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By D. S. Conochie

The world is poised for rapid growth in consumption as large, less developed economies acquire greater wealth. It might be expected that there would be a corresponding growth in waste generation, but this might not necessarily be the case. The metallurgical industry has an excellent record of process development which has allowed it to provide a high tonnage supply of low cost, high quality metals. Environmental challenges have been faced and indeed the recycling of scrap iron through the electric arc furnace has made a massive contribution to cleaning up obsolete structures and equipment of past generations. Issues in waste generation and processing still remain, and the expectation for cleaner processing and environmental performance continues to rise. The waste impact of key process developments of the last century and the recent developments in metallurgical waste processing in Canada will be outlined. The potential to use state of the art design tools to produce the next generation of zero waste processes will then be explored.

Jan 1, 2004

By Dan A. Brown

Outline ? Basic Concept of ACIP Piles ? Factors Affecting ACIP Pile Performance ? Applications: - Favorable Conditions - Unfavorable Conditions ? Design for Axial Loading ? Lateral Loading Considerations ? Summary & Conclusions

Jan 1, 2004

In practice, frothers are selected following general guidenlies and verification by laboratory and/or plant flotation tests. The terms “powerful” or “selective,” which are commonly used to characetrize frothers, have intuitive rather than scientific meaning. A research program has been set out to study fundamental properties of the flotation frothers and to identify the tests which can provide information needed to characterize and classify such flotation agents.

Jan 1, 2004

By Ian R. Morrison

"Abstract - The Izok Zn-Cu-Pb-Ag volcanogenic massive sulfide deposit is located 265 km south of Kugluktuk (Coppermine), Nunavut Territory, Canada, in the west-central Slave structural province. The Izok deposit is owned 100% by Inmet Mining Corporation and represents one of the largest undeveloped zinc-copper resources in North America. The Izok deposit is hosted within and near the top of a thick sequence of predominantly felsic pyroclastic rocks of late Archean age. The hanging-wall stratigraphy includes additional felsic volcaniclastic rocks, andesitic and basaltic flows, thin sulfide-rich iron formations, and turbiditic sedimentary rocks. The felsic volcanic rocks are intruded by intermediate dikes and sills, followed by gabbroic dikes and sills. Both intrusive suites are interpreted to be volcanic feeders to the overlying flows. All lithologies are subsequently cut by younger, irregular, granitic pegmatite and diabase dikes. The volcanic and sedimentary rocks are regionally metamorphosed to pyroxene hornfels grade. The massive sulfides occur within a large (kilometer-scale) Na-depleted sericitic alteration zone. The immediate footwall and hanging-wall rocks to the deposit are characterized by zones of muscovite- biotite-sillimanite, lesser chlorite-biotite-cordierite, and locally intense silicification and sodium metasomatism. All lithologies have been affected by younger Ca-metasomatism. As currently defined, the Izok deposit comprises a cluster of five complexly zoned composite lenses: the Northwest, North, Central West, Central East, and Inukshuk lenses. The first four lenses are amenable to open-pit mining, whereas the Inukshuk lens will require underground development. The total indicated mineral resource presently stands at 16.5 million tonnes with a grade of 2.2% Cu, 11.4% Zn, 1.1% Pb, and 60 g/t Ag. Inmet Mining Corporation is presently reviewing the economic feasibility of developing the property."

Jan 1, 2004

By J. E. Udd

"In early 2000, CANMET-MMSL was engaged by the Ontario Ministry of Labour (OMOL) to conduct an international study of the practices, in several key mining jurisdictions, of determining the criteria that are used to decide when the wire ropes used in mine hoisting are to be retired from service. Subsequently, the author visited key officials and institutions in Canada, the United States, the Republic of South Africa, the United Kingdom, Germany, and Poland. Material from the Australian province of New South Wales and Hungary was also included.The report that resulted included, among other sections: (1) the history of wire ropes and trends in manufacturing technology; (2) a review of mine hoisting practices; (3) the requirements regarding safety factors; (4) a review of the various operations and their potential future development; (5) the criteria for rope replacement; (6) potential future developments that could take place in both hoisting and rope inspection practices in Canada; and (7) recommendations.Subsequently, the report was issued by OMOL, and as a CD-ROM by CANMETMMSL. In this paper the author presents the key findings and the recommendations made in the study."

