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By A. Zhecheva

A commercial titanium alloy Ti-6Al-2Sn-4Zr-2Mo has been gas nitrided in this work, in pure nitrogen atmosphere in order to improve its surface properties. The nitriding was performed at two different temperatures, 950 and 1050°C, and for different periods of time. The influence of the initial surface roughness on the diffusion process and on the surface properties of this material was studied. The influence of the processing parameters of gas nitriding on the surface roughness, phase modifications and the microstructure of the nitrided layers has been analyzed using atomic force microscopy (AFM), X-ray diffraction and optical microscopy. Microhardness profiles were obtained on cross-sections of the samples after gas nitriding applying a Knoop indenter.

Jan 1, 2004

By Y Pan

The recycling of steel is a crucial aspect of the shift toward a sustainable metals industry. The emphasis on steel recycling through the introduction of the scrap based mini-mill concept is also matched with a desire for greater product quality and reduced environmental impact, which, in turn, has generated important innovations. There have been significant advances in the technology for recycling steel over the last 20 years and this paper will provide an overview of these developments and discuss future directions in steel recycling including scrap management, control of tramp elements, electric arc furnace technology and ladle metallurgy.

Jan 1, 2004

The transition from exploration to feasibility is a stage in the development of mineral resource projects that is frequently not handled well. The transition marks a point in the project development process where resource evaluation priorities change significantly from the discovery of mineralisation and the rapid assessment of the potential tenor of the mineralised system, to the detailed assessment of the deposit.   Information used in the exploration process tends to be of a qualitative or theoretical nature initially, but gradually becomes more quantitative in character as geological knowledge relating to individual prospects grows.   The transition from discovery and rapid exploration of a new deposit occurs at a relatively early stage in project development, coinciding with the first attempt to prepare a resource estimate for the deposit. Fundamental assumptions regarding both structural and grade continuity and uncertainty inherent in existing information need to be made so that they themselves may be addressed during the collection of additional data.   The effective commencement of feasibility studies involve the introduction of new accountabilities either as a result of appointment of a project manager, and through needing to be able to quantify: ò     the quality of data being collected for resource evaluation purposes; ò     confidence associated with resource estimates; and ò     the need to develop an audit trail for the project, required to make the resource evaluation decision-making process as transparent as possible.   Quality assurance is a concept to which exploration geologists have frequently had little exposure. Being able to demonstrate the quality of data used in feasibility studies is, however, a crucial component of the overall risk management and reduction.   Development of a transparent audit trail for data assists in demonstrating the quality of data which is frequently perceived to translate directly to confidence inherent in resource estimates.   Establishing procedures for geological data collection and management also provides a more reliable framework for making decisions that impact on project execution, again resulting in improved confidence in resource estimates and associated geoscientific data.   Regular, independent technical audits, in principle similar to audits conducted for the ongoing certification of standards compliant quality assurance systems, are a major, positive factor in effective project management and execution.   Information used in project evaluation, feasibility and development must be based on facts. Facts are effectively observations that are ideally made systematically, recorded in a systematic manner, and by being collected effectively are not subject to change.   Effectively managing the transition from exploration to resource evaluation, feasibility and project development involves recognising the nature of changes in the nature, detail and scope of geoscientific data required at each stage of project development. In doing so it is essential to: ò     recognise when the change occurs (as early as preparation of the initial resource estimate for a project); ò     accept that the change may not be gradual; and, ò     ensure that the project evaluation team is adequately resourced.   These objectives require recognition of the value of previous experience and the need to instill a true team approach amongst both staff and contractors associated with the project. Regular formal and informal communications between staff, contractors and other stakeholders in the project are an essential tool in ensuring personnel are aware of factors affecting their role in the project.

