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By A. Warczok

Chalcocite concentrate obtained by magnetic separation and flotation of Bessemer matte is processed in the Inca top blowing bottom stirring MK reactor into semi-blister copper. The semi-blister is then converted into blister copper in the multi-purpose vessels (MPV) by oxidation of iron, nickel and sulphur. High melting point NiO and Fe30 4 are formed inside the MPV s, which together with Cu20 and smaller amount of fayalite are the major constituents of the solid mush. The accumulation of solid mush and buildup requires periodic MPV cleaning by adding reductant and copper-nickel matte, a unique process called "washout". Various reductants and their combinations, such as pig-iron, 15%Si Ferro-silicon and 50%Si Ferro-silicon, have been used for the reduction of solid mush and buildup. The possibilities of using calcium carbide as a reductant and slagging flux were examined experimentally at the crucible scale. The rate of reduction of MPV buildup was determined by continuous measurement of CO and C02 contents in the offgas and the flowrate of argon carrier gas. The rate of the buildup reduction with calcium carbide was approximately five times faster than the rate of reduction with coke. Additionally, the formation of CaO results in the melting of reduced buildup and formation of a slag at 1300°C and higher temperatures. It was found that simultaneous silica addition enhanced the melting and slag formation. The results showed the strong dependence of the reduction rate on temperature. Activation energy is approximately 225 kJ/mol. Expected benefits of using calcium carbide are related to cost saving on reductant, significant acceleration of solid mush reduction, and reduced amount iron input from reductant.

Jan 1, 2007

By R. Bauer

Adaptations and redesign of the existing already very successful and proven road milling machine concept and technical innovations such as an optimized, specifically for mining application developed cutting drum, cutting housing design and cutting tools, high manoeuvrability achieved via a tight turning radius, a three disk clutch system and a cutting drum drive that allows for the acceptance of higher loads, a complete reinforcement of the chassis to withstand higher vibrations and torque, the installation of increased engine power via a modern drive unit, a specifically for mining/construction applications developed operator’s platform and finally a redesigned air intake system and the adaptation of the levelling system resulted in far more cost effective and advantageous capabilities of Wirtgen Surface Miner in soft to medium hard mining and construction applications. As the achieved results show for the first time in modern surface mining history mechanized cutting is capable to compete successfully against traditional drill, blast/ripping and other conventional mining methods.

Jan 1, 2007

By Marco Antonio Falquete

Conventional detonators and blasting caps make use, as igniters, of flame-shock-, andfriction-sensitive primary explosives, such as lead azide, lead styphnate, mercury fulminate, etc, most of them severe toxic and environmental contaminants. Sensitivity of primary explosives is one of the main causes of injuries and fatalities in explosives industry and in field applications. Intense research for a reliable, safe, and environmental-friendly non-primary-explosives detonator was conducted by the industry in the last years. A new detonator is presented, containing no primary explosive, employing only environmental-friendly substances while keeping reliability of performance. A series of performance tests is executed in prototypes of different output energies, including initiation by flame, shock tube, thermo tube (IBQ’s proprietary spark-generating tube, presented at 2005 ISEE Conference), energy transfer reliability, and extreme environmental conditions (according to MIL-STD 331B, test C1 standards). Results are compared, when pertinent, with standard blasting caps of different energy outputs, and with standard primary explosives.

