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Fault detection and identification are major challenges in process engineering and manufacturing and the key component of abnormal event management systems. Timely detection, diagnosis and rectification of abnormal or faulty process conditions can lead to savings of billions of dollars in equipment damage and lost productivity, not to mention the prevention of injury and loss of human life associated with industrial accidents. A major contributing factor to current losses in industry is the reliance on human operators to interpret high-frequency samples from hundreds or thousands of variables simultaneously. As a result, the automation of fault detection and diagnosis is seen as crucial to the successful implementation of abnormal event management, the need for which is becoming all the more urgent given the increased complexity associated with modem industrial plants. In this paper, a methodology for process monitoring that uses support vector methods to extract nonlinear features from data is discussed and applied in the diagnostic monitoring of an industrial liquid-liquid extraction column.

Jan 1, 2005

Sishen uses a state-of-the-art tracking system to track material from its position in blast blocks through various stockpiles and crushers. Qualities are blended directly to the crusher as opposed to blending from stockpiles. This poses an interesting challenge to the planning department to simulate these conditions. The software used in these simulations are Whittle 4X and Maximiser for long-term planning, Xpac for medium-term planning and Mine Works Planner for short-term planning. Geological models and mine design layouts utilise Surpac. Sishen introduced Xpac a number of years ago; the system has developed and changed over the years. With the Sishen Expansion Project (SEP), which aims to utilise low-grade material, major changes to the planning process have to occur. SEP requires that the mine have two different plants, which utilise two different ROM feeds and have different beneficiation curves. Xpac is used to produce a rolling 18-month plan, which is as close to actual operations as possible. In order to do this, the simulations have to take into account the plants beneficiation curves, stockpile movements, hauling distance and equipment needs. On top of this, the schedule has to continually consider specifications for Fe and the contaminants. Plant yields also have to be kept within a certain bandwidth. Xpac is used to simulate the above parameters, as well as generate the raw data required to produce a mine budget. The paper will also show how the 18-month planning process and subsequent planning processes are measured and aligned. Xpac has proved to be an excellent tool to achieve these goals.

Jan 1, 2005

The basic methods to remove material from underground mines are to: convey continuously, batch in trucks, or batch in a shaft hoisting system. A critical aspect in shaft hoisting is accurately batch loading the conveyance or skip. During the 20th century, the almost universally accepted method of loading was via a measuring flask. A measured quantity of material was filled into the flask as the conveyance traveled through the shaft and then, when the conveyance arrived at the loading position, it was ædumpedÆ into the skip for hoisting. Two skip loading conveyor systems have been developed in Australia: BHP BillitonÆs Cannington Hoisting System, installed in 1996, is believed to be the first conveyor loading system designed for two skips. Two parallel conveyors were installed with a two-way gate controlling feed onto each belt. Cannington was ideally suited to conveyor loading as the very high ore density and relatively low production rate required a relatively small volumetric storage capacity on the weighed belt. Newcrest MiningÆs Telfer Hoisting System, which is to be commissioned in 2005, consists of a single slewing conveyor loading each skip with 32 tonnes of ore. The development of this system eliminates the two-way transfer, improves the accessibility and minimises the excavation required. While every hoisting system must be considered on its merits, conveyor loading offers significant advantages to the Mining Industry in the 21st century.

Jan 1, 2005

By Goudschaal Mark R.

"The Museum of Science and Industry U-505 Submarine Relocation project in Chicago, IL consisted of building an underground reinforced concrete vault (37' deep) for the Museum's new U-505 exhibit. This WWII submarine was captured in 1944, had been located outdoors at the Museum since 1954 and was lowered into its new exhibit area in 2004. A unique combination of earth retention, water cut-off and underpinning systems allowed a forty-two foot (42') deep excavation underneath th is historic museum. The museum - originally built in 1893 for the Chicago World's Fair - was closely monitored for building movements throughout construction. The underpinning systems, construction activities and monitoring results are presented herein. IntroductionThe historic U-505 German submarine at the Museum of Science & Industry was restored, moved approximately 1,000' and then lowered into its new indoor home (Figures 1, 2 and 3). The new underground exhibit opened this year celebrating the 61st anniversary of the German submarine's capture on June 4, 1944. On this historic day, Captain Daniel V. Gallery, a Chicago native, led the Navy in the siege of this submarine near the coast of Africa. This U-boat was the only German sub captured by the United States Navy in WWII and the Enigma machines, codebooks and publications recovered from the sub helped the war effort."