Jan 1, 2004

By Gungor Tuncer, Ali Kahriman, Abdulkadir Karadogan

In the bench blasting, the realisation of an economic, and safe blasting is only possible with a reliable blasting design on condition that considering all sequential activities such as drillingblasting, excavation-loading, haulage, crushing (especially primer crushing). Here what we mean with a good, and reliable design is that ensures an almost displaced, adequately swelled muckpile with desired fragmentation degree for the loaders effectivity, and succesive usage. Meanwhile it must also has no environmental problems such as ground vibration, air blast, and rock flyings, or at least these matters have to be minimised. Two main parameters which have generally being questioned to achieve a safe and economic design on any rock conditions, are specific charge, and burden. In the condition of determining these elements, the other blasting parameters could be calculated according to them, and the blasting design could be completed. Within the scope of this study, it was aimed to determine the optimal blasting conditions of gypsum which is major rock unit of overburden at Sivas Celestine open pit mine. First of all, the engineering (mass, and material) and digging difficulty classifications of gypsum were done according to the current classification systems by using the results of field and laboratory studies. Then the blasting system which was being used on all rock units, was considered, and the necessary data were obtained. After previewing the site properties, predesigns were done, and applied by adopting Langefors design model. The necessary adjustments were done before, during, and after the shots, and the applications were observed. In order to determine, and record the data from each shots properly, a practical form was developed, and all data were transfered to these forms which give information about the blasting results such as muckpile displacement, and height, average particle size, back break, and rock fly existence, number of boulders etc. The blasting parameters such as burden, hole diameter, hole inclination, the amount and position of primers, bench height, delay sequence, and blasting geometry were considered for the iteration of each shots. During the applications, ANFO, gelatine dynamite, and electric delay detonators were used as explosives.

Jan 1, 2004

By O. A. Bascur, J. Patrick. Kennedy

"The lack of integration of mining and metallurgical information at sufficient detail to act is a problem. Without such data, mine cut-off grade can not be optimized on a per grade basis. It is difficult to determine economics without integration of mine transactions, stockpile inventories, process flows and assays. Actions also require real time information from manufacturing assets, but corrected for gross errors from trucks, shovels, conveyors, faulty sensors, bad instrument calibration. Validation methods must include process models to identify corrupt actionable information. This paper presents new tools that use the model the process to sift through available data, identify and eliminate gross errors, and use statistical data reconciliation to create material balanced, internally consistent values. Uses of models allow data to be unified for useby both monitoring and decision making processes.A Real Time Performance Management (RtPM) uses unifying analysis methods to empower everyone in the organization with unparallel real-time intelligence, enabling them to continuously improve performance.BACKGROUNDExtraction of metals has become a global business; new economic and environmental forcing factors are present today which were unheard a couple of years ago that are causing companies to focus on plant operations. High ROI actions can be achieved internally which will increase mining and metallurgical processing unit efficiency and reducing operating costs if the proper information is provided those in the complex that can act. Large changes are possible with many of these small steps if the barriers for action are removed. The chief impediments are lack of infrastructure including the data, computing tools and essential data and bad information.Increased demands will be placed on the types, quantity and priority of information. Metallurgical complexes are attempting to become better neighbors, increase productivity, improve customer service, and satisfy the regulators and compliance groups -- all with fewer people and less costs."

Jan 1, 2004

By Reginald Dias

Mining equipment life may be extended through preventive maintenance and the proper application of quality lubricants. There are several practices mine operators should consider implementing to preserve their equipment. An exercise in review — Begin by reviewing original equipment manufacturer (OEM) recommendations regarding servicing and maintenance intervals for each part of the equipment, especially the engine. And the verdict is — If the manufacturer’s recommendations have been followed, good. If not, owners/operators should begin periodic service work on equipment, to help minimize equipment downtime and extend engine life.

Jan 1, 2004

Editor’s note: As usual, the June issue features an industrial minerals review. And some thanks are in order. Thank you to the industrial minerals annual-review editor, to the technical committees chair and vice chairs and to the authors of the individual commodity profiles. Jim Norman of GeoTrans Inc. is the industrial minerals annual-review editor. William Langer, U.S. Geological Survey, is the chair of the SME industrial minerals technical committees and the vice chair of the technical committee for construction materials. Other technical committee vice chairs include: •Lucy McCartan, U.S. Geological Survey, agricultural minerals. •Steve Herron, Oglebay Norton Performance Minerals, ceramics and refractory materials. •Srinivas Veeramasuneni, U.S. Gypsum, chemical raw materials. •Ismail Yildirim, Imerys, fillers and pigments. •Charles Landis, BPM Minerals, sorbents, filters and process aids. •Ray Harris, Wyoming Geological Survey, specialty minerals. Their help makes possible this June industrial minerals issue. On behalf of the readers, the editors thank them

