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By M. Maldonado

This work details the application of a decentralized control strategy to a pilot flotation column working with a two-phase system (water-air). The process is represented by a multivariable system composed of three inputs and three outputs. The selected control variables are the froth depth, the air hold-up and the bias rate, whereas the corresponding manipulated variables are the set-points of the local flow controllers of tailings, air and wash water. All controlled variables are estimated using electrical conductivity based techniques. In particular, the results of a new method for estimating the bias rate, based on the measurement of the volumetric fraction of wash water under the interface, is presented. This method reduces the coupling problem associated to the bias estimation as a difference between feed and tailing water rates. Moreover, the nominal system transfer matrix can be represented by an upper triangular matrix, in such a way that the closed-loop system stability reduces to the stability of the independent control loops. The experimental results show that the closed-loop system performance, particularly that of the bias rate loop, is strongly dependent on the air flow rate, reaching in some cases the saturation point of the controller.

Jan 1, 2007

It is a common misconception that the grant of mining tenure, whether it be an Exploration Permit, Mineral Development Licence or Mining Lease, will entitle the holder to access all land within it in order to explore or mine. The ability for miners to access their tenure in order to undertake activities is critical to the industry. While significant time and energy is quite rightly dedicated to resolving native title and cultural heritage issues before the commencement of mining operations, the same cannot always be said for addressing potential impediments that arise as a result of the overlap between mining and other tenures. Miners should be aware of the overlaps that occur with other tenure and the impact of these overlaps on the minerÆs ability to explore or produce from the area. The existence of an overlap with petroleum tenure, nature refuges, national parks, wild river areas or reserves such as aboriginal land leases are all likely to have an impact on the minerÆs ability to access the area and conduct activities. In some instances, such as an overlap with petroleum tenure, Queensland legislation encourages the miner to reach agreement with the holders of the overlapping tenure. However, in other instances, such as an overlap with a national park, mining tenure is unlikely to be granted at all. This paper summarises the impacts and impediments that arise as a result of overlaps of tenure that are likely to affect mining operations. It also provides examples of how these impediments can, if possible, be overcome under Queensland legislation.

Jan 1, 2007

By Dennis Van Heerden

Southern Africa has a long history of underground hard rock mining dating back to the late 1800?s. The rock support of underground excavations has significantly changed during this period, due to improved technology, experience gained and rock support requirements by mining and geotechnical engineers. This paper examines the available underground rock support methods in Southern Africa with emphasis on the types and characteristics of: - Rock bolt types. - Rock bolt and long anchor grouts. - Thin-sprayed liners. - Sprayed Concrete. - Ground consolidations through injection methods. - Cavity and void filling with aerated cement products. [ ]

Jan 1, 2007

By Jill Murray

This study focuses on the amosite mining region in South Africa and associated health effects, compared to other mined asbestos fiber types. Historically, dust and fiber levels were high in the amosite mills and mines, and many miners and members of the surrounding communities were exposed to the fibers. Research has shown that amosite produces both benign and malignant disease. Nevertheless, the mesotheliomagenic potential of amosite is several fold lower than crocidolite. The risk of disease associated with amosite exposure is difficult to quantify. Reasons for this include the scarcity of available information, including fiber measurements, and case ascertainment, as well as the juxtaposition of the amosite and crocidolite asbestos seams in South Africa. © 2007 Elsevier Inc. All rights reserved. Keywords: Amosite; Mesothelioma; Crocidolite; South Africa; Asbestos

Jan 1, 2007

By P. H. Rodriguez

The aquatic hazard classification system of the OECD and EU requires that sparingly soluble metal substances (SSMS) be tested using the OECD Dissolution/Transformation protocol in order to quantify the release of the ecotoxicological relevant species (dissolved ions). The SSMS category contains massive forms of metals, which due to their low solubility and slow transformation characteristics are a special case. The main factors that produce the release of metal into solution are exposed surface loading, pH, and stirring rate. The classification system at present prefers the use of mass loading as opposed to surface loading, in which case the amount of metal released will primarily be a function of the pH, and mass loading. Within the framework of the European Copper Voluntary Risk Assessment, coordinated by the European Copper Institute, we have proposed and developed a methodological procedure in which we demonstrate that surface area is an intrinsic property of a SSMS and we link the exposed surface loading to the toxicity reference value in order to obtain an aquatic hazard classification for massive metals. As example, the aquatic hazard classification for copper massive will be discussed. This approach is recommended for metal massives and metal powders.

