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By C. Bazin

The separation of rare earth elements is a complex process that is industrially carried out using liquid/liquid extraction. Detailed flow sheets of solvent extraction plants for the separation of rare earth elements are rarely available in the literature which limits the opportunity to teach and test the application of data reconciliation, process optimization and control to these types of plants. The basis of a simulator for a rare earth elements separation plant is described in this paper. The simulator is used to adjust the organic phase and stripping acid flow rate in a separation circuit of heavy rare earth elements from light one?s.

Feb 27, 2013

By Harry R. Price, Behrooz Tahmasbi, Charles J. Roarty

The 2,408 meter (7,900-foot) long Middle Rouge Parkway Interceptor Extension varies in size from 1.52-meter (5-foot) to 2.36 meter (7-foot 9-inch) inside diameter. Most of the sewer was constructed in tunnel through fine sands and silts. Piping of these soils through the concrete liner eventually resulted in a loss of soil support, settlement and/or severe distress of the sewer, and the formation of several sinkholes. The repair and restoration was generally performed in the sewer and included cast-in-place concrete, shotcrete, cured in place pipe, soil stabilization, cement grouting, dewatering, and chemical grouting. As a part of the work, temporary pump stations and flow diversions were required to perform the work while minimizing discharges to the adjacent Rouge River.

Jan 1, 2007

By David Kress

Mill crushing drive systems are essential to cement producers. With the increased emphasis on operating efficiency, it is vital that these systems be dependable and reliable. No one needs the costs or headaches associated with unscheduled downtime or inefficient machinery operation. A reliable drive system starts with the proper selection of the ring, or girth, gear and continues through proper maintenance. Ideally, selecting the right girth gear brings together the gear manufacturer, the system designer and the end user. The gear manufacturer must know the details of the application, the demands that will be placed on the gear and the nature of the equipment to be driven. Similarly, the user and the system designer must be familiar with the variables that affect gear drive performance and service. For example, an application that places a torque load on the drive in excess of its rated capacity will result in gear tooth distress and, in severe cases, breakage.

Jan 1, 2000

By Andrew Howard

As the mining industry moves further into developing countries in search of new resources, its role in international development is coming under increasing scrutiny. This is a trend that is likely to accelerate, along with the potential for headaches among managers in the industry. Public interest in development and environmental issues is rising as faith in “big business” falls. This has strengthened nongovernmental organizations (NGOs) campaigning for sustainable development. And it has put more pressure on banks, governments and development agencies to curb corporate misdemeanors. Developing world governments are also becoming emboldened to reject previously agreed terms they do not consider equitable. The mining industry has begun to formulate a response to these pressures but must go much further. Societal and environmental issues must move from public relations to core strategic thinking. Abiding by rules or codes is not a relevant response. Instead, genuine support for sustainable development is required. This will involve delegating the responsibility for engaging with local communities to on-the-ground staff and developing a dialogue with local stakeholders rather than conducting an initial assessment and disengaging.

Jan 1, 2006

By M. van Elp, R. Saitua Nistal, P. J. M. Groot

Demand for construction raw materials depends on investment in housing, other buildings and infrastructure. The provision of these materials requires early knowledge of future trends in construction investment. By using scenarios possible future developments and bandwidths can be explored. Policy makers in government organisations as well as in the private sector can base their policy decisions upon these insights. In this paper we discuss the case of sand and gravel in the Netherlands. We will show that, depending on the future role of government and the degree of internationalisation, the long term demand for construction raw materials will strongly diverge. Nevertheless there are some common developments such as a decreasing population growth, a smaller share of the labour force in total population and a growing wealth. In different scenarios we will encounter different conditions for minerals provision and for sustainable development.

