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By J. P. Wilson, T. Cook, H. Kling

The Tessenderlo-Kerley Leachprocess has been shown to be effective in the removal of residual copper from molybdenite concentrates. Concentrates of varying mineralogy, including those containing relatively large amounts of chalcopyrite, have been successfully leached on laboratory and pilot plant scales. The lixiviant system is ammonia andammonium bisulfite with air / oxygen addition. An abrasive is added which greatly enhances the kinetics, and it is subsequently screened out and reused. The dissolved copper is easily recovered using existing technology. Extraction profiles, reagent consumptions, and mineralogical data are presented.

Jan 1, 1999

For many crushed aggregate producers will the finest fraction minus 4 mm represent a problem. The fine material will fetch a much lower price than the coarser products, and may even be difficult to sell in some markets. The blasting operation will strongly influence the generation of fines after both blasting and crushing. Drill hole deviation together with the drill hole diameter, powder factor and velocity of detonation are the most important blasting parameters with regard to the generation of fines. Drill hole deviation is often ignored, and many operators will just reduce the drilling pattern in order to avoid hard bottom and an excessive number of boulders. The paper presents a technical and economic analysis of how drill hole deviation will lead to an increased generation of fines in crushed aggregate production. The analysis shows that the loss of sales revenues will be much higher than the extra costs for drilling and blasting caused by compensating for drill hole deviation by putting in more holes.

Jan 1, 1999

By R P. Langford, T A. Moore

Indonesia over the last 15 years has experienced a surge in coal exploration, which has led to the development of a major export industry. This coal exploration has improved the understanding of the geology of the Indonesian coal deposits. The main economic coal deposits are of Eocene and Miocene to Pliocene age, which mainly occur in Kalimantan and Sumatra and were formed from peat deposits in an equatorial paleoclimate similar to that prevailing today. Some of these peats were domed peats, which grew above the normal water tables, under a climate of year-round rainfall; these peats grew above the level at which waterborne mineral matter can enter the system, resulting in low ash and sulphur, and locally very thick coal. It is believed that such peats have formed the unusually thick, low ash, and low sulphur Miocene coals of Indonesia. Coal deposits of Eocene age are typically characterised by thinner seams, with relatively higher contents of ash and sulphur. The Miocene coals and Eocene coals both appear to have formed in lacustrine, coastal plain or deltaic depositional environments, similar to the modern peat-forming environments of eastern Sumatra and parts of Kalimantan. The Eocene coals formed mainly in extensional tectonic settings. Miocene - Pliocene coal deposits formed in a range of tectonic settings; the most significant, for large economic coal deposits, are the foreland basin setting of the large Neogene coal deposits of South Sumatra.

Jan 1, 1999

By R. Schaller, Ch. Karcher, A. Thess

"Electron beam evaporation of liquid metals is an innovative technology increasingly used in industry to produce very thin coatings of high purity. In this process the surface of a metal ingot, placed in a water-cooled copper crucible, is heated by bombarding it with a high-energy electron beam gun. The material melts, forming a free surface and eventually starting to evaporate. The rising vapor cloud condensates as a thin film on a moving substrate. The strong energy input at the free surface gives rise to vigorous thermos capillary and buoyancy driven convective motion within the melt, leading to unwelcome heat losses. This paper aims to show how these losses can be reduced by optimizing the geometry of the crucible and by using external magnetic fields. We present both experimental and numerical results.IntroductionElectron beam evaporation of liquid metals [l] is an innovative PVD-technology which is excellently suited for the industrial production of high-quality coatings. In this vacuum process a high-energy electron beam heats up the surface of a metal ingot. The ingot melts and forms a free surface. A schematic view of the arrangement is shown in Figure 1. When the temperature of the free surface exceeds the actual (pressure-dependent) saturation temperature of the ambient gas, the liquid starts to vaporize. The rising vapor cloud finally condensates on a moving substrate located at some distance above. To guarantee a superior quality of the coating the melt is typically confined in a water-cooled copper crucible. The intensive cooling is necessary to avoid chemical reactions between the melt and the crucible walls, that is, crucible materials and their reaction products are practically excluded from evaporation."

