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By Steven R. Musselman

The bending strength and flexural stiffness of a micropile at its threaded connection is less than its intact strength and may fail due to thread slippage or by fracture through the pin (reduced cross-sectional area of male threads in the threaded zone of the casing). The mode of failure depends on the reduction in cross-section necessary for machining the threads, and details of the threaded connection such as the length of threaded connection, size and shape of threads, and the thread density (threads per inch). Based on data from bending tests conducted on 9-5/8 inch diameter micropile casing, a method has been developed to predict the ultimate moment capacity and initial bending stiffness of round threaded micropile connections. Two modes of failure were observed from four-point bending tests conducted at the University of Illinois on 9-5/8 inch casing with round threads. Threaded micropile casing connections with an effective thread length of 1.35 inches typically failed by slippage at the threads (jump out), while connections using an effective thread length of 1.89 inches failed by fracture of the pin. These two failure modes were described by W.O. Clinedinst in his report to the American Petroleum Institute on tension tests of threaded pipe casing. Clinedinst developed an empirical formula to determine the tensile strength of threaded connections. A method to predict moment capacity for threaded micropile connections by modeling the micropile cross-section and applying Clinedinst?s equation to determine the max tensile stress along the threaded connection while satisfying force equilibrium is proposed. The predicted moment capacity for threaded connections using this approach is within ten percent of measured for both modes of failure observed from the bending tests.

Jan 1, 2007

By R. S. Francis

There are no manuals or handbooks for budding mill superintendents or process plant managers. Most who obtain this level of responsibility have gained their training from watching the good and bad of their predecessors and the successful ones have themselves graduated from the school of hard knocks. This paper attempts to provide some helpful guidelines and direction for those who aspire to better manage a mineral processing facility. The authors have 20 years combined experience in senior management roles at nine different mineral processing operations in Australia and overseas, covering gold, base metals and mineral sands. This summary of tips and pitfalls will hopefully benefit future leaders in mineral processing and metallurgy.

Jan 1, 2007

By E C. F Hamman

Sunrise Dam Gold Mine is a large open pit mine 730 km NE of Perth, Western Australia. Contract mining commenced in the open pit in September 1996 in lake clays and saprolites with the first fresh rock mined late 1999, and the underground starting the first decline in October 2003. By May 2007, over 150 million cubic metres of material had been mined and the pit was 360 m deep with 80 m remaining before reaching the planned final depth in early 2008. A final cut-back in the northwest will commence in late 2007 with open pit mining in the Mega Pit expected to conclude in late 2010. The challenges of developing the pit can be divided into three phases:Soft materials û mining was in multiple staged pits and cut-backs in lake clays, saprolites, weathered material. The varying characteristics had a significant impact on mining methods and slope stability. Structural û mining was gradually exposing more fresh rock and the drive was to understand how major structures and lithological contacts impact on local and large-scale stability. This had a significant influence on mine design and scheduling. Slope angles û achieving the final slope angle is critical. This is done through application of high standards of final wall establishment and proactive geotechnical hazard identification and management. This includes dealing with the rapid rate of descent, interaction with underground excavations and managing rock fall risk. The paper discusses each of these phases, highlighting the geotechnical controls implemented to date, looking at their success and impact on mining.

Jan 1, 2007

By Leigh Freeman

The War for Talent ?McKinsey & Company 1997 and 2000 survey ?2001 book by Michaels, Handfield-Jones and Axelrod, Harvard Business School Press

Jan 1, 2007

By R. E. de Barrio, M. E. Lanfranchini, R. O. Etcheverry

"The El Abuelo Ca-Fe-magnetite skarn and related hydrothermal quartz veins are located at Cerro Pepita Hill, in southwestern Chubut province of southern Argentina, 1700 km southwest of Buenos Aires. These deposits are developed in a continental magmatic arc environment linked to the Andean orogeny. Iron skarn mineralization is mainly hosted by an Upper Jurassic to Early Cretaceous sedimentary sequence interbedded with Upper Jurassic basaltic andesite, and is spatially associated with Early Cretaceous calc-alkaline dikes. Ore grades vary between 40 and 63 wt.% Fe. In addition, anomalous metal contents (>10 000 ppm Cu and up to 81 g/t Ag) are present in the hydrothermal quartz veins.At least three paragenetic mineral assemblages have been identified in the El Abuelo exoskarn: (1) amphibole > epidote ± chlorite ± quartz, formed by isochemical contact metamorphism; (2) Fe-clinopyroxene ± Ca-garnet, formed during prograde metasomatic anhydrous exoskarn formation; and (3) actinolite ± epidote ± chlorite ± quartz ± magnetite > titanite, resulting from hydrous retrograde alteration of exoskarn. Endoskarn alteration involved an early Mg-Fe-clinopyroxene ± Fe-garnet assemblage followed by retrograde actinolite replacement of pyroxene. Lower temperature hydrothermal alteration related to quartz veins was superimposed on the skarn assemblages, showing an innermost sericite ± adularia ± pyrite ± chalcopyrite assemblage and an external propylitic halo.Some metallogenic characteristics of the mineralization and the geological setting resemble those in several iron oxide copper-gold deposits elsewhere in the world."