Jan 1, 2011

By Brad Murray

Evaluating the performance of a shielded tunnel boring machine (TBM) can be difficult because the ground cannot be observed directly and in relation to the TBM attitude within the excavation. It is difficult to determine whether performance problems are caused by ground loading, steering issues, fine muck packing against the shield, or migration of annular grout around the shield. The Arrowhead Tunnels Project in Southern California uses strain gauges on its shielded hard rock TBMs to detect shield strains early and correlate them with tunneling conditions, thereby increasing the chances that problems will be correctly diagnosed and addressed to optimize TBM performance. The frequent automatic measurement of shield strain has also been valuable by confirming whether remedial methods used to free the machine after stoppages are effective. This paper discusses the qualitative interpretation of characteristic strain patterns on the Arrowhead Tunnels TBM shields and discusses installation details and special considerations for setting up a strain measurement system.

Jan 1, 2008

By John J. Murray, Michael T. McRae, Michael A. Krulc, Kathy L. Schuler

The San Vicente Pipeline Tunnel Project involves the construction of an 8.5-foot-diameter water pipeline in an 11 mile tunnel in San Diego, California. The tunnel is located in extremely variable geologic conditions of strong granitic and volcanic rocks, weak sedimentary rocks, abrasive conglomerates, and mixed face conditions. One reach of the tunnel is a 5,200-foot mixed face reach that includes Friars Formation Conglomerate overlying granitic rock. Due to the variable ground conditions in this reach, the use of a TBM was deemed too risky and the contract documents required drill-and-blast and hand mining methods. Although it was not required, the contractor elected to construct this reach using NATM methods. This paper describes the geology of the 5,200-foot mixed-face reach, the design evaluation, and the construction challenges faced on this project.

Jan 1, 2007

By F. Dahl, P. Raleigh, J. Holzhauser, B. Nilsen

Tunnel excavation using tunnel boring machines (TBMs), has become increasingly common in recent years, despite the fact that precise evaluation of certain risks have not kept pace with the use of these machines. One of the risks easily overlooked by Engineer and Contractor alike are the effects of abrasive ground on the costs and schedule of a given project. The impacts of worn and damaged TBM cutter heads have been observed on hundreds of tunnel projects around the world. It would appear that a reliable prognosis of the abrasiveness of soils on a project would be of great importance for designers, clients and contractors alike. Several well acknowledged test and prognosis methods already exist for rock, however there is only very limited knowledge available to describe the abrasiveness of soil and its impact on soft ground TBMs. This paper will examine approaches to this problem and suggest a new approach based on a current project undergoing design.

Jan 1, 2007

By Ying Lu, Jeffrey C. Johnson, Chen-Luh Lin, Jan D. Miller, Sindhoora Puvvada

Energy dissipation and fragmentation of rock is of interest for mine-to-mill operations in order to understand breakage and to minimize energy consumption during blasting at the mine site, and comminution at the processing plant. In this regard, high velocity impact breakage of long granite cores, called bars, has been studied with instrumented strain gages to follow the energy dissipation gradient along the bar length resulting from the strain waves generated by impact. As a result of high velocity impact, three zones have been identified (fragmentation, fracture, and elastic) and these three zones have been characterized in 3D using X-ray tomography. The fragmentation zones of the granite bars were studied in detail to describe the particle size distribution and the particle shape characteristics. Finally, the experimental energy dissipation for the fragmentation zone was found to be in close agreement with the expected energy calculated from the Bond work equation, if the anisotropic granite particles are defined by length rather than by sieve size.

By Ying Lu, Jeffrey C. Johnson, Chen-Luh Lin, Jan D. Miller, Sindhoora Puvvada

Energy dissipation and fragmentation of rock is of interest for mine-to-mill operations in order to understand breakage and to minimize energy consumption during blasting at the mine site, and comminution at the processing plant. In this regard, high velocity impact breakage of long granite cores, called bars, has been studied with instrumented strain gages to follow the energy dissipation gradient along the bar length resulting from the strain waves generated by impact. As a result of high velocity impact, three zones have been identified (fragmentation, fracture, and elastic) and these three zones have been characterized in 3D using X-ray tomography. The fragmentation zones of the granite bars were studied in detail to describe the particle size distribution and the particle shape characteristics. Finally, the experimental energy dissipation for the fragmentation zone was found to be in close agreement with the expected energy calculated from the Bond work equation, if the anisotropic granite particles are defined by length rather than by sieve size.