Jan 1, 2004

By T. Fabritius, L. Hekkala, J. Härkki

The Outokumpu steel belt sintering technology is used for manufacturing chromite pellets that are charged into smelting furnace for ferrochromium production. Hot air is blown through the moving bed of raw pellets. Direct temperature and flow measurements are difficult to do in the bed of a real scale belt sintering process. Therefore, a tested and reliable mathematical model would be a valuable help for optimising operational parameters of the process and designing new constructional improvements. The aim of this work is to present a mathematical model that calculates the gas flow and temperature distribution in the bed of pellets and the atmosphere. Computational fluid dynamics program FLUENT is used to calculate the gas flow, composition and temperature of the gas in the sintering bed during processing. Energy equation for the bed, containing the effects of evaporation of water and oxidation of carbon and iron oxide, will be added to the model to obtain the temperature of the pellets. The porous media model used for pressure drop calculations in the bed is shortly discussed. A comparison between CFD-calculations and experiments with a pilot scale batch-sintering reactor are also presented. The final model can be used as an engineering tool when developing the process and the equipment further. Different designs can be easily tested with the model and the effects of the changes to the flow pattern and temperature distribution can be studied.

Jan 1, 2004

By H. R. Maggard, C. M. Bollinger

Solving the problem of detecting underwater explosions from "dynamite fishing" can be done by using a system of sonobuoys programmed to detect the acoustic waves from underwater explosions. The system includes three anchored sonobuoys, which have radio communication to a central station. Each sonobuoy will detect the direction the blast occurred, and then send the magnitude of the acoustic waves and the blast direction to the central station where the blast distance will be calculated. The central station can the send the coordinates to the authorities who can find the location using GPS systems onboard their boats.

Jan 1, 2004

By S. Xu

Magnesium alloy AM50 is of interest to automotive cradle application because of it excellent castability and good ductility. In this work, microstructure and mechanical properties of both low pressure die cast (LPDC) and high pressure die cast (HPDC) AM50 test bars are characterized. Microstructure was examined using optical microscope, scanning electron microscope (SEM) and transmission electron microscope (TEM). Phase identifications were performed using energy dispersive x-ray spectrometer (EDS) and TEM diffraction. It has been found that LPDC produces much coarser microstructure than HPDC. At the same time, the HPDC samples are more heterogeneous in microstructure and composition close to grain boundaries. Particles with various dimensions and morphologies of two different intermetallic phases, Mg17A112 and A18Mn5, were found in all the samples. Mechanical tests were performed under conditions similar to those related to an engine cradle application. LPDC samples show lower strength but better creep resistance than HPDC mainly due to the difference in grain sizes and grain boundary microstructure between LPDC and HPDC. Creep curves are well described by the empirical Andrade equation. Tensile-compressive yield and creep asymmetries were found in AM50, i.e. better deformation resistance in tension than in compression. The average yield asymmetry ratio for all the samples is 0.87. Microstructural examinations on the samples tested in tension, compression and creep showed that the deformation mechanisms in AM50 were slip plus twining at temperatures up to 125°C. The examinations indicate the important role of twining in the asymmetry phenomenon. The creep results indicate that dynamic precipitation of the Mg17A112 phase during testing is not the mechanism directly responsible for the creep asymmetry in AM50.

Jan 1, 2004

By M. Tangstad, H. Brun, P. Calvert, A. G. Lindseth

In 1999, Eramet bought the ferromanganese plants in Porsgrunn and Sauda (Norway) and Marietta (USA). With an ownership in the Comilog mine, the plants will operate with a high amount of Comilog ore. The properties of Comilog ore are reviewed and compared to a number of industrial operations. Important ore properties are chemical and mineralogical analyses, CO reactivity and mechanical strength. The advantage of Comilog ore is its contribution to lower energy and coke consumption. However, special precautions must be taken regarding the amount of fines and water introduced in the furnace, as Comilog ore is more porous compared to other Mn ores.

