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By M. Karmis

According to international projections and future energy scenarios, coal will continue to be a prominent fuel for the next 25 years. In fact, in many regions around the world, coal is expected to dominate the electricity sector until the year 2030. At the same time, with instability and volatility of oil prices, coal is also positioned as an alternative feed stock for conversion into liquid fuels. Energy economists maintain that coal liquefaction is viable at crude oil prices of $35 or more per barrel. Depending on technology and coal composition, 1 ton of coal can produce 1 to 4 barrels of oil. Increased coal production and the expanded utilization of coal also raise environmental concerns regarding greenhouse gases and the problem of handling CO2. Carbon sequestration research, currently conducted in many parts of the world, has demonstrated considerable potential for C-storage in unminable coal seams. Such geologic storage, when possible, can also be integrated into an enhanced coal bed methane recovery process Can coal fuel power plants and industrial facilities, provide diesel and other liquids and, at the same, also be used as a medium for permanently storing CO2? This presentation will provide a global perspective on these questions and stress on the need to reconsider, or even redefine, coal as the fuel for the future.

Jan 1, 2006

By B. Leong, H. Joubert

Keywords: Pyrometallurgy, furnace, auxiliary equipment, copper slag launders Pyromet has designed copper launders for tapping slag. What makes Pyromet?s launder design innovative and safe is that it does not have any cooling water channels underneath the launder runner, whilst achieving effective cooling of the runner. If matte burn-throughs were to occur through the launder runner, the risk of damaging water channels and the risk of explosions are reduced. In addition, since the cooling water channels are not harmed, the launder is easily repairable and reusable. Pyromet makes use of Finite Element Analysis to optimize the launder geometry to ensure that sufficient energy is removed from the centre of the launder. Factors considered during the launder design include the suitability of the geometry to the client?s needs, experience from existing installations, and ease of fabrication. Pyromet goes so far as to develop procedures for fabricators to ensure that fabrication issues do not compromise the functionality of the launder. When launder orders are received by Pyromet, the entire fabrication process and the functioning of the launders during operations are monitored to ensure that the launder designs are continuously improving with every installation.

Jan 1, 2006

By Scott A. Shapkoff

High strength cable strand supports are predominately used as a supplemental means of ground control in longwall and development operations in the U.S. The advantages of cable strand supports have been documented and include flexibility, strength, and ease of installation. Since the majority of cable supports installed in the U.S. today are partially grouted, and this same segment of supports has no inherent installed tension, the supports are considered currently arbitrarily strictly supplemental and therefore, cannot currently be deemed primary support (in most mining districts). This paper details and discusses two distinctly different configurations and the technical advantages of active partially grouted cable supports for certain primary support applications. The evolution of the designs for both systems is highlighted. Field data illustrates the amount of active load in relationship to installed torque and the affects that component variables have on this load measurement. Roof control patterns using active cable supports are examined as alternatives for combination patterns using primary and supplemental systems. The importance of maintaining consistent installation procedures plays an important role in the level of performance of the system. Economics comparing the installation of active cables with other primary/supplemental patterns is also included.

Jan 1, 2006

By K Rozlapa, P Waters, H Middlemis

A major challenge for closure planning at mining operations below the water table is evaporation from final void pit lakes and concentration of salts, which can impact on downstream groundwater (and surface water) flows and quality. Where such impacts are deemed unacceptable, the closure approach that is often adopted is to infill the final voids with waste rock to above the pre-mining water table to prevent the development of a pit lake and subsequent evaporative losses. BHP Billiton Iron OreÆs Marillana Creek (Yandi) mining operations face these issues. The orebody is a channel iron deposit that forms the major aquifer in the region, which will be completely mined as a series of elongated open pits over tens of kilometres. The major constraint on mine closure planning was the stripping ratio of less than one, which means that there is insufficient waste rock to infill all areas to the pre-mining water table. Hydrogeological investigations and groundwater modelling indicated that standard mine closure approaches would result in pit void lakes becoming saline sinks unless the residual void geometry was optimised to minimise evaporation and maximise throughflow. The solution developed is a cost-effective long-term mine plan that meets all mine closure objectives, and involved:the selective infilling of all pits, largely using run-of-mine waste dumping with limited re-handling; the diversion of the major part of up-catchment creek flows around the mining operations to allow mining of the resource under Marillana Creek crossings, which in turn restricted overall aquifer recharge and reduced the elevation of the long-term water table; the diversion of some minor creek tributary flows into specific locations within the mine path to induce hydraulic gradients to maintain groundwater throughflow and water quality; and close integration of mine plan optimisation (mining and waste dumping schedules) with groundwater modelling scenarios to achieve acceptable environmental outcomes. This approach is designed to result in no reduction in downstream surface water flows or quality, maintenance of adequate downstream groundwater throughflow to support groundwater dependent ecosystems, and no reduction in the beneficial use status of the downstream groundwater resource.