Jan 1, 2005

By Sayavur Bakhtiyarov

Keywords: Rheology, Viscoelastic, Oil In this paper we present the results of the rheological property measurements on viscoelastic composite materials used in oil industry. Laboratory experiments were carried out to determine important thermophysical, rheological and mechanical properties of the test materials using both the standard commercial and in-house made equipment. The composites with the paramagnetic particles (?-iron oxide) are exhibited a significant magnetic memory after magnetic treatment. The measured value of the yield stress after the magnetic treatment increased almost twice in comparison with the yield stress value of the magnetically untreated composite. The yield stress of the composite material exponentially decreases with time and reaches its magnetically untreated value after 15 hours. The yield stress also increases with the amount of the paramagnetic powder additive, and it reaches a maximum value at 8 wt-% of this additive. The obtained results provide valuable information for computer modeling of the viscoelastic fluid flow in pipes of complex geometry.

Jan 1, 2005

By Marco Antonio Falquete

A novel spark-generating tube, containing no explosive in its composition, is evaluated and compared with conventional shock tube. The product overcomes a series of problems found in conventional shock tube technology. The technologic development had multiple aims: to avoid transport and storage costs associated with explosives, to be more environmental-friendly, to obtain a high-velocity, hightemperature spark whose thermal performance could overcome poor heat transfer to the delay charge by gas convection at shock tube end, and that could cross barriers such as tight kinks, close knots, cuts, extreme environmental conditions, and long-term hot explosive emulsion exposure. The product of this development is evaluated and compared with conventional shock tube in a series of aspects and performance tests, including spark thermal performance (ignition of tougher, low sensitive delay columns, spark gap test), propagation in critical conditions of use (kinks, knots, cuttings), extreme environmental conditions (long-term exposure to hot emulsion explosive, extremes of cold, heat, moisture, underwater exposure), safety features (ignition through flame, open fire), and security against terrorist acts. Due to the safe characteristics of the tube, a series of demonstrations will be performed during the presentation. In nearly all tests and aspects, the spark-generating tube exceeds conventional shock tube, and in the rest equals shock tube, making it a more reliable alternative.

Jan 1, 2005

The fracture behavior of second phase particles and the role of matrix material on the wear resistances of the three Al-Si alloys containing 8, 17, and 19% Si were investigated using single pass scratch testing technique by applying normal loads between 0,15 and 5,00 N, in ambient air, Optical microscopy and SEM with EDS were used to analyze microstructures and morphologies of scratch tracks of the Al-Si alloys, The results showed that needle-like Si particles fractured under a load of 0.50 N, while block-like Si particles fractured at loads above 3,00 N, The Al-17% Si alloy with large number of needle-like particles (area fraction 16,4%) exhibited the highest coefficient of friction (0,8) and the widest scratch track, The Al-19%Si alloy containing high Si percentage and larger number of block-like particles (area fraction 16%) exhibited the lowest coefficient of friction (0,37) and the narrowest scratch track width. Presence of block-like particles was effective in reducing the amount of material transfer from Al-Si alloy surfaces to the counterface.

Jan 1, 2005

By D. Boufounos

The large open pit areas of surface mining as well as the huge quantities of residues generated during the digestion of bauxite with sodium hydroxide solution to produce alumina are considered as the most important environmental problems associated with the exploitation of bauxites. Aluminum of Greece, which is the only aluminum refinery in the country, located in Agios Nicolaos, Paralia Distomou, Viotia, produces almost 680.000 tones of bauxite residue annually which is pumped through pipes from the refinery to the sea bed of Antikira gulf. In order to avoid any kind of environmental problems related to this disposal method and to reduce the total volume of bauxite residue disposed of in the environment, Aluminium of Greece investigates several alternatives for bauxite residue utilization. In this framework, it also examines the potential use of bauxite residues as a filler in abandoned mining open pits. Bauxite residues are mainly composed of fine particles of silica, aluminum, iron, calcium and titanium oxides and hydroxides. Furthermore, the material presents low hydraulic conductivity, slightly higher than the limit posed for low permeability layers by the EC landfill directive. Based on these properties the dry disposal method was selected for disposing bauxite residues in mining open pits since it has many advantages such as reduced overall disposal cost, effective use of land and minimum environmental impacts. The results obtained for this method, which is investigated at demonstration scale, are presented in this paper.

