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By Jamal Rostami, Levent Ozdemir, Amund Bruland, Filip Dahl

Cerchar Abrasivity Index (CAI) is one of the commonly used tests to evaluate rock abrasiveness for cutter life/cost estimations of TBM projects. There are at least 3 style machines, 2 different pin hardness, and the test could be run on fresh rock surface VS a sawn surface. Each of these parameters has a meaningful effect on the results, but its impacts were not fully understood nor its implications well explored. This paper reviews the current practice of Cerchar testing and its implications on geotechnical investigations related to TBM tunnels and provide a set of guidelines on testing and reporting of the test results for future projects.

Jan 1, 2005

By John Trefny

Although mining is currently one of the smallest academic units on the Colorado School of Mines(CSM) campus, it is alive and well, with nearly 100 undergraduate and graduate students. For many years, Mines has had undergraduate and graduate programs in hard-rock mining. The school has recently transferred its physical mineral processing activities to the Mining Department. The program has also expanded to include tunneling, underground construction and industrial minerals. There are current discussions about increased research activities on cement and other construction materials. The Mining Department also teaches its share of what is called the “distributed core” courses with curricular requirements common to related programs, as well as mining safety and health, in conjunction with our continuing education department.

Jan 1, 2002

By P. J. Ryan

Phelps Dodge’s Candelaria copper-gold mine is located 20 km (12miles) south of Copiapó in northern Chile’s Atacama province (Region III) (Fig. 1). The Candelaria Mine is about 800 km (500miles) north of Santiago and 75 km (47 miles) east of the Pacific Ocean. Its elevation is 600 m (1,970 ft) above sea level. The Copiapó River Valley is 6 km (4 miles) northeast of the mine site. It is the only major source of water in this arid region. The average rainfall is 14mm/a (0.5 in./year). During 1995, the mine produced 521.4 kt (574,800 st) of copper concentrate containing 150 kt (165,000 st) of salable copper and 3 t (98,800 oz) of gold. The 1995 unit cash cost was less than 50 cents/lb of copper. This makes Candelaria one the world’s lowest cost copper producers.

Jan 1, 1996

By K. Saito, Y. Miyauchi, T. Nishi, Y. Kizu

At Tokushima Plant of Nippon Denko Co., Ltd. high-carbon ferromanganese is produced by the electric furnace method using lump manganese ores and sintered manganese ores manufactured from fine manganese ores. However, the distribution of manganese ores is significantly uneven on earth, and their characteristics considerably vary by ore type. It is known from experience that the production of high-carbon ferromanganese by the electric furnace method depends greatly on material ores. Therefore, to maintain stable operation in the electric furnace-smelting field, it is important to identify the characteristics of each type of material ores in advance. Thus, we evaluated the high-temperature electric characteristics of manganese ores using the electrical conductivity measuring system developed by ourselves and provided the standards for determining ores and blending ratio necessary for stable operation of the electric furnace based on the evaluation results. This time we worked for optimisation of the high-temperature electric characteristics of sintered manganese ores through modification of the characteristics because the blending ratio of sintered manganese ores in the electric furnace is high. The electrical conductivity of sintered ores having various chemical components in a high-temperature region (up to 1 550°C) was measured using our electrical conductivity measuring system and high-temperature electric characteristics evaluating method reported at INFACON 9. As the result of the measurement, we revealed that the high-temperature electric characteristics of the sintered ores depend on their chemical contents and the sintered ores can be modified to those having excellent high-temperature electric characteristics by controlling their chemical contents, so that the resources can be effectively used.

Jan 1, 2004

By John Haviland, Richard E. Danell

"BHP Australia Coat Pty Ltd (BHPAC) operates seven large open pit coal mines in the Bowen Basin ofCentral Queensland, Australia. These mines have operated for periods ranging from 16 to 37 years. All of these mines have dipping seams to varying degrees and are facing increasing overburden removal in an effort to maintain production. To ensure the economic viability of the operations, this increased level of overburden removal must ah.0 be conducted at lower unit costs."