Jan 1, 2007

By M. Tangstad, D. Lu, G. Tranell, S. Gaal, J. Safarian

The kinetics of MnO reduction from high carbon ferromanganese slag was investigated using a sessile drop technique at 1600 ºC. The effects of reductant type, ambient atmosphere and slag composition on the MnO reduction were illuminated. Two different types of industrial reductants (ground to a particle size of 44 to 106micron and pressed to pellets) were used as substrates for small slag droplets of varying composition, which were reacted in a CO or Ar atmosphere with the reaction studied in-situ. The cross sections of the reacted slag-carbon samples were subsequently studied by EPMA to find the extent of MnO reduction as a function of reaction time. It was found that the rate of MnO reduction is affected by both the type of reductant, the ambient atmosphere and the presence of metallic components in the slag. Higher reduction rates were obtained for charcoal than for coke as reductant while a CO atmosphere unexpectedly yielded faster MnO reduction than an Ar atmosphere. It was also found that metal prills in the initial slag will increase the rate ofMnO reduction.

Jan 1, 2007

By Jesús E. Gómez

A total of 260 micropiles were installed as part of a retrofit effort for two existing bridges. The micropiles consisted of hollow core bars installed under limited headroom conditions. Of the total number of micropiles, 180 were installed in submerged sand and 80 were installed in stiff, silty clay. The micropiles were drilled using a lean cement grout which was re-circulated for de-sanding and re-use. Final grout was injected upon completion of drilling to the design tip elevation. The micropiles were subject to a rigorous quality control that included grout quality testing and proof-testing of each production micropile. This paper presents a description of the procedure for installation and quality control of the micropiles. The successful proof-testing of all the production micropiles showed that hollow core bar micropiles can be used effectively in granular and fine-grained soils. Hollow core bar micropiles offer particular advantages when installed in submerged sand formations with respect to other traditional micropile types. The results of the proof load tests are presented in a companion paper.

Jan 1, 2007

By F. Chiesa

Forty aluminium A356 castings were poured on a Low Pressure Permanent Mould industrial machine, 500x700mm in platen size. The 152mm wide casting comprised three steps, 25mm, 13mm, 6mm in thickness and a 2.5mm overflow which allowed to assess the thin wall capability of the process. The casting campaign, which produced 40 parts, allowed to test the influence of various production parameters including the time of application of the pressure in the crucible, artificial cooling of the mould and casting rate. The thermal history in the mould was recorded over the 40 cycles, which allowed to construct a reliable thermal model of the mould/casting assembly. The metallurgical quality of castings representative of the various conditions was assessed in the 25mm, 13mm and 6mm plates. This included measuring the level of microporosity, the dendrite fineness (DAS), along with the tensile properties in the T6 condition. The radiographic quality per ASTM E155 was also determined. Modelling filling and solidification allowed to verify the validity of the predictions based on available relationships relating microporosity, secondary dendrite arm spacing (DAS) and local tensile properties (Quality Index, Q) to the local thermal solidification parameters.

Jan 1, 2007

By M. Doggett

All 231 Canadian primary gold mines that produced from 1946 to 2004 were analyzed with respect to their production and economic characteristics. Trend analysis revealed that the average annual capacity of Canadian gold mines, as measured by ore processed or gold produced, has increased over time. Conversely, the average grade of gold mines has decreased over time. The distribution of gold output is highly uneven: for example, the 22 giant mines producing more than 100 t (metric tonnes) of gold account for 62% of total output. Small mines producing less than 10 t Au account for 54% of total mines, but less than 4% of total gold. Each historical mine in the database was evaluated on the basis of a set of economic and technical assumptions to determine if it would be economic to develop today. Based on the net present value using an 8% discount rate, only 103 of the 231 mines were determined to be economic. About 80% of the uneconomic mines had less than 10 t of contained gold, and 63% had less than 5 t. It is concluded that these small mines would not be viable today due to a combination of real capital cost increases, and more stringent permitting and environmental regulations. The implication is that future gold supply in Canada will hinge on the discovery and development of a new generation of larger mines. Given that only one giant mine has been discovered in the past 20 years, it seems likely that gold output will decrease in the future.

