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By Jian Yang

The mechanism of resulfurization in the desulfurization process with magnesium vapor produced in situ by aluminothermic reduction of magnesium oxide was clarified in the present work. The influences of various operating parameters on the resulfurization were studied and the methods that could prevent resulfurization were proposed. There are two kinds of mechanisms of resulfurization in the desulfurization process with magnesium. One is decomposition of the desulfurization product of MgS under the inert atmosphere. The other is oxidation of MgS under the oxidative atmosphere. Under the present experimental conditions, lowering operating temperature and oxygen partial pressure in the atmosphere could effectively prevent the resulfurization. Adding CaO onto the melt surface was an effective method for preventing the resulfurization due to transformation of the desulfurization product of MgS into the more stable compound of CaS. Since addition of the activated charcoal powders greatly decreased the transfer rate of oxygen in the atmosphere to the melt surface, it also reduced the resulfurization remarkably.

Jan 1, 2006

By Durell Denysschen, Rafael Abela

The recovery of gold from old mine dumps has been carried out over the last two decades. The gold value and price together with recovery methods, determine whether it is economical to process a dump. Pre-concentration with cyclones and spiral concentrators may offer a method to process dumps considered currently uneconomical to treat.

Jan 1, 2006

By Corby G. Anderson

"Laboratory testing, plant optimization, and the interpretation and application of metallurgical technologies can be tedious, time consuming and costly. This paper outlines the use of proven statistical design of experimentation software for rapid laboratory testing and optimization of operating plants with limited representative sample utilization. This results in less costly required testing, a more thorough understanding of results and the ability to simultaneously optimize several variables and outcomes at once. At the Center for Advanced Mineral and Metallurgical Processing (CAMP), this testing methodology has been used successfully in many metallurgical development and plant optimization projects thereby confirming its real world utility and application. Accordingly, several applied examples in flotation and hydrometallurgy will be outlined in this paper. This will include flotation testing of a copper gold ore, flotation testing of a copper, cobalt and gold ore, optimization of an industrial hydrometallurgical jarosite circuit and optimization of industrial nitrogen species catalyzed pressure leaching of a copper enargite concentrate.INTRODUCTIONWhile flotation technology is now 100 years old, the testing, interpretation and application of lab results can be tedious, costly and time consuming requiring extensive sample collection and preparation. In addition, recent applications like hydrometallurgical pressure leaching and associated unit operations, such as precipitation, still remain more of an art than a quantifiable science. This paper will elucidate the application of STAT-EASE Design-Expert software to minimize required laboratory testing while rapidly optimizing multiple results and outcomes in a statistically valid manner. The STAT-EASE program is based on proven design of experiment fundamentals. In this paper, the real world application of this methodology for lab testing, plant optimization and process development will be elucidated."

Jan 1, 2006

By Sergio N. Monteiro

Natural lignocellulosic fibers are successfully replacing synthetic fibers in many engineering applications. In addition to well-known conventional lignocellulosic fibers, others with promising properties are now being considered. The present work investigated the mechanical and structural characteristics of a relatively high strength fiber, curaua (Ananas erectifolius) from the Amazon region of Brazil. The results obtained from tensile tests confirmed the superior strength while scanning electron microscopy (SEM) analysis displayed features that justify the possibility of using the curaua fiber as an effective reinforcement for polymeric composites.

Jan 1, 2006

We describe a new method of characterising the effect of dissolved materials on the rate of coalescence of bubbles in aqueous media. Single bubbles were allowed to rise to meet the surface of an aqueous solution, and the time of persistence between arrival and bursting of bubble was measured as a function of solute concentration. A laser beam was placed just above the surface of the liquid, with a detector in the light path, so that any disturbance at the surface could be seen as a break in the beam. The arrival of a bubble at the surface could be detected from the behaviour of the trace on an oscilloscope, and when the bubble broke, another significant change in the signal could easily be seen. The time between disruptions was reported as the persistence time. The effect of a homologous series of n-alcohols (C1 to C8) on the persistence time was measured, in aqueous solution. It was found that with increasing concentration of a particular solute, the persistence time increased up to a point, and then declined. However the magnitude of the persistence time was found to increase with increasing numbers of carbon atoms in the molecule. Bubbles of 1, 2 and 3 mm diameter were used. Persistence time increased with increasing bubble diameter, the maximum values observed being of order 100 secs. For a given solute, the persistence (drainage) time increased with increasing bubble diameter. The concentration Cmax at which the maximum persistence time was observed, was found to be independent of the bubble size. It decreased uniformly as the carbon number increased, and was well correlated by the function y1/2 (dy /dc) -2 I dc)-2 . There was no apparent correlation with the surface excess at maximum persistence time.

