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By M. J. Lukhele

Paper written on project work carried out in partial fulfilment of B. Tech (Mining Engineering) degree A number of high wall mining methods were developed over the years to mine coal reserves exposed on the high walls created during surface mining. The auger mining system was initially developed in the early 1940s in the United States of America. High wall mining is a method of recovering coal from seam exposed either by mechanical excavation methods or natural erosions. This is usually associated with strip-mining (opencast) where the stripping ratio is high and uneconomical to mine using the opencast mining method. This paper discusses the surface auger mining as deployed at Rietspruit Mine Services Proprietary Limited.

Jan 1, 2002

By L. K. Bandyopadhyay

The expert system component of Knowledge Base System supports the analysis and interpretation phases of ventilation design with an algorithmic program used for the solution of alternate design. The paper describes the ?ES-VENT? knowledge based system developed at Central Mining Research Institute, Dhanbad, India for an on-line diagnosing of the ventilation problems using the ?IITMRULE? expert system development tool. In the ?IITMRULE? expert system tool, it has been decided to use a backward chaining reasoning process to reach the goal state i.e. the final conclusion. ES-VENT system is made of three modules: On-line Data, Diagnostics and KBS. Each module is being a collection of several programs. The paper mainly deals with the parameters affecting the ventilation of underground mines such as air-velocity, air pressure, temperature, dust, and humidity and gas contents. The graphical presentation of these parameters on the computer and the interactive part of the developed program is expected to help a ventilation officer to determine the changes in a ventilation circuit necessary to bring the mine ventilation to the desired value. Once such changes are physically effected, the display will indicate if the changes have brought the desired effect or not on ventilation. Keywords: Ventilation network, on-line data, expert system, intelligent system, knowledge base, inference engine.

Jan 1, 2002

"A method is described for determining the viability of hard rock orebody extraction by block caving. Using a very limited amount of geotechnical data, the procedure enhances Laubscher’s empirical stability graph method by using the complex structural modelling system (ChaSM) to assess cavability and block cave tonnages.IntroductionIn considering the selection of suitable mining methods, block caving has gained popularity over other extraction systems in recent years (Butcher, 1999). This has been ascribed to the fact that block caving is the lowest cost per ton mining method, with orebodies that were in the past considered unsuitable for caving, now being successfully mined. However, even though all orebodies will cave, a problem exists in the evaluation of economic viability — it is necessary to be able to predict both when the orebody will cave and what will be the sizes of the initial ore fragments (and the associated tonnages) that report to the drawpoints. This problem is compounded by the fact that, during the scoping study phase of a project, only limited geotechnical data may exist on which to base an assessment of whether block caving is viable or not. Empirical and numerical methods of cavability assessment do not account for the full effects of geological discontinuity trace lengths, nor for the stress regime. Those require significant geotechnical data to be available. The result is that uncertainty may exist as to whether block caving is an economic option. This uncertainty is complicated by the fact that limited experience exists with the caving of more competent orebodies.This paper describes a method for assessing cavability, and for predicting the size of initial ore fragments and the tonnages reporting to block cave drawpoints, using only the level of data normally available during a scoping study. Fragment size and tonnages are assessed by identifying potentially unstable blocks and wedges in the undercut back using statistical joint data. The effects of lateral confining stresses are accounted for by comparing the in situ stress orientations with the joint orientations. To evaluate the accuracy of the method, a back analysis exercise was conducted to predict cavability and initial tonnage for a mine in which the actual behaviour is known. The method is then applied to cavability and tonnage predictions for a hard rock orebody."

Jan 1, 2002

Geopolymerization is a process by which Al-Si minerals undergo dissolution and polymerization in an alkaline solution to form a monolithic material with a high mechanical strength (Davidovits, 1991; 1994). In this study, Na-feldspar (albite) and K-feldspar (microcline) have been selected to investigate their abilities to undergo geopolymerization. The interaction between alkali metals present in the alkali-feldspars and alkali metal cations contained in alkaline solution during geopolymerization has also been studied. It has been found that both albite and microcline can be applied in geopolymerization to produce geopolymers with a high compressive strength. Although the dissolution of M-feldspar (where M = Na and/or K) in concentrated MOH solution is inhibited when the alkali metal cations of the alkaline solution differ from the alkali metals structured in M-feldspar, the resulting geopolymers are found to demonstrate a higher compressive strength. Moreover, a proper molar ratio of Si/Al in the geopolymeric gel phase and a higher average hardness of the undissolved particles remaining in the geopolymers are found to greatly increase the ultimate compressive strength of the geopolymers.