Jan 1, 1995

By Robert Morgan

The mind-set that only blasters and their helpers need training in explosives can result in risk to other employees working at mine or construction sites where blasting is conducted. Misfires are not always immediately obvious during postblast examinations performed by the certified blaster in charge; the presence of undetonated explosives may not appear until well within the muckpile as was the case in the photo, right. To avoid accidents involving misfires, follow safety procedures specified in mine safety regulations, and the ISEE Blaster’s Handbook that include the following:

Jan 1, 2004

By A. J. Farstad

Characteristics of metal/non metal mines were evaluated to determine the suitability of applying the U.S. Bureau of Mines electromagnetic location system to the problem of locating trapped mines in metal/non metal mines. Statistical distributions of mine depths and overburden conductivities show that the existing USBM EM system is inadequate for most metal/non metal mines. Alternate approaches to trapped miner location in deep mines were identified and subsequent field tests were conducted at six (6) mines to evaluate their feasibility. The approach considered to be the most promising is one which utilizes the existing manpack transmitting system, modified slightly for a dual frequency output, in conjunction with a sophisticated signal processing receiver on the surface. The main advantage of staying with a "through the earth" approach is that the underground equipment can be kept simple, easily maintained, light-weight and inexpensive.

Jan 1, 1979

By Joseph Gildner, Donald J. Phelps, Jürgen Laubbichler, Christopher Tattersall, David McAllister

The Beacon Hill Station and Tunnels portion of the Sound Transit Central Link Project consists of one mile of twin rapid transit tunnels, an underground station, portals and ancillary works constructed in an urban environment. Presently under construction, the station will set a number of North American firsts including deepest soft ground excavation carried out using the Sequential Excavation Method (SEM).Located in highly variable glacial soil deposits ranging from soft, water bearing sands to stiff, slickensided clays, the station complex and running tunnels proved to be technically challenging during design. Meeting these challenges necessitated an extensive geotechnical investigation, a trial shaft, and state-of-the-art numerical analyses to develop ground conditioning, pre-support, excavation support and structural design. A comprehensive risk identification and mitigation program, and innovative procurement strategy were incorporated into the design and contract bid documents.

Jan 1, 2005

By Thomas Schwind, Pamela S. Moran

For short tunnels, a reinforced cast-in-place lining is not economical and shotcreteis a logical substitution. In the past, reinforced shotcrete linings have been constructed with lattice girders and welded wire fabric. For the Russia Wharf Tunnel in Boston, MA, the Contractor, with the help of the Dr. G. Sauer Corporation offered the MBTA a VECP to substitute the reinforced cast-in-place concrete lining with a steel fiber reinforced shotcrete lining. The challenge was to adequately model the ductility of the steel fiber reinforced shotcrete and to test the shotcrete prior to and during construction to assure quality control. To our knowledge, this type of numerical simulation has not been used on any other tunnels in the US.

Jan 1, 2005

By R Crookes

Mine to Mill optimisation is not a recently developed concept. It is one which is finally gaining greater acceptance in the Australian Mining Industry, possibly as a consequence of the downturn in markets and certainly made possible by the development of tools and techniques to measure and predict performance of mining equipment and milling plants. Fragment size after blasting has a major bearing on the performance of all aspects of mining and a major influence on the economics of the mine and mill. The process to optimise fragmentation consists of identifying the key factors, measuring their sensitivity through a modelling and trialing program and conducting economic evaluations on the changes on both the mine and mill. Management of the Ernest Henry copper-gold mine in NorthernQueensland, Australia, has espoused the Mine-to-Mill concept and isactively pursuing excellence in blasting to drive down the total cost of mining. Ernest Henry has extremely hard, wet and heavily jointed geological conditions, and had high powder factors and a large percentage of oversize material reporting to the crusher or ROMstockpile. A blasting improvement program was undertaken betweenErnest Henry Mining, Thiess Contractors and Orica Explosives tooptimise the ore size distribution, particularly the oversize component, as a step to reducing production costs. Measures of success included bringing the rock breaker back from double shifts to part-time operation and increasing direct dumping into the crusher from 70 per cent to 92 per cent. Tools and technologies to predict and measure the performance ofindividual blasts are needed before it is possible to optimisefragmentation or the downstream processes. These include suchspecialised Orica Explosives tools as SABREX, POWERSIEVE, andPOWERLINE and commercially available drill monitors. As importantare the more common still and video camera, borehole loggers,measuring tapes, surveying equipment such as face profilers, and ahigh-speed camera if possible. There are many tools which can be applied however it is rarely necessary or possible to use all of them due to time constraints and a point of diminishing returns. The critical point is knowing what the true parameters of the blast were compared to design - only then can the predictive tools be effectively utilised. Stage one of the program has seen gradual improvement as theunderstanding grew and practices have been implemented resulting inreduced bridging in the crusher, geological mapping with respective blast designs and the oversize component under control. This paper is about a process approach which links tools and technology to understand the fragmentation drivers and then to optimising the size distribution.The continuous improvement program continues...