Jan 1, 2005

By Paul D. Tomlingson

Modern production equipment has been designed with greater productive capacity and higher reliability to meet the rigorous operating demands of the mining industry. These improvements have also made the equipment more complex and challenging to maintain. Whether these equipment enhancements contribute to more effective mining operations depends on the overall quality of maintenance. Maintenance is not a stand-alone activity. Although its quality depends primarily on maintenance, cooperation and support from other departments, coupled with the skillful guidance of mining managers, greatly influence maintenance success. Therefore, maintenance risk management must look beyond maintenance itself. Successful maintenance risk management begins with an assessment of the maintenance-related interactions of all mining departments within the mine’s stated operating strategy.

Jan 1, 2005

By G. Hangone

Paper written on project work carried out in partial fulfilment of MSc thesis This paper investigates the effects of thiol collectors: xanthates, dithiophosphates, dithiocarbamates and mixtures of these on the froth flotation performance obtained with a bornite-rich copper sulphide ore from Okiep Copper Mine with a feed grade of 1.8%copper. Batch flotation tests were used to assess the performance in terms of mass-water recovery, sulphur grade-recovery and copper grade-recovery relationships and the Klimpel rate constant for copper recovery. The results showed that the di-ethyl-dithiocar-bamate (di C2-DTC) was the weakest collector of copper sulphide minerals. Highest copper recoveries were obtained with the di-ethyl-dithiophosphate (di C2-DTP), which were accompanied with more watery froths and lower copper grades demonstrating frothing properties in addition to collector action. Superior copper recoveries were obtained with the 90% ethyl xanthate (C2-X):10% di-ethyl-dithiophosphate (di C2-DTP) and 90% ethyl xanthate (C2-X):10%di-ethyl-dithiocarbamate (di C2-DTC) collector mixtures compared to that obtained with ethyl xanthate at an equivalent collector dosage of 0.139 mol/ton ore (a dosage equivalent to 20 g sodium ethyl xanthate per ton ore). A superior copper grade was obtained with the 90% ethyl xanthate: 10% di-ethyl-dithiocarbamate collector mixture at a dosage of 0.0695 mol/ton ore compared to that obtained with ethyl xanthate at the same equivalent dosage. Keywords: flotation, collector mixtures, copper sulphide ore

Jan 1, 2005

By P Vix

A thermodynamic model of the copper Peirce-Smith (P-S) converter has been developed to predict the behaviour of magnetite in the converter slag, the amounts of slag and matte, the compositions of slag and matte, the volume of the bath, the bath temperature and the SEMTECH OPC signals. The predictions of bath temperature, slag and matte compositions and magnetite content in the slag have been validated by the industrial data. The effects of fluxing strategy, returns and skim charges, oxygen enrichment and temperature on the magnetite formation in the slag have been predicted and discussed. Some industrial applications of this model have been presented.

Jan 1, 2005

Following the Moura No 2 Wardens Court of Inquiry and subsequent changes to the Queensland Mining Legislation there is a requirement in Queensland coal mines for: a person with the recognised competencies to be appointed at each underground coal mine to the position Ventilation Officer; and the person is directly responsible for the implementation of the mine ventilation system and for the establishment of effective standards of ventilation for the mine. The Regulations require that an underground mine must have principal hazard management plans that provide for at the least the following: emergency response, gas management, methane drainage, mine ventilation, spontaneous combustion, and strata control. Other than strata control all the plans require the ventilation officer to have roles and responsibilities to develop, control, monitor and undertake actions in relation to these plans.There are also another 34 Regulations that either directly or indirectly requires the Ventilation Officer to take actions.The purpose of this paper is to outline the information that the regulators look for in sealing plans and the actions the regulators will take if the sealing does not go to plan (TARPs being exceeded).

