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By Martin Banda, Gift C. Chisakuta, Moses Chabinga

KCM made a major modification to the Nchanga Tailings Leach Plant (TLP) changing the circuit from feeding post leach thickeners in parallel with leach discharge for solid ?liquid separation to a Counter Current Decantation (CCD) configuration utilising most of the existing equipment. The new circuit is aimed at improving copper recovery from approximately 70% to 79% through enhanced wash efficiency. The re-introduction of CCD circuit at elevated throughput of 46 000-tpd design was made possible due to the EIMCO E-Duc technology design which is an auto-dilution system that enhances solids settling rate. Commissioning (manual operation) which accommodated on-going operational requirements was phased and completed in January 2004. The circuit stabilised in subsequent months and in March alone an all time record copper recovery of 81.8% was achieved which contributed an extra 779 tonnes copper above the plant?s projected production plans. 100% of the project cost was paid back by end of April 2004 This paper discusses the work involved and the challenges faced during the re-commission

Jan 1, 2005

By Maurice C. Fuerstenau

INTRODUCTION The term, chelate, from the Greek for 'claw,' has its origin in the pincer-like representation of more than one atom of a single ligand bonded to the same metal atom, forming a ring-like structure. Depending on how many attachments exist on the sphere of coordination around the metal ion, ligands are referred to as bidentate, tridentate, tetradentate, pentadentate and hexadentate According to Calvin and Martell (1952) and Somasundaran and Nagaraj (1984), chelating agents must contain suitable functional groups, and their location within the ligand molecule must enable ring formation that is sterically possible. Typical structures that meet these requirements have been given by Fuerstenau and Herrera-Urbina (1988) and are listed in Figure 1. As noted, the functional groups of these reagents contain electron donor atoms such as oxygen, nitrogen and sulfur. Basic groups, such as amino (-NH,), are those that contain an atom with a lone pair of electrons. Acid groups are those, such as carboxylic (-COOH) which lose a hydrogen ion and coordinate with the metal atom. Examples of each of these types chelating reagents are given in Tables 1-4. The specificity of chelating agents for various metal ions has long been known and was utilized early in the search for new flotation collectors. In 1927, Vivian used ammonium nitrosophenylhydroxylamine as a collector for cassiterite. Holman (1929) tested dimethylglyoxime as a collector for nickel oxide. He also suggested taurin as a collector for oxidized lead ores. DeWitt and von Batchelder (1939) suggested the use of oximes as flotation collectors. Gutzeit (1946) conducted an extensive investigation on the use of chelating agents as collectors and as depressants for gangue minerals. The depressants are those reagents that form soluble chelates with metal ions that could function as

Jan 1, 2005

By Richard Brink, Eric M. Klein, Kenneth B. Andromalos

"A portion of the roof for a 129 x 144-inch, nearly 100-year-old sewer outfall in the City of Baltimore had deteriorated to the point that it resulted in the development of a large sinkhole in a residential neighborhood. A subsequent video inspection of the sewer outfall indicated that there was a hole in the sewer outfall, and it would need to be repaired . After initial backfilling of the sinkhole and repairs to the water service lines, a conventional wood shoring system was used to support the excavation and expose the Main Outfall Sewer to inspect and repair it. This excavation was unsuccessful because of loose sandy soils and high groundwater conditions. An innovative use of a steel reinforced jet grout excavation support system was ultimately used to underpin an adjacent 20-inch water main and other nearby utilities, and provide access to the top of the Main Outfall Sewer some 22 feet below the street surface to facilitate inspection and repair of the sewer. This excavation support system was also successfully utilized in the final repair of the sewer roof by serving as a buttress for the new roof system.1.0 IntroductionThe project site is located in a residential neighborhood with brick masonry row houses situated on the south side of Chase Street and a brick masonry church on the north side of the street. Figure 1 illustrates the location of the site. The City right of way is 65 feet wide, and the street is 40 feet curb to curb. The centerline of the Main Outfall Sewer runs parallel to and a few feet south from the centerline of the street. Other utilities running parallel to the street include a cast iron 20-inch water line built about 1910, a 24-inch terra cotta storm drain, a 6-inch terra cotta sanitary sewer, a 4-inch cast iron gas line and a 40-inch electrical duct. Cross utilities included a 4-inch gas line and several smaller water and gas service lines to the church and row houses. One gas line that was not shown in the City's GIS database was exposed during the excavation."

