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By Tony Iannacchione

A close look at the Loyalhanna Limestone of southwestern Pennsylvania reveals a complex structural environment. Most exposures of the Loyalhanna occur along Chestnut Ridge and Laurel Hill within the Allegheny Mountain Section of the Appalachian Plateaus Province. Because the Loyalhanna is rated as a super pavement aggregate by the Pennsylvania Department of Transportation and because of its proximity to the population centers of southwestern Pennsylvania, the Loyalhanna has been extensively mined along these prominent anticlinal structures. Geologic and engineering analyses were performed using gas well and core logs, outcrop examinations, underground observations, and mine maps. Strata exposures from both outcrops and quarries were used to construct geologic maps, stereonet, and rose diagram projections so that the Loyalhanna's structural environment could be understood better. Many of these structural conditions cause ground control problems at local quarries. These problems ranged from small-to-moderate sized rock falls associated with roof jointing to pillar failures associated with dipping discontinuities. Stresses ranged from tensional on structural domes where weathering dominates, to high levels of compression within structural saddles. A greater understanding of these characteristics is a prerequisite to develop engineering controls, such as improved mine layouts. pillar sizes, etc., that lessen miner exposure to these hazards.

Jan 1, 2002

By Colleagues from Process and Operation departments, Guy Chevalier

"QCM's pellet plant, located in Port-Cartier, Quebec, produces up to 8.6 million tons of iron ore pellets annually. Four different types are produced: three for blast furnace operations and one for direct reduction furnaces. The paper presents the scientific approach that led to the installation of new process equipment to improve the reducibility of direct reduction pellets (DR pellet). The findings, the equipment selection and some post start-up modifications are presented.This low silica DR pellet is used in Midrex and HyL shaft furnaces. A good DR pellet has to meet strict chemical, physical and metallurgical specifications. An important metallurgical property is its ability to release oxygen when exposed to reducing gases. Considering that the market for DR pellets is expanding and being aware that reducibility is critical for our clients, a program to improve the latter was undertaken. Test work showed that one factor which has a negative effect on reducibility is the proportion of particles larger than 75 microns. Knowing that the best way to reduce the amount of coarse particles was to close our open grinding circuits, we began evaluating the most suitable classification equipment applicable to our process operations. We settled on hydro-classifiers based on their very sharp cut and their low operating costs. In light of the hydro-classifiers performance it was also decided to replace the hydro-cyclones of an already closed circuit.INTRODUCTIONAt the Québec Cartier Mining pellet plant, continuous improvement programs are aimed at increasing levels of consistency and improved chemical, physical and metallurgical properties. This is being accomplished while still maintaining pellet plant production volumes to satisfy market demands.QCM produces three types of pellets for blast furnace use: acid pellets, designated as ""BHF"", fluxed pellets, designated as ""BAF"", and low silica fluxed pellets, designated as ""BSA"". For direct reduction, a low silica acid pellet or DR pellet, designated as ""BBS"" is produced. This low silica DR pellet is used in Midrex and HyL shaft furnaces.The demand for DR pellets has been increasing during the last few years and is believed to continue so in the future. Wanting to be present in this growing market QCM found that it would be essential to work at improving its DR pellets quality. Efforts have been focused on improvements in three areas: SiO2 reduction, elimination of sticking and increasing reducibility. Improvement programs have begun with laboratory research followed by plant trials and full-scale implementation as a cooperative effort among QCM, COREM, and key customers."

Jan 1, 2002

By Yogesh Narula

Nevis Bluff Landslide - On September 17” 2000, a rockfall measuring lO,OOOm3 at Nevis Bluff, New Zealand, triggered a loday emergency. It ended when a hazardous column of rock that towered over State Highway 6 was finally shattered. The operation called for unusual and unique solutions using aerial bombing and inverted blasting techniques, not known to have been attempted before under these conditions, anywhere in the world.

