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By J. Y. Hwang, M. L. Jeong, R. C. Greenlund

Various aluminum-smelting by-products from three production sources were received and characterized. The waste materials were tested for compound identification and environmental acceptance. A coarse metallic aluminum recovery test using an Eddy Current separator (ECS) was performed using two different Circuit configurations. White dross performed equally well with either Circuit, while black dross processing shows significant difference on the separation results. It was found that ECS technology was effective for particle sizes down to 6-10 mesh.

Jan 1, 2001

By Claus Becker

The new, 2.600 m long pipe under the river Elbe in Hamburg/Germany required for 2 traffic lanes, emergency lane and space for utilities a boring diameter of 14,20 m(46,6 ft). According the geology (glacial deposits consisting of clay, sand and marl, all containing big boulders) a Slurry-Shield with crusher was selected. With a minimum cover of 7 m and a maximum pressure of 5,6 bar extensive ground treatment was necessary to make the drive feasible. The machine contains a lot of new developments. The drive was finished in spring 2000 so all experiences can be reported. A special risk sharing contract avoided completely litigation.

Jan 1, 2001

By Ron Woolf, Corry Goumans

This paper describes rock slope remediation performed along America’s first Superhighway, the Pennsylvania Turnpike and in particular, the specialized drilling equipment designed and built by Pacific Blasting to complete this work. This S-month project was performed on an existing rock cut slope within the Bedford Narrows, a gap formed by the Juniata River through Evitts Mountain. These rocks are in the folded Juniata and Tuscarora Formations within the Valley and Ridge Province and strike northeast with near vertical to slightly overturned bedding.

Jan 1, 2001

By D. Craig Camp

Microtunneling has successfully completed both horizontal and vertical curves. This paper covers the historical development of curved microtunneling and a description of one microtunneling project. The completed microtunnel is used for electrical transmission in Japan. The crossing had several concerns including right of way, social disruption, obstructions, the cost of intermediate shafts, and political restrains. In order for this drive to meet all of the imposed restrictions, four horizontal curves and one vertical curve were planned and executed in accordance with the design. Iseki Poly-Tech of Tokyo, Japan designed and built the microtunneling machine to meet the project requirements. Curved microtunneling has been successfully used on fourteen projects in Japan. The reason for a curve has been that the project could not be rerouted, short straight drives could not be used to negotiate the curve, or the project’s social and environmental conditions required a curved tunnel. The following table (Table 1) includes summary information on 14 curved microtunnling projects that have been successfully completed in Japan. The first column is a reference number. Columns two through four include basic project information. The fifth column is the total project distance completed by microtunneling. The sixth column is the project’s microtunneling duration. The seventh column is the machine type and size. All of the machines listed are manufactured by Iseki Poly-Tech of Tokyo, Japan. The size is the internal concrete pipe diameter; all of the projects listed were completed with Japanese standard concrete pipe. The eighth column contains a general description of the soil. The soil type and blow counts are approximately equal to ASTM D 2487 standards. The ninth column lists the radius of the curve and the span distance or the distance microtunneled that included the curve. The radius of a vertical curve is denoted with a “VR”, a span with both a left and right hand curve is denoted with a “S”. Other significant first events are also noted in this column. The first curved microtunneling project was completed in 1982 using a conventional microtunneling machine with standard Japanese concrete pipe and a very long radius curve while maintaining grade for the gravity sewer. The second curved microtunneling project included multiple radii curves, all in the same direction, on a single drive. In 1989, on the fifth curved microtunneling project, a “S” curve was successfully negotiated. On the seventh curved microtunneling project, completed in1995, a tight radius curve was negotiated. In 1996, the eighth project included a vertical curve. The thirteenth curved microtunneling project, completed in 1997, was the first project to utilize a microtunneling machine specifically designed to negotiate curves. The fourteenth curved microtunneling project was the accumulation of all

Jan 1, 2001

By Andy Mille

The paper highlights development of tunneling methodology in the UK during the years 1990-2000 using the example of two major tunneling contracts where there solution of difficult tunneling problems during construction has benefited the industry as a whole. The paper deals with specific difficulties on two Contracts. The London Water Ring Main 80 kms (50 miles) long tunnel average internal diameter 2.54 m (9 ft4 in) and the Brighton Stormwater Tunnel 5.2 km (3.2 miles) long tunnel with an internal diameter of 6 m (19 ft 8 in). The results of human endeavour and technological innovations will demonstrate the giant strides made in tunneling methodology in the last decade of the 20th Century.

