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By Elaine T. Cullen

Human beings are natural storytellers and story listeners. We learn very early that stories entertain us, but also give us the ?rules? about what is expected of us and how to make meaning of our experiences. Stories are integral to our lives, and have great power to change or influence how we think or how we react. They are an innate part of how we learn, and have obvious benefits to trainers or educators who are trying to impact what and how we learn. This paper and presentation discuss the social and cultural power of stories, and how they have been used to develop training for skilled blue-collar workers. Included will be examples as well as suggestions for trainers on where to find stories, what type of stories to pay attention to, and how to use them to improve occupational safety training.

Jan 1, 2008

By M. Lahtinen, P. Latostenmaa, I. Kojo, E. Peuraniemi, M. Lindgren, S. Jyrkönen, M. Jåfs

The year 2019 marks the 70th anniversary of Flash Smelting. The technology was operated on industrial scale for the first time at the Outokumpu Harjavalta copper smelter in Finland in 1949. Since then Flash Smelting technology, now owned and developed by Outotec Oyj and the first plant, now owned by Boliden Harjavalta Oy, have been evolving throughout history by optimizing the process for various feeds and raw-materials, as well as through developing the equipment and operating practices. Even though sustainability was not a popular theme during the first days of Flash Smelting, it has still been the key principle in guiding the development. This is well proven by the wide adoption of Flash Smelting for the processing of copper and nickel concentrates, mostly due to its ability to fulfil the economic and resource efficiency criteria demanded by its operators. This paper describes the history and improvements of the Outotec® Flash Smelting process by looking into the early days of operation and how the development of the process and equipment has taken place over time as a joint effort between the technology provider and the users of the technology. INTRODUCTION In the 1940s, Outokumpu Oy refined the concentrate produced in the Outokumpu mine into metallic copper initially in Imatra, and later from 1945 to 1949 in Harjavalta, based on the most modern electrical melting process of the world at that time. After the war, Finland lost a significant part of its hydropower production, and due to the increasing use of electricity, the availability of electricity weakened, and the price rose. To maintain Outokumpu's profitability, it was forced to look for a melting solution that was not based on electricity.

Jan 1, 2019

By Craig T. Jones, Zachary Q. Maassen

"Jet grouting is a method of ground improvement that relies on the erosive capacity of high-speed jets to cut and mix the ground in place with a cementitious grout. A continuous return flow of cuttings, called jet grout backflow or spoils, is expelled to the surface during the grouting process. Data from projects completed in Toronto and Ottawa is presented where BOS Solutions’ services provided significant savings compared to the traditional spoils treatment utilizing vacuum trucks for spoils disposal. These traditional treatment methods are cumbersome and expensive by nature. BOS Solutions provided an alternative solution that is environmentally friendly and capable of handling full flow to process these jet grout spoils utilizing a tank system paired with centrifuges and flocculation additives to remove the ground soils and grout product from the spoils slurry. BOS’ process produced a clean water for reuse in the project while reducing the overall waste volume by producing a dry, stackable solid that could be hauled to a landfill. Benefits observed by using the BOS process were disposal waste volumes decreased over 30% and at least a 19% reduction on disposal costs.SCOPE OF WORKJet grouting is a method of ground improvement that relies on the erosive capacity of high-speed jets to cut and mix the ground in place with a cementitious grout. A continuous return flow of cuttings, called jet grout backflow or spoils, is expelled to the surface during the grouting process. The backflow, or spoils, is a mixture of grout, water and soils. Traditionally, the spoil would be collected in in-ground pits and allowed to solidify for a few days prior to hauling to a final disposal site. For the projects completed in Toronto and Ottawa, the jet grouting work was performed at street level, in high traffic congested areas, presenting the challenge of insufficient space for the contractors to process the jet grout spoils in the traditional way. At first, attempts were made of using vacuum trucks to collect and haul the wet spoils to an off-site location where the spoils would be allowed to solidify. However, this method proved cumbersome and expensive due to the high volumes of spoils generated daily and the high number of vacuum trucks required to support the jet grouting operations, respectively."