Jan 1, 2007

By D H. Bell

Slab-buckle failures in coal sequences involve thin slab deformation in strata dipping parallel to the footwall, and are a consequence of both unloading and the weak nature of the thinly bedded rock mass. Methods of modelling and predicting such occurrences include: +        a conceptual model using a base friction table, +        a mathematical model using the Euler solution for column and beam bending (after Goodman, 1980), and +        computer analysis techniques such as UDEC (Universal Distinct Element Code after Cundall and Hart, 1993).   Slab-buckle failures have the potential to seriously disrupt production because of their volume and rapidity, and to endanger both equipment and personnel working on the pit floor.   In July 2004 a large slab-buckle failure occurred overnight after a new batter and bench had been formed at the Malvern Hills Opencast Mine in inland Canterbury. This involved the entire length of the pit (85m along strike) when a 2m thick intact slab with a total volume of ~3500m3 translated down dip 6.2m on the base of a thin coal seam to form a pronounced buckle at the toe. The coal measures consist of finely laminated mudrocks with multiple coal seams of varying thickness dipping ~45¦ to the southeast, and the opencast mine had been designed with footwall batters formed parallel to bedding with a vertical bench separation of 15m.   Back analysis of the Malvern Hills failure was necessary to investigate the controls on footwall instability, and for future mine design. An engineering geological model was created and samples of the slab material and failure surface were collected and tested to establish the required parameters for use in the Euler solution for column and beam bending. Back analysis using the Euler solution provided unrealistic results that overestimated the overall length of a stable slope by more than 10 times.   No further large scale slab-buckle failures have developed at the mine site, in part because of the slow rate of coal extraction, but precautionary drainage of the footwall slopes has been undertaken to improve overall batter stability. The location of the slab-buckle failure on a critically positioned pre-sheared thin coal seam with full hydrostatic head is considered the most probable cause of the July 2004 failure, rather than inherent instability of the generic bench and batter arrangement adopted. The use of a precedent-based engineering geology approach to future mine design is considered the most appropriate solution in the circumstances.

Jan 1, 2007

If an orebody has been drilled to achieve some level of regulatory compliance, then a number of associated geological databases will exist, representing 10 000 to 100 000 m plus of core intervals. The databases usually contain data about assays, lithology, mineralisation and geophysical attributes. They will also include location information such as collar positions and downhole surveys. Obviously this data is collected by geologists for, predominantly, geologists and mining engineers. However, from a process design viewpoint process engineers usually ignore the geology where possible and rely on a small number of metallurgical test samples. Typically these test samples are sourced from convenient and available cores or from a small number of specially drilled metallurgical holes. One of the worst instances known to the author was the design of a SAG mill using only two SAG specific test results (one for each of the major ore types) while, geologically, the orebody was defined by more than 30 000 m of drilling. This paper sets out a philosophy to maximise the use of the geological data, both for process design and in preparation for the commissioning phase of projects. Geological data is used in the identification of preferred locations for metallurgical test samples, for checking the metallurgical validity of the geological ore-type definitions, where necessary developing new ore-type definitions (geometallurgical domains) and developing mathematical relationships for the estimation of important metallurgical factors across the geological database. If the estimation of factors (for example ore competence) is considered reliable enough then there is also the possibility of feeding calculated data back into the block modelling process to allow the generation of metallurgically relevant outputs in the mine plans.

Jan 1, 2007

As part of the Australian Mineral Industries Research Association (AMIRA) P9 project, methods of characterising both the ore and the machines in flotation circuits have matured considerably over the past 15 years. Machine characteristics include gas dispersion measurements, such as bubble size, gas hold-up and superficial gas velocity. Ores can be characterised in terms of floatability parameters on a size and mineral basis. Measurements have been performed on various copper plants in many countries around the world over the last 5 years. This paper outlines the cell and ore floatability characteristics of each copper plant and provides a discussion on the differences between these plants. In general, most porphyry copper ore bodies are processed at high tonnage through several parallel banks of cells at each stage of flotation. The floatability parameters of these copper ores are very similar in terms of rate of flotation and proportion of fast, slow and non-floating material. The cell characteristics are also similar, with superficial gas velocity, bubble sizes, and gas hold-up values being of similar magnitude. Investigation of the similarities and differences of the modem copper flotation circuits has allowed an increase in understanding of the particularities of copper flotation. Comparison against other copper circuits provides a benchmark and opportunities for future optimisation.