Jan 1, 2001

By Shane Yanagisawa

The Mineral Creek Diversion Project is at the Asarco Ray Mine Complex, about128 km (80 miles) east of Phoenix, Arizona. The new tunnel will intercept the waters of Mineral Creek about 2,134 m (7,000 ft) upstream from an existing tunnel. The 5.74 m(18.83 ft) hard rock TBM will break into the old tunnel about 2,162 m (7,090 ft) in from the old portal after mining 3,888 m (12,753 ft). The TBM will mine through a series of igneous and metamorphic formations including volcanic tuff, soft volcanic ash, massive diabase, fractured quartzite, and schist. The TBM will hole through into the existing 4.88 m (16 ft) dia. horseshoe tunnel where the TBM will be disassembled and removed from the tunnel.

Jan 1, 2001

By Ronald E. Triplett, George K. Burke, Bernard H. Voor

To accommodate larger double-stack rail cars through a tunnel, the existing active tracks were to be lowered. The tunnel is an elliptical, horseshoe-shape with concrete base support, removal of which would jeopardize the tunnel integrity, particularly since the soils beneath part of the tunnel floor included soft, saturated silt overlying rock. Grouted bar anchors combined with a SuperJet soilcrete strut replaced the existing support in situ prior to floor lowering. Close cooperation and detailed timely engineering support provided a quality project. Project design and construction, ground improvement methods, and the performance of the work are described.

Jan 1, 2001

By V. Wetzig

In the past, various investigations have been carried out at the Hagerbach Experimental Gallery under accurately reproducible conditions, in order to determine the emissions emanating from blasting operations. Comparative investigations proved that the composition of the blast fumes is influenced by the choice of different explosives. It also emerged that the use of emulsion explosives leads to significantly lower concentrations of harmful substances in the blast fumes. Further investigations concerned the residues and reaction products from the explosive process which are left in the debris. Eluate tests on representative samples of debris were used to determine the concentrations of nitrate, nitrite and ammonium in the debris.

Jan 1, 2001

By Jim Wickens, Vince Lofftus, Mark Kravetz

"This paper discusses how Bald Mountain Gold Mine (Ely, NV) dramatically reduced mercury production by treating process solutions with a liquid reagent based on organic sulfide chemistry. Cherokee Chemical Co. Inc. (Vernon, CA) markets this reagent as UNR 81 1A.A summary of the bench tests comparing various reagents is given. The ensuing plant trial is discussed and successful mercury removal results are presented. Data is presented to show that early removal of mercury in the process reduces the amount of mercury collected at retort. Data is also presented to show that use of this reagent does not reduce gold recovery. Plant trial treatment costs are discussed. Finally, the potential of this technology to substantially reduce closure costs as compared to traditional mercury removal options is discussed.INTRODUCTIONBald Mountain Mine produces gold. Mercury is a costly by-product of gold production because no revenue is generated from mercury. Traditionally, mercury leaches out with gold and follows the gold throughout the processing circuit until it is eventually condensed and collected at Retort. Minimizing or eliminating mercury production minimizes worker health and safety risks, minimizes environmental liability, and reduces costs. In the long term, minimizing mercury production will make mine closure easier and less costly.Bald Mountain Mine dramatically reduced mercury production by treating process solutions with liquid reagents called UNR 811 and UNR 811A. Several reagents were bench tested before proceeding with a plant trial. The reagent complexes the mercury to form an insoluble organic sulfide precipitate. In independent tests, the precipitate passed acid mobilization tests and is considered stable."

