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By R. Sullivan, K. Joiner, B. Emery, M. de Vries, F. A. Stober, L. R. Nelson, J. M. A. Geldenhuis

Keywords: Pyrometallurgy, smelting, converting, furnace design, furnace retrofit, high-intensity smelting, copper coolers, plate coolers, waffle coolers, tap-blocks, lower sidewall air-cooling, wall hold-down system, platinum group metals, ferroalloys, ferrochrome, ferrocobalt, ilmenite smelting, ironmaking, operational readiness, operational support The paper describes the development of furnace designs by Hatch in conjunction with the smelting plants in Africa to meet the intense process requirements in certain applications; continued improvement in operating efficiency through increased throughput from existing crucibles; and improvement in campaign life and furnace integrity. The era of Hatch in Africa has seen the doubling of furnace power in retrofit projects using existing crucibles to developing the highest intensity immersed electrode operations in the world. This has resulted in minimized OPEX and CAPEX per unit of production. Through the continued development of its cooling, binding and furnace power supply technologies and working with the experienced and knowledgeable personnel at the smelting facilities in Africa, Hatch has managed to meet the challenges of ever increasing furnace process requirements associated with increased power density and superheats prevalent in the operations. In addition to developing furnace crucible designs, Hatch has also intensified its ?after sales service and support? with the construction, commissioning and start-up technical assistance and operational readiness and operational support for ramp-up to nameplate capacity and beyond. The key areas of furnace risk associated with high superheat molten material tapping has also seen the development of diagnostic systems to mitigate risks and produce early warning signals for the operators.

Jan 1, 2006

By I. A. Mutemererwa

This paper investigates the role of vertical integration between chrome ore mines and ferrochromium smelters in the location of ferrochromium production capacity in South Africa and Zimbabwe. Vertical integration is important in understanding the increasing competitive position of these two countries as observations show that an increasingly larger share of the global market has been coming from integrated producers. The paper argues that the increased vertical integration between mines and smelters in South Africa and Zimbabwe has led to a lower cost of chrome ore as an input compared with other producers. Underlying this hypothesis is the basic tenet that, more likely than not, production will take place where the costs are lowest. The paper concentrates on high carbon ferrochromium (HCFC) production in market economy countries (MEC). Using an ordinary least squares model, the study tests the relationship between low chrome ore costs and vertical integration shows a statistically significant relationship. These findings partially support the view that the control of sources of chrome ore is a major source of competitiveness. Keywords: competitiveness, ferrochromium (ferrochrome), ordinary least squares, dummy variables, vertical integration, southern Africa.

Jan 1, 2000

By Yajie Wang

High horizontal stress and its adverse effects on longwall gate entries have been witnessed in many US coal mines for the past years. It can cause cutter roofs and leads to roof falls either in the headgate or tailgate entries depending on the relative orientation of the panel to the maximum principal horizontal stress. Underground observations have shown that if the maximum principal horizontal stress is perpendicular to the panel entries, the roof is in the worst condition and if the maximum principal horizontal stress is parallel to the entries, the entry is in the best condition. However, little has been done about the high horizontal stress effects on panel entries subject to different orientations of high horizontal stress. In order to design a longwall panel and control the roof effectively, the redistribution and concentration of high horizontal stress field must be fully understood. Using 3-D finite element analysis, this paper presents the high horizontal stress redistribution and concentration for a retreat longwall face with different orientations of high horizontal stress. Based on the results, possible roof failures for different orientations of high horizontal stress are analyzed. A panel design criterion is recommended.

Jan 1, 1996

By K. Burke, G. Zhan, A. Mayer

A cover with capillary barrier effects (CCBE) is being constructed on the AA Leach Pad at the Barrick Goldstrike Mine site near Carlin, Nevada. The purpose of the cover is to eliminate/minimize infiltration of meteoric waters into the leach pad. Laboratory and numerical analyses indicate that Carlin Formation siltstone (TCS), a locally available material, has the necessary hydrologic characteristics when placed on the leach pad to act as a CCBE. A pilot study has been conducted on a small-scale test cover placed on the AA Leach Pad to examine the cover performance under irrigated conditions. The preliminary test results demonstrate that the designed cover is capable of preventing meteoric water infiltration.