Jan 1, 2017

By W. Sondermann

"AbstractThe construction of a distribution centre of minerals for a global mining and resources cooperation demanded the control of deformations and displacement of the stack reclaimer facilities on very inhomogeneous subsoil conditions. The variation of quality from soft clay with CPT values below 1 MPa up to rock formations were the challenge in design and execution of all the foundation works.The advanced design considerations were resulting in a barrier wall system to limit the deformations of the up to 40 m deep bored pile of the stacker-reclaimers, whereas the layout of the barrier wall and the stiffness of the elements had a major impact on the residual lateral forces to be absorbed by the bearing structure.IntroductionA large international raw material distribution organisation is currently building an iron ore and pellet distribution centre on the north-western coast of Malaysia. The distribution centre will handle around 90 MTPA (million tons per annum) of iron ore and includes accompanying plants for loading and unloading iron ore and pellets, pelletizing plants as well as corresponding storage space for these raw materials. The total storage space extends about 800m north to south respectively 1400m east to west and is about 200m from the coastline. The project area is located in a wide valley basin, bounded by a range of hills to the north. The existence of soil with low bearing capability in the area designated for the plant meant that measurements for ground improvement were required in the storage areas, in order to combine the needs of iron ore and pellet storage areas with requirements of the loading facilities as the overall project demand.Project LayoutThe iron ore distribution centre and the pelletizing facility both consist of an import/export jetty, material handling facilities, pellet plant and the associated infrastructure. This publication describes the execution of ground improvement and foundation works for the loading and storage system, which consists of five rows of stockpiles and four intermediate rows of stacker-reclaimers. The total area of these systems comprises 278,881 m2 (Fig. 1)."

Jan 1, 2014

In spite of a global economy that continues to seesaw and a U.S. Congress that is at odds with the president and themselves, cities around the world are still spending billions on their infrastructure. And that bodes well for the underground construction and tunneling industry and the professionals who work in it. In June, 1,405 of those professionals gathered in San Francisco, CA for the Rapid Excavation and Tunneling Conference (RETC). In addition to the first rate technical programming, attendees were able to see first-hand the latest in tunneling technology from 127 exhibitors who occupied 152 booths. Two short courses preceded the conference and two field trips were offered following the conference.

Jan 1, 2011

By Xuan Li

Aluminum slag is generated when aluminum metals are recycled through a smelting process in the presence of salt. There are small amounts of aluminum metals trapped in the aluminum slag. This research aims at evaluating the use of aluminum slag as an expansion agent for the production of lightweight concrete by taking advantage of the residual aluminum metals in the slag. The research identified key elements of producing lightweight concrete products through utilizing various mixture components including sodium hydroxide (NaOH), lime (CaO), cement, and gypsum. The volumetric expansion rate was investigated and the density and strength of the products were determined. The results show that aluminum slag can be utilized for the production of lightweight concrete products.

Jan 1, 2010

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

By David J. Baxter

Use of bored displacement piles has experienced significant growth in the UK piling market sector, largely due to their environmental advantages over other piling methods and through cost benefits. Bored displacement piles are a cast-in-situ construction which can be formed with minimal production of spoil and offer low noise and vibration compared to driven displacement piles. A large variety of bored displacement piles have been developed. This paper describes a standard system for their classification. The development of the different types is described along with the factors which have led to their increased use. Consideration is given to processes undergone by the soil during pile installation and design approaches for bored displacement piles are compared. Comparisons are made between the different classifications of bored displacement pile. Comments are also made on the installation of such piles. It is concluded that complex changes occur in the stress states of the surrounding soils. Such effect of the pile installation on the soil should be accounted for and there is a need, therefore, to further refine the design process for these piles.