Jan 1, 2002

Mine rehabilitation is a sustainability issue that has been revisited ad infinitum; however, the persistent lack of demonstrated on-the-ground performance and an increasingly intractable rehabilitation liability in Queensland continue to erode the credibility of the mining industry and regulatory bodies. For at least ten years the need to change the current, process-based approach to rehabilitation to an outcomes-based approach has been apparent. The ISO 14001 series temporarily diverted attention from this important point, however it would appear the limitations of an ISO 14001 approach are now more widely accepted. It is proposed that a successful outcomes-based approach cannot be achieved without meaningful community engagement. The apparently intractable nature of the rehabilitation issue will continue to generate conflict and criticism unless all stakeholders are encouraged to participate in the process of developing robust and practical outcomes for rehabilitation. Sharing the responsibility will ensure the best possible outcome. It is important to recognise the valuable resources inherent in community groups, many of whose committed volunteers have considerable expertise in relevant areas. Community groups should not be seen as adversaries but as allies in the process of solving problems that affect the wider community. Several projects that can be seen as test cases for the engagement of stakeholders exist, and in this paper the process of achieving multiple stakeholder engagement in the context of Environmentally Sustainable Development is discussed.

Jan 1, 2002

By Arthur E. Morris

Process modeling software is used extensively in process engineering, but there is a notable lack of affordable software for educational uses. This paper describes two educationally oriented software programs for thermochemical modeling of processes involving metals, minerals, and ceramic materials. Both programs run as Excel@ spreadsheet files. The first is FREED, a thermodynamic database program containing datafiles for 2500 species. It contains the entire U. S. Bureau of Mines and most of the U. S. Geological Survey database, plus data for scores of other species drawn from various sources. Several modules are available for manipulating and viewing the data. The second program is THERBAL, for making thermodynamic calculations using FREED data. Equilibrium calculations can be made for systems with non-ideal solutions, for a specified set of pressure, temperature, and input amounts of reactants. An optional heat balance is also calculated. The results are displayed as tables or charts in Excel worksheets. Examples of the use of THERBAL will be given for the reforming of natural gas for DRI production, DRI production, and EAF steelmaking. Some observations will be made on its use in the classroom. The development of FREED and THERBAL was initially carried out at the Department of Metallurgical Engineering, University of Missouri - Rolla as part of a project to preserve and enhance the Bureau of Mines database. The current versions were developed privately by the authors.

Jan 1, 2002

By P J. White, J V. Lawless

Low-sulphidation epithermal gold deposits, which form in quasi-hydrostatic convective hydrothermal systems, frequently contain chalcedony within high-grade ore, which has been interpreted to be a crystallisation product of amorphous silica. To deposit amorphous silica rather than another silica polymorph at elevated temperatures requires very high silica concentrations, because of its relatively high solubility. Only extreme boiling caused by decompression followed by wall rock heating upon structural dilation, can achieve this. As gold deposits with amorphous silica it must be produced by the same mechanism, particularly since extreme boiling is also a very effective mechanism for gold deposition. Recent developments support this view; the first is the detailed isotopic analysis of chalcedony-bearing high-grade veins reported from Hishikari, Japan, in which oxygen isotope results are indicative of extreme boiling and hydrogen isotopes indicate initial deposition of amorphous silica. The second is the finding of chalcedony within geothermal pipe work in the Rotokawa geothermal field in New Zealand. Rotokawa is a comparatively hot field (335¦C at depth); hence separation of the steam-water mixture produced by the wells is undertaken at a comparatively high temperature (220¦C) to minimise down-stream silica scaling. Even so, silica scale, some of which is chalcedony, does occur, under similar conditions to that in low-sulphidation epithermal deposits. Evidence of chalcedony forming under these conditions, reinforces the interpretation that decompressive boiling is the main deposition mechanism for gold in low-sulphidation epithermal deposits. It is possible that there is sufficient drop in temperature due to decompression that, at least initially, the silica deposits directly as chalcedony. Low-sulphidation epithermal gold deposits that do not contain chalcedony, such as those in the Philippines, may form at temperatures too high for chalcedony to directly form. The recognition of decompressive boiling as the main deposition mechanism in low-sulphidation epithermal deposits means that exploration can focus on zones where this has taken place by combining paleohydrological reconstruction and structural geology.