Jan 1, 2005

By Bruno Bussière, Guosheng Zhan, Michel Aubertin, Vincent Martin, Robert P. Chapuis

The study evaluates the hydrological behaviour of exposed and covered waste rock dumps. The objectives were to determine the major factors influencing unsaturated flow in waste rock dumps and covers, and to improve the in-situ, laboratory and numerical modeling characterization methods. Using material properties obtained from in-situ and laboratory tests, waste rock dumps of different configurations, with and without covers, were modeled. It was found that a properly designed “Store, divert and release” (SDR) cover allows most of the water to be diverted downslope and discharged outside of the waste rock dumps. The SDR cover seems to work efficiently even in extreme storm events. The numerical modeling results show that the unsaturated hydraulic properties (e.g. air entry value and water entry value) of the materials largely control the infiltration of water into waste rock dumps.

Jan 1, 2005

By M. D. Seke

The flotation response of a Pb-Zn sulphide ore from the Rosh Pinah Mine (Namibia) was studied in the presence of inorganic depressants such as sodium cyanide and zinc sulphate. Poor flotation selectivity was observed in the rougher concentrate of the galena circuit despite the use of a large amount of sodium cyanide. Batch flotation tests have shown that the use of cyanide alone is not efficient for the depression of sphalerite from the Rosh Pinah ore when milling is carried out according to the current plant particle size distribution. The use of both cyanide and zinc sulphate improved the selectivity between galena and sphalerite much better than cyanide alone. Flotation selectivity is limited by the mineralogical texture of the Rosh Pinah ore sample. Microscopic analysis has shown that the presence of sphalerite in the galena concentrate is also due to poor liberation between galena and sphalerite, especially in the middlings. Hence, selectivity could be improved by regrinding the rougher concentrate prior to the cleaning stage. Keywords: sulphide ores, flotation, flotation depressant, mineralogy.

Jan 1, 2005

By A. Ashrafi

The electrochemical deposition of polypyrrole coating on different pretreated aluminum-alloy 7075 substrates was carried out using cyclic voltammetry, The pretreatment of specimens consisted of mechanical polishing and/or electrochemical etching, In the latter case, an aqueous solution of phosphoric acid and ethanol was used, The electrodeposition solution was 0,25 M pyrrole and 0,1 M oxalic acid in double-distilled water, The cyclic voltammetry scan rate used was 700mv/s, Morphology of the coatings was examined using scanning electron microscope (SEM), Using the Tafel experiment, corrosion resistance of the coated substrates was investigated in 0.1 M NaC1 solutions, Results obtained revealed that electropolymerization of polypyrrole on 7075 aluminum alloy would increase the resistance against corrosion in 0,1M NaC1 solution, Also it was observed that, compared with mechanical polishing, electroetching pretreatment would be more effective.

Jan 1, 2005

By Naj Aziz

n Australia, the common method of laboratory testing of bolt for load transfer capacity determination is by short encapsulation push testing. Some concerns are raised about the validity of the test methodology, as the method does not reflect on the actual load transfer characteristics of bolt in real field situation. Thus, laboratory testes were carried out to examine the load transfer mechanisms of bolts in both the push and pull conditions. Tests were conducted by shearing a short resin encapsulated bolt out of a cylindrical steel sleeve. Three types of bolts with different surface profile configurations were tested. The study was complemented with numerical simulation of the test methods. Irrespective of bolt type the average shear load and shear stress values were found to be greater in push test, and the displacement at peak shear load was greater in pull test. The average shear stifhess values were greater in push test. The numerical simulation of the bolts provided a clear understanding of the stresses and strains generated by different bolt profiles during both the pull and pull testing process, thus allowing a better appreciation of the load transfer mechanism process.

