction of indicated performance when ground into cement. Examples this paper give an insight into the use of minerals from Northland in some of the more important construction projects in modem New Zealand.

Jan 1, 1999

The GPS and information technology industries are now applying considerable development effort to what is being termed machine control and machine information systems, in particular focusing on the industries the of mining construction and agriculture. GPS based systems are demonstrably finding common acceptance and adding commercial value to many machine applications in industry. This has been the first step in the evolution of the information age that is now reforming mining practices. Adding the technologies of wireless data communication, modem computer databases, and networked PC's mining is on the verge of a new era in overall process management. This paper is a general discussion of what the information age means to miners and a general description of new mining operation technologies available to day from the Caterpillar technology alliance.

Jan 1, 1999

By Joel Darmstadter

The position of the coal industry in America’s fuel and power picture remains one of prime importance. Measured in Btu terms, the industry is the country’s leading energy producer and an important exporter. Foreign coal sales yield annual proceeds of about $4 billion. Coal’s one-fifth share of the nation’s energy consumption is nearly as high as that of natural gas. Coal is the electric utility sector’s principal fuel supplier. It accounts for about55% of the electricity generated at power stations.

Jan 1, 1999

By E. W. Hawk

The power generation industry may be required to reduce CO, emissions if regulations related to global climate change are enacted. Coal-fired generation, which emits 82% of the power sector CO2, would be a likely target for CO2 reduction. Compliance with the Kyoto protocol will require a 30% reduction from the projected year 2012 emission level even with moderate load growth. This paper describes an analysis of power industry CO2 reduction options and their costs to assess how a generator would make compliance decisions under a mandatory CO2 emissions reduction program. Carbon sequestration, fuel switching and new plant construction are considered.

Jan 1, 1999

By V. V. Nazimko

Abandoned coal mines cause subsidence and structural damages. Shallow abandoned mines induce the most severe and harmful damages. In addition, they produce time-dependent subsidence which is difficult to predict. Backfilling of underground cavities with waste materials have been used to prevent the time-dependent subsidence or to mitigate its effect. However, this procedure is expensive. A new drill and blast technique has recently been proposed to prevent surface damage from time¬dependent subsidence over abandoned mines. It utilizes the principle that blasting in the caved rock and roof in the vicinity of a cavity will dilate the ground and create a self-supporting effect owing to increase in the volume. Physical modeling has demonstrated that artificial dilation of caved rock using the drill & blast technique creates positive effects due to the following sequence of events: the dilated rock creates a supporting effect for the suspended rock strata and reduces its span which decelerates 3.4 times the process of caving. The roof span is reduced by the next caved layer, which causes the hole boundaries to incline to each other. This effect converts the process of caving from a developing mode to a reduction mode. Finally, the sinkhole zone assumes a triangular shape with a negative angle of draw 64-700 in contrast to a rectangular shape of the chimney zone for natural caving. Vertical dimension of the triangular zone is 3.87 times of the room height. Final surface subsidence decreases at least 2.09 times; displacement 1.31 times, slope 2 27 times; curvature 3.42 times, horizontal strain 1 21 times in comparison to natural caving of the ground over an abandoned mine.

Jan 1, 1999

By C. L. Lin

The image-based On-line Particle Size Analyzer (OPSA) system has been developed at the University of Utah to measure particle size distributions under plant conditions where overlapped and segregated particles are being transported on a moving belt conveyor. Evaluation of the OPSA system at several plant sites has been completed. The results show a consistent agreement between the particle size distributions obtained from the OPSA system and those obtained from laboratory screen analysis of belt samples. These results and the stable performance of the OPSA system during the field tests suggest that continuous quality control of crushed products is possible using the OPSA system.

Jan 1, 1999

Martha Mine is an open pit gold-silver mine, located within the township of Waihi, 150km southeast of Auckland and is operated as a joint venture between Normandy Mining Ltd. 67 %) as Manager and Otter Gold Mines Ltd. (33%). The deposit was historically mined, by underground methods from 1888 to 1952, producing 5.5 moz of gold and 30 moz of silver, from 11 mt of ore. The current operation began in 1988, producing, to June 1999 - 867,245 oz of gold and 5.5 moz of silver from 9.5 mt of ore. The licensed reserves were due to be mined out by late 2000. Consents were granted in December 1998 to allow the expansion of the operation through to 2007 accessing an additional 7.5 mt of ore at 3.4 gpt Au and 26.0 gpt Ag for 800,000 oz of gold and 6.4 moz of silver. The key elements of the expansion are: 1. Pit enlargement 2. Upgraded crushing and material handling facilities 3. Construction of a second tailings storage facility 4. Upgraded water treatment capacity 5. Increased operating capacity This paper presents an update of expansion activities to date.