Jan 1, 2002

By Rene Cane, V. I. Lakshmanan, John Starkey, Richard May

"The Agrium Kapuskasing Phosphate Operation mines and processes up to 6,000 t/d of phosphate ore. Run-of-mine crushing to minus 6 inches is done in a toothed roll-crusher, while grinding is done in a SAG/ball mill circuit with no coarse recycle classification of the SAG mill discharge. The primary grinding mill is an 18 ft. diameter x 9 ft. EGL, 1500 HP variable speed SAG mill and the secondary mill is a 13 ft. diameter x 21 ft. long, 2000 HP fixed speed, ball mill. When hard ore was treated, the SAG mill restricted the tonnage that could be ground. When soft ore was treated, the ball mill and spiral classifier overloaded and restricted throughput.Recommendations from a plant benchmark and an ore hardness testing program, on how to better utilize installed energy in the Agrium SAG mill when treating soft ore, and how to obtain best results when treating hard ore, were checked in a pilot plant investigation in the 3 ft. diameter Starkey-PRO Pilot SAG Mill. Correlation between the ore hardness testing and the results from the 3’ Pilot SAG mill was very good. In addition, the work indicated the results that could be expected for the different ore types when using either smaller SAG discharge grates and/or a vibrating screen with 10 mesh square opening cloth.INTRODUCTIONAgrium Kapuskasing Phosphate Operation consists of a 6800 t/d open pit mine and a concentrator, near the Town of Kapuskasing in Northern Ontario. The two major ore types are sandy ore and cemented ore. Sandy ore is fine, soft and easy to grind in the SAG mill while cemented ore is harder, more blocky and difficult to grind in the SAG mill. The ratio of sandy to cemented ore in the deposit is thought to be in the order of 80:20 but can range as high as 5050, so it was important for the grinding circuit to have the ability to treat sandy ore alone."

Jan 1, 2002

By Maureen McGuiness

"The pastefill circuit at the Bell Allard Mine in Matagami, Quebec started up in August 1999. The surface pastefill plant produces a cemented paste which is sent underground by gravity through a vertical pipeline in the mine ventilation shaft. Difficulties with paste flow during the start-up highlighted the importance of understanding paste rheology and the effect of operating procedures on line wear. By June 2000, the original circuit had been modified to include a paste pump to transport the paste to the shaft.The steps taken during the paste plant commissioning are discussed. The final flow sheet is presented, focussing on the use of instrumentation to ensure full column flow and proper distribution underground. Resistance modelling and accelerated curing of samples are examined as possible ways of predicting paste resistance to ensure compliance with the mine’s paste specifications.INTRODUCTIONCommissioning a new plant can be difficult and time consuming. The start-up of Noranda’s Bell Allard paste backfill plant was no exception. Since the first day it went into operation, the paste circuit could not meet the tonnage and paste quality requirements of the mine because the paste would not flow by gravity into the vertical pipeline in the mine’s ventilation shaft.Diagnosis of the pastefill problems proved difficult. It was only when the rheology of the Bell Allard paste was understood that the flow problems were solved. To ensure that the paste placed in the stopes meets mine requirements, two methods of paste resistance prediction are being developed."

Jan 1, 2002

The Beverley uranium mine û now in production in the remote north of South Australia at1000 tonnes per annum û was established to meet a projected, but little-recognised shortfallin primary supply of uranium for the nuclear industry in the early part of the 21 st century. Inthe context of AustraliaÆs lack of bi-partisan support for uranium mining and the nuclearindustry, a four to five year window of opportunity existed from 1996 to establish the mine.During this period, Beverley achieved a number of firsts including: the first ISL mine inAustralia; the largest ISL mine in the world and the first to produce more than 500 tonnes ofuranium in its first year; the first to be established under a new Native Title regime in SouthAustralia; and the first to be established under a revised South Australian Mining Act.Beverley was brought into production against the background of: hostile opposition fromanti-nuclear activists; a suspicious and at-times hostile media; a regulatory and politicalcommunity that was unfamiliar with ISL mining; commercially unsophisticated Aboriginalgroups; an inexperienced engineering industry; and the vagaries of development in a remote,semi-arid location with neither population nor infrastructure. The lessons that can be learnedfrom Beverley showed that û like much in life û flexibility and timing are crucial.