Jan 1, 1999

The Northside Storage Tunnel Project in Sydney includes over 20 km of TBM driven tunnels, over three km of declines and major caverns and pump rooms. The paper describes methods used for design on the project. Emphasis is given to the refinement of the use of empirical rock mass classifications, and to the use of discontinuum numerical methods. The use of empirical rock mass classifications in Sydney sandstone has usually led to conservative design because the systems are based on a random orientation of joints in the rockmass. Because the joint sets are usually oriented in a way that is beneficial for tunnelling, limits must be placed on the parameters used in the classifications system. The paper discusses these limits and the derivation of the parameters. The use of numerical methods in Sydney sandstone is discussed. Continuum methods have their uses, but discontinuum methods are preferred. The use of UDEC has been validated against a previous project, the New Southern Railway. Recommendations are given for UDEC models. In Sydney's geology, so advantageous for tunnelling, the challenges of this project have been to make the best use of the good conditions, while maintaining safety for the workforce and the future operators of the project.

Jan 1, 1999

By J Vann

Mineral Resource and Ore Reserve estimation is a challenging and demanding field, requiring application of professional knowledge, skill and experience of the highest order. If the many potential pitfalls are to be avoided, however, there are two other requirements which are of equal, if not greater, importance:good communication, and common sense. Estimation of Mineral Resources and particularly of Ore Reserves is almost always a team effort, involving a number of disciplines. Good teamwork requires good communication, both between team members and between the team and other parties having an interest in the process. Breakdown in these lines of communication can have far reaching effects on the project under consideration. The need to use common sense during a Resource or Reserve estimation exercise would seem to be self-evident. It is surprising, however, how often rigid adherence to procedures and methods prevails at the expense of clear thinking, usually with adverse and sometimes fatal effects on the project under consideration. This has become increasingly true as computerised methods have assumed a central role in Resource/Reserve estimation. The critical question that estimators should ask themselves at all stages of the process is: æIs what is being done sensible given the data available, what is known of this deposit and the purpose of the exercise?Æ

Jan 1, 1999

With commodities suffering dramatically low real prices, mining business margins are under intense scrutiny. Unfortunately, management systems developed early this century for manufacturing are driving counterproductive behaviours that choke productivity. The paper and presentation will explain this and present a proven methodology for increasing productivity. This will be supported by operational examples from Australian and American mining management to demonstrate the importance of modern business performance measurement and analysis systems. It will explain the importance of management systems in driving organisational change to sustain superior productivity and margins. The paper will explain why many executives and managers confuse production (a measure of volume) with productivity (which measures efficiency and effectiveness). It will explain how this and other counterproductive managerial and operator behaviours and attitudes are driven by traditional business management systems exacerbated by managerial and consulting fads. The paper will begin with the simple principle that to improve results one needs to first improve the process producing the result û and will show how this is often violated. Improving productivity then boils down to:accurately identifying opportunities using sound, modern measurement, analysis and reporting systems; methodically improving operating and commercial processes, and changing peopleÆs behaviours and attitudes to sustain changes in practices. The paper will include fundamentals of applying sound measurement and analysis to:processes directly, eg cycle time charts and their impact in cyclical (non-continuous) operations commonly used in rock breakage; drivers of productivity; and process results themselves since correct analysis identifies opportunities accurately. The paper will cover the importance of practical leadership and the need to follow a simple, solid plan for changing systems that drive behaviour. Overall, it will highlight use of modern performance Measurement, Analysis and Reporting systems to drive behaviours and improve margins - without capital investment û and make executive and managerial work easier and more effective.