Jan 1, 2007

By Wenbing Guo

Strip pillar mining method is one of the most important techniques for mining subsidence control in China. Mining depth is one of the most important factors that affect subsidence in strip pillar mining method. Six numerical simulation models were set up in this paper to simulate surface subsidence of strip pillar mining at different mining depths. The mining depth in these models ranged from 300 to 800 m. The simulated results were compared and analyzed. The results showed that the subsidence factor of strip pillar mining is related to mining depth. While other things being equal, the subsidence factor of strip pillar mining increases logarithmically with increase in mining depth. Their quantitative relationship was established based on the simulated results.

Jan 1, 2007

Membrane technology has been available for over 36 years, but has been used sparingly in the general mining industry. However, recent developments in polymer chemistry, spiral wound element construction, pretreatment equipment and techniques and an expanded understanding of membrane fouling and cleaning techniques have dramatically improved the reliability and robustness of membrane based systems in the mining industry. Harrison Western has expanded the use of this “new” technology to enhance the use of membrane technologies to separate metals from large volume heap leach mining solutions containing copper, zinc, and iron, gold or silver. Moreover, membrane technologies are ideally suited to fractionations that add value to processing fluids from refineries like separating metals from acids or concentrating acids and producing high quality process fluids. Finally, wastewater from Acid Mine Drainage (AMD) or, as in the case of the Newmont Yanacocha Mine in Peru, the treatment of excess barren leach solution created during the rainy season, can be cost effectively processed to meet World Bank Standards for surface discharge. Polymeric membranes, specifically thin-film composites, have been developed that will purify, fractionate or concentrate gold, silver, copper, zinc or nickel. Recent applications have been developed for spiral wound modules that operate across the pH spectrum from 0 to 14. Systems using membranes have been constructed that operate on feed streams from 140° C to 300 centipoise. Opportunities exist to apply membrane technology to concentrate gold, silver, copper, zinc or nickel using thin film composite membranes. Engineered membrane types can operate across the spectrum from low pH (<2) acid applications to high pH > 10 cyanide applications. Incorporating HW EMS™ membrane technologies into current mining operations could allow one to increase production because the membrane technology would be used to pre-concentrate heap leach solutions, and therefore, increase utilization of existing extraction and refinery capabilities.

Jan 1, 2007

By Johanna van Deventer, Sean Scott, Rene du Preez, Steven R. Izatt

In order to meet the stringent specifications associated with the production of LME Grade A cobalt cathode, producers need to ensure that a number of impurities, including Cd, are removed from the advance electrolyte to ppb levels (~0.1 mg/L). Conventional options include ion exchange using amino methyl phosphonic acid resin and solvent extraction using D2EHPA. More recently a Cd-selective resin, employing Molecular Recognition Technology (MRT), became available from IBC Technologies, Inc. These three potential unit operations were evaluated in parallel at Mintek. MRT was identified as the most technically feasible option. Results obtained on a cobalt advance electrolyte, containing 55 g/L Co, 6 mg/L Cd and 60 g/L Na2SO4, are presented in this paper.

Jan 1, 2007

By V. McLemore, N. Dunbar, K. Donahue

There are three principle lines of evidence that indicate the clay minerals found in the Goathill North (GHN) rock pile at the Molycorp mine are predominantly a product of hydrothermal alteration, not weathering. The unweathered drill core and samples from GHN have similar types and abundances of clay-mineral groups based on XRD analysis. Chemical analyses from the electron microprobe reveal similar chemical compositions for the hydrothermal alteration clays in drill-core samples and clays found in the rock pile. Textural evidence gathered from petrographic and microprobe examination also suggests a hydrothermal origin for clay minerals.