Jan 1, 2002

By B. Bichel

For the last 70 years, molten blister copper has been transferred by rail in hot metal cars from the Copper Cliff Smelter to the Copper Cliff Copper Refinery (ex Ontario Refining Company) where it was processed in two (2) reverberatory anode furnaces by poling with logs, cast on four (4) wheels, and then electrorefined. This practice was modernized in 2001 with the installation of two (2) rotary anode furnaces at the. Copper Cliff Smelter which employ steam and. natural gas for reducing and which provide a significant reduction in emissions. A new casting shop with a single anode casting wheel is used to cast regular and stripper constant weight anodes which are transported by truck to the Copper Cliff Copper Refinery for anode preparation and electrorefining. This paper provides an overview of the copper circuit at the Copper Cliff Smelter and a description of the CDN$31 million capital project.

Jan 1, 2002

By Tony Francelj, D. Scott Scovira, Remi Proulx

The Meikle Mine is a high-grade, underground gold mine that utilizes a primary and secondary stoping method with delayed backfill. The newly developed Rodeo Mine will start production using similar mining methods in late 2001. The combined production for the mines will be 4100 stpd of ore in 2002. Dilution of the secondary stopes resulting from blast induced overbreak of the backfill placed in the primary stopes was an issue identified as being a major contributor to the total mining cost at the Meikle Mine. To address the overbreak issue, a low-density, polystyrene enhanced bulk emulsion was developed and introduced to the mine. The density and energy of the emulsion was varied until an optimal level was reached. The use of a low-density bulk emulsion has greatly reduced the overbreak of the primary stope backfill when blasting the secondary stopes. Benefits to the mines include reduced secondary stope dilution, lowered total mining cost, and increased revenues.1

Jan 1, 2002

By Bao Xiancheng

Jinlong's copper flash smelting process started up in April 1997. In the early days of production, lots of equipment and process problems were encountered. But, through continuous improvements in equipment and operation, the designed productivity was reached two years later and the smelting operation has been greatly upgraded since then. After more than 4 yew of production, we have made great achievements, such as increasing the flash furnace availability, significant improvements in operation control, optimization of concentrate burner's structure and operation, and smooth operation of the whole smelter. This paper outlines Jinlong's operational achievements made after commissioning, and discusses problems that were encountered and their countermeasures. Operational experience is also summarized

Jan 1, 2002

By K. Nona C. Liddell

There is a significant amount of early work that has been largely forgotten that deals with the validity of the pseudo-steady approximation for liquid-solid reactions. Much of this was originally published in the chemical engineering literature but is highly relevant to hydrometallurgical processes. The purpose of this paper is to summarize some criteria that were been developed by various authors for determining the error associated with use of shrinking core models for liquid-solid systems.

Jan 1, 2002

By Keith Cramer

As a leader in the development of metal extraction technology, Avecia continues to pioneer advancements for the processing of copper through leach, solvent extraction, and electrowinning of copper. From the initial patent of the second generation of oxime 5- nonylsalicylaldoxime in the 1970's; to the effective use of modifier technology; and development of computer assisted modeling programs, Avecia is driving SX technology to maximize extraction productivity. Keys to consider when advancing productivity are: 1) high quality, high performance products; 2) a responsive, partnering approach to technical service; and 3) tools to aid in the education of industry wide technical personnel with a view on continuous improvement. The focus of this paper is on the advancement of tools to aid in the education for optimization of processing copper through solvent extraction. One such tool is Avecia's own customized solvent extraction modeling program called MEUM. MEUM is currently used world wide to analyze plant operations, test ideas for improving operations, assist engineering companies in design, and to teach basic solvent extraction concepts. Recently MEUM has also been incorporated into a University setting. In the spring of 2000 Avecia worked with the University of Melbourne to integrate MEUM into their Mass Transport tutorial class. Students completed exercises to evaluate how operational changes affected a solvent extraction plant's performance. This paper introduces the basic functions of the program and discusses the successful implementation of MEUM into the University of Melbourne curriculum.