Jan 1, 2001

By Robert Cooke

This paper shows how technology developed to analyse stabilised slurries can be applied to paste flows. The rheological characterisation of paste mixtures using the generalised yield pseudoplastic rheological model is described. It is noted that the slump test does not provide a complete rheological characterisation of a paste. Methods for calculating pipeline pressure gradients for laminar and turbulent flow are presented. The minimum pressure gradient is an important consideration to ensure that solids do not settle on the pipe invert. Important points to be considered for a pipe loop test programme are noted. The usefulness of the pseudo shear diagram for scaling pipe loop test measurements is demonstrated. Issues to be considered for the design of paste reticulation systems are discussed.

Jan 1, 2001

By W. G. Davenport

Most pre-t 988 Outokumpu flash furnaces were built with blast heaters. Many continue to use them. Blast temperatures in these smelters· are typically 400 to 700 K (Table 2. 1) This chapter: (a) shows how hot blast is included in our calculations (b) evaluates the effects orhot blast onauthothermal65% Cu matte production.

Jan 1, 2001

By M. J. Michaud, M. J. Lavigne

"Abstract - North American Palladium Ltd. operates its Lac des Iles open pit palladium mine 85 km north of the city of Thunder Bay, Ontario. The Roby Zone deposit occurs within the mafic/ultramafic Lac des Iles Intrusive Complex (LDI-IC), which was created by multiple pulses of magma of varying composition within several closely spaced chambers. Chaotic lithological distribution, the presence of magmatic breccias, and the rarity of rhythmic layering suggest a dynamic intrusive environment with disruptive magma pulses. As of December 31, 2001, measured and indicated resources for the 950 m long by 815 m wide Roby Zone deposit totalled 159 Mt grading 1.55 g/t Pd, 0.17 g/t Pt, 0.12 g/t Au, 0.05% Cu, and 0.05% Ni at a palladium cut-off grade of 0.7 g/t. The Roby Zone contains an additional 73 Mt of inferred resources at similar grades.The Roby Zone is dominated by varitextured gabbro containing pipes and pods of breccia, and large blocks (~60 m across) of varying lithology. Mineralization at Lac des Iles occurs as: (1) a PGEand base metal-rich magmatic matrix of breccia (breccia ore); (2) mineralized dikes or sills (gabbronorite in North Roby ore); (3) lower-grade mineralization in varitextured units that are host to the distinctive breccia ore and envelope the North Roby ore; and (4) high-grade mineralization associated with strong silicate alteration exemplified by high-grade ore.The close spatial association of the mineralized breccias with both varitextured units and silicate alteration leads to an interpretation that the energetic magma that created breccia was charged with a dissolved fluid, and that this deuteric fluid exsolved at high temperatures to migrate through crystal mush, enhancing crystallization along its pathways, resulting in variable grain size. This transformation occurred at high temperature and produced sulfide-poor, varitextured gabbro-hosted mineralization exemplified by some of the mineralization in the North Roby Zone, and also found throughout the Roby Zone. The association of hydrous silicate alteration with mineralization can be explained by continuing fluid migration during cooling and continued metal transport. Résumé - North American Palladium Ltd. opère la mine à ciel ouvert de Lac des Iles située à 85 km au nord de Thunder Bay, Ontario. Le gisement Roby Zone est encaissé dans le complexe mafique/ultramafique de Lac des Iles (LDI-IC), lequel représente une intrusion polyphasée créée par plusieurs pulses magmatiques de différente composition à l’intérieur de chambres magmatiques fermés. La distribution chaotique des lithologies, la présence de brèches magmatiques, et la quasi-absence de litage rythmique suggèrent un environnement magmatique dynamique perturbé par l’introduction de nouveau magma. Au 31 décembre 2001, les ressources mesurées et indiquées s’élevaient à 159 millions de tonnes titrant 1,55 g/t Pd, 0,17 g/t Pt, 0,12 g/t Au, 0,05% Cu, et 0,05% Ni, pour une teneur de coupure de 0,7 g/t Pd. De plus, la Roby Zone contient 73 millions de tonnes de ressources inférées à une teneur similaire.La Roby Zone est principalement encaissée dans un gabbro de texture hétérogène (varitextured) caractérisé par des cheminées et des lentilles de brèches et des énormes blocs (environ 60 m de diamètre) de plusieurs lithologies. Au Lac des Iles, la minéralisation en EGP et en métaux de base se retrouve dans la matrice magmatique de brèches (breccia ore), dans des dykes ou des sills minéralisés (gabbronorite dans la zone North Roby ore), comme minerai de basse teneur encaissant le minerai de brèche (breccia ore) et enveloppant la zone North Roby. Du minerai de haute teneur est également associé avec une forte altération en silicates dans la zone high-grade ore.L’étroite association spatiale entre les brèches minéralisées et les unités de texture variée (varitextured) et l’altération en silicate suggère que le magma énergique qui a causé la bréchification était chargé de fluides. Ces fluides deutérique"