Jan 1, 2007

The link between exploration success and new ideas from research and development (R&D), although often assumed, is rarely well explained or well illustrated. One issue is understanding the role of innovative ideas in the exploration process, and another is determining the relative contributing factors to an exploration success. A useful measure of gold exploration success over an extended time period and geographic area is discovery rate (&#952;): Discovery rate &#952; = gold discovered/exploration expenditure (usefully expressed as tonnes of gold per $1 million). The total gold discovered is strongly leveraged to discovery rate, as any increase in &#952; typically has a positive effect on exploration expenditure. Hence, improving the discovery rate is a key driver for a sustainable mineral industry, especially for gold. There are very few ways to influence &#952; beyond innovative R&D ideas and breakthroughs, and well-motivated and trained staff. The Australian gold industry has experienced exceptional exploration success with 9956 tonnes of gold discovered from 1979 to 2003, inclusive. This equates to: Discovery rate &#952; = 0.9 t/A$1 M Two-thirds of this gold has been found in the Yilgarn craton of Western Australia (6265 tonnes Au). Without this exploration success, there would have been no platform on which to build the current gold industry and to take advantage of elevated gold prices and advances in mining and processing. Several causes of the Western Australian gold success have been proposed, and more than one may be correct. Gold price, and mining and processing advances have all had influence; but exploration success and discovery of gold were essential to add to the miniscule resource base of 1979. A comparison of the exploration methods used to search for gold in the Yilgarn craton in 1979, and 1990, highlights a small number of breakthrough ideas introduced to the industry during the 1980s, and in most cases emanating directly from local R&D. By the 1990s, these ideas were being used in most gold exploration programs in the Yilgarn craton, and are still used today. These six breakthroughs are: epigenetic timing of gold deposit formation (ie after formation of rock sequence), chemical and mechanical role of host rocks, relevance of carbonate alteration haloes, gold dispersion in the regolith, optimal sampling media, and appreciation of landforms in exploration program design. Interestingly, gold exploration science in Western Australia entered the 1980s period without rigid paradigms in place regarding gold deposit formation; there was a balance between descriptive and genetic models, there was scope to research gold deposits from microscopic to global scales and there were highly effective industry research uptake processes in place: it is suggested here that these favourable conditions contributed to the exploration success and industry growth.

Jan 1, 2007

By K. H. Al-Rawahy

Mineral resources comprise of metallic, non-metallic, and fossil fuels. Our civilization, and the associated economic and industrial developments are inherently dependent on the availability and use of minerals. This is evident from historical development and identification of civilization eras throughout human history: the stone age, the iron age, the bronze age, and the current computer age. This paper deals with the depletable fossil fuel sector of minerals; this is represented by crude oil, natural gas, and coal. Fossil fuels provide approximately 80% of total global primary energy supply; the rest being provided by renewables (wind, hydrothermal, solar), nuclear, and biomass. Economic, industrial, and population growth will, inevitably, lead to an increase in demand for energy. In general, per capita energy consumption is correlated with per capita income, with the US showing the highest energy use per capita, and South Asia having the lowest. This paper examines the underlying interrelated issues (factors) of energy reserves, production, scarcity, depletion, economic, and technological factors and impact on long term availability and thus sustainability. Is it possible to extend the time to economic depletion of these resources? This will have an impact, direct or otherwise on total energy availability, and the inter-temporal allocation of the resource. Specific economic and physical parameters relevant to mineral supply and their respective impact on depletion, and inter-temporal welfare are investigated. These variables include own price, substitute price, population, income, technical innovation-both on supply as well demand, and resource substitution.

Jan 1, 2007

The use of QemSCAN in providing mineralogical input to detailed ore and product characterization has proved of immense value in recent years. In this paper, a brief review of selected Cu-case studies is presented to demonstrate the versatility of automated, quantitative mineralogy by QemSCAN. This versatility ranges from measurement and analysis strategies through to data processing and presentation. As a rapid diagnostic service, it is common to find that only grain size, the degrees of liberation and/or ore mineral modal mineralogy are of interest. By contrast, the detail afforded by the simultaneous determination of both gangue and ore minerals can alert mineral engineers to fatal flaws and attributes deleterious to processing that are directly a function of silicate and other gangue mineralogy. Examples of the latter effects include the influence of micaceous minerals and acid consuming species, while the former include fluorine minerals, which can provide both processing and environmental challenges.