Jan 1, 2002

The Jundee gold mining operation is located in the Western Australian Yandal Greenstone belt. Jundee is a mature operation encompassing multiple and complex underground ore resources, dwindling open pit reserves, large surface stockpiles, small satellite resources and two near-mine but stand alone process plants. The imminent completion of continuous open pit mining and the associated drop-off in total mill feed precipitated a review of the strategic mine plan and development of options that would optimise the exploitation of the remaining mineral resources and the utilisation of the existing plant and infrastructure.An initial review of the strategic decisions to be made, available options as well as the quantity, complexity and co-dependency of the strategic variables quickly led to the conclusion that an Operations Research style modelling approach would be appropriate. An 'off-the-shelf' program engine by the name of WHATSBEST! (LINDO Systems Inc.) was chosen on the basis of price, reputation and ease of use. The model was formulated with the unknown variables (being the ore mining rates) expressed as a proportion of the maximum achievable ore mining rate from each source. Costs were defined as variable or fixed, with this definition being a key aspect of the modelling process. The critical application of the model was in determining the optimal extraction rate of ore, the destination (ie Jundee or Nimary mill) and the sequence of extraction of each ore source that maximized the cash flow of the operation. The program was designed to be able to quickly derive an optimal result from the many variables, replacing the previous laborious iterative process of arriving at an acceptable answer by means of several large and static spreadsheet models. This paper presents the process of selection, formulation, application and scope of operation of the turn-key linear and non-linear program strategic model now used as part of the Jundee Operation strategic decision making process.

Jan 1, 2002

By Maurice Guillaud

The most striking innovations on diaphragm-wall construction plant are those associated with continuous real-time trajectory monitoring of the excavating tool (either a grab or a hydro-cutter). The recent equipments are fitted with clinometers and gyrometers to control deflection, rotation or deviation from the vertical, thus allowing to install diaphragm-walls with a verticality accuracy of less than 0.3%. One of the greatest advantages of extensive use of on-board IT systems on the Hydrocutters and hydraulic grab machines is that it aids quality control by automatically producing complete real-time reports of all excavating data (verticality, depth, type of ground, rate of progress, stoppages, etc.). These reports are available to the Engineer, providing the total transparency required for Works Supervision and the Quality Assurance Plan. They also provide the Contractor with input data for databases used for optimising efficiency and progress criteria on future jobs.

Jan 1, 2002

By R. B. Nourse

The depressed market for Ferrochrome worldwide has forced most producers in this industry to scale down production. Inevitably, many furnaces have been mothballed for prolonged periods, awaiting an upturn in the Ferrochrome market. In contrast, the Platinum industry is experiencing relative stability combined with good prices and they have been looking for cash cows to take advantage of these market conditions. It is, therefore, rather convenient that Platinum and Ferrochrome producers are virtually neighbours in the Bushveld complex of South Afiica, since there is an abundance of spare furnace capacity around (albeit for Ferrochrome). Against this backdrop, Pyromet Technologies (Pty) Ltd, who are currently designing a slag cleaning furnace for Anglo Platinum, was requested to perform pilot scale testwork on a 200kW furnace, in order to establish the suitability to process platinum concentrate and converter slag in a furnace designed for Ferrochrome. This paper provides an overview of the configuration, test conditions, operation and results achieved during the testwork. It also discusses the critical issues, such as refractory consumption, copper cooling and electrical parameters that need to be addressed when converting a Ferrochrome Smelter into a Sulphide Smelter.