Jan 1, 1999

By J. C. Ashby

Electric utility response to certain amendments of the Clean Air Act has resulted in a production of several types of alkaline coal combustion byproducts. Alkaline combustion byproducts are gaining increased usage for acid mine drainage mitigation and abatement as research leads to a better understanding of their beneficial applications. Since January of 1997, Mettiki Coal Corporation has been injecting alkaline flue gas desulphurization byproducts from Virginia Electric?s Mt. Storm Unit #3 wet limestone scrubber into abandoned portions of the active Mettiki mine. This paper provides an overview of the key design, transportation, regulatory, and environmental issues faced in the project.

Jan 1, 1999

By M. J. Virnig, B. D. Boley, G. A. Wolfe, J. M. W. Mackenzie

A flowsheet for the recovery of nickel and cobalt from laterite ores has been developed which involves acid leaching followed by hydroxide precipitation of the metal values and then releaching of the hydroxide cake with ammonia. Investigations of the chemistry of extraction of nickel by LIX® 84-I and a developmental reagent, XI-84-IT, along with the physical properties of the organic phases are described. Based on these investigations, suggestions with regard to design of a solvent extraction plant and operating conditions are made.

Jan 1, 1999

By David G. Paton

"Electromagnetic surveys were conducted at the BXL Bulk Explosives Limited Mixing Plant andsurrounding area to characterize runoff from the site and possible impacts of salinity. The BXL Plant is located at the edge of a depressional area and any escape of soluble ions, such as nitrates, would have ended up in the slough to the west of the plant. Two electromagnetic (EM) instruments were used in the survey. A Geonics EM 3 1 was used in October 1997 and in June 1998, a new multifrequency instrument, a GSSI GEM 300 was also tested. Both instruments were individually mounted on a plastic sled with Teflon runners and towed with an ATV quad. Position was determined using a Trimble Pro XL global positioning system (GPS) with a real time correction mode Landstar receiver for an accuracy of about *l m. Both GPS and EM instruments were set to collect data at 1 second intervals. The quadrature maps for both instruments showed essentially the same information, namely of very high conductivity, appearing to emanate from the mixing plant. The levels of conductivity were highest where the saline water appeared to pool, at the southern end of the slough. Soil sampling locations were identified from the EM maps and navigated to using the real time GPS. Composite samples were collected by hand using a Dutch auger, from two locations, in increments of O-1 5, 15-30, 30-60 and 60- 90 cm. The analysis of the soil samples indicated a complete absence of nitrate or ammonium ions; the major anion was sulphate, indicating naturally saline subsoil conditions. The GEM 300 made the collection of data more efficient, as only one pass was required to collect the data from four depth intervals. The EM survey combined with the real time GPS allowed rapid characterization of the site with respect to soil salinity and proved to be cost-effective for Phase l/ Phase 2 site assessments and targeting sampling locations."

Jan 1, 1999

WMC was a late entrant into Indonesia in mid-1996, but had considerable experience and success in exploring in Asia, particularly the Philippines since 1988. Given the geological similarities to the Philippines and IndonesiaÆs superior æcradle to graveÆ Contract of Work (CoW) tenure system, the entry into Indonesia was a logical decision but nonetheless a result of detailed planning. At the time of WMCÆs entry, Busang in Kalimantan was still a 60 moz wonder and the euphoria of this apparent discovery had overflowed into every aspect of exploration. Many junior mining companies and tenement speculators were clamouring for properties in Kalimantan, whilst other serious and capable explorers had to compete for properties and exploration personnel in an era of high and often unrealistic expectations. The picture in late-1998 and through 1999 is dramatically different, as the worldwide downturn in the price of most metals coincides with financial and social crises throughout most Asian countries. The impact of this has been particularly severe in Indonesia and when coupled with the negative sentiment of the Busang fraud has resulted in an exodus of junior companies and also some of the majors. This is understandable given the much publicised social unrest, uncertainty of government, mooted changes to the eighth generation CoW, increasing illegal mining and heightened community expectations. The reality however is somewhat different and although clearly a crisis in many respects, it is also a time of great opportunity.