Jan 1, 2004

By Vanessa M. Torres

Cia. Vale do Rio Doce is currently developing Niquel do Vermelho Project. The laterite deposit is located at Carajas Mineral Province at less than 15 km from Sossego Copper Project, scheduled for start-up in 2004. The available infrastructure, includes paved roads, large capacity railroad and port complex owned by CVRD, power supply and good quality water. The project was evaluated in the past for ferronickel production. In the late 1990s, CVRD switched its attention to investigating the usage of pressure acid leaching. The combination of good metallurgical behaviour for pressure acid leach (PAL) process route with reasonable mineable grades, and existing infrastructure justified the start of engineering studies in 2002. The project approach at the engineering phase is based on the dual objective of minimizing risks while maximizing project profitability and value. CVRD is currently completing the Niquel do Vermelho prefeasibility study. This paper outlines the main outcomes of the study and future perspectives for the project.

Jan 1, 2004

By Nicholas Zabaras, Deep Samanta

"Solidification of metal aluminum and aluminum alloys is modeled on uneven surfaces characterized by sinusoidal curves. Wavelengths and amplitudes of these sinusoidal surfaces are varied to study their effects on processes like solidification, macro-segregation and inverse segregation. Solidification and macro-segregation are modeled using a slightly modified form of a stabilized finite element method developed recently to model high Rayleigh number solidification and porous media flows. For pure metal solidification, the effect of varying amplitudes and wavelengths is observed in heat transfer, fluid-flow ~nd phase change processes. The relative importance of shrinkage driven flow and solutal convection on the redistribution of solute for an alloy solidifying in a rectangular cavity is compared. The analysis is then extended by modifying one of the surfaces to a sinusoid. In this case the effects of varying amplitudes and wavelengths are studied in heat transfer, fluid flow, phase change, macro-segregation and inverse segregation processes.1 IntroductionTransport phenomenon during solidification of alloys is a major cause ofcasting defects such as segregation, micro-voids, hot tears, porosity, internal and surface cracks. Heat flow across metal and mold surfaces directly affects the phase change process and plays an important role in determining freezing conditions within the metal. In alloys, natural convection and shrinkage play an important role in determining the final solute redistribution, macrosegregation and evolution of solid macromorphology. Surface unevenness plays an important role during the early stages of solidification. It influences the heat transfer rate and fluid flow in the melt, which in turn affect the morphology and shape of the solid-liquid interface. The effect of surface unevenness on solute redistribution is important during solidification of alloys, where solute driven flow in the mushy zone is prominent. Thevik and Mo in [7] and [8] used a one dimensional model for studying surface segregation and macrosegregation in alloys under the influence of exudation and solidification shrinkage. Air-gap formation in their model was expressed through a variable convective heat transfer coefficient at the boundary. Tsai et al. in [3] and [4] have modeled macrosegregation in an aluminum-copper alloy driven by shrinkage and solutal convection. They used a single domain model based on mixture theory and solved the transport equations using finite difference methods. Our aim is to model solidification of aluminum followed by macrosegregation and inverse segregation in aluminum-copper alloys on uneven surfaces by finite element methods. These surfaces are modeled as sinusoids characterized by amplitudes, ?s and wavelengths, As, By varying As and ?s, changes in heat transfer, fluid flow, phase-change and macrosegregation are studied."

Jan 1, 2004

By Maria I. De Rosa

Table 55 and figure 19 show the number of fires and fire injuries for stone mills by state during 1990-2001. Table 55 also shows the injury risk rates, employees' working hours, and lost workdays. In all, 118 fires occurred in 33 states. Seventy-six of the fires caused 82 injuries (including 8 fires and 6 injuries involving contractors). The yearly average was 9.8 fires and 6.8 injuries. The Ewhr value was 873 x 106 hr (In = 0.019), and the LWD value was 1,911. Missouri had the most fires (16 fires and 9 injuries), followed by Pennsylvania (15 fires and 14 injuries), Michigan (9 fires and 5 injuries), and Virginia (7 fires and 5 injuries). Of these states, Virginia had the highest injury risk rate value (In = 0.09 1). Table 56, partly illustrated in figure 20, shows the number of fires, fire injuries, risk rates, employees' working hours, and lost workdays by time period. The number of fires and fire injuries decreased during most of the periods, with a sharp increase during the last period. The number of employees' working hours increased throughout the periods. The In values follow patterns similar to those shown by the injury values. Tables 57-63 show the number of fires by ignition source, method of detection and suppression, equipment involved, location, and burning material by time period. Figure 21 shows the major variables related to fires for 1990-2001. Table 63 shows the fire injuries per number of fires causing injuries and total fires by year, ignition source, equipment involved, and location.

