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By A. Robles

The main goal of the present work is to propose a viable alternative for selective arsenic elimination from copper smelter flue dust without the need of a global leaching scheme for all the individual components of the flue dust. Using this alternative, the inherent copper recovery problems are avoided. Arsenic precipitation is also considered for regenerating the solution and completing the process cycle. The experimental results for arsenic extraction and precipitation are satisfactory. Concentration of NaOH used was relatively low. The main reason for succeeding in high arsenic extraction and low NaOH consumption is due to the previous water washing of the flue dust. Water washing dissolves much of the iron and copper that are present in certain percentage as sulphate.

Jan 1, 1999

By R. A. Lowe, P. B. Malla

Smectite is a common impurity in the kaolins of Georgia.This impurity is harmful to the low-shear rheology of kaolin slurries in concentrations as low as a few weight percent. The deleterious effect of smectite on the low-shear rheology is due to the swelling of the mineral. Montmorillonite containing clays were treated to precipitate a compact brucite layer {Mg(OH)2} in the interlayer region of the expandable layer silicate mineral. This treatment forms ahydroxy-Mg-montmorillonite with characteristics similar to chlorite. This treatment effectively reduces the swelling capacity of the mineral and improves the rheological properties of kaolin slurries contaminated with smectite impurities.

Jan 1, 1999

By M Malec, J Szczerbinski

Hazards in underground mines are concomitant with the mining of mineral deposits and have their source in a minerÆs work environment. The authors of the paper have undertaken a trial classification of these hazards into three groups, depending on the sphere of their occurrence:lithosphere, ie rock mass, atmosphere, ie air in mine workings, and technosphere, ie machines, equipment and facilities in mine workings. The lithosphere creates such hazards as bumps, rock outbursts, the atmosphere is a factor causing fires, methane explosions and climatic hazards, whereas accidents concomitant with an operation of machines and equipment occur in the technosphere. Assuming that the number of accidents in the mining industry, concomitant with hazards, reflects the degree of safety, it has been shown, that in Poland they are under control to a large extent.

Jan 1, 1999

By Y. V. Swamy, B. Bhoi, H. S. Ray

Low-grade manganese ores with low Mn/Fe ratios can he enriched through selective carbon reduction of iron oxide to magnetite followed by magnetic separation o f the magnetite. Thermogravimetric analysis (TGA) was used to assess the preferential isothermal reduction of pure M1702 and Fe2O3 using solid carbon. This was followed by reduction of a synthetic analogue of composition comparable to an actual low-grade ore (i.e., Sandur manganese ore, Sandur, India). The carbothermic reduction of the manganese ore converts the hematite and goethite minerals to magnetite (Fe3O4), with the magnetite then going into the magnetic, fraction. The resultant nonmagnetic ,fraction becomes depleted of iron with an enhanced manganese content. These results show that it is possible to reduce the iron from 22% to 5.85%, thus increasing the Mn/Fe ratio from 1.52 to 6.2 with a manganese recovery of about 50%. The recovery was, further improved by grinding the magnetic fraction to -75 µm.

Jan 1, 1999

By Jorj O. Osterberg

The Osterberg (O-Cell) Method makes it possible to separate the side shear resistance (skin friction) from end bearing. The O-Cell is placed on or near the bottom of a drilled shaft and after the concrete is poured and cured, an equal upward and downward pressure is applied. From the test, the load-upward deflection curve in side shear and the load-downward deflection curve in end bearing are drawn. Typical curves are shown where the ultimate load in side-shear is reached and where the ultimate load in end bearing is reached. Several examples of tests in which the test load reached ultimate loads far in excess of what was expected are shown. The side shear in rock sockets is shown to be much larger than generally estimated. Examples are given of where side shear is smaller than expected and the reasons discussed. Disturbance of the sides of drilled holes due to poor construction techniques and ways to avoid these conditions are considered. Examples of bottom hole disturbance are given and ways to prevent the disturbance are discussed. A graph showing the actual measured capacity of drilled shafts compared to the estimated capacity as a function of the hardness and strength of the soil or rock is presented.