Jan 1, 2001

By L. J. Leach

Quench and tempered Cr-Mo plate steel was found not to contain a fully martensitic structure as a result of either slow slack quenching or insufficient hardenability at the cooling rates used. The resulting microstructure contains bainite in combination with martensite. It is necessary to examine the implications of bainite for the toughness of the final product. Loss of toughness arises primarily from the inter-lath carbides that typically form in upper bainite. An investigation into the effect of upper bainite in a martensitic matrix of a steel grade containing 0.17% C, 0.1% Cr, 0.54% Mo, and 20 ppm Bindicated lower toughness than in a fully martensitic structure.

Jan 1, 2013

By Piyush K. Dutta

This report describes the design, development, manufacture and incorporation of noise control features on a jumbo drill and the results of successful tests of this drill in surface and underground mines. The noise-reducing features developed under this program are applicable to future designs of jumbo mounted drills that can be cost effectively manufactured and have the potential to reduce noise levels at the operator's position from 115-120 dBA to 95 dBA or less without a reduction of currently attainable drilling rates.

Jan 1, 1985

The development of Western Mining Corporation's first commercial gold heap leaching operation is described. The laboratory testwork requirements for determining the amenability of ore to heap leaching techniques is discussed. Heap construction and operating practices are described; and production statistics and operating parameters are presented. It is shown that for a specific low grade gold ore a treatment cost optimization can be performed. Taking cognizance of the ore grade, percentage gold recovery, operating costs, and the gold sale price, it can be determined whether Carbon-In-Pulp (C-I-P) or Heap Leaching should be employed as the extraction process. The examples presented in this paper refer specifically to Kambalda and should not be used in themselves as generalities.

Jan 1, 1987

By R. Benito

This paper describes the application of modern data-analysis tools, such as data mining, to determine a representative cost driver for haulage activity. This cost driver was subsequently used to trace incurred haul costs by bench for openpit optimization. For this purpose, large amount of previously unused cost and production data from an open pit mine was extracted, loaded, transformed and integrated into a data warehouse. Predictive modeling was performed using Microsoft Decision Trees algorithm to compute expected unit haul costs by bench for future mine expansions. Finally, a sensitivity analysis was carried out to determine the effect of two cost drivers (if any) for incremental haul costs in the final pit outline process.

Jan 1, 2008

By P. R. Day, W. K. Webster

"The introduction of large boreholes underground initially involved taking the techniques of open-pit bench blasting to the production stope, but with deeper boreholes and narrower stopes more controlled techniques must be developed in order to maintain good stope walls and prevent dilution of ore or structural damage to pillars due to blasting overbreak. The points discussed are drilling accuracy and drill pattern, the relationship between open-pit wall control and underground mining, the varied explosives products and initiation devices available, and some of the many ways that variations in loading, such as deck charging, etc., can produce desirable results.IntroductionThe use of large-diameter blastholes for underground mining began ten years ago and today they are widely employed in a variety of orebodies and stope configurations. These big blastholes, which range in size from 4.5 to 8 inches in diameter, were originally employed in the same manner ' as open-pit bench blasts; that is, the stope was silled out to full width and all holes were drilled vertical and parallel. This was suitable for competent, massive orebodies, however the popularity of the big drills saw their usage in more narrow stopes, often with poor ground conditions. The dipping orebodies and small drill sublevels resulted in inclined drilling.Today, there is full-ring drilling of 4.5-inch holes. Some 6.5-inch holes are drilled up to 350 feet deep. A 350-foot borehole may contain 6000 to 7000 pounds of explosive. The detonation of this size of charge weight within the confines of an underground stope can have considerable effect on the stability of stope walls and adjacent pillars. Obviously, precautions must be taken to minimize the damage which would result from the large charge weights possible with these big boreholes."