By Richard F. Flanagan, Robert H. Marshall

The Republic of Singapore’s Public Utilities Board is implementing the Deep Tunnel Sewerage System Project. The project’s deep tunnel component, 48 km of deep, large diameter sewer tunnels has been successfully completed (the works are in the defects liability period). Six International Design/Build tunnel contracts utilized eight Earth Pressure Balance TBMs ranging up to 7.23 m in diameter to deal with varied ground types ranging from deep soft clays to fresh granite. Numerous access/workshafts were constructed and using various support systems. This paper provides an assessment/overview of the tunnel contracts, tunnel excavation methods and equipment, and the shaft systems. Suggested enhancements to similar future projects are provided.

Jan 1, 2007

By M. Perolo, A. Contini, E. Ramelli, G. Borgonovo, L. Locatelli

This paper presents the ground settlement monitoring system used during the construction of two tunnels bored by two EPB TBMs, beneath the existing and active railway embankment in Bologna (Italy). The tunnels run close to large buildings and beneath bridges and other infrastructure. Data are collected from remote total stations and from electro levels installed directly on the railway tracks. The automated monitoring system acquires and analyses data then sounds an alarm in the event that there is a problem. Alarms are sent out in case of excessive tilt or settlement. Data is provided through a dedicated web application for multiple-party access, to gather, manage and store monitoring data.

Jan 1, 2007

By Vladimir G. Kochnev

Crushing and grinding account for the major portion (60 to 80 percent) of the overall expenses for ore processing. Autogenous (AG) and semiautogenous grinding (SAG) have been considered a step forward in comparison to conventional grinding circuits with several stages of crushing and using ball (and/or rod) grinding mills (Bassarear, 1982, MacPherson, 1989, Pithois, Casalis, 1983, Maripuu et al., 1983). However, there remains room for improvement to existing AG and SAG technologies and both technologies have immense economic benefit potential. Experience gained by the Technics & Technologies of Disintegration Ltd. (TTD) in the research of grinding processes shows that grinding in AG and SAG mills can be performed in a more effective way. The company's approach comprises the following elements: ? Novel mill design. ? New liners and lifters. ? Novel discharge grid design. ? Technique of treating material of critical particle size. Comparative tests that demonstrated the usefulness of these innovations are described in this article. Currently, there are hundreds of AG and SAG mills in operation throughout the world. Application of new internal elements of the mills and reconsideration of the circuit design of the existing grinding equipment using present technological solutions would significantly increase the throughput rate and diminish power requirement.

Jan 1, 2008

By Donald E. Raab, Lee W. Saperstein

INTRODUCTION The Premise Not much time has to be spent in a tunneling project to realize the tremendous interdependence that exists among the various unit operations. The research that is to be described attempts to examine one set of these linked operations, namely, the effect of cutters on muck handling properties. All too often research focuses on too minute an aspect of a problem for the results to be of much immediate, practical use. The goal of this research is to avoid this specificity. Apologies are tendered if this goal is missed. It is known that the mode of flow of bulk solids under the influence of gravity -- emptying a bin or hopper -- is dependent on several basic parameters. The size of the particles and the distribution of sizes (consist) determine whether the solids will first flow out of a given aperture; the cohesion of the solids will determine if flow will continue after the bin is opened; and the angle of internal friction determines the size of the flow regime (1,2,3). It is well understood that the latter two parameters affect the behavior of bulk material on a conveyor belt. Cohesion of material to a belt is always an undesired problem. Heaping of material on a belt depends on the material's internal friction. It is also known that varying the particle size, and the packing density of the material can affect the material's angle of internal friction (4,5). The question was posed whether sufficient variation in a mechanical tunneling machine's (mole) cutting function could be arranged to affect materially the handling properties of the muck