Jan 1, 2006

By Peter Fischer

Between 45,000 and 50,000 claims for subsidence are submitted each year to the German hard coal industry. In order to improve the service to claimants a quality management was established in 2005. This paper describes the process now used for handling these claims. A quality check has also been carried out by way of a customer survey, which was performed by an independent research agency. The results of the survey are presented in this paper. In Germany, research into mining subsidence mainly involves the prediction of ground movements caused by deep mining operations. Special areas of research are subsidence reducing aspects of the extraction panel planning, especially from the point of view of mining dynamics, as well as securing and restoration measures. This work seeks to prevent or minimize mining-induced damages close to the surface, for instance, buildings or infrastructure installations (such as pipelines), or underground mine openings (e.g. shafts). Roof collapses and surface fractures caused by shallow mine workings of an earlier era currently constitute a special area of investigation.

Jan 1, 2006

By K D. Wilkes

The WEMCO Heavy Media Drum Separator was first introduced by WEMCO in California in the 1940`s, initially from their base in San Francisco and later when the company moved to Sacramento. The WEMCO Company became a part of EIMCO Process Equipment in 1985, and in 2002 EIMCO became a part of the GL&V Group when Dorr-Oliver EIMCO was created. Throughout this period of time the WEMCO Drum has been installed on a variety of different applications and is now operating at the heart of many of the world?s largest Minerals and Coal Processing Plants, as well as being used by many smaller producers and metal re-cycling operations. This paper looks at the practical aspects of using WEMCO Drums in a representative range of processing applications.

Jan 1, 2006

By David Arana

The use of gas-water dispersion of a molten material flow onto a vibrating surface is developed as a process to minimize water pumping requirements, minimize the risks of explosions, and minimize the post solidification dewatering and fines handling equipment requirements. The process uses existing vibration transport technologies and common plant utilities. Plant trials using the smaller footprint and the progressive molten particle cooling time have yielded encouraging results. The results are analyzed and reported.

Jan 1, 2006

By Peter Kong

This paper provides a general discussion of atmospheric-pressure plasma generation, processes, and applications. There are two distinct categories of atmospheric-pressure plasmas: thermal and nonthermal. Thermal atmospheric-pressure plasmas include those produced in high intensity arcs, plasma torches, or in high intensity, high frequency discharges. Although nonthermal plasmas are at room temperatures, they are extremely effective in producing activated species, e.g., free radicals and excited state atoms. Thus, both thermal and nonthermal atmospheric-pressure plasmas are finding applications in a wide variety of industrial processes, e.g. waste destruction, material recovery, extractive metallurgy, powder synthesis, and energy conversion. A brief discussion of recent plasma technology research and development activities at the Idaho National Laboratory is included.

Jan 1, 2006

By A. A. B. Douglas

In this paper the origins of the mortar intruded concrete concept and its development and application in the construction of watertight bulkheads in South Africa are described. The events leading to the commissioning and execution of the West Driefontein Experimental Plug and the Virginia/Merriespruit Boundary Plugs, and their roles in the proving of the technique, follow. The development of the first Transvaal and Orange Free State Chamber of Mines Code of Practice for Mortar Intrusion Concrete for Underground Plugs and Bulkheads, Johannesburg, November 1962,is explained. The saga of the October 1968 flood and subsequent salvage of the West Driefontein Gold Mine is recounted. The paper concludes with mention of the validation programme carried out for the Placer Dome Western Areas Joint Venture and their South Deep water barrier programme.