Jan 1, 2007

By H. Sano

Most of the dust generated from the copper smelting process in Chile has been stored after the stabilization by hydrometallurgical process because it contains high concentrations of arsenic. However, in recent years, the dust generation has increased because of degrading the quality of concentrate. In addition, the environmental regulations become stricter. On the other hand, valuable metals such as copper and zinc are contained in the dust at high concentrations and it is desirable to recover them. In this study, the effect of dust recirculation to the smelting process was examined in order not only to decrease the amount of dust but also to recover copper. Dust generation and the distribution of arsenic, lead, zinc etc. among the matte, slag and gas phases were evaluated as a function of the amount of recirculated dust, partial pressure of oxygen and temperature. It was found that the direct dust return to the smelting process was quite effective for the recovery of copper and the reduction of dust generation, but the acceptable dust amount was limited by the produced matte quality.

Jan 1, 2007

By Sigurd L. Lamhauge, Karl Gunnar Holter, Svein E. Kristiansen

An innovative sprayable waterproofing membrane in combination with the traditional Nordic method of waterproofing with polyethylene foam sheets was used for the waterproofing of the tunnel. The sprayable membrane was integrated in the final sprayed concrete lining in a sandwich structure, hence constituting a composite water-proof lining based on sprayed concrete. The spray able membrane was applied in areas with small to moderate water ingresses, making up approximately 50% of the total area requiring waterproofing in the tunnel. State-of-the-art application technology with a computerized spraying robot was used. A consistent application of the required thickness at a high speed was thereby achieved.

Jan 1, 2007

By J. O. Marsden

Parts I and II in this series of papers presented the chemistry of medium-temperature pressure leaching of copper sulfide concentrates and reviewed the metallurgical development of a process to effectively recover copper using medium-temperature pressure leaching and direct electrowinning (DEW). Part III reviewed the large-scale demonstration of the MT-DEW-SX process at Bagdad, Arizona. Key features of the process were the use of superfine grinding of the concentrate (to a P98 of 12 to 15 µm and a P80 of 6 to 7 µm), pressure leaching at 160ºC with 1,380 kPa (200 psig) oxygen overpressure, DEW to produce LME Grade A cathode, recycling some of the lean electrolyte to the pressure leaching step, and treatment of a lean electrolyte bleed by solution extraction (SX). Recycling of lean electrolyte provided all of the acid required to effectively dissolve copper and convert approximately 65% to 70% of the sulfide sulfur to elemental sulfur, resulting in an acid-autogenous process for pressure leaching. This paper (Part IV) discusses the development and design of a full-scale commercial application for the Morenci operation in Arizona.

Jan 1, 2007

By M. Yavuz

Multiple Criteria Decision Making (MCDM) is one of the most considerable branches of Operation Research. MCDM refers to making decisions in the presence of multiple, usually conflicting, criteria. The problems in MCDM are classified into two categories: Multiple Attribute Decision Making (MADM) and Multiple Objective Decision Making (MODM). However, very often the terms MADM and MCDM are used to mean the same class of models and mostly confused in practice. Usually, MADM is used when the model cannot state in mathematical equations and otherwise MODM is used (Hwang and Yoon, 1980). Decision-making (DM) is extremely important stage in Mining Engineering like other engineering branches. Every mining engineer makes several decisions in daily mining applications. Most of the decisions made by mining engineers are completely instinctive according to their past experiences and there is not any DM method applied in DM process. Analytic Hierarchy Process (AHP) is one of the well-known techniques solving the decision problems. The AHP is very simple, and understandable method especially non-numerical data considered in DM process. Equipment selection is one of the prominent problems of mining engineering. Mining engineers have to make difficult decisions when equipment selection stage. As the decisions in the equipment selection have radically influenced the economic life of any mining scenario, these are considered as complex MADM problem. So, the decision maker can evaluate the subjective criteria in the problem of equipment selection. The decision maker wants to maximize more than one objective criterion for equipment selection stage. Among the number of alternatives, the most suitable equipment must be selected according to objectives and alternatives. MADM applications can help the decision maker to reach the optimal solution for the equipment selection. In the mining industry, MADM methods can be applied for the equipment selection because it is a process that includes subjective and objective criteria affecting the selection of equipment among the alternatives.