Jan 1, 2004

By Kim Wiwchar, Elizabeth Mbaja, Lynne Dang, Jim Furey, Anita Marks

"Suncor Energy Inc., located north of Fort McMurray, Alberta, commenced pilot scale operation using a CPT 4’ diameter flotation column in March 2003. This larger scale trial follows two previously successful flotation column bench scale tests. They included an April 2002 trial with a 2.4” inner diameter column from the University of Alberta and a 20” diameter CPT column in August 2002. The column receives middlings stream feed from one of Suncor’s deep cone separation cells and is operated in parallel with a set of WEMCO flotation cells. The recovery, tails losses, and concentrate quality are being compared between the two systems. The column, to date, has been tested with all types of run of mine ore grades. Variables such as wash water flow and temperature, sparger nozzle size and location, sparger air/water flow rates, and column residence time has been adjusted to achieve better recovery and final product quality.Used in many mineral processing applications, column flotation is primarily used for the final stage of sulphide cleaning and flotation of phosphate or iron ore. As well, mechanical cells are often used in combination with a column to retrofit an operation and to produce a cleaner product.Initial results prove that this is the first successful application of a flotation column in an oilsand application. If viable, it will be an inexpensive process for recovery of bitumen from a middlings stream and able to produce a final product suitable for froth treatment.INTRODUCTIONSuncor’s oilsand is surface mined from the Athabasca Oilsand deposit north of Fort McMurray, Alberta. The oilsand is then mixed with hot process water (HPW) and the bitumen is slurried in a pipeline. Large separation cells as shown in Figure 1 float off the bitumen product, which is then steam or static deaerated and sent to Secondary Extraction for further cleaning. The tails stream from the cell is sent to the Final Tails Pumphouse (FTPH) for processing. The tailings flotation froth product gets recycled to the separation cell oilsand feed. The tailings are pumped from the FTPH to tailings ponds. The middlings stream is drawn off the separation cell approximately 9’ from the froth overflow level. It runs down, by gravity, to the scavenger banks for bitumen recovery. It was from this stream off of the Line 6 Separation Cell that the feed to the Canadian Process Technologies Inc (CPT) flotation column was taken."

Jan 1, 2004

By B. van Beek, J. Ndlovu, K. T. Hara, J. M. A. Geldenhuis

This paper describes the development of an alternative technique for measuring the matte level height in sulphide smelting furnaces. The initial studies involved applying electrochemical oxygen probes in a smelting furnace to measure the oxygen potentials of the matte and slag phases. However, these measurements were not successful as a result of low temperatures, preventing there ference electrode from attaining equilibrium during the measurements. These trials were followed up by using oxygen probes containing a (Mo + MoO2) reference electrode instead of the(Cr + Cr2O3) reference electrode used previously. It was shown that with some further development work, it should be possible to measure the oxygen potential of these mattes accurately. Further measurements were performed with a magnetic sensor in sulphide mattes. It was shown that an electronic signal, which is proportional to the magnetic susceptibility of the surrounding material, was generated during immersion into liquid matte. These measurements were extended and done in a smelting furnace. Initial results indicated that when the magnetic sensor was dipped through the slag layer into the matte, a signal was generated as soon as the sensor came in contact with the matte. Measurements are ongoing in order to record (on a computer for improved accuracy) the signal as a function of distance when the sensor is immersed through the slag layer into the matte phase. The magnetic sensor measurements may be the solution to a matte level measurement problem that has existed for a few decades in matte smelting furnaces.