Jan 1, 1982

By Murad Y. Abu-Farsakh

This paper presents the analyses of load-transfer (t-z) behavior of twelve prestressed concrete (PSC) instrumented test piles that were driven in different locations of Louisiana. The load transfer method is an efficient and practical tool for the analysis of single driven pile to predict the ultimate load. The test piles were instrumented with vibrating wire strain gauges in order to calculate the shear transfer for different soil layers during the static load test. The static load test was performed on all the test piles after 10 to 14 days of end of driving. Empirical load-transfer models were proposed previously by different researchers (Fleming 1992, Hirayama 1990, Krasinski 2012, Bohn et al. 2017) after analyzing the instrumented test pile results. For this study, load transfer of each soil layer was measured and compared with the previously developed existing model. The stiffness parameter (M) for the hyperbolic equation was calibrated in order to best match the measurements. The good agreement of the proposed curves was then confirmed by applying them to assess the overall load-settlement curve of other pile load test results available in the literature. INTRODUCTION The load transfer mechanism (stress-strain relationship) for an axially loaded pile usually comprises of three loading mechanisms: axial deformation in the pile (z), soil skin friction along the shaft (qs), and soil end-bearing (qb). The development of soil skin friction with axial deformation is referred as the t-z curve, and the development of soil end-bearing with axial deformation is referred as the q-z curve. Figure 1 presents the load transfer mechanisms in an axially loaded pile and the corresponding spring mass models for t-z and q-z curves (API, 2002). In order to construct the load transfer curve in clay under vertical load, the axial load transfer (t-z) curve and end-bearing load transfer (q-z) for that particular soil should be assessed separately. The axial load transfer (t-z) method is probably the most widely used technique to study the problem of single axially loaded piles. Therefore, the load transfer through the shaft of the pile and are getting more and more important compared to the only the pile capacity analyses. The load transferred from shaft to the surrounding clay soil is a function of the width of the pile and the surface roughness of the pile and clay properties. The development of a representative procedure allows the assessment of the t-z curve in soil (sand and/or clay) that leads to the prediction of a nonlinear vertical load-settlement response at the pile head.

Jan 1, 2018

The Peelwood district of New South Wales is located some 65 miles south of Bathutst on the Tuena-Crookwell road. A number of occurrences of lead-zinc-copper ore are known from this district but only three mines, Peelwood, Cordillera and Mt. Costigan, have achieved any significant production. The purpose of the paper is to describe the mineral composition of sulphide ores from these three localities.HISTORYNo published information on the geology of the Peelwood area is available. Came (1899) reports that, at the time of cessation of mining operations in 1888, the Peelwood mine had produced some 600 tons of copper metal and regulus, the Cordillera mine had yielded 9000 tons of ore at the recoverable grade of 2·5 per cent Pb, 2·5 per cent Cu, 90z/ton Ag and 1 dwtjto:p. Au, but that no production figures were available from Mt. Costigan. No further work was carried out on these properties until 1951 when the Electrolytic Zinc Company of Australasia instigated a programme of geological mapping and exploratory diamond drilling (Whitten, unpublished data, 1953). The Peelwood district was recently mapped by Mutton (unpublished thesis, 1960) from whom the following geological summary account was taken.GENERAL GEOLOGYAll rocks in the Peelwood area belong to a series of interbedded fine grained sediments and volcanics that are thought...