Jan 1, 2002

The integration of mining and mineral processing technologies into new advanced mining systems is considered to offer several benefits, including selective mining, reduction in waste, increased productivity, flexibility, and improved resource utilization. This paper focuses on underground hardrock mining and the integration of pre-concentration technologies into future mining systems as representing realistic, shorter-term integration options. Control of fragmentation to optimize grinding, pre-concentration of ores, in situ leaching, and modular mining/mineral processing systems are possible with existing technology. Current research is directed toward development of integrated underground systems that minimize surface activity and minimize or eliminate surface waste disposal. Results from a simulation model of an integrated underground pre-concentration system are presented.

Jan 1, 2002

The interaction between ore-bearing fluids and the siliciclastic rocks typically hosting orogenic gold deposits in Phanerozoic metamorphic terrains result in the development of a distinctive alteration halo. Along with petrological changes such as the replacement of chlorite by carbonate and the growth of sericite, characteristic geochemical modifications take place within this alteration envelope. These include variations in elemental abundances and more or less pronounced shifts in the H, C, N, O, and S isotopic signature of the ore system. æFingerprintingÆ these isotopic trends can provide exploration with additional vectors towards the ore zone, and yields valuable information regarding the source of the hydrothermal fluids and the solutes contained therein. Data from radiogenic isotope systems such as Sr-Rb, Ar-Ar, Xe-Ra, Pb-Pb, Re-Os, Sm-Nd, and U-Pb can constrain the kinematic history of ore-hosting structures, provide important clues concerning the absolute timing of gold emplacement, and enable the detailed characterisation of associated intrusives with respect to their magma source(s) and crystallisation age. Although high analytical costs, long turn-around times and the potential for misinterpretation prevent isotope systems from offering a æquick & dirtyÆ analytical method that would provide a significant advantage in exploration for orogenic gold mineralisation, the development of integrated four-dimensional ore genesis models depends heavily on constraints obtained from isotope mass spectrometry.

Jan 1, 2002

By M. H. Al-Dabbagh

In this paper, the authors outline the deficiencies of PERT/CPM as a method for scheduling complex projects such as mine development. In particular, PERT/CPM networks cannot accommodate logical nodes (events) or stochastic branches (activities). The Graphical Evaluation and Review Technique (GERT), developed by Pritsker and. co-workers, is introduced as an alternative to PERT/CPM that overcomes many of the deficiencies of the latter and enables a more realistic analysis of complex projects that are subject to significant uncertainties. A brief overview of GERT network structures and network analysis is given and a PC implementation of the method is described. The technique is illustrated by application to the development of an open-pit gold mine in Saudi Arabia.

Jan 1, 2002

A standard practice of auditing mill designs has developed in the mining industry. The purported aim of this task is to ensure that the mill being offered conforms to the design specification, thus reducing the purchaserÆs risk. However, careful examination of the auditing methods used in the past shows that this is not the case. In some cases, what auditors have been providing is effectively a quality assurance check of the input data, not a full independent audit of the vendorÆs design. It will be shown that these past auditing methods have contributed to the stagnation of mill specification development. This lack of specification improvement combined with the current trend towards increased allowable fatigue stress ranges can result in an increase in risk for the purchaser.

Jan 1, 2002

Problems caused by water discharge from surface mine ventilation shafts can be significant and are usually unforseen. The discharged water is often hyper-saline or acidic and can cause environmental degradation over a wide radius. It can also lead to recurring power pole fires and primary fan breakdowns. A range of solutions to the water discharge problem has been implemented in many Australian mines. In most cases the solutions have been ad hoc, with the overall cost and effectiveness varying tremendously. This paper reviews and contrasts the practicality and effectiveness of the various available remedial options.