Jan 1, 1999

By Richard W. Kimball, Richard F. Coon

This paper describes drill and blast excavation and groundwater control measures at the Lake Mead Intake No. 2 project. The construction includes a deep access shaft, intake shaft, surge chamber, forebay chamber, intake tunnel, 22 well shafts and East Tunnel. Grouting ahead of the excavation face was used extensively during shaft and tunnel construction. Lake Mead Intake No. 1 was constructed in the early 1970’s under less severe groundwater conditions and this work was delayed by ground conditions and water control problems. Excavations for Lake Mead Intake No. 2 must be completed in 23 months to meet SNWA’s water delivery schedule.

Jan 1, 1999

By K Akiro

Volcanogenic massive basemetal sulphide and gold mineralisation of predominantly low sulphidation style has been located within Lower Tertiary basaltic and felsic volcanic and sedimentary sequences at Ufuo, in the Left April River area, northwest Papua New Guinea. The four discrete massive sulphide bodies, which have been so far identified, occur within a 3 +5 km area situated within a north west trending structural corridor. The sulphide bodies are all localised on the margins of the corridor where the bounding major through going faults are transected by regional faults. Mineralisation is characterised by massive pyrite-bornite-sphalerite-barite-quartz-anhydrite deposition with later galena-tennantite-chalcopyrite. Minor phases include enargite, goldfieldite and bismuth sulfosalts. Jasperoidal silica lenses and bioturbated sediments are closely associated with the massive sulphides. Basemetal sulphide mineralisation is also closely associated with phyllic-style quartz-sericite- altered host rocks underlying the massive sulphide lenses. This mineralised phyllic alteration is localised to fractures, veins and breccias that cross-cut propylitic style alteration characterised by quartz, epidote, chlorite, adularia and zeolite. The mineralised system possesses several hydrothermal features consistent with a copper-rich submarine exhalative volcanic hosted massive sulphide (VHMS) system, ie discrete massive sulphide bodies with abundant barite, associated jasperoidal silica and bioturbated sediments. However, exploratory drilling of the alteration zone underlying each of the massive sulphide bodies has not identified a well-defined zoned alteration pipe that is characteristic of such systems. The alteration is also similar to that of a porphyry-related low sulphidation system in which phyllic alteration has overprinted a regional propylitic style assemblage. The presence of sporadic enargite (and ?tennantite/tetrahedrite) suggest there were intermittent pulses of acid fluids in the system probably derived from exsolved magmatic SO2 which flowed directly to the surface along reactivated faults. The occurrence of tellurium and bismuth minerals is also consistent with a magmatic contribution to the metalliferous hydrothermal fluids. It is proposed that the VHMS orebodies are the products of submarine exhalative deposition generated by a crystallising magma emplaced within crust of on-going tectonism. Ufuo mineralisation is similar to many VHMS deposits elsewhere in that it is unclear whether the metals are derived from the magma directly, or via seawater leaching of the wallrock. Additional studies such as oxygen isotope analysis may assist in resolving this issue. If the metals are shown to be of direct magmatic origin then there may be good prospects for discovering economic-grade porphyry-related mineralisation at depth below the massive sulphide deposits.

Jan 1, 1999

By Fogarty J. G H

Ausmelt Technology has a unique capability of removing the impurities, phosphorus and sulphur, from the feed materials to the process. Sulphur is removed to the gas phase almost completely because of the interactions of ore and coal in the reaction region at the top surface of the slag bath. Phosphorus is removed to the slag phase, with both basic and higher, controlled iron oxide levels in slag being achieved in the process. The significance of these features of the process relate to the production of pig iron with very low levels of these impurities for the further processing to steel, and to the treatment of high phosphorus and high sulphur raw materials. The marketability of pig iron and the raw materials are discussed in relation to this feature of Auslron.