Jan 1, 1974

By William H. Langer

Large amounts of limestone fines co-produced during the processing of crushed lime-stone may be useful in the sequestration of carbon dioxide (CO2). Accelerated weathering of limestone (AWL) is proposed as a low-tech method to capture and sequester CO2 from fossil fuel-fired power plants and other point sources such as cement manufacturing. AWL reactants are readily available, inexpensive and environmentally benign. Waste CO2 is hydrated with water to produce carbonic acid. This reacts with and is neutralized by limestone fines, thus converting CO2 gas to dissolved calcium bicarbonate. AWL waste products can be disposed of in the ocean. Feasibility requires access to an inexpensive source of limestone and to seawater, thus limiting AWL facilities to within about 10 km (6 miles) of the coastline. The majority of U.S. coastal power-generating facilities are within economical transport distance of limestone resources. AWL presents opportunities for collaborative efforts among the crushed stone industry, electrical utilities, cement manufacturers and research scientists. There is a concern that CO2 generated from human activities is contributing to climatic and environmental changes. Approximately one-third of anthropogenic CO2 emissions come from burning fossil fuels to generate electricity. Each power plant is capable of emitting several million tons of CO2 annually. A variety of other industrial processes, such as cement manufacture, oil refining, and iron and steel production, also emit large amounts of CO2. The level of atmospheric CO2 can be reduced by capturing CO2 from point-source emissions and storing or sequestering it in isolation from the atmosphere (U.S. Department of Energy, 2003). In 1999, G.H. Rau and K. Caldeira proposed a geochemistry-based method that is referred to as accelerated weathering of limestone (AWL) in a paper titled ?Accelerating carbonate dissolution to sequester carbon dioxide in the ocean ? geochemical implications.?

Jan 1, 2009

By W. Collingwood

As open pit mines continue to grow deeper and productivity continues to increase, the management of respirable dust and noxious gases can become a challenge. The natural wind flow in open pit mines is often recirculatory. This recirculation traps dust and gases in deep open pit mines. This problem is particularly acute in high latitude open pit mines due to a phenomenon known as an atmospheric inversion. In the winter, arctic and subarctic regions experience short days and long nights. This deficit of solar radiation creates a situation in which cold, still air accumulates near the bottom of the pit. In open pit mines, this can result in unhealthy accumulations of gases and other contaminants in the open pit mines. In this study, the natural wind flow patterns in and around open pit mines were investigated using a computational fluid dynamics (CFD) program. Two dimensional models were created for a variety of pit geometries. The effect of depth, slope angle, and wind speed on the recirculation pattern in the pit was examined.

Jan 1, 2011

By Jacek B. Stypulkowski

This paper discusses the challenges faced by the design team of the under-river crossings of electric transmission feeders in New York City, a densely populated urban area. The under-river crossing of a 345 kV feeder was initially designed as Horizontal Directional Drilling (HDD), but was redesigned as a utility tunnel because of site con¬straints on both sides of the river. Multiple studies addressed location, available tech-nologies and costs. Multiple soil investigation phases addressed design aspects of HDD, as well as tunneling. Contractual issues varied from a design build alternative with Geotechnical Data Report (GDR) to design tender approach with GDR & Geotechnical Baseline Report (GBR).