Jan 1, 2006

By Antonio Karzulovic, Ricardo Sepulveda, Manuel Schellman

Mantoverde Division of Empresa Minera Mantos Blancos S.A., Anglo American Chile, developed an open pit mine to exploit copper oxide ore. Mantoverde mine is located in the Province of Chañaral, Northern Chile, about 1,020 Km far from Santiago. Currently, the East wall of the mine is reaching the condition of final pit. To evaluate the possibility of a pit optimization on this wall a geotechnical study was performed, including slope stability analyses by limit equilibrium and numerical methods. As a result of this geotechnical evaluation, it was decided to allow a probability of failure of 12% for instabilities affecting up to 600,000 tonnes, and use steeper slopes on the East Wall of the mine. This paper describes this geotechnical evaluation and how the results of the stability analyses were used to define a flexible slope design, which allows modification if the observed slope behaviour deviated from the expected one.

Jan 1, 2006

By H. Venkatesh, Balachander R.

This article discusses the method that was adopted for controlling damage to rock mass while excavating an underground powerhouse cavern at Tala Hydroelectric Project. It discusses in detail the near field vibration studies carried out and the safe vibration levels established for that rock mass condition.

Jan 1, 2006

By Bjöm Böhle

Top-down construction (or cut and cover construction) is providing important advantages when comparing with conventional construction techniques for commercial developments with deep basements, underground car parks or near surface infrastructure and traffic tunnels. Main features are substantially reduced restrictions to surface usage, avoidance of intervention with adjacent property, provision of rigid substructures resulting in minimal deforma­tions and settlements and, last but not least, accelerated construction pro­gramme. The present contribution illustrates the construction method in general and elaborates in detail on the special foundation works for a major urban commercial high rise development requiring a six level basement structure.

Jan 1, 2006

By R. L. Derick

On a regular basis, mine personnel should obtain air samples directly from active underground areas as well as remotely from sealed locations. These samples provide mine officials with data relative to the makeup of the various atmospheres. Should conditions underground change, these results can provide a baseline that can assist officials in determining the extent of change. Relating the concentrations of individual gases to time, applying gases to equations, and examining their change over time are tools that have been successfully used to determine if a heating event exists and, if so, the extent of the emergency. These atmospheric status equations have either been developed for the mining industry or adapted from other industries. They serve as tools to assist personnel in determining the condition of underground mine atmospheres. As long as the problem area continues to be ventilated, certain gases, gas ratios, and equations can be used to determine if a fire exists, what type of material could be burning, and what quantity of coal is burning. Once the mine or the involved section has been temporarily sealed, gases, ratios, and gas-derived equations can assist personnel in determining how conditions within the sealed volume are changing over time. To alleviate potential explosions when fresh air is once again introduced into the sealed volume, equations and a diagram have been developed to predict the likelihood of an explosive atmosphere. Similarly, prior to commencing recovery of a mine or section, equations exist that can assist in determining if the fire will rekindle when air is reintroduced. This paper serves as an overview to remind and/or instruct readers about gas-sampling methodologies and gas analyses to assist in determining the status of underground atmospheres.

Jan 1, 2006

By M. Fafard, M. Dupuis, P. Goulet, J. Bédard

Start-up of a Hall-Heroult cell is a delicate task that can affect pot performance and pot life. Modem practices for high amperage cells involve preheating the lining before the molten electrolyte is poured in. Different preheating methods and heat-up schedules are used throughout the industry, and the optimum between a short start-up and damage minimization to the cell is elusive. Direct electrical coke-bed preheating is one of the most common techniques. This practice typically results in a non-uniform surface temperature distribution and can generate detrimental thermal gradients in the cathode blocks. Numerical modeling is an invaluable tool to study this complex problem and can help improve the preheating procedures. The modeling of the mechanical response of the lining is critical to detect risks of cathode block cracking or the development of gaps where liquids could leak into. Taking into account the baking of ramming paste, the quasi-brittle nature of carbon and the contact interfaces between different materials are examples of key elements to consider. A finite element slice model of a cell was built and simulations of different electrical preheating scenarios were performed using the inhouse code FESh++ to demonstrate what can be learned through thermo-chemomechanical modeling. The potential industrial application of the model is discussed.

Jan 1, 2006

By F. Habashi

Siberia, a vast country rich in mineral resources and a large number of different ethnic groups. To the east of Lake Baikal is Buryatia with capital Ulan Ude. The Buryat are closely related to the Mongolians. Ulan Ude is connected to Ulaan Baatar (Ulan Bator) the capital of Mongolia by train – a 26 hours trip. Getting a visa to Russia is not a simple case. Visits to metallurgical research laboratories, Lake Baikal, and historical museums are enriching experience.