Jan 1, 2004

By L. R. Nelson

A review is presented of the furnace cooling system design and operating developments since the initial furnace start-up in January 2001 of the Chambishi DC-arc furnace to produce ferrocobalt alloy. The furnace operating conditions present a number of challenges to the furnace designers and operators, in particular, to provide a sustainable lining that can withstand the highly corrosive siliceous slag (roughly 50% SiO2). This is exacerbated by the dual requirement of operating this slag in a relatively highly superheated state (?T ?400°C when tapped at 1550°C) to ensure that the ferroalloy can be tapped (estimated 1370°C alloy liquidus temperature) prior to atomization. The core design challenge occurs at the alloy-slag interface, where a single refractory type cannot simultaneously meet the dual requirement of both adequate alloy and slag corrosion compatibility. Progression by the fourth furnace campaign to involve a retrofit of the bath sidewall to HATCH high-intensity, water-cooled, copper Waffle coolers and tap blocks is described. This involves operation of the entire slag bath, the slag-alloy interface and a portion of the alloy within a more chemically compatible refractory/slag (and possibly at times even an alloy) freeze-lining. Due to the high furnace power density employed (up to 500 kW/m2 hearth area), coupled with the large slag superheat needed, the resulting imposed peak bath sidewall heat fluxes are substantial, especially in the alloy (typically averaging 170 kW/m2), and on occasion have exceeded 1000 kW/m2. The performance of the HATCH Copper Waffle coolers under such aggressive process pyrometallurgical conditions is described. Aspects of the design and especially operating strategies to effect sustained production at up to 38 MW power input are also discussed.

Jan 1, 2004

By Joint Micropiles Committee

"The three types of specifications which are used for micropile work are: • Performance Specifications: The contractor is permitted control over certain design and/or construction procedures but must demonstrate to the owner through testing and/or certification that the final product meets the specified performance criteria. This method allows and encourages the contractor to provide a competitive and/or innovative micropile design within the framework of the overall design requirements. The responsibilities for the work are shared between the owner and the contractor. • Open Specifications: These leave the scope and design of the installation up to the micropile contractor. This method is the most common for securing bids on temporary micropile work. The responsibility for design and performance is clearly placed on the contractor. Open specifications are not recommended for permanent applications. This method allows the contractor to select the most economical micropile system. • Prescriptive Specification: The Owner describes specific procedures that must be followed, but which may not necessarily describe the objective of the work. When prescriptive specifications are used, the owner is responsible for the proper performance of the system. The contractor is responsible for satisfying the details of the specifications.Performance specifications are the most common and best reflect the challenges and interests of micropile technology and applications.The owner, designer and contractor will together be responsible for the tasks associated with the design, installation, acceptance, and performance of the micropiles. The installation of micropiles requires specialized equipment, techniques, and appropriate workmanship. Not every detail of the work can be specified, and not every potential problem can be anticipated. Therefore, a contractor who has demonstrated experience in micropiles must be selected to execute the work required."

Jan 1, 2004

By A. M. Hearn, J. R. Henning, A. S. J. Van Rensburg

The lining, together with the electrodes, forms the heart of the operation of a submerged arc furnace. Subsequent to a lining failure on M12 furnace during the early 1980s, Metalloys was active in investigating the concept of thermally efficient ?freeze? linings for its furnaces. The theory revolved around that, not only would, thermally efficient linings result in significant cost savings, but they would also last longer as a result of being subjected to less harsh operational conditions. After having proved the concept on the .smaller. furnaces, Metalloys decided to implement the concept on its largest submerged arc furnace, M12 Subsequent to having recovered from an impending failure of a lining installed in 1981 in M12 in the mid 1980s, Metalloys managed, through rigid lining management, to extend the life of this lining to 1999. At the end of 1999 the decision to replace the lining in the furnace with a ?freeze? lining was made and planning and design proceeded in earnest. This paper discusses the options considered in making the final decision. The features of the design of the lining are also discussed. Consideration is given to the furnace shell cooling system as a result of its importance in maintaining the thermal equilibrium in the lining. Note is made of the fact that the purchase of a .freeze. lining is an expensive exercise but that the time savings in the installation of the lining and the efficiency improvements during operation far outweigh the additional capital cost. The experience on M12 has been that the payback period of the marginal capital expenditure is less than three years. As a result of the opportunity to reline a furnace the size of M12 not presenting itself very often, the learning points from the installation of the lining and the operational advantages and disadvantages are significant. Finally, the point is made that the project had its pros and cons but overall the success of the project has been evident and, as such, the ?freeze? lining is likely to become the norm at Metalloys.