By R. L. Loofbourow

R. L. LOOFBOUROW 26.1-WATER FLOW, USE, EFFECTS, CONTROL Sec. 4 discusses ground water as a mineral resource. This section deals wits its control. 26.1.1-IMPORTANCE Flows of water have an important effect on the cost and progress of many deep excavations. The existence of water limits the methods which can be used in some and presents hazards in others. Lowering the water table may reduce the flow of springs and wells, with legal liability. Some mine water is used directly, some must he treated before discharge, and some contains dissolved solids which can be recovered profitably. Loss of life, property and production from flooding is grim, yet scores of mines have worked safely for generations under ground-water reservoirs, lakes and even the sea. The need for better control of mine water is measured by the severity of recent floodings, concern with the quality of the effluent, and direct and indirect costs of working wet ground. There are improvements in freezing in shaft sinking. pumps and their controls, treatment of mine water before it is pumped, bulkhead construction and certain efforts to reduce inflow. 26.1.2-PUMPING COST VS. COST OF WET WORK Direct operating and capital costs of pumping are more evident than indirect items, such as provision of extra standby power and maintenance facilities, The total of all these items is the cost of pumping water from an excavation. This is only a part of the extra cost of working wet as compared to dry ground. Less productive methods, less efficient equipment and more expensive explosives may have to he used in wet work. Wet rock plugs certain equipment. Maintenance is higher and labor less efficient. The cost of any means of keeping work drier should he weighed against the higher cost of working wet. The true difference in the cost of working wet ground, compared with dry, probably is known at only a few places (see checklist of cost items. Sec. 26.4.13). An extreme comparison of mining wet and dry ore is available from Ambrosia Lake, N.M. (Fig. 26-1). Between 1963 and 1967, a wet and a dry mine were worked by the same company under conditions otherwise comparable. Average operating cost at the wet mine, pumping 1,600 to 1,800 gpm. was $16.06 per ton of ore. The comparable figure for the dry mine was $7.50. Principal differences included the fact that the wet mine was worked from drainage levels below the, ore with rail haulage, the dry mine in the ore with off-track equipment loading and hauling to the shaft. In the wet mine, ore packed in chutes, cars and skips and froze in surface bins, stockpiles and trucks. Wet-mine costs included drilling drain holes, building and maintaining ditches and pumping water containing abrasive solids.

Jan 1, 1973

PolyMet Mining is developing the NorthMet property near Duluth, Minnesota. Laboratory investigations had led to the development of the PLATSOL process to dissolve in one step the base metals (copper and nickel) as well as the gold and PGM’s. To complete the pre-feasibility study, a fully integrated ten-day pilot plant trial was undertaken, comprising of: high temperature (>220ºC) pressure oxidation in the presence of 5-10 g/L chloride (the PLATSOL process), followed by solid/liquid separation, gold plus PGM’s recovery from solution, conventional Cu SX/EW and recycling of the copper raffinate to the autoclave. The concentrate tested was a NorthMet bulk flotation concentrate assaying 14.7% Cu, 3.05% Ni, 0.14% Co, 26.7% S, 1.4 g/t Au, 2.2 g/t Pt and 9.9 g/t Pd. Laboratory results were fully confirmed and with minor adjustments of the laboratory PLATSOL® conditions, the following leach extractions were obtained during the pilot plant trial: Cu 99.6%, Ni 98.9%, Co 96%, Pd 94.6%, Pt 96% and Au 89.4%.

Jan 1, 2001

By Russel Delmar, Rick Everdell, Harry Charalambu, John Tait

Award of the Design/Build Agreement for construction of Ontario Power Generation’s (OPG’s) Niagara Tunnel Project was made after an intensive 8-month international procurement process. The 14.4-m diameter × 10.4-km long rock tunnel will divert 500 m3/s of water from the Niagara River to the Sir Adam Beck hydroelectric generating complex. The procurement process and Design/Build Agreement included features to address the owner’s requirements regarding risk allocation and cost and schedule certainty, while encouraging innovative ideas from the industry, both technically and commercially. The process included an international expression of interest and prequalification, followed by an invitation for design/build proposals to qualified proponents, and comprehensive proposal evaluations and negotiations with several respondent proponents. An honorarium was provided to the unsuccessful participants in the proposal stage. The resultant negotiated Design/Build Agreement includes Owner’s Mandatory Requirements, negotiated contract terms and conditions, performanceincentive bonuses and liquidated damages for schedule and water delivery performance, a multistaged Geotechnical Baseline Report, joint risk management, references to preexisting community impact agreements and measures to reduce impact on tourism. It also addresses regulatory approvals and permits, an owner controlled insurance policy that required reference to the International Tunneling Insurance Group (ITIG) Code of Practice for Risk Management as a condition of coverage, site specific safety, security and environmental plans, formal team building, a dispute review board, and escrow documentation.

Jan 1, 2007