Jan 1, 2006

By Raffaella Granata

The paper deals with the remediation of two areas formerly utilized for the disposal of hazardous wastes in a petrochemical plant. The works, designed on the basis of the criteria of maximum safety and minimum environmental impact, consisted in the confinement of the contaminated soil and groundwater within surface caps and perimetrical cut-off walls embedded in the underlying clay layer. The cut-off wall is 0.8 m thick and has a maximum depth of 33 m: it was designed to guarantee, as a minimum, the level of safety for a landfill for hazardous wastes, in accordance with the applicable National Standards. It was constructed with self-hardening mud and with the installation of an HDPE geomembrane. The HDPE liner of the cut-off wall was then sealed to that of the capping to obtain the complete encapsulation of the contaminated soil. A system of piezometers allows the monitoring of the cut-off efficiency measuring the fluctuations of the groundwater table and testing the chemical contents. Some wells installed within the contaminated areas will contribute to guarantee the full efficiency of the system in case of state of emergency, controlling the water-table level inside the confined areas.

Jan 1, 2006

By E Widijanto, A Srikant

PT Freeport Indonesia operates a copper-gold mine located in the remote highlands of Papua, Indonesia, about 3500 km east of Jakarta. Currently, the district produces about 240 000 tonnes per day (tpd) of which about 45 000 tpd come from the DOZ Block Cave and the rest is mined from the Grasberg Open Pit. Over the next ten years, ore production from large block caves in the area is expected to reach about 200 000 tpd, replacing a large part of the production from the Grasberg Pit. Block cave mining alters the hydrological characteristics of the area being mined and when the cave expresses itself at the surface in the form of subsidence, it increases the entrapment area for surface water. Operating a large block cave mine in a region with an average annual rainfall of 5500 mm in steep mountainous terrain and complex geological and hydrological features presents a challenging scenario for dewatering or depressurisation of the area. The high rainfall infiltration and entrapment in stacked mines operating within an essentially single orebody, coupled with the presence of fine-grained and clayey material within the draw points of the block cave, creates mud rushes or wet muck spills, which can endanger the personnel and interrupt production. This paper outlines the problems caused by high water inflow into the DOZ Block Cave and the efforts undertaken to ensure the safety of the miners and continued achievement of desired production rates from underground mining in the district.

Jan 1, 2006

By P J. Fourie, J R. Walklate

Gravity separation techniques have been in use in the mineral sands industry for decades; from the Reichert cone to Wilfley tables, Wright sluices and the Kelsey Jig, all attempting that elusive perfect gravity separation. Just as the gravity separation industry evolved, Richards Bay Minerals also evolved in their use and approach to gravity separation. This paper discusses the history of gravity separation at Richards Bay Minerals and briefly comments on future developments. History Primary Concentration Richards Bay Mineral?s (RBM) first mining concentrator and mineral separation plant commenced operation in 1977 to process ilmenite, rutile and zircon bearing dunal deposits along the northern Natal coast. The orebody contained a greater proportion of non-valuable magnetic heavy mineral in the SG range of 3 to 4 compared to West Australian and Florida USA deposits, making mineral separation more difficult(1). The deposit was mined using two dredges feeding a floating 2000 tph concentrator. Concentrator feed was screened and fed to two four-stage circuits consisting of primary, scavenger, cleaner and recleaner Reichert cones [see Figure 1]. The primary units were fed at a rate of 80 tph and a density of 60% solids by weight.

Jan 1, 2006

By Marek Dworzanowski

Dense medium separation (DMS) is critical to the operation of coal and diamond beneficiation plants. It is also utilised in iron ore, manganese, chromite and andalusite beneficiation as well as pre-concentration for platinum-bearing UG2 ore. Gravity concentration plays an important role in the processing of diamonds, coal, gold, platinum, titanium minerals, zircon, chromite, iron ore and manganese. The DMS and Gravity Concentration operations and technology in South Africa conference will focus on the operation of DMS and Gravity Concentration circuits in the South African Mining Industry. The current status of the technologies and equipment employed will be presented as well as future developments. The conference was set up to showcase South African DMS and Gravity Concentration operations and provide a forum where operators, technology and equipment suppliers can engage in knowledge sharing. The papers cover a wide spectrum of topics, including descriptions of operations, optimisation projects, new capital projects, equipment applications, process monitoring and process selection. Most commodities and unit processes associated with DMS and Gravity Concentration are covered. The conference venue was selected to be the CSIR Convention Centre in Pretoria. The CSIR has contributed to DMS research in South Africa and it is located not far from many coal, diamond, gold, platinum and chrome mines that extensively utilise DMS and Gravity Concentration in their beneficiation plants. I believe that the papers and presentations submitted for this conference will provide a valuable future reference for DMS and Gravity Concentration, thus making the work of all the contributors to this conference highly rewarding and worthwhile.