Jan 1, 2007

By Terry W. Mellors, Robert J. F. Goodfellow

The underground industry has been forced to reconsider risk management sincethe introduction and implementation of the “Joint Code of Practice for Risk Management of Underground Works in the UK” published in 2003 and the subsequent international version published by the ‘International Tunneling Insurance Group’ (ITIG) in January 2006.What does this mean for major tunnel projects in the US and elsewhere? The discussion will highlight the implementation of the Codes to date, risk management principles embodied in the Codes and the use of risk registers as a projectmanagement tool and the management of risk.

Jan 1, 2007

By C. J. Badenhorst

Oxides of sulphur are corrosive and are produced when sulphur-containing fuels are burned. Sulphur dioxide (SO2) is a colourless gas with a characteristic, irritating, pungent odour. Exposure routes to the human body are mainly through inhalation and skin and/or eye contact. Symptoms of exposure to SO2 may include irritation of the eyes, nose, and throat; rhinorrhea (discharge of thin nasal mucous); choking; cough; and reflex bronchoconstriction. To protect employees against the ill health effects of SO2 exposure, they are often required to make use of respiratory protection whenever entering areas were the SO2 levels exceed the statutory limits. The use of respiratory protective equipment should always be a last resort and should be considered only after other control measures have failed to reduce occupational exposure levels to below the occupational exposure limit or whilst other control measures are being investigated or implemented. Whenever the use of respiratory protection equipment is considered, it should always be used as part of a comprehensive respiratory protection plan. It is also extremely important that all potentially exposed persons are adequately and comprehensively informed and trained.

Jan 1, 2007

By Gordon T. Clark, James R. Struthers, Celal Kirandag

INTRODUCTION Project Background The Washington State Department of Transportation (WSDOT) hired the Seattle office of Parsons Brinckerhoff to lead a team of consultants to produce an Environ-mental Impact Study and perform conceptual and preliminary engineering. The pur-pose of the Alaskan Way Viaduct and Seawall Replacement project is to replace the existing earthquake damaged and aging viaduct and sea wall, adjacent the downtown waterfront of Elliott Bay, with structures that have improved earthquake resistance and that maintain or improve mobility and accessibility for people and goods along the existing corridor. With an estimated replacement cost over $4 Billion and construction duration exceeding 8 years, it is one of the largest transportation design projects on the West Coast of the United States today. Seattle, Washington is a city of over 2 mil-lion people in the Northwest corner of the United States. Ever since the Klondike Gold Rush in 1897, Seattle has been considered a departure point to Alaska. Because of this, the street along the waterfront was named the Alaskan Way in 1930. Alaskan Way Viaduct and Seawall The Alaskan Way Viaduct (AWV) carries State Route 99 along the shoreline of Elliott Bay through downtown Seattle and is a vital part of Seattle’s highway system. The viaduct carries approximately 110,000 vehicles per day or 25% of all north-south traffic through Seattle (Figure 1). It is 3.4 km (2.1 mile) long with 3 lanes in each direction and was constructed of cast-in-place reinforced concrete between 1952 and 1956. The wear and tear of daily traffic, salty marine air, and several earthquakes have taken their toll on the facility. Studies in the mid-1990s provided early evidence that the viaduct was nearing the end of its useful life. The viaduct’s increasing age and vulnerability was apparent by crumbling and cracking concrete, exposed rebar, weakening column connections and deteriorating railings. In early 2001, a team of structural design and seismic experts began work to determine whether it was feasible and cost-effective to strengthen the viaduct by retro-fitting it. In the midst of this investigation, a 6.8 magnitude earthquake shook the Puget Sound region (the Nisqually Earthquake, located 56 km (35 miles) from Seattle and deep below the surface) caused moderate damage to the reinforced concrete structure. WSDOT closed the viaduct for inspection and repairs intermittently for several days over a period of several months.