Jan 1, 2007

By P. K. Sahoo, C. R. Ray, S. S. Rao

Good operation of Soderberg electrodes is dependent upon high quality electrode paste coupled with better electrode management procedures. Without having a good electrode operation, it is not possible to obtain the best outcome from the furnace. In other words that is a good way to say how important the proper electrode operation is. Good electrode performance depends on the slipping rate and current levels, which decides the shape of the baking curve at the level of just below the contact clamps. Negative curvature of baking zone in the central part is considered dangerous because shrinkage takes place outwardly creating abnormal stresses in the electrode. Soft breakages occur when the baking zone comes below the clamps and the casing cannot take the current. This paper deals with various factors affecting baking characteristics leading to soft breakages and also presents case studies in a closed 48MVA furnace with smelting for charge chrome. In case studies in a closed furnace, it has happened that the energy for baking at the low current operation before breakage has been lower than the actual slipping has demanded. At low current there should not be problem, but a problem can occur when the current for some period is raised above the current carrying capacity of the casing. So data for electrode operation in actual period was studied and presented in this paper.

Jan 1, 2007

By M. Mankosa, G. Taylor, G. Luttrell, J. Yasalonis

Several industrial-scale HydroFloat separators have recently been installed at Mosaic’s South Fort Meade beneficiation plant for the purpose of improving phosphate recovery and throughput capacity. This technology was implemented after numerous laboratory, bench-scale, and on-site, pilot-scale test campaigns. The results from this detailed test work provided sufficient justification for the complete retrofit of the existing coarse and ultra-coarse flotation cells. Data indicate that the metallurgical results obtained with the full-scale separators are consistent with that obtained during both the bench- and pilot-scale evaluations. The apparent benefits, theory of operation, and commissioning of the equipment are also discussed.

Jan 1, 2007

By Desiree Willis

Disc cutters have determined excavation rates of rock tunneling projects for more than 50 years. First developed in 1956 by James S. Robbins, disc cutters (then 279 mm or 11 in. in diameter) were used to bore limestone of 190 MPa (27,500 psi) unconfined compressive strength (UCS) and were loaded with 7.12 t (15,700 lbs) each. Modern cutters have reached up to 508 mm (20 in.) in diameter and are typically loaded with up to 31.7 t (70,000 lb) to economically bore through the hardest of rock up to plus 400 MPa (60,000 psi) UCS. New developments, such as larger cutter diameters, are geared to increasing the bearing capacity and wear life of the cutting structure. This, in turn, increases cutter life, cutter load and cutter penetration. Disc cutters have also been re-designed on a small scale for use in hard-rock utility installations. Additional variables also affect the three factors, including cutter spacing on the cutterhead, cutterhead diameter and cutter materials.

Jan 1, 2007

By S. Agarwal, S. Frimpong

The creation and maintenance of a healthy working environment in surface mining operations require sustained efforts in pursuing advanced research initiatives toward the development and deployment of powered haulage technologies. This paper contains progress summary on a frontier research in truck dynamic control, vision and collision avoidance. This research is required to provide solutions to challenging problems regarding operator visibility in truck haulage in a surface mining environment. The paper focuses on truck control kinematics and dynamics, truck-haul road interactions, intelligent truck sensing, intelligent truck collision avoidance system, integrated system for situational awareness, augmented visualization and operator interface, and field testing and error variance modeling of developed technologies. A sensor suite of four subsystems, including front-side stereo-camera, front-side Doppler radar, close range sonar proximity sensors, and rear-side camera system have been recommended for developing a 360° truck operator vision to allow safe operations. This research initiative is significant because it will provide a strong basis for developing technologies to improve truck haulage safety in surface mines and construction sites.