Jan 1, 2006

By Ketan H. Trivedi

This paper describes the method of analyses used for the design of temporary and permanent Secant Pile Walls, describes various aspects of construction including, guide walls, sequence of pile installation, plan alignment and verticality tolerance, methods of drilling (auger, wash boring, cased and open holes), lateral bracing for secant piles, cutting of keys in secant pile walls for the connection of permanent floor slabs, sealing of water leaks and waterproofing. The paper concludes with a brief case history of a secant pile wall project recently constructed in New York City.

Jan 1, 2006

By Mike Fabius

The Lakehead Region Conservation Authority is responsible for slopes along the Kaministiquia River, one of the largest tributaries to Lake Superior in Canada. After arresting toe erosion for a mile of riverbank, the remainder of the slope required stabilization to stop further crest regression and to protect the houses, street and services at the top. Stabilization of the 100 ft. high slope was tendered as design-build with a target safety factor of 1.3 and a design life of 75 years. The successful bid was a system of 1.4 inch diameter soil nails up to 40 feet long, installed perpendicular to the slope on a 3 to 5 foot grid. The conventional shotcrete facing was replaced with a ?green? biotechnical facing and special transverse plate heads on the nails. The key to keeping costs low proved to be installation with light equipment working on the slope, and driving the nails without drilling or grouting. Rather than tension, the design was based on bending in the nails, similar to a laterally loaded flexible pile. The paper describes the design and installation of this innovative system. The design is discussed in terms of soil properties, nail resistance as it varies with depth, failure modes, corrosion protection, root design and nail head design. Construction challenges are discussed. The system is compared to an adjacent anchored soldier pile wall built along the same slope 20 years ago. Post construction monitoring results confirm predicted performance.

Jan 1, 2006

Current design guidelines for the surface catalysed oxidation of Fe(II) on Fe(OH)3 (Ochre) in passive mine water treatment systems are based largely on empirical data as the details of rates and mechanisms have not fully been revealed. Also the effects of elevated carbonate concentrations, typical of many UK minewaters, on the surface catalysed oxidation rate are unclear. In order to move away from empirical design and towards sound engineering that is based on geochemical and hydrological understanding it is necessary to quantify these reaction rates. In this study the effects of Fe(OH)3 and carbonate on the rate of Fe(II) oxidation by dissolved oxygen have been investigated with an aim to delineate the reaction mechanism. Experiments were conducted under well-controlled conditions. Preliminary results indicate that the surface catalysed reaction is an order of magnitude faster at pH ~6.4 with 200 mg/l Fe(OH)3 than the homogeneous rate and is dominated by an elevated rate of removal and oxidation of Fe(II) from the solution phase. It is also apparent that the oxidation rate of actual adsorbed Fe(II) is substantially retarded with respect to the homogeneous rate. Carbonates were not shown to affect the surface rate within the bounds of this preliminary study.

Jan 1, 2006

By Glen Mc Gavigan

The roof of the Sishen cave is being mined in order to exploit 6.8Mt of high grade ore. The cavity is filled with quartzite backfill in order to support the roof in the event of collapse. The cave dips at approximately 37o, is 260m along dip and 70m along strike and has a total volume of 261,391m3. GPS and optical monitoring techniques were attempted to detect subsidence but proved to be impractical. The GroundProbe Slope Stability Radar (SSR) uses differential interferometry to measure sub millimetre movement in a rock face. The SSR was applied in a non production situation and detected subsidences of 38mm/day before visual signs of instability were detected. The rate of deformation detected was slowing as a result of the roof coming to rest on underlying backfill. Monitoring during production drilling detected a sudden subsidence of 18.6mm/hour which resulted in the evacuation of personnel from the area. Further inspection of data showed that the rate of deformation was slowing and production was allowed to continue without further incident. The SSR has helped dispel the fears of workers and has proven that subsidence can be accurately measured and delineated with the SSR.

Jan 1, 2006

By J. E. McGill

The junior and small-scale mining sectors in South Africa play an important role in the livelihoods of numerous communities. Mining presents an opportunity, in the post-1994 democratic era, for many individuals to obtain access to much required empowerment and socio-economic development. These sectors are, however, not without numerous characteristics that pose problems for operators, legislators, and other role-players. Mining is inherently risky, with operators experiencing frequent difficulties and challenges throughout the life of mine. Opportunity exists, and needs to be enhanced, for junior and small-scale prospects and operations to include technical risk assessment techniques in documentation presented in search for funding, and in optimizing monthly planning and longer-term functioning. The focus here is to explore how the risk management cycle may currently be applied to a mineral resource suitable for exploitation by the junior and small-scale mining sectors. No management process can create additional value in the ground, but various available mechanisms can go a long way to quantifying the inherent risk that exists, highlighting the need to manage the risks and hopefully allowing the entrepreneur access to the intrinsic opportunities of the emerging mining sector in South Africa.

Jan 1, 2006