Jan 1, 2005

By C Katongo

Ground condition at No1. Shaft varies across the mine. The different ground conditions arise as a result of the differences in the rock strength and structure, seismicity and induced stresses in abutments areas. Apart from being a major cause of Fall of Ground incidents/accidents, adverse ground conditions where encountered has affected the rate of development advance as well as production. This implies that for support to be cost effective Geotechnical section has to ensure that support is designed to prevailing ground demand to ensure the safety of personnel and minimize loss of production. We have also seen changes in mining methods as a result of change in ground conditions. To avoid incurring unnecessary costs through remedial works resulting from ground deterioration and collapses of development openings due to inadequate support, the principle in engineering design is ?Do it right the First Time?, and this can only be achieved through good understanding of Geotechnical environment. The paper discusses the different ground conditions encountered in various development ends at No.1 Shaft. It also discusses the principles of ground support, failure mechanisms, types of ground support systems employed, and the different techniques used to select support systems, and quality control techniques in underground support installation.

Jan 1, 2005

Through the use of structural analysis programs such as Unwedge and considering the shear strength of applied fibrecrete it can be shown that fibrecrete can provide a higher factor of safety in a ætypicalÆ underground development excavation than standard rock bolts. This paper describes the progression of ground support from an æas requiredÆ component of mining to the use of bolts and surface support as a mandatory requirement. With the mandatory requirement for surface support, fibrecrete has been considered and applied as a secondary feature but simple analysis and practical observations indicate that it may be considered as primary support. The key elements to its implementation are: When is it safe to work under fresh fibrecrete and how do we practically determine this? How much ground support does fibrecrete provide? How can we reduce the cost of fibrecrete? An examination of these questions indicates fibrecrete can be much safer,less expensive and quicker to install than normal ground support elements. This paper explores practical examples from sites where significant benefits have been achieved by mine operators.

Jan 1, 2005

By T Gartner

This paper describes the design, manufacture and site services associated with the supply of mine hoists for the new mine under construction by Falconbridge Limited in Ontario, Canada. Two new shafts are being sunk, and the hoisting equipment at each shaft can be summarised as follows: Ventilation shaft:4.66 m diameter double-drum second-hand hoist, originally in operation at San Manuel Mine, Arizona, to be used as the shaft sinking hoist. The second-hand hoist presented a challenge in that during its previous life, the hoist had been intensively operated during service at San Manuel Mine, and this paper describes the scope of refurbishment work undertaken, both electrically and mechanically, to ensure future reliable operation, together with the requirement to meet Canadian and Ontario regulations and codes of practice. 3.05 m diameter new single drum auxiliary hoist to be used as a second means of egress. Main shaft:4.57 m diameter new double-drum hoist to be used initially as the shaft sinking hoist, and subsequently to be converted to the equivalent of a single-drum multi-rope hoist for service duties during the production phase; 5.49 m diameter new double-drum hoist to be used for skip hoisting during the production phase; and 3.05 m diameter new single drum auxiliary hoist.The new hoists are all designed to comply with SABS requirements such that hoisting with reduced rope safety factors will be possible in the future. This paper describes the principles involved both mechanically and electrically. Particular attention is paid to the conversion of the main shaft service hoist from a double-drum sinking hoist to a multi-rope hoist.This paper describes the ac electrical powertrains (drives and motors) used that eliminate the need for harmonic filters and reactive power compensation equipment since they exhibit no negative effects on the utility electrical network system. This paper describes the logistical challenges of installing, commissioning and setting to work a series of five hoists in a short time frame.

Jan 1, 2005

This paper outlines the role of commissioning in the project cycle, shows how to get organised for commissioning and describes the principal commissioning activities. Emphasis is placed on appointing key commissioning staff early in the project to coordinate the preparations for commissioning and on detailed planning and tracking to ensure that the required commissioning activities are performed satisfactorily. The management of safety during commissioning is reviewed.

