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By A Scott, S Kanchibotla, J Segui

The æMine to MillÆ concept is not new. In fact, it is the underlying objective of every mine. Unfortunately, in many operations the management structure and reporting systems have created independent æbusinessesÆ within the overall mining enterprise. This has created incentives to optimise the performance of each component of the operation rather than the enterprise as a whole. The Mine to Mill Conference organised by The AusIMM in October 1998 documented a number of case studies where run of mine ore was not presented to the mill in the best possible form for subsequent stages of comminution and processing. A number of examples were quoted where modest expenditure in the mine had a very significant impact on downstream process efficiency and hence costs. Examples included:the minimisation of fines in the mining and handling of iron ore; the management of fines in blasting and crushing for a copper heap leach operation; the control of blast damage, mining recovery and dilution in open cut coal operations; and the optimisation of mine fragmentation to increase mill throughput in gold and copper operations. The latter topic has been trialed at a number of mines and is referred to as æMine to MillÆ fragmentation. A number of æMine to MillÆ type investigations have been reported in the literature including Pease et al, Simkus and Dance, Nielsen, Scott et al, Kojovic et al, Kanchibotla et al, Bulow et al and Hawkes from the 1998 Mine to Mill Conference. In addition, a number of studies are in progress or the results have yet to be published. These studies have demonstrated the feasibility of obtaining the data required to characterise the breakage behaviour of ores and to model the impact of changes to blasting practices on process efficiency. Characterising the breakage behaviour of ores is a vital step in the management of fragmentation and comminution in mines. The characteristics of importance to fragmentation fall outside the parameters conventionally required to describe the economic geology of a deposit. æMine to MillÆ optimisation of fragmentation means that the mining engineer needs information from the geologist in order to be able to help the metallurgist. Providing this information requires close interaction between these groups.

Jan 1, 2000

By H. Matsuda, T. Iwashita, H. Awata, H. Liwei, D. Hirabayashi, Y. Saito, S. Ozawa, Y. Goto

"The present study is concerned with investigating the effect of chemical treatment on enhancing the HCl absorption capacities of coal burnt ash and slag. It was found that the HCl absorption capacity of coal burnt ash discharged from fluidized bed combustor was improved by hydration with water and 5% polyethylene glycol solution. This phenomenon was based on an increase of the specific surface area of treated coal burnt ash. The HCl absorption capacity of hydrated ash with polyethylene glycol solution was almost equivalent to that of standard CaO and Ca(OH)2. In particular, the specific surface area of hydrated ash with polyethylene glycol solution was found to be 19 m2/g, which was more than over eight times larger than that of raw sample. Hydrated slag treated with lON sodium hydroxide solution also showed high HCl absorption capacity, with highly improved surface area. It was found that the absorption capacity of slag for HCl depended on the treatment time, showing the maximum absorption capacity for 12 hours of hydration treatment.IntroductionA large amount of coal burnt ash, slag and dust are discharged from such industrial processes as coal combustion and metal refinery etc., and it becomes an serious problem to recover and diminish these solid wastes because of the shortage of dump sites and subsequent metal elution to the environment. Figure 1 shows the present situation of reutilization of coal burnt ash and slag in Japan [1,2]. It is shown in this figure that these solid wastes are recycled as materials in the fields of earthwork, agriculture and forestry etc. A part of these solid wastes, however, is still dumped to landfill. To decrease this dumped amount, the development of environmentally friendly reutilization technique for these solid wastes is of great importance."