Jan 1, 1999

By P. Molera

"In Catalonia, between the 10th century and 1878, some installations were developed which at first were called ""factories"" and later ""fargas"", since they manufactured iron and steel of low carbon content. Because of its excellent quality, the fame of this metal spread from Catalonia to many countries. Fargas were started in Corsica, the Low Countries, Germany, Oriental India, Madagascar, Finland and along the rivers Orinoco and Mississippi among others. The extractive process used in these fargas has passed into history as the ""Catalan Farga Process"", ""Catalan Process"", or just ""Farga Catalana"". With this technology, raw material was obtained for the fabrication of tools, nails, weapons, grilles, etc. to supply the national and export markets. Aside from meteorites and native iron, found as metallic nodules in basalts in Greenland and Palestine, the ancient civilizations, which had no means to reach the fusion temperature of iron (1535°C), obtained iron by a direct process. Similar processes were used until quite recently (1930s) by certain tribes in Central Africa; holes in the ground were filled with iron ore and coal, and combustion encouraged by blowing air by mouth or with bellows made of animal skins. Thus without melting the iron it is possible to reduce the mineral and obtain a porous and impure metallic mass, which is purified on forging by mechanical squeezing. With a process very likely similar, the famous column at Dehli weighing 6.4 m.t. was built about 300 B.C."

Jan 1, 1999

By F. J. Klingler, K. M. Swaffar, M. M. Rabbaig

The Detroit Water and Sewerage Department has undertaken a $1.2 billion effort to capture and treat combined sewage overflows from various outfalls along the Detroit and Rouge Rivers in Detroit, Michigan. This program is planned to include a 455,000 m3 (120 million gallon) storage and treatment tunnel which will capture overflows from 19 outfalls along the Rouge River. The tunnel is currently in the conceptual design phase, with the bid date planned for mid-year in 2001,and completion planned for August 2005. The total design and construction cost is currently estimated to be approximately $450 million. Current concepts are for the storage and transport tunnel will be 6.1 m (20feet) in finished diameter, with a total alignment length of approximately 12,200 m(40,000 feet). The main tunnel will extend through the Traverse and Antrim Shalerock formations, while approximately 5,500 m (18,000 feet) of various diameter connecting tunnel will extend through both rock and soft ground. The project will include a total of 10 drop shafts, 13 riser shafts, various connecting structures, and a 455,000 m3/day (20 mgd) pumping station. This paper will present a discussion of the design philosophy, subsurface conditions, the various planned components, and the expected design and construction considerations for the proposed Upper Rouge Combined Sewage Overflow Tunnel.

Jan 1, 1999

By K. Pathak

Loaders and dump trucks are the most commonly used surface-mining equipment. Negligence of the safety-engineering aspects of dump trucks may result in serious accidents in a mine. A reduction in the risk of an accident due to the deployment of trucks can he achieved by engineering analysis, risks assessment, improved safety features, active safety devices, condition-based maintenance, in-built protection systems, etc. This paper presents some cases of accidents in Indian surface coal mines and advocates a systems approach to safety.

Jan 1, 1999

By M. L. Smith

"In the Phosporia formation of SE Idaho, ore quality varies by depth, seam and distance along strike; phosphorus recovery is sensitive to these variations. Plant ore feed can be blended over time to minimize this fluctuation by using a combination of mine production and inventory stockpile scheduling. Mixed-integer and goal programming has been used to optimize short-term mine production, but the seasonal nature of mine haulage requires the use of stockpiles both at the mill and the mine. The contents of the stockpiles can also be optimized as part of the production scheduling problem, but introducing inventory control introduces a nonlinear term into the formulation. A solution using a piecewise linear formulation is modelled and solved using AMPL/Cplex, and solution strategies are discussed for similar large-scale problems. IntroductionIdaho’s minable deposits of phosphate rock are found in the Meade Peak member of the Phosphoria Formation; two separate zones of this formation are mined with a combined thickness of 30 ft to 60 ft. A generalized stratigraphic section of the Phosphoria section is shown in Figure 1, illustrating the degree of complexity encountered when scheduling mine production. Alteration of the formation results in higher grade ore zones near the surface and variable in P2O5 levels between seams and along strike. This variability is seen as well in other quality characteristics critical to the production of acid and elemental phosphorus. Further, plant recovery and nodule quality are sensitive to variations in ore feed; variability in SiO2, carbonates, moisture, organics (carbon), P2O5 and other constituents of the ore can strongly affect plant recovery. Because ore quality characteristics can vary as a function of the alteration zone (or seam) being mined as well as the depth and distance along the strike of the formation, scheduling of mine production can have a highly significant effect on recovery in the plant. As illustrated in Figure 1, there are nine seams containing 20% to 35% P2O5. Phosphoric acid and elemental phosphorus production requires an ore content of 30% and 25% P2O5, respectively. Variability between numerous beds that are mined and quality variation within a seam due to alteration greatly complicates production scheduling with the result that erratic mill feed characteristics greatly decrease recovery."