Jan 1, 2007

By F. Crundwell, A. J. Lathwood

A number of base-metal operations would like to increase production to take advantage of the higher metals prices. In general, this higher production should not be achieved with major operating changes. In hydrometallurgical facilities, leaching and pressure leaching represents one area where upfront limitations may be a bottleneck to the capacity of the entire plant. An assessment of the capacity of the leaching tanks and autoclaves was performed using a predictive model within the AweSym flowsheet simulator. The model is described, and the results of the application of the model to a number of different leaching reactors are presented. It is argued that the leaching number, which relates the residence time, particle size and the leaching rate, is of prime importance. Finally it is shown that there are some unexpected catastrophic events in increasing production capacity without a thorough understanding of the leaching operation.

Jan 1, 2007

By Robert Vinson

This article examines the spatial variability of dust concentrations within a coal miner?s breathing zone and the impact of sampling location at the cap lamp, nose, and lapel. Tests were conducted in the National Institute for Safety and Health Pittsburgh Research Laboratory full-scale, continuous miner gallery using three prototype personal dust monitors (PDM). The dust masses detected by the PDMs were used to calculate the percentage difference of dust mass between the cap lamp and the nose and between the lapel and the nose. The calculated percentage differences of the masses ranged from plus 12% to minus 25%. Breathing zone tests were also conducted in four underground coal mines using the torso of a mannequin to simulate a miner. Coal mine dust was sampled with multi-cyclone sampling cans mounted directly in front of the mannequin near the cap lamp, nose, and lapel. These four coal mine tests found that the spatial variability of dust levels and imprecision of the current personal sampler is a greater influence than the sampler location within the breathing zone. However, a one-sample t-test of this data did find that the overall mean value of the cap lamp/nose ratio was not significantly different than 1 (p-value = 0.21). However, when applied to the overall mean value of the lapel/nose ratio there was a significant difference from 1 (p-value < .0001). This finding is important because the lapel has always been the sampling location for coal mine dust samples. But these results suggest that the cap location is slightly more indicative of what is breathed through the nose area.

Jan 1, 2007

By S. Saeb, C. Francke

Introduction Although mining in one form or another has existed for millennia, the use of numerical methods for mine design is a relatively recent development. The basic physics that control the behavior of rock or soil have been known for centuries, but it wasn’t until the last half of the twentieth century that analytical methods that could accurately predict the behavior of a large, irregular rock mass were developed. Before the advent of modern computers combined with differential and integral analytical methods, numerical methods available to mining engineers were limited to closed form solutions for simple excavation geometries. Today, mine-scale three-dimensional stress analyses can be performed on a relatively inexpensive personal computer. Many of the recent advances in rock mechanics modeling are the result of research funded as part of nuclear waste repositories around the world. The large scale exacting performance requirements of waste repositories are frequently very different from traditional rock mechanics projects. These facilities are designed and built under tighter control and scrutiny because of the potential hazards they present to the public. Therefore, a great deal of research towards advancing rock mechanics and numerical modeling resulted from these projects. Much of the repository research is applicable to commercial mines. The advances in modeling programs have been paralleled by advances in computer equipment. Today, a moderately equipped personal computer can handle most mine geomechanical modeling projects in a reasonable period of time. While the learning curve varies, an engineer with modeling experience can develop a medium sized model in a few days. The relatively low investment cost of geomechanical modeling today makes it accessible to most mining operations. The benefits of a solid geomechanical modeling program include reduced operating costs, improved safety, and reduced design costs.

Jan 1, 2007

By W. Reed

During the 20th century, the increased emphasis on worker health and safety and the advent of new mining equipment and methods led to many changes in mine face ventilation practices. Efforts by government and private industry to improve and modify ventilation practices resulted in better health and safety conditions for workers. This paper examines factors that had a significant influence on mine face ventilation design during the past century. Several “milestone” events are discussed along with the impact they had on worker health and safety. Significant ventilation research efforts by government and private industry are presented. This brief ventilation history highlights innovative ventilation designs and a consistent commitment to mining health and safety.

Jan 1, 2007

By Robert McClure, Frederic Leclercq, Ricardo Chavez

With significant vibration control and fragmentation challenges facing them, the CBS quarry (department of the Nord) successfully integrated a technical partner and mine to mill optimisation to deal with a difficult environment. For the last three years, CBS has been conducting a global production monitoring program similar to the mine to mill concept used in the mining industry. This concept consists of optimising the drilling and blasting while monitoring the effects on the downstream chain (vibration control, loading, hauling, crushing, plant output). Blast optimization is ensured by systematic control of the blast geometry (volumes, patterns, bench and face anomalies, drill deviation) and by the use of constant specific energy blasting. Constant specific energy optimises the work of the explosive in a blasting operation and, when combined with a high accuracy programmable electronic blasting system, reduces the impact of blasting on the environment and enhances blast performance. These techniques ensure consistent blasting results and hence improved site productivity. The improvements achieved have been identified thanks to an effective system designed to monitor the key production parameters.