Jan 1, 2004

By N. Kumar Kittusamy

Operators of construction equipment perform various duties at work that expose them to a variety of risk factors that may lead to health problems. A few of the health hazards among operators of construction equipment are: (a) whole-body vibration, (b) awkward postural requirements (including static sitting), (c) dust, (d) noise, (e) temperature extremes, and (f) shift work. It has been suggested that operating engineers (OEs) are exposed to two important risk factors for the development of musculoskeletal disorders: whole-body vibration and non-neutral body postures. Method: This review evaluates selected papers that have studied exposure to whole-body vibration and awkward posture among operators of mobile equipment. There have been only few studies that have specifically examined exposure of these risk factors among operators of construction equipment. Thus other studies from related industry and equipment were reviewed as applicable. Conclusion: In order to better understand whole-body vibration and postural stress among OEs, it is recommended that future studies are needed in evaluating these risk factors among OEs.

Jan 1, 2004

By N/A N/A

Aw a rd winners from the University of MissouriRolla. Back row from left: Seok Bin Lim, Chris B o l l i n g e r, Adam Kre s l e r, Scott Geer, Joseph Cohn, and James (Buck) Hawkins; Front ro w f rom left: Dr. Worsey, Trish Robertson, and Fio G i a n a

Jan 1, 2004

By William Monaghan

Over the period 2000 to 2003, roof falls have accounted for 4 to 14% of the fatalities in underground mining operations. The National Institute for Occupational Safety and Health (NIOSH) is conducting research to reduce the frequency, exposure, and risk of these events through an ongoing program of field and laboratory studies. One area of research involves the evaluation of polyurethane grouting technology that is commonly used to stabilize fractured mine roof strata. Concurrently, NIOSH is conducting work to evaluate the application of ground penetrating radar for advanced delineation of problematic mining areas. In this study, NIOSH partnered with Sub-Technical, Inc. who injected a polyurethane grout (also known as glue) into a roof area of NIOSH's Safety Research Coal Mine. The mine roof area was scanned using ground penetrating radar technology before and after grout injection in an attempt to determine the extent of grout infiltration. A comparison of the pre-and post-grouting radar records showed a significant change at a mine roof depth of about four to five feet. The interpreted radar records were then compared with drill core information, borescope evaluation of roof-bolt holes in the study area, and underground observations. At this site, the interpretations of the radar records correlated with data obtained from the core holes, borescope evaluations and underground observations. This study showed that ground penetrating radar technology can be a useful tool for detecting changes in mine roof due to the injection of the grout.

Jan 1, 2004

By B. McLaughlin

Agnico-Eagle started sinking the Penna Shaft in 1995 with a hoisting plant capable of hoisting 1800 t/d from a 2240 m deep shaft. Exploration success led to the installation of a hoisting plant capable of extracting 4500 t of ore and 1800 t of waste per day from a depth of 2210 m. The introduction of a new rope selection factor, permitting a safety factor of 4.0, represented the breakthrough required for a cost-effective project. This paper describes the process taken to introduce the new rope selection factor and its impact on the original plant.

Jan 1, 2004

By Patrick R. Taylor

Keywords: Thermal Plasma, Electroreduction, Electrolysis, Transition metals, Waste treatment, Molten oxides, Chromium oxide. An innovative process to treat transition metal oxide waste materials from diverse sources is presented. This technology involves using reverse-polarity DC plasma driven electrolysis in molten oxides. The process results in the recovery of the transition metal and other heavy metals from waste. By-products generated throughout the processing was converted to environmentally acceptable slag. The significance of this technology is that the treatment of the waste is accomplished in one step which in turn lowers the cost of remediation. Moreover, this process uses high temperature properties of thermal plasmas, which makes it possible to use molten oxides instead of halides as electrolytes. Chromium was successfully reduced from chromium oxide through the plasma driven electro-reduction process. It was shown that the selection of the appropriate ionic conducting oxides was critical for the formation of a slag that would enhance the reduction of chromium oxide.