Jan 1, 2000

By Y Yang

Despite the importance and usefulness of basicity in metallurgical slags, the optimum quantitative expression of it has remained elusive, partly due to the fact that the precise concept of basicity has not been properly clarified. The two basic approaches to the concept of basicity are the Lux-Flood, which perceives basicity in terms of the activity of the free oxide ion, aO2-, and the Lewis, which perceives basicity in terms of the ability to donate negative charge. The former has been almost universally adopted in the area of metallurgical slags, while the latter has been increasingly accepted in the field of glass chemistry. In this paper, some difficulties of the Lux-Flood approach are pointed out, including the need for indirect measures of aO2-, which have proliferated in recent years. Accordingly, it is suggested that the Lewis approach has a good deal to commend it, and that the quantification of it in terms of optical basicity is the best measure of basicity available, which should therefore be more widely applied in metallurgical slags than it currently is. The fact that there are intrinsic problems in evaluating the optical basicities for the transition metal oxides is acknowledged, and a new scale is recommended. The patterns of iso-optical basicity lines in ternary systems are shown to agree well with the pattern of iso-activity and iso-capacity lines under appropriate conditions.

Jan 1, 2000

By D. Y. Wang, G. Y. Sha, X. L. Shen, D. R. Gu

The study of the volatilization kinetics of zinc and lead in pellets made of zinc-leadbearing dust mixed with coal powder, in a nitrogen atmosphere and at a temperature range between 1100 °C and 1300 °C, shows that the reduction temperature has a significant effect on the volatilization rates of zinc and lead, and that both the particle size of the coal powder and the extra carbon content has no effect on the volatilization rates. The obtained activation energies for the volatilization of zinc and lead are 79.42kJ/mol and 88.74kJ/mol respectively. The volatilization rate of zinc is controlled by the reaction between the zinc oxide and carbon monoxide while that of lead is controlled by the lead evaporation reaction, and the diffusion of gaseous lead through the gas boundary layer covering the surface of the reduced liquid lead.

Jan 1, 2000

By J. D. Robertson

An in situ water sampling device has been developed to measure biologically-available or “labile” metals in natural waters and effluents. The active mechanism involves the use of a polyacrylamide gel layer to quantitatively control metal transfer to a trace-metal-adsorbing, gel-imbedded resin. Because the resin only adsorbs free metal ions (the gel sampler methodology is a kinetic speciation technique), and because metal bioavailability is related to the free-ion activity, the device provides a direct measure of the biological-availability of metals in the environment sampled. The prototype consists of a layer of ion-permeable polyacrylamide gel which separates the solution to be sampled from an ion exchange resin. Because approximately 90% of the polyacrylamide gel is water, mass transport through the gel is diffusion-controlled, and is therefore well defined. Metal ions are rapidly bound by the resin, creating a steep concentration gradient in the gel. The amount of labile trace metal that accumulates on the resin can be related directly to the concentration of the metal in solution, the exposure time and the molecular diffusion coefficient of the labile species. In addition, the passive nature of this device affords it the potential to address many of the limitations presented by conventional sampling methods, such as sample contamination introduced during collection or filtration and changes in trace metal speciation prior to analysis. Laboratory studies and limited field trials indicate that the sampler behaves as anticipated and illustrate that biologically- available metal concentrations in many environments are a small fraction of the total concentrations and often significantly less than the dissolved concentration. The implications of this on regulatory criteria are discussed. Additional field trials and correlation with bioassays are currently underway.