Jan 1, 2005

By Yundong Ma

In this paper the dynamic process of rock deformation and failure in the roadways of the #9 coal seam, Wuhushan Coal Mine by was simulated using the software "Rock Failure Process Analysis System (REPA)" [I]. Based on the simulation results, this paper analyzes the failure process, characteristics and weighting of the overburden as the longwall retreat mining proceeds. The roadway's behavior including deformation characteristics, failure mechanisms, stress distribution in the surrounding rocks and the effects of various support systems on roadway stability were analyzed and studied. While simulating the rock failure process with REPA, the model stresses can be obtained through two approaches: (1) the stress is reflected by the grayscale of pictures in the model failure process and (2) the model stress can be obtained by muti-element information, which is one of the commands in RFPA system. Data files of stress can automatically be created, and curves of stress and displacement of each element can be displayed in each step of computation. Keywords: Rock Failure Process Analysis System (RFPA); roof control; roof to floor convergence; combined support

Jan 1, 2005

By A B. Christie, F P. Bierlein

Lode gold deposits of the Western and Eastern provinces, South Island, New Zealand , formed as a part of the Cordilleran-style tectonism during Tasman/Tahua and Rangitata orogenesis along the Paleozoic-middle Mesozoic southern Gondwanan margin. These deposits, hosted by lower grade greenschist facies sedimentary rock sequences of the Buller, Takaka, Torlesse, and Caples terranes, universally show geological features that are consistent with the orogenic gold deposit model, and genetic features are generally suggestive of a metamorphic origin, with the possible exception of a magmatic fluid source for the mineralisation at Sams Creek. However, ore fluid chemistry in Mesozoic deposits of the Eastern province, particularly the low concentration of non-aqueous volatiles and the very dilute nature of the fluids, is uncharacteristic of most orogenic gold deposits; this must be explained by either a unique fluid source or fluid type, which we believe unlikely, or an unrecognised significance of relatively rare gas-rich fluid inclusions in the deposits. Absolute age data for gold deposits in both provinces remain equivocal, thus hindering definition of the exact temporal relationship between ore formation and terrane accretion, regional metamorphism, and magmatic arc emplacement. Mercury and antimony occurrences in subgreenschist grade parts of the Haast Schist may target the upper levels of unrecognised orogenic gold deposits. If low-grade, high-tonnage intrusion-related gold systems occur on the South Island, then they are most likely to be discovered in association with the small molybdenite-, scheelite-, or cassiterite-bearing quartz stockworks spatially related to the Karamea and Median batholiths.

Jan 1, 2005

By B. Salopek, D. Rajkovic, D. Rumenjak

In decision making support system, that are used in various fields of environmental protection (environmental impact assessment, environmental management systems, setting environmental standards and regulation, etc.), it is often important to apply various mathematical environmental engineering models. The question of linking environmetal engineering modeling to decision making support system used in environmental protection is not yet methodically solved. The reasons for that could be manifold. Decison making support systems, used in environmental protection, because they are simply taken from bussines decision making, are not often adequate for specific problems raised in environmental protection. On the other hand, there are great number of types of models in environmental engineering, what urges the problem of finding the way of their proper linking with decision making support systems. The application of fuzzy logic in that field is estimated as one of possible solution of the problem.

Jan 1, 2005

By J. R. Donald

For processing copper, continuous converting has been successfully employed in a variety of locations, but for nickel, there has yet to be a successful commercial implementation of continuous converting technology. At Inco?s Copper Cliff smelter, there are specific requirements for the production of Bessemer matte relating to downstream processing that makes continuous converting for nickel mattes even more challenging. The nickel carbonyl refineries require very low iron levels in the matte, and the sulphur deficiency must be carefully controlled such that the appropriate quantity of PGM-rich metallics are produced from matte separation. The present paper outlines continuous converter technologies that have been implemented in copper, and evaluates their potential for nickel converting. The challenges of producing a Bessemer matte to the required specifications are discussed. The economic and environmental driving forces, and the challenges of justifying a novel technology in place of productive existing equipment, are discussed.

Jan 1, 2005

By E. Nickel

"Bi- and multilateral banks as well as export credit agencies in the OECD countries, but also numerous commercial banks, last year committed themselves to compliance with the World Bank’s standards. These environmental and social guidelines, also known as the Safeguard Policies, are the strictest international standards in the area of financing of major investment projects. The Safeguard Policies are procedural and quality guidelines by means of which socially and environmentally relevant impacts can be taken into account in the planning and implementation phase of a project. Objectives of the Bank Safeguard Policies are to ensure that environmental and social issues are evaluated in decision-making, to reduce and manage risk of projects and programs, and to provide a mechanism for consultation and disclosure of information. They are often referred to as the "10+1 Safeguard Policies," since ten of the guidelines address environmentally and socially relevant issues, while one guideline is exclusively concerned with public participation ("Public Disclosure"). In the presentation, the transparency of risk management measures and emergency response plans in pipeline projects will be discussed as an indicator of sustainability. The discussion is to be carried out on the basis of the results of an evaluation of several major pipeline projects, which have been financed at least in part by multilateral banks over the past few years. The controversies surrounding some of these projects due environmentally and socially relevant impairments connected with the investments have also been addressed by the Extractive Industry Report of the World Bank. Pipeline construction was the investment type chosen for the examination to be presented here, since pipelines frequently start in remote, unspoiled regions, and their routes often cross various natural zones and areas with various social structures. The question of safety during construction and operation of the line is always central to these projects; not only for the responsible authorities but also for other societal groups involved, such as environmental associations."