Jan 1, 2007

By J. Font

The RAF or copper fire refining process at the Caletones smelter of CodelcoChile consists of several pyrorefining stages that successively lowers the levels of S, Fe, Pb, As, Sb, Te, Se and to some extent 0 in the copper melt, allowing the production of high quality fire-refined copper of 99.93 % purity (RAF copper). This chemical feature of the RAF copper is only achieved by quite long processing times, and a considerable consumption of fluxes and fuels in the RAF vessels. The main goal of this study was to improve the RAF process performance by thermodynamic considerations and industrial scale tests, i.e., an in situ approach for the process as featured by intensive sampling, characterization and subsequent modifications. Thus, both theoretical and industrial data were derived, and based on kinetic and thermodynamic evaluations, a higher operational standard was achieved for the RAF process. These new operational practices allowed enhancing the overall economic of the RAF process, by reducing the time and operational costs, and consequently increasing the availability of the vessels.

Jan 1, 2007

By J B. Holman, P A. Weber, P Lindsay

Underground and opencast coal mining has occurred since 1896 on the Stockton Plateau, West Coast, New Zealand. Acid Rock Drainage (ARD) from historic and current mine workings has had an adverse environmental impact on the surrounding aquatic environment. The two main catchments affected by ARD from historic and current mine workings are the Mangatini and St Patrick Stream catchments. Solid Energy New Zealand Ltd (SENZ) is using active (e.g. alkali dosing) and passive (e.g. engineered cover) technologies to mitigate the adverse environmental effects associated with ARD contaminated waterways. This paper discusses the passive technologies. Principal strategies include the capping of high capacity potentially acid-forming volumes of overburden. The mudstones were found to generally have the highest sulphur levels compared to other overburden lithologies. Areas with high mudstone volumes are prioritised to be encapsulated and 390 Ha is planned to be capped in the Mangatini catchment in the near future. &nbsp; Monitoring beneath granite, cement kiln dust and coal combustion product covers show oxygen can be reduced to less than 10% of atmospheric levels. Laboratory column leach tests that were subjected to oxygen flux rates of 10 % showed reducing oxygen ingress into acid-forming material can result in significant acid load reductions. &nbsp; The oxygen content below the cement kiln dust cover was generally lower than 5% and water quality measured in lysimeters beneath this cover improved after 50 weeks of emplacement. Column leach tests containing saturated samples were undertaken to determine the most appropriate water medium in preventing pyrite oxidation. The sample saturated with ARD (pH ~ 3) had a negligible acid production rate and leached very minor Al concentrations although Al is soluble at low pH. This indicated saturating waste rock dumps with ARD can be an effective method in mitigating ARD formation.

Jan 1, 2007

By A R. Bye, T R. Stacey

Anglo PlatinumÆs Potgietersrust Platinums (PPRust) operates three open pits and plans to excavate 90 Mt of rock in 2007. With pit slopes expected to reach a height of 400 m, the geotechnical department has a key role to play. Over the last four years PPRust has successfully implemented new geotechnical strategies and tactics to reduce risk, improve safety and maximise profitability. A large database of core logging, face mapping and rock testing data has been assembled and used for failure analysis, geotechnical zoning and rock mass ratings. The data has also been used for optimising blast designs on a daily basis through the use of a geotechnical block model. This greatly improves blast fragmentation and therefore loading and milling efficiencies. The slope design process involves limit equilibrium analysis, numerical modelling, rock fall analysis and block modelling. Slope management includes comprehensive limit blasting and visual inspections, and state-of-the-art slope monitoring equipment, namely the GroundProbe radar, Riegl lasers and GeoMoS automated prism monitoring. The risk-consequence approach has been used in slope optimisation, where all the slope analyses, operational controls, costs of failure, economic analyses of various slope designs and fault tree analyses are used to determine the ideal slope designs. These activities added over $25 million of value to the operation and also ensured compliance with Anglo AmericanÆs acceptable risk level. The successful mining of the optimised slopes is to due to the greatly improved geotechnical knowledge and slope management. PPRustÆs geotechnical work is used as a benchmark for Anglo American open pit operations. The focus of the paper will be on the value added to the operation by all aspects associated with slope management.

Jan 1, 2007