Jan 1, 2002

By Valentin Choquenaha Bombilla, Oscar Alvarez Muiloz

"Tintaya’s basic production line is copper concentrate, which has an important gold content. The process used is flotation; the objective of the metallurgical department is to obtain the best results in the copper recovery without neglecting the gold, using very specific reagents. Copper recoveries are considered high, nevertheless every day emphasis is placed upon increasing those recoveries. Regarding gold, optimum recoveries could not be achieved with flotation; and implementation of a gravity circuit was considered.According to microscopy studies, the coarse and very fine grains of gold in native form are lost to tails. The native gold due to its high specific gravity is concentrated at the underflow of the cyclone, remaining in the circulating load of the circuit. It reaches three times the concentration compared to the head grade entering the ball mills. This re-circulation generates very fine and laminated gold particles inside the ball mill, passing to the classification stage making a short circuit to the overflow of the cyclone.The very coarse gold particles as well as the thick flakes of gold do not react favorably to the conventional flotation process; thus studies that have included gravity separation have been conducted to increase the gold recovery. Part of the research included concentrating tables, jigs, and Knelson Concentrators. The Knelson Concentrator proved to be the best selection in terms of metallurgical performance and recoveries considering the throughput and operation conditions of the Tintaya Plant.The gravity concentration circuit with the Knelson Concentrator was commissioned in BHP Tintaya in October 1998, as per the flowsheet shown later on. Presently the global gold production surpasses any estimated expectations.Present efforts are directed towards showing the evaluation and optimization of the different parameters that govern the performance of the Knelson concentrator, as well as illustrating the difficulties and successes throughout the operating period.In the first year of operation 200 tons of gold concentrate have been produced with an average concentrate grade of 320 gramdton, having paid back in full the cost of the automated KC-XD- 48 Knelson Concentrator, the peripheral equipment, and the cost of the installation."

Jan 1, 2002

MIM Holdings Limited has acquired a reputation for the successful application of R&D to develop break-through technologies for the mining industry. The Isa Process tank-house technology has been licensed to copper refineries throughout the world, and almost 40 per cent of the worldÆs copper is refined using this technology. Isasmelt copper and lead smelting technology is either in use, or is currently being installed, by eight companies in eight countries around the world. Jameson Cell technology is widely used in the coal mining industry and increasingly in the base-metal industry. The IsaMills developed at Mount Isa and McArthur River made it possible to develop the McArthur River and George Fisher orebodies. This paper will address the need for innovation and then discuss the development of the IsaMill and Isasmelt technologies. It will conclude with some comments about why MIM has been so successful in developing such technologies.

Jan 1, 2002

By John Lemke

Current practice for monitoring static pile load tests commonly consists of measuring load and displacement at the top of a pile. This is typically accomplished by monitoring dial gauge movements, line pressure of a hydraulic jacking system, and electronic load cells on occasion. While this testing approach provides useful information for one boundary condition (the top of the pile), a system that measures movement and/or strain along the entire length of the pile can provide additional useful data that can be used to refine pile design. Automated data acquisition systems provide the essential ingredient that can integrate these types of sophisticated instrumentation devices into a standard pile load test program in a cost effective way. This paper provides a general overview of pile testing instrumentation and describes a newly developed chain of instrumentation modules that can be embedded in a pile to gather additional testing information. The new system can measure forces and movements within the test pile synchronously with measurements at the pile top, and the direct application of this system to axial and lateral pile testing is illustrated. This is particularly relevant to the design of ACIP and drilled displacement piles since determination of the reinforcement cage length is important from the standpoint of both seismic design and foundation cost.

Jan 1, 2002

The modern theory of sampling of particulate minerals essentially consists of a recent generalization of the procedures for applying and calibrating the formula usually known as ?Gy?s Formula? for sampling variance control, in which the central concept is a parameter called the liberation factor l. A model which can be experimentally adjusted was proposed by one of the authors several years ago, based on geostatistical considerations. This new model, which relates the liberation factor to the sizes of the fragments and mineral grains, solves the usual difficulties faced in the past, and permits predictions that are well verified in practice. Unfortunately, an older, arbitrary and less general formula is still widely used. The vast majority of today?s misapplications of Sampling Theory of Particulate Materials can be traced back to the use of this antiquated and generally incorrect model. Following a brief history of the models used for the liberation factor and a description of its main variable, the liberation size, and to illustrate the importance of proper modelling of l, this paper presents demonstrative calculations of the absurdity of the incorrect model using the particular case of gold mineralization as an example, followed by some more positive examples of application.