Jan 1, 2006

By Sung-Mo Jung

Experiments were carried out on a system with artificially prepared slags in a graphite crucible, in order to examine the possibility of recycling BOF slags produced in the steelmaking process. More than 80% of FeO and P2O5 was reduced within 20 minutes and the FeO reduction rate was greater than that of P2O5. P2O5 reduction began after more than 60% of FeO was reduced. Increasing slag basicity enhanced the reduction of FeO and P2O5. Temperature also improved slag reduction. The overall reduction rate was controlled by the chemical reaction at the slag/carbon interface. The reduction rates of FeO and P2O5 were second and first order with respect to their respective contents. Most of the reduced phosphorous is believed to vaporize in the form of P2 gas.

Jan 1, 2006

By Reza Y. Khaksar

Presented is a rigorous solution for the three-dimensional stability analysis of vertical shafts (excavations) subjected to the self-weight of the soil based on the upper-bound theorem of limit analysis approach. A rigid-block translational collapse mechanism is assumed, with energy dissipation taking place along planar velocity discontinuities. This mechanism is optimized to obtain the critical failure mechanism giving the lowest factor of safety for stability of shafts. Based on comparisons with other solutions, the method is generally found to be accurate in predicting the stability of vertical cuts.

Jan 1, 2006

By Steve J. Czehura

The Butte quartz monzonite is the host rock for early porphyry copper style mineralization and subsequent mesothermal-epithermal, enargite-gold style veining that transects the district. The east-west Anaconda system veins sustained mining for over a century. They include the Emma, Anaconda-Original, Syndicate, Badger-State and Alice-Rainbow veins, each with strike lengths of more than 3,660-m (12,000-ft) and vertical continuity in excess of 1,370-m (4,500-ft) with mining widths from 1.5- to 15-m (5- to 50-ft). These characteristics are unique to Butte. The incredible dimensions and tenor of these veins have yet to be surpassed and Butte is still touted as being the “Richest Hill on Earth.” The Anaconda Company was formed in 1895 to develop underground copper reserves in the district. It eventually consolidated all operations under one company. Production from underground mining continued through the mid-1970s. Openpit mining in the Berkeley pit began in 1955 with the extraction of supergene ores, along with the remnants of deeper horsetail zones inaccessible to the underground mines.

Jan 1, 2006

By D. L. Murr, J. R. Jensen

Testing was conducted on a Minnesota Iron Ore concentrate with Cook Clay as a binder using compressive sheer mixing to enhance the performance of the agglomeration mechanism. The testing was conducted on a bench scale at the Midland Research Center the summer of 2004. Results of the test program will be presented that shows the impact of compressive sheer mixing had on the strength achieve in a green ball.

Jan 1, 2006

The Martha deposit is an economic giant epithermal gold deposit, with mined and unmined resources of more than 218 000 kg (7 Moz) Au. The Au-Ag, base metal sulphide-bearing quartz lodes in the Martha deposit form an extensive braided pattern within hydrothermally altered andesite wall rock. There are five main quartz lodes: 1.      Martha, 2.      Welcome, 3.      Edward, 4.      Empire, and 5.      Royal.   Information from historic mine plans and reports has been used to determine the depth distribution of economic ore within the Martha deposit. Economic ore (average of 10 g/t Au) in the Martha underground mine was at a maximum width and strike length between a vertical depth of 160 and 350 m. Below this depth the quartz-sulphide lodes continue, but the grade declined to sub-economic grades (< 4g/t Au) at about 575 m depth and economic ore shoots were localised, mainly on the hangingwall side of the lodes. Samples from exploration drill holes indicate that this decrease is associated with a depth zonation from electrum-bearing Zn-Pb-Cu-Ag sulphide ore (average 10 g/t Au) to sub-economic (< 2 g/t Au) electrum-poor Zn-Pb sulphide mineralisation.

Jan 1, 2006

By A. M. Brown, P. V. Straznicky

Dimpling as a means of flush countersinking rivets is an old process predominantly used in secondary structures. The introduction of GLARE as an aerospace material has renewed interest in dimpling and its possible application in primary structures. The dimpling process is able to prevent the creation of a machined knife-edge in the thin aluminum plies of the GLARE sheets. In addition, dimpling eliminates the need to use reduced height rivets, such as the NAS 1097 rivet style. This investigation expands on an earlier study into dimpling of GLARE by Rans and Straznicky. In order to tailor the dimpling process to GLARE, FEM simulations were developed. After verification, a study was performed to find the best parameters for dimpling GLARE3-2/l. Coupon fatigue tests were carried out and the dimpled joints demonstrated increased fatigue lives over the conventional machine countersunk joints. Future wide panel fatigue tests are planned to confirm the usefulness of dimpling thin GLARE laminates.