Jan 1, 2007

By B. Burke

Magnesium and its alloys are attractive materials for use in automotive and aerospace applications because of the low density and good mechanical properties. However, difficulty in forming magnesium and the limited number of available commercial alloys limit their use. The present paper reviews the efforts to improve the attractiveness of magnesium through non-traditional processing, and presents preliminary results of current work on producing magnesium alloys via powder metallurgy P/M. P/M can be used to alleviate the formability problem through near-net-shape processing, and also allows unique chemical compositions that can lead to new alloys with novel properties. The feasibility of producing magnesium powder metallurgy products utilizing the industrially dominant process of mixed powder blending, uniaxial die compaction and controlled atmosphere sintering was investigated. An alloy composition based on the commercial Mg alloy AZ31 (3% Al, 1% Zn) was used to facilitate comparison to similar wrought products. The optimal processing conditions (compaction pressure, sintering time and temperature, and quenching temperature) were found to maximize sintered density and mechanical properties.

Jan 1, 2007

By A. J. Van Der Merwe, N. A. Barcza, M. Boyes, N. R. Clarke

Oriel Resources has with the support of SRK (Cardiff) and DRA and Mintek (South Africa) carried our a Definitive Feasibility Study (DFS) to recover high grade chrome ore from its Voskhod deposit very close to Chromtau that is near to Aktobe in Kazakhstan. Voskhod is a large podiform ore body that contains nearly 20million tons of chromite grading about 48% Cr2O3 and with a Cr/Fe ratio of over 3/1. Selected bore hole core samples were obtained from the confirmation drilling programme during the DFS phase of the project in 2005 for pilot plant test work to design the mineral beneficiation plant. The chrome ore is characterised by four main types, namely high grade lumpy and chip sized ore, high-grade fine ore, lower grade (subordinate) lumpy ore and lower grade fine ore. Gravity separation tests carried out by Mintek showed that the large density difference between the high grade (at over 3.7t/m3) and lower grade ore (at less than 2.97t/m3 ) should ensure very good separation in the DMS drum and DMS cyclone stages resulting in high recoveries of Cr2O3 - rich chromite ore products. Very high chrome ore grades of up to 64% Cr2O3 and Cr/Fe ratios of 4 to 1 were obtained at an 80% mass yield from selected samples of lumpy and chip ore size fractions. The overall predicted recovery from the design work on the mine and plant is expected to be closer to about 70% of the ROM (Run of Mine) feed. DRA has completed the design of the mineral processing plant to recover about 900 kt/a of chrome ore from the 1.3 Mt/a of ROM feed. The plant has been sized to handle up to 1.5 Mt/a and will also be able to address the variability in ore feed as different regions in the deposit are mined. The lumpy high-grade product and the chips size fraction is expected to grade around 48% Cr2O3 and the fine concentrate between 56 and 58%Cr2O3 The ratio of products is expected to be about 70, 15 and 15 percent respectively but will vary to some extent during the expected 20 year life of the mining operation based on including the associated adjacent Karaagash deposit together with the Voskhod deposit. The prediction of the product split from the processing plant depends on many factors such as the geology, mineralogy, mining, handling and metallurgical processing. An overall process flow model has been developed that covers the ROM ore, the various types of chrome ore feed to the mineral beneficiation plant, the projected products and the subsequent smelting of the chromite ores to produce High Carbon Ferrochromium. The model allows the optimisation of the quality of the chrome ore in terms of Cr2O3 content, Cr/Fe ratio and recovery to be studied. This information can also be evaluated in terms of the economic requirements for smelting High Carbon Ferrochromium (HCFeCr) at a given location. Oriel is planning to supply chrome ore to Ferrochrome plants mostly in China and Russia. The use of the model will assist to maximise the value of the Voskhod project to its owners and also assist the users of the chrome ore in selecting the appropriate supply quality to meet their needs for a given smelter operation. The smelting of high grade Voskhod ore requires a limited addition of about 5 to 7% quartz to flux the MgO and Al2O3 and about 25% coke as a reducing agent to produce an alloy containing from about 65 to 74%chromium depending on the Cr/Fe ratio.