Jan 1, 2000

By P Bourke, S Ronkainen

Since the early days of flotation, process technicians have known that the speed at which the froth is recovered over the lip of the cell has a very direct and consistent influence on the grade and recovery of the circuit. No plant would deny that, even to this day, one of the most important aspects of a process technicianÆs job is ensuring that the froth is moving at a desired and controlled speed over the lip. Unfortunately, process technicians cannot watch the froth throughout the entire shift, as there are always other problems to attend to. A considerable amount of work has thus been done to develop a æsystemÆ that automatically measures the speed of the froth. This measurement would then be used in simple controllers to emulate the steps taken by the process technician in correcting deviations of the froth speed from its desired level. Many of the earlier attempts to measure speed were ineffective, as they were unable to cope with turbulence on the froth surface. The FrothMasterÖ instrument makes use of machine vision technologies to measure the speed of the froth over the lip of a cell at a very high sampling rate. This instrument produces an extremely reliable and accurate measurement of the froth speed (as well as other parameters such as bubble size and froth stability). As we will show, the effectiveness of the speed measurement in controlling the performance of the plant is a testimony to its reliability. Three FrothMasterÖ units have recently been installed on the Cadia Hills Gold Mine in New South Wales (Australia). The objectives of this installation were:to control the mass-recovery of two Tank Cells in series on the same level where differences in the hydrostatic head between the two cells result in the cells pulling inconsistently with respect to each other; control of the concentrate grade (per cent copper) from the first rougher; reduction in the frother consumption in the rougher circuit by monitoring the froth speed. A simple controller was designed to react to disturbances in the same way that human operators react. This was done after consultation with the metallurgists and the process technicians at Cadia. The controller had two functions: Stabilisation: The stabilising controller made use of three manipulated variables (level, frother addition rate and aeration rate) to control the froth speed to a setpoint. Optimisation: The optimising controller adjusted the froth speed setpoint based on deviations of the grade (measured in real-time by the OSA) from a setpoint. The plant metallurgist adjusted the grade setpoint based on information about the ore. The results from a 21-day trial have shown the following:The ratio of concentrate mass-recovery between two cells in series on the same level has been successfully balanced, thereby overcoming problems due to differences in hydrostatic heads. It is possible to control the speed of the froth, in mm/s, to within five per cent of its setpoint using the aforementioned manipulated variables. It has also been shown that, for reliable control, it is necessary to control more than just one variable (eg level or air). The grade of the first rougher concentrate has been controlled to within 0.3 per cent of the grade setpoint for long periods of time, which has important implications for the circuit recovery. The frother consumption has been reduced significantly. This paper will thus show that substantial progress has been made to demonstrate the value of using on-line froth speed measurements in flotation plant control to obtain real financial benefits.

Jan 1, 2000

By D R. Lueking

A technology involving separate unit processes for the generation and use of ferric ions for the oxidation of sulphidic minerals has been developed. The technology utilises a stand-alone automated bioreactor for ferric-ion generation (termed SAAB-FIG) and produces a low pH, ferric ion-rich leach liquor with a high oxidation potential. This leach liquor is then employed, in a separate unit process, to oxidise sulphidic minerals and regenerate ferrous iron that may subsequently be recycled to the bioreactor for the continual generation of ferric ions. The technique was successfully applied for the recovery of copper from chalcocite (Cu2S) and chalcopyrite (CuFeS2), as well as other ores and concentrates containing copper sulphide minerals. Coarse ore, ground ore and concentrates were treated with acidic solutions containing 8 to 12 (g/L) Fe(III) ions at a variety of temperatures. This process yielded over 50 per cent of the contained copper from both chalcopyrite and chalcocite samples. Maximum reaction rates and copper recoveries were found to be highly dependent upon temperature and pH and leach liquors containing bacterial cells displayed little difference in their leaching efficiency when compared to cell-free leach liquors.

Jan 1, 2000

By M. Vallée

Several reviews of mineral project performance in the past 35 years indicate a pattern of occasional, but recurrent, mining project failures due to shortcomings in geological information and estimation, mineral processing and metallurgical testing, feasibility study objectives and requirements, and project start-up methods. A commitment to quality assurance and continuous improvement methods and to obtaining “ENOUGH DATA, OF APPROPRIATE QUALITY” is essential. Recent international and Canadian proposals for mineral resource and ore reserve definitions have taken a nonprescriptive stance that will undermine the formulation of requirements, guidelines and industry standards for efficient deposit delineation and estimation, and for the determination of project feasibility. To help reduce problems, every feasibility study supporting a mine development and production decision should be based on objectives and methods adequate to reach completion targets similar to the bankers’, as a good business target for a profitable project. In a resource/reserve system, the use of reserve should be restricted to a project that meets required technical, economic and legal feasibility requirements for successful project implementation, and the definitions of these categories should provide explicit limits. Current shortcomings will limit the ability of the Qualified Person to provide “adequate professional practice,” fulfill his/her professional responsibilities to his employer or client and provide adequate information to the investing public. We must take advantage of present opportunities for Setting New Standards for the new Millennium.