Jan 1, 1961

By N. Romani, R. Provost

"Commissioning of a circulating dry scrubber (CDS) plant was recently completed at an existing facility in Québec, Canada. The CDS plant treats the sulphur dioxide off-gas emitted from rotary kilns in order to meet increasingly stringent environmental requirements. This installation enables the existing facility to reduce their sulphur emissions by over 90%.Proper planning of the different commissioning stages and staffing an integrated team are the most important factors required for a successful plant start-up. A strong Operational Readiness plan must be in place as early as the start of construction in order to ensure a smooth transition from commissioning to operations. Plant performance can meet or exceed performance criteria within the required timeframe if the proper group dynamic and good communication is established between construction, commissioning and operations teams.The road blocks encountered are often from systems that one assumes will operate without trouble such as air-conditioning, or design assumptions that were taken years earlier in feasibility process stages, namely the capacity of existing systems that will connect the new plant to the existing facilities. The challenges associated with rectifying these issues in addition to the requirements to properly start-up and operate a new plant without impacting production are great, and it is imperative to have the necessary resources to react quickly to any problems.IntroductionCommissioning of a circulating dry scrubber (CDS) plant was recently completed at an existing facility in Québec, Canada. The CDS plant treats the sulphur dioxide off-gas emitted from rotary kilns in order to meet increasingly stringent environmental requirements. This installation enables the existing facility to reduce their sulphur emissions by over 90%.The CDS ProcessA general overview of the CDS process is presented in Figure 1 below. The combined, de-dusted off-gas from multiple kilns is sent to the CDS, which acts as an entrained fluid bed, where the gas is contacted with a water mist, re-circulated solids and hydrated lime. The SO2 from the gas stream and the available calcium hydroxide (Ca(OH)2) from the hydrated lime dissolve in the water and react to ultimately form calcium sulphites and gypsum. The solid residue (referred to as CDS residue), is the primary by-product of the process."

Jan 1, 2016

By G. Bonnell, W. Lidkea, M. C. Bétournay, E. Edwardson

"Hydrogen fuel cells are a known technology, having been applied to stationary (e.g equipment, buildings, and power plants) and vehicle applications (e.g transit buses and space shuttles). There is currently a growing need to provide alternate power systems to diesel fuel for underground mining vehicles to improve underground air quality and reduce production costs and greenhouse gas emissions.To date, however, fuel cells have not been exposed to underground mine air and physical conditions. A testing program was carried out to provide information on the vulnerabilities of fuel cells as part of a number of proof-of-concept projects to apply hydrogen power to underground mining vehicles. The fuel cell type of choice for the industry, the proton exchange membrane, would function at the range of temperatures encountered in underground and surface operations, and use hydrogen that is stored under low pressure and risk.A small fuel cell stack was tested in a cooperative project between CANMET, the Fuelcell Propulsion Institute, Inco, the Ontario Ministry of Labour, Sandia National laboratories, and H-Power. This article will review the tests carried out to measure the effects from high humidity, mineral dust, diesel emission gasses and diesel particulate matter, as well as from shock and vibration provided to the unit in underground conditions at Inco’s 175 Orebody minesite and Stobie mine. The test results provided will show that the unit was not affected by the underground conditions; physically and electrically, the unit performed without any reduction in operation or adverse effects imposed."

Jan 1, 2005

By M. C. Bétournay

Hydrogen fuel cells are a known technology, having been applied to stationary (e.g. equipment, buildings, and power plants) and vehicle applications (e.g. transit buses and space shuttles). There is currently a growing need to provide alternate power systems to diesel fuel for underground mining vehicles to improve underground air quality and reduce production costs and greenhouse gas emissions. To date, however, fuel cells have not been exposed to underground mine air and physical conditions. A testing program was carried out to provide information on the vulnerabilities of fuel cells as part of a number of proof-of-concept projects to apply hydrogen power to underground mining vehicles. The fuel cell type of choice for the industry, the proton exchange membrane, would function at the range of surface operations, and use hydrogen that is stored under low pressure and risk. A small fuel cell stack was tested in a cooperative project between CANMET, the Fuelcell Propulsion Institute, Inco, the Ontario Ministry of Labour, Sandia National laboratories, and H-Power. This article will review the tests carried out to measure the effects from high humidity, mineral dust, diesel emission gasses and diesel particulate matter, as well as from shock and vibration provided to the unit in underground conditions at Inco?s 175 Orebody minesite and Stobie mine. The test results provided will show that the unit was not affected by the underground conditions; physically and electrically, the unit performed without any reduction in operation or adverse effects imposed