Jan 1, 2004

By M. Özer, F. Boylu, G. Önal

In this study, the fine coal waste subjected to the experiments is taken from the waste stockpile of Soma Coal Plant. The possibilities of its evaluation and the production of clean coal were investigated. For this purpose, Reichert Coal Spiral and Shaking Table are used. The minus 1 mm coal waste includes 60.43% ash and 50% minus 38 micron material by weight. The microscopic observations of the screen fractions were shown that the clay minerals are in fine sizes and the coarser size fractions contain silica and carbonate minerals as ash forming materials. The tests were conducted after desliming. The commercial grade clean coal product containing 29-35% ash with a calorific value of 3800-4200 kcal/kg (15.91-17.58 MJ/kg) was obtained by gravity methods.

Jan 1, 2004

By M. A. W. Bryson

It is well documented that a significant amount of the new PGM (Platinum Group Minerals) production that is coming on stream now, and over the next few years, is to come from the UG-2 reef. Clearly the reservations, or perhaps the perceived reservations, attached to the processing of this ore are no longer there. What were the metallurgical issues that delayed the exploitation of the PGM values from this reef? Traditional furnaces treating Merensky concentrates were not able to accept the concentrate produced from a UG-2 plant due to the relatively high chromite content of this product. The chromite reports to an insoluble spinel phase that accretes in the furnace, resulting in the necessity to shutdown and dig the furnace out periodically. This was clearly not an attractive economic option, so producers stayed away from it in the early days. The Merensky ore had all higher base metal credits anyway, and you needed them to get a matte fall, so there was no driving force to look seriously at the UG-2 reef. Platinum demand at this time could be easily met from the Merensky ore, so the motivation to tackle more complex ores was not there. The low price of PGMs meant that these operations were not particularly profitable and there was little effort directed at improving the operations. Concentrators were generally not run very efficiently and the emphasis was on cost reduction through increasing milling rates.

Jan 1, 2004

1. In 2002, a total of 2,820 contracting companies reported employment at coal mines to MSHA.

Jan 1, 2004

This publication is provided on an "as is" basis without warranties of any kind, either expressed or implied including, but not limited to warranties of title or implied warranties of merchantability of fitness for a particular purpose. The information contained in this publication is for general information purposes only. It does not constitute professional, technical, financial or other advice to the user of this publication and must not be relied upon as such by any person whatsoever. The use of this publication is at the users own risk. The authors/creators of the information contained in this publication have tried to ensure that the information contained herein is correct, but errors or inaccuracies may exist or the information may be incomplete, unreliable or no longer up to date. Therefore, no warranties of any nature whatsoever are given and any liability to any person in respect of anything and in respect of the consequences of anything done or omitted to be done, wholly or partly in reliance upon the whole or any part hereof, are disclaimed, including and without limitation any contractual, dialectal, direct, consequential or financial damages or losses. On no account will Organisers and/or any of the contributors or any person or entity involved in creating, producing or distributing the information and or software available in this publication be liable for any such damages arising out of the use of or inability to use this publication. Copyright Reserved The South African Institute of Mining and Metallurgy P O Box 61127, Marshalltown 2107, South Africa www.saimm.co.za All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical photocopying, recording or otherwise without the written permission of the copyright owner. Although the greatest care has been taken in the compilation of the entire contents, the editors and publishers do not accept responsibility for errors or omissions. First Edition Copyright February 2004 Proceedings ISBN: 0-9584663-5-1 (1 volume and CD-ROM)