Jan 1, 2000

By R. A. Jankowski

Although the number of operating longwall mining systems has remained relatively constant, longwall production levels during the last five years have increased significantly. In the United States, longwall mining now accounts for approximately 50% of all underground coal production. While longwalls are highly productive and offer other advantages, operations employing this method of mining continue to experience dust-compliance problems. This increased longwall productivity has meant that far more dust is being produced. An improved understanding of the longwall face-ventilation system and the advancement of face-ventilation technologies are necessary to ensure all face personnel are allowed to work in an environment that is free of excessive levels of airborne respirable coal mine dust. The Dust and Toxic Substances Control Branch, National Institute for Occupational Safety and Health, Pittsburgh Research Laboratory, examined several basic principles of the long wall face-ventilation system and has evaluated the effectiveness of numerous improved face-ventilation techniques for longwall mining systems. These include identifying improved techniques for measuring face-ventilation parameters on longwall mining sections and investigating the fundamental relationship between face airflow and the entrainment and dilution of respirable coal mine dust. Studies have been completed to determine the impact on face dust levels of using belt entry air to ventilate the longwall. Novel methods have been identified to increase the face air¬flow and to manage face airflow to effectively minimize dust exposure to face workers. Unique systems of auxiliary face ventilation have been developed and evaluated at full-scale, simulated longwall test facilities. The theoretical and applied aspects of each of these principles and technologies are discussed. Application of these results throughout the longwall mining industry, as documented from surveys conducted in the early 1980s and 1990s, have reduced the health hazard associated with excessive exposure to respirable coal mine dust.

Jan 1, 2000

WMC Limited, owner/operator of Olympic Dam, the worldÆs largest underground uranium mine and the fourth largest underground copper mine has now completed an expansion that has been classed as a benchmark in the mining industry. To achieve a production increase from 3.4 to 9.25 Mtpa from an underground mining operation in two years was a major challenge, it was essential to review the overall materials handling system from æthe face to the stockpileÆ. The challenge was two-fold:How to deliver 30 000 tonne of ore per day to the processing plant, from a single underground mine? To provide the processing plant with a consistent metallurgical feed. This paper traces the transformation from the old to the new materials handling system at Olympic Dam.

Jan 1, 2000

By Patrick R. Taylor

Glass is used for immobilization of radioactive and hazardous wastes due to its durability and ability to accept a variety of waste constituents into its network structure. Alternative high temperature vitrification techniques have the advantage of increased throughput, increased waste loading and being applicable to variable and heterogeneous waste streams. However, the increased processing temperature places further concerns on the increased volatilization of contaminants, and increased corrosion and erosion of me Iter components. A database of melt properties at higher temperatures, such as partitioning, viscosity, density and electrical conductivity, in the temperature range of 1400-20000 K are being developed.

Jan 1, 2000

By BRETTMANN TRACY

Jan 1, 2000

By N N/A

To the members of The South African Institute of Mining and Metallurgy We have audited the annual financial statements set out on pages 239 to 245. These financial statements are the responsibility of the Institute?s Council. Our responsibility is to express an opinion on these financial statements based on our audit. Scope We have conducted our audit in accordance with statements of South African Auditing Standards. These standards require that we plan and perform the audit to obtain reasonable assurance that the financial statements are free of material misstatement. An audit includes: ?examining, on a test basis, evidence supporting the amounts and disclosures in the financial statements ?assessing the accounting principles used and significant estimates made by management ?evaluating the overall financial statement presentation. We believe that our audit provides a reasonable basis for our opinion. Audit opinion In our opinion, the financial statements fairly present, in all material respects, the financial position of the Institute at 30 June, 2000, and the results of its operations and cash flows for the year then ended in accordance with South African Statements of Generally Accepted Accounting Practice.