Jan 1, 2001

By Joachim Leonhardt

Hundreds ofbolt-indicators were already used successfully in the German deep hard coal-mines to increase the safety and economy. The bolt-indicator offers the simple possibility to show roof-bolt (anchor-) loads. to indicate weak points as well as to optimize the anchor density and the dimension: The bolt-indicator is mushroom shaped and consists of coated metal. It is inserted between the anchor plate and the flanged nut. The loads appearing at the anchor are transferred to the bolt- indicator and can be recognized visually at the cylindrical part by the amount of the surface coating. Examples are used to clarify the application aims, operation and usage of the bolt-indicator and its yielding advantages in practice.

Jan 1, 2001

By B. J. Arnold, N. Terblanche

The features of the ‘Turbo’ froth flotation column will be discussed, including the double aeration system that improves flotation yield while not sacrificing grade, the internal launder system, and the unique feed/tailings sump that evens out flow to the flotation column preventing upset conditions. Results from various test programs and installations will be presented.

Jan 1, 2001

By W. G. Davenport

All Outokumpu flash furnaces burn some hydrocarbon fuel. Hydrocarbon combustion supplements heat from Fe and S oxidation and provides local heating in cool; parts of the furnace. Adjustment of hydrocarbon fuel combustion rate is an effective way of controlling furnace temperature. More oxygen and more oxidation of Fe?and S in the flash furnace continue to diminish the need for1hydrocarbon fuel. Still, as Tables 2.1 and 3.1 show, all flash furnaces use it. Oil is the most common fuel -natural gas, coal and coke are also used. This chapter demonstrates how hydrocarbon fuel is included in our flash furnace matrix. It shows that: (a) three new variables, mass hydrocarbonfoel. mass CO2 in offgas and mass H2O in offgas are inserted (b) carbon and hydrogen balances are added (c) hydrocarbon fuel quantity is specified (d) ,the oxygen balance is modified to include CO2 and H2O (e) the enthalpy balance is modified to include hydrocarbon fuel, CO2 and H20.

Jan 1, 2001

By B. J. du Plessis

Automation of the conventional grinding circuits of Palabora Mining Company (PMC) required that adequate instrumentation and a control system had to be put in place, after which extensive testing had to be done to evaluate different grinding control strategies. The objective was either to optimize the particle size from the grinding circuit, or to increase milling circuit throughput while maintaining particle size at existing levels. Prior to automation of the process as described below the circuits were controlled manually. No on-line information on cyclone feed densities, cyclone feed flow or cyclone overflow particle size was available. This type of control relied heavily on interpretation of the process parameters by the operator and on his ability to make informed decisions on what the set points should be. An integral component of the automation process was the installation of a SCADA package (SysCad SDX) for implementing the on-line control strategy. A self-correcting model for prediction of cyclone particle size was developed and implemented on the SDX. The model is calibrated using values from the particle size analysers while they are operational. If the particle size analysers choke or fail for any reason, the model continues to provide a good estimate of the particle size. This technique ensures that a continuous particle size indication is available compared to the intermittent reading from the instrument. The continuous signal allows particle size to be used as a process variable for control purposes. A strategy was developed and implemented which allows for the production of a controlled grind size from the conventional milling circuit to the flotation circuit. The grinding control strategy allows for the control of particle size from the individual cyclone overflows. This strategy allows the operator of the process to increase or decrease production rate by specifying a coarser or finer grind size required for flotation.