Jan 1, 1999

The Goonumbla district of central-west New South Wales, Australia, hosts four significant porphyry Cu-Au deposits that contain a combined probable ore reserve of 71.7 million tonnes at 1.2 per cent Cu and 0.5 g/t Au. Mineralisation in the Goonumbla deposits is associated with narrow, pipe-like intrusions of quartz monzonite porphyry, in which several intrusive phases have been recognised. Five textural characteristics have been used to distinguish the various intrusive phases recognised in the Goonumbla porphyry deposits: (1) phenocryst abundance; (2) nature of the groundmass; (3 and 4) proportion and mineralogy of the mafic and non-mafic phenocrysts; and (5) the presence or absence of anhedral quartz grains in the groundmass. In addition, each intrusive phase is classified according to its estimated original quartz, alkali feldspar and plagioclase contents. Features common to all of the intrusions are that they contain two types of plagioclase and two or three types of K-feldspar phenocrysts in variable proportions. Most of the intrusions also contain apatite micro-phenocrysts. The groundmass textures range from aphanitic through granular to euhedral K-feldspar in a quartz matrix. With only one exception, all of the intrusive phases recognised are either quartz monzonite porphyry or mafic (>5 per cent mafic minerals) quartz monzonite porphyry. The exception is a biotite - phyric monzodiorite, which occurs in the basal portions of one of the deposits. Textural variants of intrusive phases at Goonumbla have been investigated to establish whether specific combinations of characteristics indicate mineralised intrusions, while others suggest barren ones. Some correlations between intrusion types and Cu and Au grade have been recognised. The most important textural characteristic that relates to high grade mineralisation appears to be the low proportion of mafic minerals, because the quartz monzonite porphyry intrusions hosting most of the mineralisation in the two deposits studied contain

Jan 1, 1999

By T. Mudder

The objectives for closure of a hard rock mine include minimizing long term environmental liability, attaining regulatory compliance, and maintaining geotechnical stability, while closing as cost-effectively as possible. Proper planning for closure should come during the feasibility study, design and permitting phases, and during operations as updates. The lack of a proper or updated closure plan can result in severe environmental and economic consequences. Effective mine closure is the result of a combination of innovative concepts, long-term commitments, and multi-party cooperation. The purpose of this paper is to discuss concepts, commitments, and cooperation as they relate to an effective closure plan.

Jan 1, 1999

By J. H. Schloen

"One of the most important phases in Canada's relatively rapid development of its metal mining and refining industries was launched in 1928 when the directors of Noranda Mines Limited decided to establish an electrolytic copper refinery ""somewhere in Eastern Canada”. Noranda's president, J.Y. Murdoch, had already evolved the company's ""mine to market"" policy and was determined to prove the economic feasibility of refining Noranda copper in Canada. The time appeared to be ripe as buoyant business conditions continued into 1929. In addition, proven ore reserves at the Horne Mine in northwest Quebec had virtually tripled and the price of copper had reached a healthy 15 cents per pound. Letters Patent incorporating the company bearing the date February 6, 1929 had been granted by the Secretary of State in accordance with an application that specified a capital structure of $2 million divided into 20 000 shares with a value of $100 each. Noranda assumed 70% of the original investment in the proposed refinery, while the Nicholas Copper Company of New York (which later became Phelps Dodge Corporation) and British Metal Corporation Ltd. of London, England, each were responsible for 15%. Nicholas Copper Company agreed to supply the design and to supervise the construction of the refinery and British Metal Corporation would act as sales agent and market the refinery's products."

Jan 1, 1999

By Fathi Habashi

The year 1987 marked the centennial of the beginning of modern hydrometallurgy. On October 19, 1887 British Patent No. 14174 entitled Process of Obtaining Gold and Silver from Ores was issued*. The discovery was made by John Steward MacArthur (Fig. 1), a chemist-metallurgist, supported and assisted by Robert and William Forrest, two brothers practicing medicine in Glasgow. The discovery was made in the basement of their clinic. The process, which became known as the cyanidation process in reference to the alkali cyanide reagent used, immediately received industrial success in New Zealand in 1889 and in South Africa in 1890t. It displaced the chlorination method which had been in use. In 1903 MacArthur was awarded the first Medal of the Institution of Mining and Metallurgy in London1131 - The cyanidation process was responsible for the doubling of gold production in the world in the two decades which followed its first application (Fig. 2). To the modern metallurgist, it may be surprising to think of MacArthur coming across an obscure reagent such as an alkali cyanide as a leaching agent for gold ores. It is the purpose of this paper to discuss the background and the factors that led to this invention, the development of the understanding of the process, and the application of modern technology.