Jan 1, 1999

By J. Nielen van der Merwe

During the process of pillar extraction at the Welgedacht Colliery, an unexpected pillar collapse resulted in the entrapment of equipment. The area was visited soon after the event to evaluate the stability of the area for the purposes of extracting the equipment. It was found that the area had stabilised sufficiently to allow work without undue risk to the safety of workers. The equipment was reclaimed successfully. A subsequent investigation into the reasons for the collapse was conducted. It entailed detailed underground and surface subsidence observations and numerical modeling. It was found that none of the perceived negative factors that were present at the time could result in pillar loads that were sufficient to cause the collapse. It was concluded that the local pillar strengths were less than the nationally used value and that they were possibly further reduced by aging.

Jan 1, 1999

By Sergio Demetrio

Over a period of nearly a hundred years throughout this century, the company direction and management of copper smelters in Chile has evolved from one characteristised by a paternalistic, autocratic style to one which empowers the local management team and people for running the smelter as a successful business. This paper discusses the evolution of the present style of management amidst changes in the Chilean Government, the mining industry and society since the beginning of this century.

Jan 1, 1999

Direct reduced iron (DRI), produced by the reaction between iron ore and reducing gasses, is used as a source of low-residual iron, in addition to ferrous scrap and pig iron, in the production of steel mainly through the electric arc furnace (EAF) route of steelmaking. The main DRI technologies in use are those of Midrex and Hyl, but in recent years a myriad of newer processes emerged based on variations in feedstock, reducing agent and fuel sources. Since the beginning of the nineties, DRI has increasingly emerged as a cheaper, low-residual iron feedstock for EAFs, which have traditionally relied almost entirely on ferrous scrap feed. The main stimulus behind the interest in DRI has been the increasing popularity of the EAF and the ?mini-mill? set-up as the favoured steelmaking option compared to the traditional and much less flexible blast furnace/ basic oxygen converter. This, however, has been creating a problem with regard to availability of low-residual scrap, resulting in upward pressure on high quality scrap prices and leaving DRI, traditionally the ?expensive alternative?, as a much more competitive consideration. The second main determinant has been the increasing production efficiency of existing steel plants which, in the light of improvements such as continuous casting and near net shape casting, has been constraining the supply of low-residual domestic scrap, traditionally the prime source of EAF feed. The explosion of current and proposed DRI projects has been accentuating the mounting interest of global role-players in assuring the availability of reliable sources of low-residual iron units for the future, especially in cases where definitive competitive advantages exist with regard to proximity to primary sources of iron ore and fuel (gas or coal).

Jan 1, 1999

By D. Kump

The Bullfrog Mine is an underground gold mine that uses the underhand-cut-and-fill mining method. The portal was established on June 18, 1991. Mining is expected to be completed by the summer of 1999. This paper starts by discussing what it took to get from nothing to 2000 tons-per-day backfill, and ends with a hindsight commentary on things that did and did not help.