Jan 1, 2004

By E. Contestabile, B. von Rosen

Recently, the Canadian Explosives Research Laboratory (CERL) completed its investigation of a truck accident, which involved 18,000 kg of commercial explosives, 13,000 kg of which was ANFO. Over the three years of the investigation unconfined burns of piles of ANFO were performed. In its final phase of the investigation, two burn trials were performed in an attempt to recreate the accident and the ensuing fire, to identify probable mechanisms that led from burning to detonation. Two full-scale tests were performed using complete tractor-trailers. In each test, the trucks were placed in a jack-knifed position with the majority of the explosives located on the ground in front of the trailer. The explosives were placed in a manner to provide maximum confinement and to maximize the possibility of explosion/detonation while remaining as faithful as possible to the perceived accident geometry. The tests were instrumented using thermocouples and video cameras and observations were made on the burning characteristics of the explosives, tractor-trailer and tractor-trailer components. In each test the explosives burned calmly for approximately 80 minutes. There was no evidence of explosion or of unstable burning. The heat caused several truck components to rupture violently. These included the tires, some engine components, the spring brake chambers and possibly the fuel tanks. Of these, the most violent were the truck tires. Although no quantitative data was gathered on rupture violence or fragment velocity, it is speculated that several truck components might produce fragments with sufficient energy to initiate heat-sensitised explosives under favourable circumstances.

Jan 1, 2004

By Jeff Bird, Xijia Wu, Prakash C. Patnaik

"Prognosis and health management (PHM) is an evolving suite of technologies intended for application to the life cycle management (LCM) of mission/safety critical systems, with anticipated results, which will: - Reduce life cycle cost - Enhance operational safety and readiness - Assist in maintenance decision-making - Enable autonomic logistics While it is emphasized in the United States that future multi-mission fighter aircraft such as Joint Strike Fighter (JSF) must have PHM capabilities, Canadian initiatives also recognize the need to implement such schemes for future and legacy military and civil aerospace systems. With respect to four major technology areas of PHM, i.e., i) advanced sensors, ii) data analysis and fusion, iii) life consumption evaluation, and iv) predictions with reliability/risk assessment, there has been advanced technologies developed by NRC and others within Canada: - Aircraft/engine instrumentation and airborne data recording systems - Signal analysis and data fusion - On-line engine health monitoring - Physics based models for engine material failure modes and life prediction - Autonomic crack growth analysis for damage tolerance of engine components - Mission severity analysis algorithm - Probability, reliability and risk assessment This presentation reviews the above technologies in relevance to PHM, emphasizes the need to have physics based models and outlines the future R&D needs for integration and implementation of these technologies suitable for the advanced and legacy aircraft."

Jan 1, 2004

By F. Habashi

The first documentary evidence for the use of fire to extract a metal was furnished by the wall paintings of the ancient Egyptians showing workers using the blowpipe and bellows to increase the temperature to melt gold in a crucible. Furnaces grew in size and complexity, coke replaced charcoal in the blast furnace, and the Industrial Revolution took place in England that gradually spread worldwide. More metals became known and new techniques were introduced for their extraction. Among these, metallothermic reactions became prominent in the nineteenth century immediately after the discovery of the electric current and its use to liberate the alkali metals from their salts. Once these metals became available, they were used to produce aluminium from alumina that resisted all other methods of attack. Aluminium, now available on a large scale, was used to decompose the most stable compounds and liberate more metals that became the basis of modern civilization.

Jan 1, 2004

By Lewis A. Martin

Researchers from the Spokane Research Laboratory, National Institute for Occupational Safety and Health, in cooperation with engineers from the Department of Mining and Geological Engineering, Montana Tech, Butte, MT, conducted tests to evaluate the tensile strength, fiber count, and adhesion of shotcrete applied to panels at the Chief Joseph Mine, a research and training facility operated by Montana Tech. The tests were conducted in the mine ramp 45 m (150 ft) inward from the access portal at a 15.25-m- (50-ft) long test area divided into five 3-m- (10-ft) long sections. The shotcrete was applied with an Aliva 240.5 machine fitted with a predampener. Different amounts of fiber were entrained for each panel. Background data for the tests were obtained from earlier tests in Nevada, where the typical amount of fiber in the shotcrete is 6.54 kg/m3 (11 lb/yd3). All shotcrete was applied to a minimum thickness of 76 mm (3 in). Cylindrical cores were drilled at the wall-rock interface, and adhesion was tested after 28 days of curing. The goal of this research is to reduce the need to install multiple supports at the advancing face by creating a safer mining system that limits the time miners are exposed to unprotected roof.

Jan 1, 2004