Jan 1, 2002

By A B. Christie, R Barker

Recent studies carried out to support the development of a strategy for the New Zealand mineral industry by the NZ Minerals Industry Association have included investigations of mineral potential, and the development of scenarios for realising this countryÆs mineral potential by 2010. New economic research is applying a general equilibrium model to quantify the opportunity cost of this potential. The model analyses separately four categories of land (private land and three categories of Crown land) and identifies four distinct mineral classes û precious metals, industrial minerals, coal and aggregate. It investigates the economic effect of the increased availability of mineral resources on the mining industry itself, on other industry sectors and on the NZ economy generally, including its impact on unemployment, GDP and household welfare.The analyses suggest that increases in the level of GDP of between 1.9 per cent and 3.4 per cent may be obtained by utilising New ZealandÆs mineral wealth to varying degrees. The mineral industry sectors are significant beneficiaries under all scenarios; mineral output increases by between two and five times its current level. However, the flow-on effects to the rest of the economy, and to households, are also significant. The analyses show that household income, adjusted for changes in consumer prices, can be expected to increase by between 1.6 per cent and 2.7 per cent. This results largely from increased employment.

Jan 1, 2002

By A D. Strand

The Coeur dÆAlene mining district in northern Idaho, USA is the second largest producer of silver in the world. The Proterozoic Revett Formation hosts most of the mesothermal Ag-Pb-Zn vein ore in the district; it consists of informally designated lower, middle, and upper members. All three members show up to an order of magnitude of southward thickening across the regionally significant Osburn fault. Changes in thickness of the Revett Formation across the Osburn fault reflect a major, down-to-the-south, crustal-scale fault that:was active during sedimentation, was periodically reactivated during the structural and metallogenic history of the district, and likely provided first-order control over regional fluid flow during mineralization events. Where vein structures intersect favourable strata, they produce rich ore; where vein structures cross unfavourable strata, they are poorly mineralised or barren. The most favourable host rock in the district is quartzite, which accounts for the large production from the quartzite-rich Revett Formation.The district has five main types of hydrothermal alteration:feldspar destruction, hydrothermal bleaching, carbonatisation, sulfidation, and silicification. Feldspar destruction is the most extensive and pervasive type of alteration, involving the district-wide absence of feldspar from Belt Supergroup rocks. Hydrothermal bleaching results from the destruction of hematite; it forms alteration envelopes that extend for tens to hundreds of metres into the wall rocks around many of the mineralised veins. Siderite alteration is most diagnostic of mineralisation, forming alteration envelopes that extend for tens to hundreds of metres into the wall rocks around all mineralised veins. Fine-grained arsenopyrite and/or fine-grained pyrite commonly form alteration zones adjacent to high-grade ore shoots that extend for metres to tens of metres into the wall rocks. Widespread silicification is most easily recognised by the presence of numerous quartz veins.

Jan 1, 2002

By K. Burke, K. L. Myers, R. Espell

Barrick's Goldstrike AA heap leach pad is an HDPE-lined facility that was used for gold recovery from low-grade ores using conventional cyanide heap-leach technology. The pad was operated from 1987 through 1999. Goldstrike prepared a unique reclamation plan for the AA leach pad facility to provide for a cost-effective, environmentally sound facility closure and to fulfill the State of Nevada's closure requirements. The traditional Nevada leach pad closure procedure involves rinsing to reduce the cyanide concentration to an acceptable level followed by reclamation. However, rinsing does not typically reduce certain metals and compounds, and some constituents may increase in concentration with rinsing. A closure scenario to effect limited infiltration through installation of a capillary cover for the leach pad was developed. The capillary cover was constructed by placing a fine-grained layer above the coarse-grained spent leach material to create a capillary break. In an arid climate such as in Nevada, the fine-grained layer will rarely reach saturation, and the cover will be able to store water during precipitation events and will allow removal of water through evaporation and transpiration (ET) during the growing season. A 1.22-m (4 ft) cover thickness was selected as the optimum design cover thickness. The drainage network on the surface of the recontoured AA heap leach pad was specifically designed to enhance the re vegetation, reclamation and sediment yield control aspects of the AA heap leach pad closure, while resulting in a natural looking surface that is compatible with the surrounding topography. Adjacent natural topographic features were used to establish target design parameters for recontouring and erosion-control design.