Jan 1, 2007

By N. Wachgama, J. P. T. Kapusta, R. U. Pagador

The Thai Copper Industries smelter (Thai Copper) is located some 200 km southeast of Bangkok near the MapTaPhut deep sea port in one of the industrial centres of Thailand. Although construction of the complex started in the mid 1990s, the smelter, acid plant and refinery were completed in 2004. Thai Copper is a state-of-the-art copper smelter processing imported concentrates with a total yearly capacity of 165,000 tonnes of cathodes. It employs the El Teniente Technology where concentrates are blended and smelted continuously in a primary smelting reactor to produce high grade matte or white metal. The white metal is converted in batches to blister copper in Hoboken siphon converters equipped with Air Liquide Shrouded Injector (ALS I) Technology for sonic injection of oxygen enriched air. Final refining is carried out in two anode furnaces prior to anode casting and electrorefining. Thai Copper and Air Liquide Canada executed a technical assistance agreement in late 2005. Pre-commissioning of the shrouded injectors took place in July and November 2006 while hot commissioning occurred in December 2006. This paper presents the major technical aspects of the joint commissioning, including the establishment of operating practices specific to shrouded injection converting. Preliminary results of this first commercial implementation of ALSI Technology in copper converting are also provided.

Jan 1, 2007

By Richard Peaker, Jens Lichter, Alexander V. Potapov

"The recent combination of Computational Fluid Dynamics (CFD) and Discrete Element Modeling (DEM) can provide considerable insight into the performance of flotation cells. One area of interest from a fundamental equipment design perspective has been the influence of flotation cell size and the inflow rate on the metallurgical performance of the cell. One of the specific design objectives when increasing the size of flotation cells, or increasing the feed flow to the flotation cell, is to ensure that the feed stream flowing into the cell does not have an opportunity to bypass the mechanism.This paper describes the initial modeling efforts to quantify the inter-relationship of cell size, inflow rates, and feed and discharge box placement, on the retention time distribution of solids in the flotation cell, and the fraction of particles that bypass the mechanism on a size by size basis.INTRODUCTIONThe great majority of newly installed cells in mineral processing plants world-wide are of the cylindrical tank design and this tank shape offers a number of hydraulic advantages over the older style of square cells. Cylindrical cells give symmetrical flow patterns and by careful design of the mechanism and tank internals, the flow patterns generated can concentrate the more intense mixing in the lower portion of the cell to promote good solids suspension and particlebubble contact. Simultaneously, cylindrical tank design gives a more quiescent upper zone for particle-bubble transport into the froth zone. These symmetrical flow patterns are naturally disturbed in normal operation by the slurry inflow and outflow from the individual cells. The challenge for flotation cell designers is to determine the magnitude of these flow disturbances, and to assess whether or when the inflow and outflow rates have a sufficient impact on the hydraulic flow patterns so as to potentially affect the metallurgical performance of the flotation cell."

Jan 1, 2007

By C. A. Rawlins

Deep underground mines use refrigeration systems to provide a reasonably comfortable ambient environment to increase productivity and to maintain safety as a priority. Deep level gold mines maintain the environment at an acceptable temperature, i.e. 27°C. However, the increasing cost of doing so through refrigeration is becoming a significant factor in the economic viability of mines. This paper discusses of the important facet of energy losses in cooling reticulation systems, laying with the specific emphasis on the subject of chilled water transport pipe insulation and its thermo-dynamic relationships. Aspects relating to the deterioration of open cell-type insulation materials such as polyurethane/styrene foams and the use of Phenolic resins that have good fire retardation properties have been investigated. The thermal conductivities of these insulation media are good (meaning below 0.05 W/°C)However, they are known to be negatively influenced by water vapour ingress and vapour pressure differences that result in the ingress of water into the material by means of absorption, condensation, hygrospicity, permeability and capillary action, to name a few of many. The overall effect on mine cooling efficiency takes in the two forms: first by the loss of refrigeration or increased chill in the water temperature arriving in a given section and second, by a loss in transfer efficiency when the gap between the arriving water temperature and the actual air temperature decreases. Keywords: Conductivity, vapour, insulation, fluid, thermal, temperature, pressure, transport, refrigeration.

Jan 1, 2007