May 1, 2005

By Charles Hart

In this paper it is the author's intention to show the extent and character of foreign ores now known to be available; these deposits may be in active production or held in reserve until economic conditions may make them active. He hopes to show the relation existing between these ores and the American supply, and which of the former are now producing or will in turn come into production when our better ores have been exhausted. This phase of this discussion must of necessity include some data as to the present rate of consumption and a study of the changes we may expect here and abroad in the general steel trade and its sources of supply in raw materials. It is obvious that the occurrence of coal, ore and limestone in relation to one another and the proximity of a market are the elements in control of this feature of the problem. If the foregoing situation is favorable, all the other questions may be solved, for it is clear that with proper basic conditions finance, labor and operations will fall in line. We present a short outline of the present methods of carrying on the foreign iron ore trade, believing that it is of general interest in comparison with our own highly specialized methods, and that with the exhaustion of our better ores we will be compelled to seek a part of our supply abroad. A partial list of iron ores, with incomplete analyses (Table I), is added, to give a better understanding of the general situation and explain to some extent the reason for things being as they are in the iron and steel trade of the world and to help in bringing this paper to an informing conclusion. The question of the world supply of iron ores has been a subject for study on the part of geologists and engineers for many years, and found its best results in the Eleventh International Geological Congress, appropriately held at Stockholm, Sweden, in 1910. The proceedings are published in two volumes and are undoubtedly the best records available on this subject at the date of publication. It should be borne in mind, however, that much has happened in the 20 years since these figures were assembled. There is just as much known ore at present as at that time, minus the quantity consumed, plus newly discovered reserves. The World War had great effect upon this situation; during that time explorations were greatly reduced and the settlements after the

Jan 1, 1929

By M. W. Hildyard

A blast was engineered close to a tunnel in a deep-level mine with the purpose of studying the wave interaction with the tunnel. Numerical modelling of seismic wave propagation was used in both the forward planning and the back-analysis of this experiment. This paper presents the forward analysis. A likely model for a propagating blast was investigated and developed. This model predicts the influence of the velocity of detonation of the blast and the rise-time of the blast on the radiation pattern, and hence on the expected positions of maximum velocity at the tunnel surface. An attempt was made to quantify the parameters of the blast model, using waveform data from two other blast experiments. The blast model caused particle velocities which were an order of magnitude lower than these measured velocities. Large values for blast pressure were required to match the amplitudes of the recorded velocities. An alternative ?effective? source with a similar mechanism but increased diameter was proposed to account for the higher velocities. It was established that distant velocities scale with the square of the borehole diameter. A calibration blast at the experimental site was also modelled. Agreement in the waveforms was not sufficient for conclusive statements to be made about the validity of the source model. However, the modelled waveforms show an encouraging correspondence with some measured waveforms. This gave confidence that the model could be used to examine wave propagation around the tunnel, and allowed a scaled source to be developed for forward analysis of the main experiment.

Jan 1, 2001

By D. Vogt

A brief summary of the propagation characteristics of rock provides the necessary understanding to design effective radar surveys. Measurements of the electrical properties of the major Bushveld platinum-bearing horizons and their host rocks show that radar is an excellent tool for both short -and longer-range mapping. Experimental work confirms the performance predictions. High frequency, 500 MHz ground-penetrating radar (GPR) is a first-rate tool for mapping features in the hangingwall of the orebody, locally known as a ?reef?, for the purposes of determining hangingwall stability. The triplet chromitites above the UG2 have been clearly mapped, as has the Leader Seam above the UG2. Borehole radar at lower frequencies has been used over longer ranges to map reef elevation. Potholes in the UG2 are clearly distinguished in range and elevation to within metre accuracy. The nature of the slump in the various footwall horizons is also apparent. In future, as GPR is routinely applied, it is likely to become used for other purposes. Borehole radar is being developed to operate at higher frequencies, which will allow it to be deployed from boreholes that are within 5 m of the target horizon. Keywords: GPR, borehole radar, Bushveld Complex, UG2, Merensky, pothole, triplet