Jan 1, 2006

By Peter E. Price

Salt dome hosted metallic sulfide deposits are the product of a complex evolutionary system involving halokinesis, cap rock development and diagenesis, and the generation, migration, and accumulation of basinal brines and hydrocarbons. Hydrocarbons play an important role in: (1) the production of calcite cap rock which hosts some of the metallic sulfide and sulfur concentrations, and (2) the generation of the reduced sulfur available for metallic sulfide precipitation and sulfur formation. Hydrocarbons and related fluids also are involved in the transporta¬tion and remobilization of the metals. Hydrocarbon consumption, in the course of cap rock development and sulfide mineralization at Hockley dome, is estimated to have been 6.4 million barrels of oil or 114 million cubic feet of methane. Mineral textures, including cap-rock banding, sulfide bands in anhydrite, and fine sulfide mineral banding indicate both episodic fluid influx and fluid compositional differences through time. Features such as pyrite "shells" and sphalerite and marcasite hemispheres may have been localized by hydrocarbon droplets and /or bacterial colonies. Marcasite mineralization in shallow strata above and flanking Hockley dome is best developed over the western and southern parts of the dome. This pattern mimics the known distribution of sulfide mineralization, which is dominantly marcasite, in the underlying cap rock. The iron sulfide paragenetic sequence in the sediments is pyritohedral and cubic + pyrithohedral pyrite followed by marcasite which is encrusted by cubic pyrite. Sulfur isotopic averages for the three stages are +20.8, -20.2, and +6.4 per mil, respectively. These values generally coincide with cap rock sulfate (+20 per mil), cap rock hosted metallic sulfides (-20 to +4 per mil), and sulfur in hydrocarbons (+5.8 per mil). Hydrocarbon compositions indicate provincial variations in oil composition and generation history. Long Point and Boling domes, which have an intergrown sulfide-sulfate-sulfur mineral assemblage indicative of mixed reducing-oxidizing environment, contain oils that are less mature than Hockley dome which appears to be more mineralogically segregated. Sterane biomarker compositions of the oils at Hockley, Long Point and Boling domes indicate a local, dominantly terrestrial source. An oil sample from supracap sandstones on the northeast flank of Hockley dome contained over 750 ppm combined Fe, Zn, Pb, and Co, indicating that hydrocarbons are carrying or remobilizing metals. Cap rock calcite and anhydrite also exhibit provincial variations in strontium isotopic ratios. Calcite and anhydrite cap rocks from several sulfide mineralized domes in the Houston diapir province have strontium isotopic ratios that are more radiogenic than Jurassic sea water (>0.7078). A calcite sample within massive sulfides at Winnfield dome also has a high 87Sr/86Sr ratio (0.7085). Variations in strontium isotopic ratios with strontium content indicate the mixing of at least three Sr-bearing fluids in the cap rock environment, one of which may have been the metal carrier. Anhydrite residues from diapiric salt have strontium ratios up to 0.7100, considerably more radiogenic than Jurassic seawater. These high ratios indicate either that salt and anhydrite recrystallized sometime post-Jurassic in the presence of a fluid with a high 87Sr/86Sr ratio, or that they precipitated in the Jurassic from a fluid with a higher 87Sr/86Sr ratio than Jurassic seawater. Salt domes with cap rocks containing metallic sulfides have only been found in basins that have geopressured zones. Waters from geopressured zones in the vicinity of mineralized salt domes have salinities that are two or more times higher and iron and base metal concentrations that are three to one thousand times higher, than geopressured fluids from other parts of the basin.

Jan 1, 2013

By P. Schilizzi, A. Jarosz, M. Karmis

This paper is concerned with subsidence prediction methods and in particular with two techniques, one based on profile functions and the other on influence functions. Profile function methods provide a tool for a fast calculation of subsidence on a line across a mine panel. Influence function methods, on the other hand, allow for a more detailed calculation of ground movements, in any mode and at any depth, on a grid or at any specific point. In more detail, the hyperbolic tangent profile function, as developed by VPI&SU from field data pertaining to the eastern U.S. coalfields, and an influence function method currently being adapted for the same region, are presented and discussed. The applicability, advantages and limitations of these techniques are examined and comparisons are presented with field measurements. Computer software developed for the application of these prediction methods, for two widely used personal computer systems, are also discussed and a number of examples are presented demonstrating the potential of such programs.

Jan 1, 1986

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

The structural design of a mine haul road involves the determination of cover thickness requirements above the in-situ or sub-grade material. The specification of these layerworks is a critical component in the overall road design process. Poor design often leads to premature failure of the road, safety is often compromised and productivity and equipment service-life will certainly decrease. Historically, the California Bearing Ratio (CBR) cover-curve design method has been widely applied to the structural design of mine haul roads. More recently, established mechanistic design principles have superceded the CBR approach to haul road design, using a multi-layer model to represent the various road structural layers. The structural design and associated layer thickness requirements are then determined following a maximum strain criterion. This paper develops a case-study evaluation of the CBR cover-curve and mechanistic design methodologies and through a comparative analysis of layerworks and materials, highlights how improved structural design can be achieved mechanistically.