Jan 1, 1999

By M. Nagamori, A. J. Plumpton

"Commercial HCl-leaching of magnesite and serpentine yields highly concentrated aqueous solutions containing 25 mass % to 33 mass % MgCl2. The partial molar enthalpies and heat capacities, the ionic activities of Mg2+ and Cl–, and the Raoultian activity of H2O have been assessed for the concentrated MgCl2-H2O solutions at temperatures of 348 to 373 K. These thermodynamic data are used to calculate the pH of aqueous MgCl2 solutions saturated with a Mg-bearing mineral such as magnesite, serpentine, brucite, forsterite, enstatite or talc. On the basis of these thermodynamic data, technico-economic aspects are discussed as to neutralization with pulverized MgCO3, water evaporation from the MgCl2 solutions, and ore composition including such minor constituents as CaCO3, FeCO3 and Fe3O4. IntroductionA major magnesium electrolytic reduction plant operates in Quebec, where another will begin its production in the year 2000. One uses imported magnesite ore as raw material, while the other will utilize local asbestos tailings (serpentine). Both processes produce a concentrated salt solution of 25 mass % to 33 mass % MgCl2 by leaching the ore with concentrated hydrochloric acid. Thus, the two processes differ mainly in the HCl-leach and related operations. After the HCl-leach of the ore, the serpentine process yields about 25 times more wet cake to filter and wash than the magnesite counterpart. A comparative cost-engineering study with respect to slurry filtration and cake washing has been published elsewhere (Blackburn and Nagamori, 1994). By contrast, the present study considers the thermodynamics and technicoeconomics of the HCl-leach itself for both ores."

Jan 1, 1999

By N. E. Ablesimov

Electron probe X-ray microanalyser of a coating deposited with "Elitron¬22A" electrospark alloying (ESA) set (anode - Cr, base-catode - chrome vanadium steel) has shown that the zone of phase forming can be divided into three parts: the coating itself, diffusion zone and a thermal affection zone in the base material. Waves of iron and chrome concentrations have been found in the diffusion zone. The authors interprete them as a phenomenon of substance self-organizing in the 30 pill deep diffusion zone, characterized by a change of compositions during the transfer of material from the coating to the base: coating - 20 µm (FeCr2), diffusion zone - 30 µm (Fe3Cr, FeCr, Fe4Cr, Fe2Cr), base - steel (Fe - 87 %, Cr - 12 %, V - I %). This ESA phenomen has been noted for the first time. It may be relative to the phenomenon of periodic formation of secondary products during the mutual diffusion of reacting substances in the case of a one-way reaction. Similar regular structures may appear in the diffusion zone during ESA of vanadium steels with vanadium, manganese steels with manganese and so on.