Jan 1, 2000

By W lethlean, Laurie Smith

When coarse gold is present in an ore, there are advantages in physically recovering this gold in the grinding section of the ore processing plant. This reduces the risk of the coarse gold being locked up in the grinding section equipment, reduces the quantity of activated carbon to be eluted and reduces the risk of gold passing out of the cyanide leaching circuit only partially dissolved. The free gold may be recovered by various mechanical means utilising the significant difference between the specific gravity of the gold and waste minerals. Frequently, sulphide minerals and ball mill attrition steel in the form of fines and chips are present in the ground ore and behave in a similar manner to the gold in the concentrating process. These materials must be removed to produce a concentrate suitable for direct smelting and several stages of cleaning, sometimes utilising different physical principles, may be required. The removal of these materials invariably results in a loss of gold from the final concentrate. The rejected materials containing significant quantities of gold are returned to the grinding section, consequently the opportunity for a high and early recovery has been lost. The quantity of gold returned to the grinding section will vary according to the number and type of cleaning stages and the physical characteristics of the materials and the gold but surveys of the gravity concentration processes suggest that it may be as high as 50%. To maximise the recovery of gold from the primary gravity concentrate, some operations batch cyanide leach this concentrate with or without additional reagents. The method of agitation and solution recovery vary. The most common method of agitation is by a high-speed propeller mixer and the least expensive but time-consuming method of solution recovery is by decantation after settling and by repeated decant washing. The pregnant gold solution is either introduced into the main ore leaching circuit or the gold is recovered by direct electrowinning. After commissioning in 1994, Union Reefs Gold Mine (URGM) experienced below expected recovery of gold from the gravity concentrate generated from the Knelson Concentrators. It was shown that the recovery into the Knelson Concentrate was high but that the subsequent mechanical concentrating techniques of tabling and magnetic separation resulted in significant gold being returned to the grinding circuit.

Jan 1, 2000

By M Fishwick Tapia

This paper was prepared and translated from the final report of the investigation into the Codelco Chile Salvador DivisionÆs air blast which occurred in the Inca-West area. In this section of the block cave mine, a stable arch formed covering an area of approximately 15 000 m2 . This zone subsequently collapsed producing a massive air blast. The collapse followed a series of planned extraction activities and occurred on 5 December 1999. This paper discusses the cave back arching event and the measures that were taken in order to induce the controlled collapse. This was to minimise risk to personnel, equipment and installations. The results obtained to date are presented.

Jan 1, 2000

By Slav Tchepak

The King's Wharf development is located in Sydney's Darling Harbour area. The site was originally used for industrial maritime purposes, which over the years has been reduced to accommodating leisure craft only. The site has been filled with various materials, resulting in fill materials varying from soils, to concrete and rock fill. A prestigious new residential development at the site required piles to found in Sydney sandstone that occurred at depths ranging from 1 to 27m. The selection of appropriate pile types is discussed, as are details relating to the design and construction of cast insitu Omega piles and CFA piles. A number of issues needed to be addressed relating to the piling, including the design of the piles, the potential for liquefaction of the fill material due to earthquakes, penetration of the piles through the fill materials, installation of the piles to a satisfactory positional tolerance and pile performance. A number of piles were dynamically tested to prove pile performance and these results are presented and compared with design expectations. The project was successfully completed on time and budget, indicating the selection of pile types in the difficult ground conditions to be appropriate.