Jan 1, 2004

By Joel Moskowitz, George J. Tamaro

"A new office complex is being constructed within 25m of the Hudson River in New Jersey. The project, about 140m by 100m, will include 4 basements under the entire footprint. The perimeter was to be secured by a 0.8m thick diaphragm wall, laterally supported by high capacity tieback anchors to rock. Columns were to be supported on footings or piers to rock at a nominal bearing pressure of 3.8MPa at depths up to 17m. Although some variation in rock quality was observed in borings, a substantial vertical seam of weathered and/or decomposed rock, 1 to 2 meters wide by as much as 8 meters deep, was encountered during construction necessitating field redesign. In some locations, the seam dipped below rock that is more competent. Footings were redesigned for support on drilled caissons, or soft rock was excavated and replaced with concrete necessitating a reduction in bearing pressure of the footings by one half. The tower covering the south half of the site was topped out in 2002 and the garage levels in the north half of the site were completed in 2003.PROJECT DESCRIPTIONIn September 1999, a major investment company began the due diligence process to evaluate a property on the shore of the Hudson River in Jersey City, New Jersey for a new multi-use complex. The site offers a spectacular view of lower Manhattan directly across the river from the site of the former World Trade Center. The site, covering two city blocks, was previously occupied by manufacturing and office facilities of Colgate-Palmolive.The building footprint is approximately 140m by 100m, the southern half of which is occupied by a 260m tall office tower, shown in Fig. 1. As of this writing, design of the structure for the northern half of the site has not been finalized, but it is expected to comprise an 11-story office building. A glass-covered atrium will occupy the street that formerly separated the two blocks. As part of the due diligence process and preliminary design evaluation, alternatives were considered to accommodate various numbers of parking places, both above and below existing grade. A major consideration for below grade parking is the proximity of the Hudson River some 25m east of the east building line."

Jan 1, 2004

By P. L. Richard

An open pit a mine can be thought of as a business unit, with capital, operating and maintenance costs that exceed those of many large business enterprises. Truck-and-shovel operations have an inherent “looseness” to them, unlike manufacturing or processing operations where production components are tightly coupled (through conveyors, material flow in pipes, assembly lines, and so on). Effective monitoring and control of truck-and-shovel operations requires a combination of both information systems and performance management. Production monitoring systems can impact operations at three levels: minute-byminute decisions during the shift, procedures, and policies. The technology of production monitoring ranges from real-time data collection to manual entry of time card data into a computer. Time card information is too coarse to effectively manage a multi-million dollar fleet of mobile equipment, so a higher level of production monitoring is required. People issues affect whether the implementation will be a success or a disappointment. Considerations that affect the people issues are discussed, including common obstacles, and key success factors. A balanced scorecard approach must be used, since uni-dimensional measures of performance like tons produced give no indication of whether the production was achieved at the expense of another factor.

Jan 1, 2004

By H. F. Letient, D. C. Johnson

At the 25th Annual B.C. Mine Reclamation Symposium in September 2001, Huckleberry Mines Limited received the Jake MacDonald Reclamation Award for its exemplary mine waste management plan, conceived to prevent the onset of acid rock drainage (ARD) and facilitate reclamation of the site. The mine is an excellent example of a total mine waste management plan, with all materials scheduled in detail for the life of the mine. The filling plan for the waste management facility takes into consideration the requirement for permanently flooding the potentially acid-generating rock. From an acid generation point of view, the tailings fall in the zone of potentially acid-generating material. To avoid long-term ARD concerns, it is planned to float pyrite out of the tailings toward the end of the mine life, thereby generating a non-potentially acid-generating tailings stream which will be used to cap the deposited mine waste. The pyrite-rich tailings will be discharged into the deeper portion of the impoundment. On closure, a permanent water cover will be maintained over the mine waste. Only beaches of non-potentially acid-generating tailings will remain exposed. Mining will be phased to also allow one of the pits to provide storage for potentially acid-generating rock and to be flooded at the end of mine life.

Jan 1, 2004