Jan 1, 1999

By J. Wagner, P. Eger, G. Melchert

In 1991, LTV Steel Mining Company decided to close an open pit taconite mine in northeastern Minnesota, using a passive treatment approach consisting of limiting infiltration into the stockpiles and wetland treatment to remove metals. Over 50 million metric tons of sulfide-containing waste had been stockpiled adjacent to the mine during its 30 years of operation. Drainage from the stockpiles contained elevated levels of copper, nickel, cobalt and zinc. Nickel is the major trace metal in the drainages, and prior to closure annual median concentrations ranged from 1.5-50 mg/L. Copper, cobalt and zinc are also present but are generally less than 5% of the nickel values. Median pH ranges from 5.0 to 7.5, but most of the stockpile drainages have pH greater than 6.5. Based on the chemical composition of each stockpile, a cover material was selected. The higher the potential a stockpile had to produce acid drainage, the lower the permeability of the capping material required. Covers ranged from overburden soil removed at the mine to a flexible plastic liner. Predictions of the reduction in infiltration ranged from 40% for the native soil to over 90% for the plastic liner. Five constructed wetlands have been installed since 1992, and have removed 60-90% of the nickel in the drainages. Total capital costs for all the infiltration reduction and wetlands exceeded $6.5 million, but maintenance costs are less than 1% of those for an active treatment plant. Since mine drainage problems can continue for over a hundred years, the lower annual operating costs should pay for the construction of the wetland treatment systems within seven years.

Jan 1, 1999

The Gold Ridge Mine is an open-cut gold mine in the Solomon Islands. The mine is owned and operated by Gold Ridge Mining Limited, a wholly owned subsidiary of Ross Mining NL. At the invitation of the Solomon Island Government, project construction commenced in July 1997 and gold production commenced in August 1998. The mine is the countryÆs first, and represents a major milestone in the development of the Solomon Islands. At the time of project approval and construction, there was a growing awareness in the country of the potential impacts of mining in the tropics, partly due to unfavourable publicity surrounding a number of other mining operations in the Pacific region. The management of environmental impacts was therefore an important consideration in the approval of the project, and continues to receive a high level of attention from the Government and community. Ross Mining did not commit to the Gold Ridge Project until it had satisfied itself that all waste rock and tailings could be safely contained on-site, and that the standards normally expected of a mine in Australia could be met. Ross Mining approached the approval, construction, and operation of the Gold Ridge Mine with a set of operating principles that met Government and community concerns. These were:best practice environmental management; operation of the mine in accordance with standards expected of mining operations in Australia; independent peer review of key technical aspects; on-going consultation with Government and community; and equitable transfer of wealth to landowners and the local community. As a consequence, the Gold Ridge Mine has developed into a successful mining operation with a high level of support from local landowners, the general community and the Central and Provincial Governments of the Solomon Islands.

Jan 1, 1999

By G. Bonifazi

Certain deposits of incoherent materials which are near the surface and exploitable by open-pit mining may be characterized in real time before they are mined through an analysis of ground-surface imagery. If the slice to be stripped is not overly thick, in fact, surface texture and color properties may be extrapolated to its entire thickness. Image analysis techniques to process ground surface images acquired in situ (or in the laboratory shortly after their acquisition) which yield pattern vectors representative of RGB color component distributions and HSB texture parameters have been developed. The techniques were applied to a mineral sandy ore deposit containing three different lithotypes. Geostatistical analyses showed that the data used to characterize the lithotypes were reliable. The correct recognition of the lithotypes was carried out using a multi-barycenter classification algorithm. Such in situ image-analysis procedures open the way to the proper selection of the ore to be mined, or the proper way for run of mine (r.o.m). processing, or the appropriate blend to be processed before or at the same time as the mining process itself is enacted.

Jan 1, 1999

By S. Sener

In this investigation, the changes in the grindability of both ulexite and colemanite related with the different structural modifications created by the heat treatment were examined with respect to work index (Wi). The effects of the heat treatment temperature and time on grindability index were also investigated. It was observed that, heat treatment significantly affected on the grindability of ulexite. The work index of original ulexite was found 7.11 kWh/shton and decreased to 3.5 kWh/shton level within 200-480°C for 60 minutes. On the other hand, the work index of original colemanite was found as 6.48 kWh/shton and no appreciable change was observed when heated up to 320°C. Thermally assisted comminution can be used to improve the grindability characteristics of ulexite. Besides, the different behaviour of ulexite and colemanite under heat treatment can be used for their separation. The artificial mixture of ulexite and colemanite could be separated with over 90% recovery by utilizing their different grindability characteristics by thermal treatment, semi-autogeneous grinding and screening.