Jan 1, 2007

By M. Mabuza

Two Rivers Platinum Mine (TRP) is a 55:45 joint venture between African Rainbow Minerals and Impala Platinum, respectively. TRP is situated on the farm Dwarsrivier 372KT, in the southern sector of the eastern limb of the Bushveld Complex. Dwarsrivier is underlain by rock formations of the Critical Zone (Winterveld norite-anorthosite) and the Main Zone (Winnarshoek norite- anorthosite). Two economically significant PGE-bearing layers namely the Merensky Reef and the UG2 chromitite are found within the upper Critical Zone. These are approximately 140 m vertically apart, separated by a series of barren norites and anorthosites. At Two Rivers Platinum, only the UG2 chromitite layer is currently being mined for PGEs. The UG2 sub-outcrops north/south along the Klein Dwarsrivier river valley with a very gentle dip to the west of 7º?10º. At Two Rivers the UG2 averages about 120 cm in thickness, overlain by a waste pyroxenite parting about 20 cm thick, above which is a leader seam about 20 cm in thickness. The mineable cut consists of the leader seam, the waste pyroxenite parting, the UG2 chromitite layer including 25 cm of pegmatoidal pyroxenite footwall, below the UG2 reef to a minimum of 185 cm trackless mining cut. The mining method is a mechanized bord and pillar layout, which will yield a total of 185 000 tons at full run of mine production from the underground UG2 mine.

Jan 1, 2007

The corrosion behaviour of a low carbon steel was investigated in synthetic seawaters with and without Sr2+. It was found that strontium substitutes for calcium in aragonite, rather than precipitating as discrete strontianite (SrCO3). The aragonite deposits that formed in the presence of Sr2+ were finer than those that formed in the absence of Sr2+. It is believed that an increase in the strontium content of aragonite induces a decrease in its solubility, which in turn results in a higher nucleation rate of the precipitates. Furthermore, the growth rate of aragonite is decreased by the presence of Sr2+in the solution. It is concluded that Sr2+is an essential ingredient in any artificial seawater when calcareous deposits are investigated on steel. Keywords: corrosion, seawater, calcareous deposits, strontium, aragonite.

Jan 1, 2007

By Peter L. McSwiggen

The mineralogy of the Biwabik Iron Formation changes dramatically from west to east as the formation nears the basal contact of the Duluth Complex. This reflects a contact metamorphism that took place with the emplacement of the igneous Duluth Complex at tem¬peratures as high as 1200 °C. However, the mineralogy of the Biwabik Iron Formation also varies vertically through the stratigraphy of the unit. This variability in both the vertical and horizontal dimensions makes it difficult to predict exact horizons where specific minerals will occur. The iron-formation has been subdivided into four broad stratigraphic units (lower cherty, lower slaty, upper cherty, and upper slaty) and into four lateral mineralogical zones (1-4). Zone 1, the westernmost zone, is characterized by quartz, magnetite, hematite, carbonates, talc, chamosite, greenalite, minnesotaite, and stilpnomelane. The silicate mineralogy in Zone 2 of the Biwabik Iron Forma¬tion changes very little. However, the minerals begin to change dramatically in Zone 3. Most significantly, Zone 3 is characterized by the appearance of grunerite in both a tabular form and a fibrous form. In Zone 4, the original silicate minerals have completely reacted, and a new suite of minerals occupies the iron-formation. These include grunerite, hornblende, hedenbergite, ferrohypersthene (ferrosilite), and fayalite.

Jan 1, 2007

By Walter G. Kutschke

Four significant soil nail wall projects in the eastern United States were recently completed with a combined area of 175,000 square feet of finished shotcrete surface. These projects required the use of innovative design and construction methods in order to address various challenges, including slide-prone back slope materials, perched water, highly erodible rock materials, curved wall alignments, very tight construction tolerances and unexpected subsurface conditions. Special focus is given to issues such as bench excavation, soil nail installation methods, shotcrete mix design, anticipated shotcrete quantities, shotcrete nozzlemen qualifications and weather conditions, in order to provide a lessons-learned database for future soil nail wall design and inspector considerations. These projects also underscore the importance of design engineer and soil nail wall contractor qualifications as well as effective communication with the owner.

Jan 1, 2007

By N. M. Can

The effects of microwave treatment on the floatabilities and magnetic susceptibilities of some sulfide minerals, namely, pyrite, chalcopyrite, galena and sphalerite, were studied. Pure mineral samples were prepared in -425+212-µm, -212+106-µm and -106+38-µm size fractions. Microflotation and magnetic separation tests were carried out on the samples after microwave treatment at 600, 950 and 1,300 Watts for 5, 20, 60, 90, 120 and 240 seconds. The maximum temperature values of the samples were measured during the microwave treatment, and possible altera-tions on the mineral surfaces were determined by X-ray diffraction (XRD) analysis. The effects of microwave treatment are discussed based on the result of microflotation and magnetic separation tests. The results revealed that pyrite, chalcopyrite and galena were heated very quickly and that their surface temperatures reached ~700° to 900°C, while the temperature of sphalerite reached only ~130°C. The floatability of pyrite, chalcopyrite and galena were decreased when microwave energy and the duration of treatment were increased, owing to oxidation of the mineral surfaces caused by relatively high temperature. As expected, there was no change in the floatability of sphalerite. The magnetic properties of pyrite and chalcopyrite were improved by the increase in microwave energy and the duration of treatment to such an extent that 90% of the feed separated as magnetic product. But no change was observed in the magnetic properties of galena and sphalerite.