Jan 1, 1999

By P. J. Cook

Comminution is one of the fundamentals of mineral processing, requiring large expenditures to be made on capital equipment, installation, power and maintenance. The trend toward lower grades and higher operating costs, mean mining operations are becoming increasingly marginal. The challenge is to improve and more importantly, utilize crushing and milling technologies that provide for reduced capital and operating costs whilst providing increased unit efficiencies. The Svedala Barmac Autogenous Crushing Mill presents such an opportunity by providing many of the cost savings and production increases required by its ability to produce a finer mill feed size and realize reduced energy consumption. This paper briefly describes the operation of the Svedala Barmac Autogenous Crushing Mill and reviews its benefits towards improving the efficiency of crushing and milling operations.

Jan 1, 1999

By Fathi Habashi

"On August 3, 1888, German Patent No. 43977 entitled ""A Process for the Production of Aluminum Hydroxide"" was issued*. The discovery which led to the patent was made by the Austrian chemist Karl Josef Bayer (1847-1904) (Fig. 1) who was at that time in Russia, and the process became known as the Bayer Process in his honour(1)(2)- The process imediately achieved industrial success, displacing the pyrometallurgical process that had been used until that time to produce alumina. The Bayer Process involved the pressure leaching of bauxite with NaOH solution to obtain sodium aluminate solution from which aluminum hydroxide was precipitated by seeding. Today bauxite is not only the principal source of aluminum but also of gallium, both metals being effectively recovered by the Bayer Process. The purpose of this paper is to outline the historical background of this discovery and its importance to hydrometallurgy."

Jan 1, 1999

By J. E. Friant

The Mini-DiscTM cutter drill bit is a radical design departure from the traditional tri-cone rockdrill bit. Miniature disc type cutting tools as small as 3.25 inches (82.5 mm) diameter are fitted to a bit body to cut individual concentric kerfs. The action is the same as that commonly used on large tunnel boring machines but miniaturized. The high performance rate and efficiency of a disc cutter are the result of producing a large proportion rock chips rather than sand or powder. The Mini-DiscTM drill bit, referred to as the “Disc Bit” has other unique features as well. It can be re-greased between runs. It can be rebuilt in the field in about 15 minutes, cutters can be replaced and the Disc-Bit appears to require less down hole hydraulic power than conventional bits. Thoroughly tested in the laboratory, the bit has recently been undergoing field trials in well drilling, blast hole drilling and shaft drilling. As any engineer knows, the laboratory can not shake out all the problems but it eliminates the more glaring weaknesses. Performance results have been exhilarating, and a few mechanical problems were discovered and largely overcome. This paper is a progress report.

Jan 1, 1999

By 1980, the U.S. mining community had reached a broad consensus regarding coal pillar design. The pillar load could be estimated from tributary area theory, and the pillar strength from empirical formulas and laboratory coal strength testing. Then the growth of longwall mining required new thinking. Recently, powerful design methods have emerged from analysis of large data bases of real-world pillar successes and failures. These include the Analysis of Retreat Mining Pillar Stability (ARMPS), the Analysis of Longwall Pillar Stability (ALPS), the Mark-Bieniawski rectangular pillar strength formula, and guidelines for preventing massive pillar collapses. Sophisticated numerical models have also helped transform the pillar design landscape. In the process, our understanding of pillar mechanics has been greatly enriched. A new paradigm divides pillar failure into three categories:

Jan 1, 1999

Soil improvement technologies have been widely employed over the recent decades to overcome tunnelling problems in difficult grounds, their range of application growing proportionally to the technological development. The constant advancement in the different mechanical (flexible and more powerful equipment) and electronic (enhanced reliability and direct quality control) aspects of these technologies, fostered the confidence of engineers and tunnellers and, ultimately, allowed the entire tunnel industry to approach difficult excavations in a safer and cost effective manner.This paper outlines the main features of commercially available soil improvement techniques, with particular emphasis on permeation grouting and jet grouting. These two technologies, developed concurrently in Europe and Japan, and there customarily adopted in the design of underground structures, have known extensive and extreme applications worldwide in recent years. Case histories and current practice of soil improvement techniques, as they apply to tunnelling, are also rendered.

Jan 1, 1999