Jan 1, 2001

By Donald Hurd, James Rowland, Richard Mainiero

In previous conferences the authors have reported on toxic fumes generated by the detonation of ANFO. The research reported here extends the earlier work to include an emulsion blasting agent and ANFO/emulsion blends. Explosive mixtures were shot in 4-inch Schedule 80 steel pipe (outer diameter 4.50 in (11.43 cm), inner diameter 3.83 in (9.72 cm)) in a chamber in the experimental mine at the Pittsburgh Research Laboratory (PRL). Following each shot, the fumes in the chamber were analyzed using on-line instrumentation.

Jan 1, 2001

By R. E. Moore

Refractories are unique ceramic materials, which are used in large quantities in steel making furnaces, metal smelting vessels, and glass melting tanks. They are required to possess high thermal shock properties and good slag corrosion resistance as well as creep resistance at high temperatures. Therefore, they are made from very refractory minerals such as lime, periclase, corundum, spinel, and zirconia. Slags are vitreous materials produced as a residue in steel refining processes. They cover a wide range of compositions and may contain pure oxides, silicates, and sulfides as well as fluoride phases depending on the melting and smelting processes. These minerals exhibit spectacular cathodoluminescence color under electron bombardment; therefore, cathodoluminescence (CL) microscopy is found to be a superior technique for the characterization of refractory corrosion by slags. Examples included in this study are (1) reaction of fluorine containing mold slags with ZrO2-C nozzle refractories promoting crystallization of the Cuspidine, Ca4Si2O7(F,OH)2, (2) corrosion of fusion cast refractories in TV panel glassmaking furnaces and formation of glass defects, and (3) reaction of spinel based castable refractories with copper smelting slags.

Jan 1, 2001

By Ü. Atalay, G. Alaeddinoglu, G. Özcengiz, G. Özbayoglu, Z. Özdemir

In this study, bacterial pre-treatment was applied before cyanidation in order to enhance the solubilization of silver from Artvin-Kafkasör ore Direct cyanidation process was found inefficient to recover silver from the ore. Only 40.36% silver recovery was obtained with direct cyanidation while silver recoveries of above 60% were obtained after bacterial treatment. Thiobacillus ferrooxidans was used as the microorganism in pretreatment tests. Effects of various parameters such as pulp density, duration, inoculum size and particle size on silver recovery have been investigated in this study.

Jan 1, 2001

By R. C. Milici

The primary factors that determine the marketability of coal from various supply centers in the U.S. are coal quality and supply; i.e. low sulfur, moderate- to high- Btu coals have large market areas when compared to less expensive but poorer quality coals. Price is the major factor in the competitive marketing of similar coal products. Good quality, (moderate- to high- Btu, low sulfur) coals from the Powder River and central Appalachian basins are marketed over large areas of the country, and central Appalachian coal is widely distributed in foreign markets, primarily as coking coal. In contrast, poorer quality bituminous coal (low calorific value and/or high sulfur) from the Illinois Basin, northern Appalachian Basin, and lignite from the Gulf Coast is marketed in or near the States in which it was mined even though the price at the mines may be lower than mine prices for central Appalachian coal. Widespread distribution of sub-bituminous Powder River Basin coal is enhanced by its exceptionally low mining costs, which offsets transportation costs to distant markets.

Jan 1, 2001