Jan 1, 1999

Flotation testing has been done at laboratory scale on hematite mineral and ore samples using stage additions of various hydroxamates. Chemisorption of hydroxamate species onto the hematite surface was inferred from the results, possibly involving both the undissociated hydroxamic acid and hydroxamate ion as maximum recovery occurred close to the pKa of the hydroxamic acid. Flotation testing on a specular hematite ore containing 40 per cent Fe and 42.5 per cent silica gave highest iron grades in concentrate at pH 6, in contrast to published data which suggested pH 9 as the optimum value for ore processing. Using octyl hydroxamate, a rougher concentrate assaying 67 per cent Fe at 51 per cent recovery was obtained using four stage additions of 50 g/t at pH 6. For lower grade concentrates still meeting the chemical analysis for pigment grade micaceous hematite (minimum Fe assay 60 per cent) iron recoveries of 80 per cent were possible for stage additions of 50 g/t octyl hydroxamate in the pH range 6-8.

Jan 1, 1999

By D. A. Salinas G., A. H. Castillejos E.

Pachuca tanks are commonly used in the hydrometallurgical industry to carry out leaching operations. The fluidynamic characteristics of the liquid phase, resulting from the injection of gas into the draft tube, are important to achieve the complete suspension of the mineral particles and has a decisive influence in the mass transfer processes occurring in this reactor. This study investigated the effect of different design and operating characteristics on the liquid velocity field. using a laboratory-scale Pachuca tank. The transparent model was filled with water, and air was injected through the bottom in the absence of mineral particles. The liquid velocities over the whole reactor were measured under several experimental conditions using particle image velocimetry (PIV). This technique allowed to obtain a very detailed picture of the liquid motion even in the draft tube, as long as bubbles were absent from the measured field of view. The experiments have shown that the liquid velocities increase with increasing the draft tube to tank diameters ratio, the distance from the conical bottom to the draft tube entrance, or the gas superficial velocity. On the other hand, an increase in the water level with respect to the draft tube outlet caused a decrease. A mathematical model, which used the no-slip model, to calculate the variation of axial effective density along the two-phase region, was found to predict liquid velocity fields which agree very satisfactory with the experimental results obtained under all the conditions studied.

Jan 1, 1999

By Thomas E. Newman

This paper is a case study using new laser-terrain-mapping technology by EagleScan, Inc., for creating topographic maps. Holnam, Inc., has used this technology to create maps and volumetric calculations of several mines in the United States. The information is superior to conventional methods through accuracy, manpower, time, and cost. Holnam, Inc., was the first cement manufacturer to use the Digital Airborne Topographic Imaging System (DATIS?). The technology uses the DATIS? to produce high-resolution terrain maps and volumetric assessments of any area. DATIS? is a mapping instrument that integrates (1) a Light Detection and Ranging (LIDAR) instrument to measure terrain elevation using laser light, (2) a large-format digital camera, (3) a relative position Global Positioning System (GPS) to measure aircraft position, and (4) an Inertial Measurement Unit (IMU) to measure aircraft attitude. The DATIS? can measure up to 220,000 elevation samples per mil. The system continually collects data on the aircraft's position and measures the time for each laser pulse transmission to return from the ground, giving each sample a GPS reference. The system can operate at night, in overcast sky, and during high-wind conditions and can measure terrain below vegetation cover, unlike standard aerial photography used for traditional surveying and mapping. Surveyed ground-control panels are no longer necessary with this new technology, and only one ground GPS base station located within 60 mi from the aircraft position is required. A computer elevation-point data file is created with the x, y, z coordinates of each laser elevation sample. With this file, CAD engineering programs can create topographic maps that rival products using conventional aerial mapping techniques. Volumetric measurements of stockpiles and pits are also available due to the high density of points collected from an area. This new technology radically changes the turnaround time for map users, giving a product in the format used by today's cartographers. The time line from flight to maps is measured in days instead of weeks.

Jan 1, 1999