Jan 1, 2005

By Leonardo Flores

"Minera Escondida operates two open pits on a porphyry copper district, southeast of Antofagasta, Chile. During 2005, ore will be delivered exclusively from one pit to two concentrators, while from 2006 both pits will provide ore to these plants. Annual testing programmes on drillhole samples, have allowed for the construction of hardness block models since 2000. These models have delivered two main hardness descriptors, the Bond work index and the SAG power index. These parameters and plant operational specifications have been used as input information to forecast, the expected throughput and ball mill product size (P80) for each block of ore. Two forecasting techniques have been used, an in house model, strongly dependant of bond work index and MinnovEx´s CEET2, dependant of Bond work index and Sag power index and other parameters. Model performance has been evaluated from reconciliating on a monthly basis, the forecasted throughputs against a recalculated plant throughput which accounts for losses in tonnage not caused by ore hardness but instead by unscheduled plant operation problems. The model performance for 2003 was ± 2% yearly and ± 5% quarterly, well within the expected ± 3% and ± 10%. INTRODUCTIONThe Escondida porphyry copper district is located 140 km SE of Antofagasta, Chile at 3150 m.a.s.l, at 24°16’ South latitude and 69°04’ West longitude (figure 1)."

Jan 1, 2005

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

pNumerical modelling has been used to examine the relationship between the results of two commonly used methods of assessing the propensity of coal to spontaneous combustion, the R70 and Relative Ignition Temperature tests, and the likely behaviour in situ. The criticality of various parameters has been examined and a method of utilising critical self-heating parameters has been developed. This study shows that on their own, the laboratory test results do not provide a reliable guide to in situ behaviour but can be used in combination to considerably increase the ability to predict spontaneous combustion behaviour./p

Jan 1, 2005

By M R. Drumond

The present work presents a new theoretical interpretation of the flotation process, which can also be applied to other mineral processing physical unit operations. This interpretation is part of the æModelo OperacionalÆ (Operational Model) that was developed as an attempt to establish a new theoretical basis for mineral processing unit operations. In the case of flotation, a book was edited by one of the authors in Brazil (Mass Concentration by Froth Flotation, in Portuguese and Spanish).The model establishes a link between a natural phenomenon (migration of particles from the pulp to the froth) and a real industrial phenomenon (mass concentration by operational interference). In this model, flotation is viewed as a phenomenon of macromolecular mass transport (of particles) between froth and slurry phases. Mechanisms for mass transport and particle flow between phases as a function of the hydrophobic potential in each phase are discussed. By establishing the so-called equilibrium distribution curve between phases it is possible to calculate macroscopic balances that are related to metallurgical results, which in turn are a function of the operational line that is required by the process itself. The number of cleaning stages and their efficiencies can also be determined by simple laboratory-scale experiments.

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 P J. Harper

Maximising shareholder value is a widely stated strategic goal of many mining companies. Mining projects can be capital intensive and achieving good returns is essential to encourage future investment in the industry. Despite the widely accepted importance of shareholder value, the minerals industry is often accused of providing relatively poor returns when compared to other industries. There are many recent and well publicised examples of minerals companies that have failed to deliver value to their shareholders. There are numerous business improvement initiatives employed within the mining industry to assist mine operators improve performance. Some are more effective at creating value than others. Benchmarking is one technique that is commonly used to identify performance gaps and target and prioritise opportunities for improvement. However to be effective, Benchmarking must be used appropriately and result in actions that lead to measurable operational improvement. When conducting a Benchmarking project it is important to remember that the aim should be to improve value. For this to be achieved, the strategic goals must be incorporated into the process. This paper details a structured and comprehensive approach to conducting a successful Benchmarking project. Focusing on Benchmarking as a technique for measuring and improving operational performance in underground mines, the underlying drivers of best practice in underground mining are identified.

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