Jan 1, 2000

By Sanjeeva Latchireddi

"Deteriorating ore grade and high demand of metals has tremendously influenced the unit capacity of SAG mills. Pebble circuits have been added to the existing SAG circuits to increase their unit capacity. To make the pebble circuits justifiable, the grate openings are increased almost to 4.5 inches to draw large quantity of pebbles. The inherent transportation problems associated with SAG mills in closed circuit with pebble fraction are more complicated than the single stage SAG mill operation, because the coarse pebbles behave significantly different to that of slurry in pulp lifters. In addition, operation of mills at higher speed, to take advantage of precise design of high release angled shell lifters significantly reduces the discharge efficiency of the conventional pulp dischargers. The presence of a sizable quantity of pebbles in the pulp lifter limits the space available and reduces the flow gradient through the grate thus increases the load inside the mill and hence the mill power-draw. This paper analyses all the problems associated in discharge of slurry and pebbles in SAG mills with pebble circuits. The Outokumpu patented Turbo Pulp Lifter (TPLTM) aims at eliminating the inherent material transport problems to ensure good grinding conditions. Recent installation of TPLTM in a 26-ft SAG mill has proven these claims by reducing the specific power consumption while increasing the mill capacity.INTRODUCTIONThe conventional wisdom is to look at the semi-autogenous grinding (SAG) mill as just another grinding mill in which ball charge, mill filling, and mill speed are varied to attain maximum throughput. Liner design for the SAG was also approached more from a wear perspective rather than a metallurgical and hydraulic-flow perspective. The extensive research work carried out by Latchireddi and Morrell (1997,2003a and 2003b) has demonstrated to think of the SAG as more of a pump in which the grates and pulp discharger end (“impeller”) were designed to efficiently discharge the product sized particles smaller than the grate size with minimal recirculation out of the mill.The rock load in the mill is essentially depends on ore characteristics and the discharge rate of broken particles. The discharge rate of the product material depends on how efficiently the discharge pump (grate and pulp lifters) is operating. Similar to the impeller design affecting the pump capacity, the pulp lifter design affects the discharge capacity (or mill throughput) of the SAG/AG grinding mills. The general arrangement of AG/SAG mills discharge system is shown in Figure 1."

Jan 1, 2007

By Shimi Tzobery, Jay Davenport, Raymond Henn, Sam Bandimere

Over the past several decades, the use of cement-based grouts using ultra fine cement as a replacement for portland cement has begun to gain acceptance as an alternative to chemical solution grouts used in permeation grouting. The amount of information currently available on grouts made with ultrafine cement is limited. The authors used a previously developed field testing program to perform additional tests to evaluate the permeation performance of portland and ultrafine cement-based grouts. For the first time, the 2003 testing program included an attempt to determine the 28 day compressive strength of the sand permeated by the grout.

Jan 1, 2005

By Gerald T. Homce, James C. Cawley

Electrical arcing injuries are the most common form of electrical injury in mining. MSHA data show that 381 "non-contact electric arc burn" injuries occurred in the mining industry from 1996 - 2005. A more detailed study of data from 1990-2001 showed that five types of apparatus - circuit breakers, conductors, nonpowered hand tools, electrical meters and test leads, and connectors and plugs were involved in two-thirds of the lost workday injuries. Many of the protections from electrical arcing injury available to workers in other industries stem from the application of National Fire Protection Association Standard 70E - Standard for Electrical Safety in the Workplace (NFPA 70E). NFPA 70E is a generally accepted industry guideline document, but excludes underground mining from its scope. Many of its practices and procedures, however, can be applied in the mining workplace to supplement the existing electrical safety requirements of Title 30 Code of Federal Regulations. This paper describes how NFPA 70E can be applied to mining workplaces after an analysis of the mine power system electrical arcing hazards has been completed (and Hazard/Risk Categories determined) using the tables from NFPA 70E or the calculation method as described in IEEE 1584. NFPA 70E can then be used to determine the levels and types of personal protective equipment (PPE) needed to protect miners against burn injuries. Appropriate lockout and tagout (LOTO) procedures for use in the mining industry are also described. Suggestions for better selection of electrically-rated hand tools are included. Recommendations for electrical meter selection and use based on transient withstand capability are also discussed.