Jan 1, 2005

By James T. Ludwiczak

Drilling and blasting in a Karst (sinkholes and mud seams) environment has long been a problem for blasters, miners, quarry operators, contractors, and developers. While one cannot change the geological conditions, one can take some measures during the bidding process and the initial preparation of the blasting program to help reduce some of the problems. During the geotechnical investigation and developing the test/core drilling grid, the owner/developer needs to take some additional measures that will provide important data to the blaster to help reduce the problems associated with blasting this type of geology. The owner/developer must also understand that, due to the geologic conditions, the results of the blasting will not be ideal and there may be additional blast-related costs. If provided the proper geologic data, the blaster can develop drilling patterns and blast designs that will help reduce some of the more problematic areas.

Jan 1, 2005

By Cathleen J. Webb, Arden D. Davis

The Homestake Gold Mine at Lead, South Dakota, has been proposed as the host site for the Deep Underground Science and Engineering Laboratory. The laboratory will house neutrino experiments in mine workings at the 7400-foot depth, as well as research in geomicrobiology, rock mechanics, and ground-water flow. Initial plans for the laboratory were developed in 2000 after Homestake Mining Company announced the closing of the underground gold mine. Homestake’s owner, Barrick Gold Corporation, had agreed to donate the mine for a laboratory if it could be protected from environmental liability. That initial agreement was delayed, and Barrick turned off the mine’s pumps in 2003, allowing lower levels of workings to begin to flood with water. In early 2004, the Governor of South Dakota signed an agreement with Barrick that would indemnify the company and eventually transfer ownership of the mine to a state laboratory authority. South Dakota’s governor also announced plans to ask the state legislature for funds to help in the initial construction of the laboratory. A consortium of scientists from several states is currently preparing a detailed laboratory proposal for the National Science Foundation.

Jan 1, 2005

By D McInnes

Rather than look at the problems associated with sampling, this paper deals with the issue of sampling and blending to optimise revenue û predominantly in the mining industry. An example of the use of this methodology in the agriculture industry is also presented. Mining companies, in particular, are experiencing a boom in commodity prices and many believe the industry is in the middle of a æsuper cycleÆ. Production levels are being escalated dramatically to meet the demand coming from China and India. This in turn has further stretched the capacity of our rail and port infrastructure û resulting in significant shipping queues around most Australian commercial ports and increased demurrage costs for the producers. Mining companies are now looking for effective scheduling, planning and blending to maximise production and reduce demurrage charges û given the current infrastructure constraints. Mining companies can no longer use spreadsheets to run their business. This paper further looks at how these outcomes can be met by optimised blending using an integrated supply chain management system such as MineTrak together with effective sampling and analysis.

Jan 1, 2005

By John M. L Lewis, Antoine F. Mulaba-Bafubiandi

In the irradiation of ore particles by microwave energy preferential absorption of this energy occurs in minerals having specific dielectric properties (Bradshaw, 1999). This leads to a selective heating of the various components of within the ore particle matrix. The result is a differential thermal expansion of such components and the resulting induced stresses become ideally concentrated at mineral grain boundaries (Kingman et al., 2000). Dependent upon the relative composition of absorbent, opaque and reflective components this may lead to enhancement of the inter-granular fracture of the ore particles in the initial comminution process (Fandrich et al., 1997). The potential is thus a greater proportion of free mineral grain within the fractured ore particle that may lead to improvement in subsequent mineral separation processes. As the composition of the ore dictates the result of such a treatment (Kingman et al., 2000) it is essential to evaluate the response of each ore sample on an individual basis. This paper reports on results obtained from two ore samples: the one being the zinc ore from the Black Mountain mine (South Africa) and the other a pre-concentrated sample of handpicked cobalt?copper mixed oxide ore from the Gecamines (DRC). The equipment and methods used to simulate the comminution of the samples and evaluate the level of the value liberation will be described along with the results obtained. Using King (1975), Kanellopoulous and Ball (1975), and Gungor and Atalay (1998), a comparison between the behaviour upon microwave irradiation of sulphide and mixed oxide ores leads to conclude that while the technique (i.e. microwave irradiation) is appropriate to the zinc sulphide ore, it does not seem to lead to exceptional results for the oxide.

Jan 1, 2005