Jan 1, 1999

By Eric R. Bauer

Skin failures of roof and rib in underground coal mines continue to be a significant safety hazard for mine workers. Skin failures do not usually involve failure of the support systems but result from rock or coal spalling from between the support elements. For instance in 1997, over 800 miners were injured by roof and rib falls, of which 98 pet were the result of skin failures. Also, nearly 80 pct of the roof and rib failure injuries occurred at or near the working faces in development sections. The face area is a zone where the potential for skin failure accidents and injuries and roof and rib failures, in general, is high because of mining activity, ground readjustment due to changing stress conditions, and the higher exposure of mine workers. In addition, failures occur where the roof and rib are unsupported. This paper features a review of the roof and rib accident statistics resulting from skin failure, highlighting the incidences by average days lost, in-mine location, state, MSHA District, and worker activity at the time of injury. A detailed analysis of recent fatalities caused by skin failure is included. Also discussed are the causes of roof and rib skin failures, current methods and support materials for skin surface control, as well as a historical literature review of skin failures and control methods.

Jan 1, 1999

By Toshia Ishii, Jun Kubota, Noriko Kubo

"For steel continuous castings, it is essential to control molten steel velocity at the meniscus, since the velocity is closely related to surface defects on the resultant products. Argon gas is supplied with molten steel into the mold through the submerged entry nozzle to prevent nozzle clogging. In this study, to investigate the influence of argon gas on molten steel flow, a numerical simulation was carried out by a two-phase model. Simulation results indicate that as argon gas bubbles ascend near the nozzle by their buoyancy, they induce the molten steel flow with them and resulted a meniscus molten steel flow from the nozzle to the narrow face of the mold. This flow direction is opposite to the case without argon gas. The calculated data are compared with the experimental data. The comparison shows generally good agreement between the measured and the calculated data. IntroductionIn a steelmaking process, molten steel carried by a ladle is first fed into a buffer vessel called tundish. From the tundish, it is then fed into a continuous casting mold. Molten steel solidifies gradually in the mold (the primary cooling zone) forming a solidified shell. As the solidified shell is just thick enough to support the molten steel at the mold exit, it is withdrawn through the mold by pinch rolls. It is progressively thicken as it is further cooled with water sprays in the secondary cooling zone. At the end of guide roll zone, completely solidified steel is cut into desirable lengths. Schematic view of a typical continuous casting is shown in Figure 1."

Jan 1, 1999

By Walter E. McCulloch

Recent laboratory bench scale and pilot plant metallurgical tests at Mountain States R and D International have demonstrated that some copper ores because of relatively coarse copper sulfide mineralization can be preconcentrated by heavy media separation (HMS). In tests with a copper ore from the AMT Copper Creek project near San Manuel, Arizona, HMS preconcentration rejected about 75 to 80 percent of the feed as a minus 13 mm gravel. The HMS concentrates copper recoveries were about 93 to 95 percent. With the incorporation of HMS preconcentration, significant capital and operating costs savings have been projected for the proposed AMT Copper Creek concentrator. An overview of the HMS preconcentration step development for the AMT Copper Creek project is presented. Also presented are other potential applications of HMS preconcentration for copper ore processing.

Jan 1, 1999

By A J. Burchell

The introduction reviews the tunnelling carried out in Singapore since the early 1980s. Between 1983 and 1990, Phases 1 and 2 of the mass rapid transit system were constructed. These included some 20 km of bored and cut and cover tunnels together with 18 underground stations. Some particular points of interest in this massive project are briefly commented upon. Reference is also made to other underground or underwater schemes undertaken during this period such as the proposed large caverns project and the submerged tunnel to Pulau Seraya. A description of the subsurface works, now under construction in Singapore, follows. This includes an all underground North-East railway line 20 km long with 16 stations. At a budget of US$ 3 billion, this is a major civil engineering undertaking. Another project is the extension of the railway to Changi Airport which involves 3.5 km of twin tube tunnelling together with a major underground station which is fully integrated into the airport terminals. An on-going program of further major railway extensions over the next 10 to 15 years is in place and an outline is given of some of the most important underground sectors. Other proposed projects such as the underground roads system and the deep level sewers are briefly described. Together they demonstrate the very significant volume of underground construction scheduled for the next century in Singapore.

Jan 1, 1999