Jan 1, 2000

By Norihisa Iida, Yutaka Koshiba, Tsutoipu Masui

"Mitsubishi Materials has many years of experience in the production of oxygen free copper (OFC) and its alloys with a fully continuous-casting process. Four grades of OFC, commercial, electronic, superconductor, and ASTM class I are available according to user needs such as stabilizer for superconductivity, magnetron, and ultra-vacuum systems. Along with Cu-Ag and CuSn, we offer OFC based copper alloys such ·as Cu-Cr-Zr, Cu-Fe-P, Cu-Ni-Si and others, that are suitable for lead frame and connectors. Within the maximum sizes of 260mm X 1050mm for cakes and 385mm diameter for billets, we are very flexible and can adjust the ingot size to customer’s requirements. Other products that we can supply are semi-finished products such as hot rolled sheet, ·forged blank, extruded rod and finished products like mold for continuous casting of steel, ring mold for non-ferrous casting and backing plate for sputtering target.IntroductionMitsubishi Materials Corporation developed mass produced high quality oxygen free copper and. high copper alloy ingots in the 1960's. We produce 60,000 - 70,000 tons annually giving us 22 - 23% share of the world's market.Our oxygen free copper and. copper alloys are produced with a fully continuous casting process using only high-grade copper cathodes from our Naoshima and Onahama refineries. The raw material is melted and cast in' a carefully controlled atmosphere resulting in a product with low impurities and excellent properties.Using a controlled atmosphere it is possible to produce high quality copper alloys including active elements like chromium (Cr), zirconium (Zr), titanium (Ti), and magnesium (Mg) which are difficult to produce using standard batch casting methods.Using our own cakes and ·billets we produce and supply worldwide wrought materials like molds for ferrous and non-femous casting. These products receive special patented thermo-mechanical· treatments resulting in high strength and excellent conductivity with low cost."

Jan 1, 2000

By S. J. Thiele, T. Newton, W. Magalhäes, T. Takayama, J. Welsh

Companhia Paraibuna de Metais (CPM) is presently pursuing a zinc production expansion project. Besides increasing production, the goal of the project is to address existing problems while providing a platform for a proposed twofold increase in production in 2003/2004. Therefore, the current expansion strategy was formulated to address present and future requirements. Computer simulation modeling and full scale plant testing are being used to generate data to optimize the operating conditions and to perform a sensitivity analysis. The initial phase of the project, which will boost CPM's capacity to 86,000 t/y of marketable zinc, is to be completed in September 2000.

Jan 1, 2000

By G. Sterzik, W. A. Jankola, T. L. Salway, D. J. McKay

At Trail, British Columbia, Cominco's zinc leaching and solution purification processes include direct pressure leaching of zinc concentrates, leaching of fume from the lead smelter, leaching of calcine and electrolyte purification. These processes have been adapted to match the unique characteristics of Cominco's integrated zinc and lead operations. Recent modifications include changes to the purification process and iron-residue handling circuits. In 1997, a new five-compartment autoclave, complete with ancillary equipment, was installed in the pressure leaching plant. This paper discusses these changes, the current flowsheet and further improvements.

Jan 1, 2000

By R Brake

The Enterprise Mine (EM) is located at Mount Isa and is wholly owned by Mount Isa Mines Limited (MIM). This high-grade copper mine extends from about 1000 m below surface to almost 2000 m below surface. A recent $400 million upgrade has taken the operation from a production rate of 1.3 Mtpa to a capacity of 3.5 Mtpa. The effects of high surface ambient temperatures in summer, combined with the depth of the mine and high virgin rock temperatures results in heat stress in the working place that, without intervention, would exceed the levels that human physiology can withstand. It would also result in significant decreases in productivity and high accident rates even where work is possible. Moreover, with a very hot and deep mine, the needs of æegressÆ and entrapment of workers during a mine emergency must be carefully considered. Enterprise Mine has taken a æsystems approachÆ to the issue of working productively, healthily and safely in heat. This involves setting limits of thermal stress for workers, understanding productivity decrements when working in heat, establishing productive and healthy environmental targets, developing engineering solutions to meet these targets, creating a well-educated workforce with respect to working in heat and then developing health protocols to ensure workersÆ health is protected. Refrigeration must be added to the mine to provide acceptable and productive conditions underground. By the time the mine is commissioned in 2000, Enterprise mine will have an installed refrigeration capacity of in excess of 40 MW(R). The ventilation engineering principles proven over many years at the other Isa underground mines are tailored to æfloodingÆ the mine with air to remove the heat, which is the main contaminant. This principle will not work at the Enterprise Mine, for reasons discussed below. With the underlying ventilation principle no longer satisfactory, a complete review of the entire ventilation principles and engineering solutions was required for the Enterprise Mine.

Jan 1, 2000