Jan 1, 2007

By T. Nishi, D. Teguri, K. Saitoh

In recent years the requirement for high carbon ferro-manganese (HCFeMn), which is the key product of our company, has increased due to bullish demand for steel products. In our Tokushima works, we have 2 closed types of electric furnaces (1F and 2F), with which we are manufacturing HCFeMn. In order to meet the increase in demand, we made various modifications to these furnaces and we tried to increase the furnace operating loads. Especially for 1F, we deepened the furnace. In this paper, we report the results of this modification. The operational situations of the above-mentioned two furnaces are different because they have different individual profiles. As for 1F prior to modification, the depth of the furnace was one meter shallower than2F, because 1F was designed for the manufacturing of SiMn. On the other hand, our Tokushima works specialized in HCFeMn 14 years ago. However, the profile of 1F was not optimized for HCFeMn. In comparison to 2F, 1F was more difficult to stabilize due to the smaller tolerance for the adjustment of the electrode length, the metal / slag level, and the coke-mixing ratio. We deepened 1F by 770mm by disposing of the furnace rolling mechanism. We consequently achieved a 10% increase in production capacity. This meant the operating load was enhanced from 24.5MW to 27MW, the furnace became more stable and the tapping speed of both metal and slag increased, all which made the tapping easier than before.

Jan 1, 2007

By L. Haavanlammi

The Outokumpu HydroCopper® process is a chloride based atmospheric leaching process alternative that can treat a variety of different concentrates. Chalcopyrite and other copper sulfides can effectively be leached under atmospheric pressure in strong, aggressive chloride solution using copper (II) ions as oxidant. Impurities are removed from the solution as carbonates and ion exchange. Copper is precipitated from the purified pregnant leach solution as copper (I) oxide, which is filtered and reduced by hydrogen gas to metallic copper powder, which is melted and cast into copper product. Sodium chloride solution from copper (I) oxide precipitation is decomposed in a chloralkali electrolyser, to products of which are circulated back to the process. The process has been designed for copper concentrates and is a fast and economical way to produce copper wire rod directly from concentrate. The process can efficiently handle impurities like arsenic and mercury, which can be harmful in the pyrometallurgical processes. The process has been tested in the laboratory and 1 ton/day demonstration plant scale and it has been proven to be commercially viable. The process has been designed to meet the strictest directives for emissions. Other environmental factors are carefully considered to obtain the highest possible eco-efficiency.

Jan 1, 2007

By C. Carrasco

Caletones Smelter, Division El Teniente of Codelco Chile, has used Teniente Converter (TC) as the only smelting unit since November 2000. The modernization project considered the shutdown of the last reverberatory furnace, the installation of the fourth Teniente Slag Cleaning Furnace, the installation of a new fluidized bed dryer and the modification of the concentrate injection system into TC. The modernization project and related investments allowed for the increase of the smelting capacity up to 1.25 million t of concentrate annually.Next stage of the smelter expansion in the year 2004 considered the increase of the smelting capacity up to 1.44 million t/year. The expansion required technology modernization and the installation of the new equipment, such as concentrate injection system, oxygen plant, fluidized bed dryer and storage bin. Currently the annual smelting capacity is about 1.35 million t of copper concentrate, being limited by sulphuric acid plant treatment capacity. This paper presents the technology and production evolution in the Caletones Smelter in the years 2000 - 2006, demonstrating the potential of development and competitiveness of Teniente Converter as world-wide recognized smelting/converting reactor.

Jan 1, 2007

By J. Drzymala

Particle beneficiation tests are often conducted to determine how the recovery of a key component of a particle mixture varies with overall product yield, i.e., the separation curve. The results can be misleading when an attempt is made to determine the effect of feed grade by comparing separation curves representing different feed grades or key component concentrations. This is a shortcoming of the conventional recovery versus yield diagram, which may not appear to be affected by feed concentration. To overcome this shortcoming, a method is presented for transforming and normalizing the recovery and yield coordinates so that the separation curves representing dif-ferent feed concentrations are directly comparable.

Jan 1, 2007