Jan 1, 2002

By Alain Bouchard, Germain Labonté, Jim Barrett

"Mill feed materials that are not run-of-mine ore are often a challenge for mineral processors and tend to accumulate in stockpiles, where they remain unprocessed for many years and become “slow moving inventories”. During a complete re-evaluation of the Clarabelle Mill operation (38,000 ton/day capacity) in 2000, it was concluded that there was an opportunity to assemble a 5,000 ton/day custom circuit to treat such stockpiles in the equipment that remained available during regularly scheduled maintenance shut-downs.This project was part of the larger Mill Redesign Project and involved testing the intended flowsheet under a number of operating scenarios for the first material to be treated: spent refractory bricks. The laboratory focus was on how to maximize returns using the available equipment and reagents.The circuit was successfully commissioned in the fall of 2000. As the brick stockpile was depleted, other potential feeds were evaluated at the laboratory, as well as in the new custom circuit itself. Processing of the spent refractory brick has yielded a significant contribution to the profitability of INCO. Significant opportunities lie ahead for generating more value from other slow moving inventories.INTRODUCTIONIntegrated mining operations tend to have slow moving inventories along the path from the mines to the finished products. Spent refractory bricks from furnaces and converters and furnace bottoms are materials that often end up in long-tern stockpiles. Such stockpiles are a challenge, although they represent small tonnages on an annual basis, because they are unique materials, which cannot be readily brought into the process at a rate anywhere near that at which they are produced, due to the high contents of deleterious components such as chromite or magnesia. Accumulation over years will eventually yield a metal inventory worthy of consideration given the right opportunity, such as availability of spare equipment or peak metal prices."

Jan 1, 2002

The gold salting fraud at Busang on the island of Kalimantan, Indonesia was exposed in early 1997 and resulted from the independent drilling, sampling and assaying of PT Freeport Indonesia which reported assays from the South East Zone with negligible concentrations of gold. Since then, a number of legal actions directed at former Bre-X directors, consulting firms and financial or broking institutions are at various stages and are based on numerous allegations surrounding the supposed existence of obvious and numerous warning signs or æred flagsÆ. These include: the absence of references to visible gold in the drill logs; the alluvial nature of the gold grains; the high gravity recoveries; the invalid comparison with Kelian; the absence of outside scrutiny and the lack of external review/audit and surface depletion of gold. The focus on the red flags has been at the expense of the numerous positive indications or ægreen flagsÆ. These include the morphology and chemistry of the gold grains, the gravity testwork, the amalgamation results, the role of external consultants, the results of a review by one of North AmericaÆs leading minerals auditing groups, the behaviour of the gold at surface and the presence of references to visible gold in the drill logs. The flawed nature of the discussion of the technical facts surrounding Busang has prevented a meaningful and informed discussion about what actually happened and has, therefore, prevented the formulation of meaningful remedies for the future.

Jan 1, 2002

By H. Maleki

In this paper, long-term measurements in five underground mines are presented to demonstrate how these measurements can be applied to stability evaluations and design of underground excavations. These case studies address both the global aspects of strata response to mining activities as well local ground behavior and support loading. The measurements include static (stress and deformation) and geophysical. Case studies quantify pillar behavior, roof-floor deformation patterns, overburden response, and microseismic activities. Large-scale studies quantify the nonuniform nature of overburden deformation and collapse. Local measurements address yield and stable pillar load deformation characteristics, as well as the performance of support systems under combined axial and lateral loads.

Jan 1, 2002

By R. Bokotko, J. D. Miller, J. Hupka

Laboratory results from an initial study on the removal of SO2 from gas mixtures are reported using air-sparged hydrocyclone (ASH) technology. Tap water and alkaline solutions were used for absorption and the influence of gas flow rate, water flow rate and length of the ASH unit were investigated. Complete removal of SO2 was possible with very favorable kinetics. The efficiency of sulfur dioxide absorption from air using the ASH is compared with the efficiency of conventional technology.

Jan 1, 2002