By J. Daavittila, P. Jokinen, M. Honkaniemi

In the latter part of the 1980?s Outokumpu Chrome in Tornio, Finland, was in a situation when its twenty-year-old ferrochrome plant was becoming inefficient to sustain economically sound production. The company made extensive studies on the then available processing methods to find out the best possible processing route. As a result the whole plant was practically rebuilt and expanded. When equipment was proven in practical operation an application for FeMn production was developed. Now when Tornio FeCr-plant is considering the expansion the same type of exercise is to be performed with today?s challenges, which will be discussed in the paper. These challenges include increasing costs or decreasing quality of raw materials, increasing energy costs, stricter environmental regulations and demand of better working conditions. The possibilities to respond to these challenges will be discussed in the paper. The future and continuing development with FeCr includes the better utilization of process dusts and a lower consumption of energy. By adapting the latest automation tools to better control of the process even higher efficiencies can be achieved with present technology. New processes are considered for development in the future and some possible technologies will be described.

Jan 1, 2004

Effect of Lattice Impurities on Electronic Properties and Surface Adsorption of Sphalerite - A Density-Functional Theory Study

Sep 13, 2010

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

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

Jan 1, 2004

By M. Dhainaut

This paper presents computations of the electric field inside a furnace. We first look at the effect of contact between two coke particles from an electrical point of view. We give values for the amount of contact resistance in the total resistance of the system formed by the two coke particles. We show that the effect of contact resistance decreases rapidly with increasing contact area. We then look at the complete electric field inside a full scale furnace. The aim is to evaluate the amount of current that short-cuts the metal bath for different vertical positions of the electrodes. We show that electrodes high above the metal bath are undesirable since they offer a larger surface of conductive charge materials where current can flow through. On the other hand, deeper electrodes force the current to go the whole way down to the metal bath. Ohmic heating along this path ensures a high temperature of coke and slag that are beneficial for metal recovery.

Jan 1, 2004

By Charles Deacon

The mining industry is constantly taking greater cognisance of their operating costs as a strategy to counter the effects of falling commodity prices. As a result, optimal operating efficiency is more important than ever. One such operation is that of blasting. Considering the relative increasing costs of explosives and accessories it is desirable to optimise the number of blast-holes fired by maximising their individual output. This achievement may now only be possible following the advent of higher technologies in the form of modified explosives and electronic detonators. This paper reviews and introduces some techniques of blast monitoring, types of operations where each is most suited, resulting modifications to blast designs, and identifies some pitfalls to watch out for when analysing the results.

Jan 1, 2000

By Judy B. Jones, Bradley A. Crenshaw, Theodore DePooter

This paper reviews groundwater issues leading to a secondary grouting program at the Chattahoochee Tunnel that was implemented subsequent to the contact grouting program. The secondary grouting program was developed based on infiltration data, geology, and testing programs. This paper includes a brief description of the geological features encountered, as well as describing the grouting program. The success of this grouting operation has been quantified by several methods, and is presented to help others project the costs and benefits of this type of program. Review of initial results and refinements of techniques are also discussed.

Jan 1, 2005

By Ammar Henchiri, Godfrey McDonald

"Breakwater Tunisia S.A.’s Bougrine mine is located in a semi-arid region of Tunisia characterized with Triassic salt domes. Due to extensive agricultural land-use in the mine area, a zero-discharge tailings facility design and high water recycling rates to the concentrator were chosen to minimize the environmental impact to the surrounding area. The process water supply has an accumulation of naturally occurring salts due to high evaporation rates and the need to recycle 70% of the process water. The elevated salt content of the process water had an adverse effect on the efficiency of the flotation reagents, which led to the production of lower quality zinc concentrate.The impact of the water salinity on the zinc concentrate quality was documented by extensive laboratory testing. A feasibility study was prepared and a decision was made to install a reverse osmosis plant for desalination of the process water. A plant was constructed during 2000 which currently supplies up to 85 m3/hr of de-mineralized water, equal to approximately 45% of the total process water requirement. The salinity of the process water decreased from about ten to twelve grams per litre before installation to less than three grams per litre. Together with minor modifications to the concentrator circuit, Breakwater Tunisia has increased the zinc concentrate grade from 50% zinc to 55% zinc without compromising the zinc recovery rate of approximately 84%.This paper discusses the successful installation of a reverse osmosis desalination plant that allowed Breakwater Tunisia to improve the grade of the Bougrine mine zinc concentrate and thus increase the net smelter return.INTRODUCTIONBreakwater Resources Ltd., through a wholly owned subsidiary, Breakwater Tunisia S.A., acquired the Bougrine underground mine and related assets in September 1997. During the winter of 1997/1998, the company rehabilitated the mining equipment, modified the concentrator circuit, developed a new mine ventilation system and prepared a new mining production program. The mine was reopened on May 2, 1998 and was in commercial production as of June 1, 1998."

Jan 1, 2003