Jan 1, 2002

By B. C. Jago, H. Derbuch

"The Freightrain kimberlite is located on the Brodeur Peninsula, Baffin Island, Nunavut. Twin Mining is exploring the pipe and adjacent land (79 claims/655 km2) using a combination of airborne geophysics, soil sampling, diamond drilling, trenching and bulk sample processing. The pipe originally was discovered by Cominco Limited in 1975, re-evaluated in 1993 by Lumina Investment Corporation, when it was staked as the Zulu pipe, and subsequently covered by three claims in 1998 by Helix Resources who called it Freightrain.The Freightrain pipe coincides with a strong, ovoid-shaped aeromagnetic anomaly. It is the only surface exposure of kimberlite within a 30 km long linear trend of fourteen aeromagnetic anomalies that are up to 600 m in diameter.The pipe is exposed in the crater facies, near the transition into diatreme facies as indicated by the occurrence of pyroclastic kimberlite characterized by abundant olivine macrocrysts, juvenile lapilli and kimberlite autoliths set in a serpentine-calcite matrix. Olivine, Cr-pyrope garnet and chromite are the most abundant macrocrysts; clinopyroxene, ilmenite and phlogopite mica occur in minor to trace amounts. Garnet and chromite harzburgite, garnet lherzolite, garnet-spinel lherzolite and rare eclogite dominate the xenolith population.Garnet and chromite mineral chemistry indicate encouraging diamond prospectivity and that potentially diamondiferous garnet and chromite harzburgite were the principal sources of diamond in the mantle at the time of kimberlite eruption.Single clinopyroxene grains define an ~42 mW/m2 sub-continental geotherm that is rooted in the diamond stability field. This compares to a slightly hotter geotherm (~48 mW/m2) for adjacent Somerset Island kimberlites with an origin in the graphite stability field. This data accords with the general lack of sub-calcic Cr-pyrope garnet, diamond inclusion chromite and diamond in Somerset Island kimberlites."

Jan 1, 2002

By Bobby Michael (Mike) Roberts, G. M. (Mike) Bernard, Ronald R. Kelly

This paper describes Cananea's successful implementation of the world's first mobile high angle conveyor (MHAC™) to achieve multiple-lift stacking of their primary crushed (2,500 mtph) low-grade ore. The mobile high angle conveyor answered Cananea's needs to stack a second lift, 30-meter high, on their Quebalix I pad. The mobile high angle conveyor is a custom unit that was designed by Terra Nova Technologies (TNT) in conjunction with Continental Conveyor and Equipment Company (CCE's 100th HAC). The stacking system expansion project also includes a rail mounted tripper on the existing overland conveyor and a custom designed "corridor conveyor" to build the corridor for the upper mobile HAC tracks and tail of the existing mobile stacking conveyor. Mexicana de Cananea, part of Grupo Mexico, is a large copper producer in Sonora Mexico and has been in operation continuously for over 100 years.

Jan 1, 2002

By Michel Bustamante

The Arbre viaduct, 200 metres long, is the most important structure on the Belgian portion of the High Speed Train line between Paris and Brussels. The particular geotechnical conditions of the soil with carboniferous limestone affected by karstic phenomena, has prompted the designer to found the viaduct on systems of high capacity vertical and batter micropiles. The design of the working micropiles was validated by full scale tests performed on instrumented micropiles. The size of the structure and the deformation criteria to be met when HS trains are crossing the viaduct, together with the lack of references for such innovative structure, called for monitoring the movements of the piers as soon as the link was open to traffic. The authors report on the results of loading tests on micropiles and the results of settlement structure monitoring for a period of 4 years. Settlement of the foundation is estimated taking into account the group effect.

Jan 1, 2002