Jan 1, 2006

By Tim Hurley

On Friday, May 27, 1983 at about 6 p.m., an avalanche occurred at the Revenue-Virginius Mine. Six mine personnel and two contract diamond drillers were trapped when the avalanche covered and blocked the portal, the only access into the mine. The San Juan Mountain Range in southwestern Colorado is an old volcanic caldera. It has dikes and other intrusions, many of which are mineralized with sulfide ores rich in silver, gold, lead, zinc and copper. Several peaks rise above 4,260 m (14,000 ft) and the district has been the location of avalanches dating back to prehistoric times. This is evidenced by the numerous snow-slide chutes that are infamous enough to be named on topographic maps.

Jan 1, 2006

By P. Talonen

Since the last Iron Control in Hydrometallurgy Symposium in Montreal in 1996, the Kokkola zinc plant has increased its capacity from 175,000 t/y to 280,000 t/y by installing an atmospheric concentrate leaching process, which has also affected iron control in the leaching circuit. Major changes have been made at the jarosite residue pond; a subterranean plastic wall reinforced with bentonite and cement has been built around the pond. A new water collecting system that is used for groundwater level control in the pond area was installed. With these two investments in the pond area, it is now possible to prevent any seepage flow from the pond into the surrounding environment. Water pumped from the residue pond is treated in the water treatment plant. This paper describes the behavior of iron in Kokkola's current leaching processes. The treatment of the jarosite, the improvements to the residue pond and the water treatment process are also described.

Jan 1, 2006

By K. Goshtasbi

The mechanical behaviour of schistose sedimentary rocks such as slate show a great amount of anisotropy. Hence, the schistocity plane is essential when investigating the mechanical behaviour of such rocks. The presence of such rocks in civil projects causes non-symmetric deformation and their behaviour is unpredictable. In this research, the anisotropic strength behaviour of slates is studied. Uniaxial and triaxial tests were conducted on specimens having orientation angles (ß) of 0, 30, 45, 60, 75 and 90 degrees. The triaxial tests were done at confining pressures of 3, 5 and 10 MPa. The effect of anisotropy on uniaxial and triaxial strength, cohesion, angle of internal friction and Hoek and Brown's m and s constants were investigated. The results indicate that the strength of slates in uniaxial and triaxial compression exhibit a U-shaped anisotropic behaviour. In-order to evaluate the most suitable criterion for predicting the anisotropic strength of rocks in uniaxial and triaxial compression, an investigation was carried out on various criteria. In uniaxial compression, the Liao and Huong and Ramamurthy criteria had good agreements with the test results. In triaxial compression the Hoek and Brown and Mc Lamore criteria had better agreements with the test results. It should be noted that in-order to utilize these criteria, a large number of tests must be carried out. However, as the Ramamurthy criterion needs fewer test results, it can be the most suitable for investigating the behaviour of anisotropic rocks in triaxial compression. Keywords: Slate, anisotropy, schistose, failure criteria

Jan 1, 2006

By Henk E. Brassinga

In Rotterdam a number of underground parking facilities have been built and are under development in the inner city, and in the suburbs. These parking facilities are located at already densely built areas. The design of these constructions has to take into account the impact of the building activities and that of the final construction on the surroundings. In this paper some examples of the different building methods of newly realized underground parking facilities are described, and problems that occurred during the construction are pointed out. In the soil conditions as present in Rotterdam the cost effectiveness of underground facilities can be improved by deepening the parking facility, and at the same time reducing the surface area so that the total parking volume remains constant. In this way the total volume of the diaphragm walls and the costs of the project is reduced.

Jan 1, 2006

Like it or not, CPD is upon us. As from 1 January 2006, all registered engineering professionals, i.e. professional engineers, professional engineering technologists, professional certificated engineers and professional engineering technicians, were required to undertake CPD in order to keep their professional registration current. The rules regarding CPD have been gazetted under Government Gazette No. 28328, Board Notice 131 on 23 December 2005, and they also appear on the ECSA website?www.ecsa.co.za. For the convenience of our members they are reproduced in full in this issue of the SAIMM Journal.

Jan 1, 2006