Jan 1, 2005

By P Duplancic and C R Lilley, R Hudson, D Beck

For deep block and panel caving mines, undercut or extraction level instability can have as much impact on overall recovery as underbreak or the premature ingress of waste. If the area of the mine affected by excessive convergence is small, recovery is usually possible. However, there are several examples of entire blocks that were abandoned prematurely due to footprint collapse. Clearly, such global instability has a major impact on recovery and must be avoided – this is one of the essential tasks for the design team.The design problem is complex. The planning engineer must ensure that the footprint has sufficient capacity to withstand the maturing loads in the cave, accounting for the effects of stress path, geological structures and the rock mass conditions. These are often uncertain and only sometimes quantified.The demand on the footprint will also be influenced by decisions and actions taken during production, especially related to draw, which can worsen a developing problem. Perhaps most importantly, the design decisions that favour stability and lead to lower deformation also negatively impact on idealised cave flow. Many engineers aim to minimise the size of extraction level pillars, to improve theoretical future resource recovery but in fact this can reduce recovery if widespread deformation ensues due to the undersized pillars.In 2014, PT Freeport Indonesia undertook detailed numerical analysis to quantify the effects of variability in rock mass conditions and geological structure on overall footprint performance. The analysis accounted for a range of stress paths and maturing cave loading scenarios sourced from a calibrated whole-of-cave deformation-flow model. The intent was to replicate some of the diversity and distribution of pillar deformation outcomes that may be seen in practice at Freeport.The discontinuum finite element analysis was able to replicate damage localisation around persistent structures, a realistic distribution of drive deformation and show how small areas of instability can evolve into major problems if poorly managed. The limits of pillar size and ground support as solutions to a number of different instability problems was also investigated, showing that pillar size alone was not a sufficient remedy for all adverse circumstances.In this paper, we describe the workflow for numerical analysis of footprint deformation. We discuss the compromises and considerations for balancing the sometimes competing needs for efficient extraction levels pillars, ground support and prudent draw strategy.CITATION:Beck, D, Hudson, R, Wilson, A D, Duplancic, P and Lilley, C R, 2016. An investigation of factors affecting the long-term reliability of extraction level pillars in deep block and panel caves, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 295–304 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By Kyoosang Yoo

The report presents the results corresponding to the analysis of a lining system for tunnels in soil and soft rock in creep-active ground. The purpose of the analysis is to evaluate the performance of a lining at each construction stage. The steps include: 1. Accurate representation of the initial undisturbed state of stress 2. Excavation, 3. Lining installation 4. Injection of mortar and its curing, and 5. Short-, medium- and long-term creep behaviour in the surrounding soil/rock. The response of a prototype tunnel is simulated using the computational finite element framework MSC.marc2008.

Jan 1, 2010

By K. Severin, B. Flanigan, P. Marion

“Plutonic-related” gold deposits in Interior and SW Alaska (Tintina Gold Belt) vary significantly in size, grade, vein/deposit morphology, depth of emplacement, distance from causative pluton and metal association. Metal associations such as Au-Bi and Au-As-(Sb-Hg) are a good empirical indicator of depth of emplacement and distance from causative pluton and have been used successfully in exploration. Results from a variety of analytical techniques also suggest a phenomenological cause for these metal associations, e.g. gold and bismuth have linked metallogenesis at high temperatures and thus are best correlated at deposits that are deep and/or close to causative intrusions.

Jan 1, 2000