Jan 1, 2011

Ore samples generally require preparation before analysis. Serious problems can occur with contamination degradation and particle size effects. Both grinding element contammation and sample cross contamination havebeen bound to be related to sample hardness and operator technique. For best results with minerals relevant to the steel industry, the use of Siebtechnik-type mills required a combination of careful planning, short grinding periods and intermediate sieving of the sample. The results may be extended to most mineral, rock, and refractory sample preparabons.

Jan 1, 1978

Typically, large volumes of data are collected during geotechnical investigations for mining projects but rarely is this done in a comprehensive manner that enables all aspects of the geotechnical environment to be evaluated. A geotechnical core logging process has been developed to record mechanical and structural properties of the rock mass. The method enables data for a wide range of rock properties and geotechnically significant major structures to be collected including rock strength, joint surface condition, fracture frequency and fracture orientation. The logging method is unique in that sufficient data is collected to enable the independent determination of all the major rock mass classification systems including rock mass rating (RMR), (Bieniawski 1976, 1989; Laubscher, 1990) Norwegian Geotechnical Institute (NGI) tunnelling quality index (Q) (Barton, Lien and Lunde, 1974) and geological strength index (GSI) (Hoek, Kaiser and Bawden, 1995). The logging system has been specifically developed to allow better and more precise appreciation of rock mass and structural conditions across the project area thereby optimising the use and application of the available geotechnical data and improving confidence in the outcomes of geotechnical investigations. This paper describes the core logging process with case examples showing how the logged data can be used for underground and open pit mine design.

Nov 25, 2010

Flue dust from the sintering of base metal sulphides was leached to remove cadmium and arsenic. Leach liquor contained cadmium, zinc and small amounts of other base metals as chlorides. Results are reported of the use of a cation exchange resin Zeocarb 225 to separate the base metals from the arsenic. The resin was eluted with sodium chloride or sulphate to give a solution of relatively concentrated cadmium suitable for recovery by zinc cementation. The limited solubility of sodium sulphate presented some practical problems which were investigated. Another problem was the precipitation of lead sulphate in the resin during elution.INTRODUCTIONWhen lead-zinc sulphides are sintered prior to smelting, the gases passing to the flue are mainly uncondensable but contain a certain proportion of sublimates and dust particles which deposit in the flue or are carried, after condensation in the gas stream, to some form of dust extraction equipment.The recovered dust is a complex mixture of base metal sulphates, sulphites, sulphides, chlorides and oxides, the composition depending on the original concentrates. A large proportion of the cadmium and some of the arsenic originally in the concentrates finds its way to this flue dust, the treatment of which can be a convenient means of removing these elements and controlling their concentrations in the main lead-zinc smelter circuit. However, disposing of this material represents an appreciable waste of base metals as well as a serious toxicity hazard.Sulphide Corporation Pty. Ltd. was faced with this problem in planning the flow sheet of the new lead-zinc smelter at Cockle Creek, N.S.W. From a test run carried out on a pilot plant at Avonmouth, U.K., using a mixture of lead and zinc concentrates, a sample of dust was obtained for...

Jan 1, 1960

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 Peter Fullagar, Adel Vatandoost, Steve Walters, Toni Kojovic

"Traditional comminution tests are a vital component in every mine plant design. Comminution behavior governs both the cost of equipment and its operating efficiency. Most comminution tests are conducted off site on a limited number of samples, owing to the high costs and long lead times involved. Therefore a strong incentive exists to find alternative means for efficiently characterizing comminution behavior for a truly representative suite of samples. The potential for inferring comminution behavior from drill core is investigated in this paper. Our approach involves development of small scale comminution tests on the one hand, and measurement of a wide range of core attributes on the other. Our focus is the relationship between petrophysical properties and comminution behavior.Petrophysical properties of archival diamond drill core from the Ernest Henry Mine (Queensland, Australia) have been measured using a Geotek multi-sensor petrophysical core logger. We have investigated the relationship between the petrophysical properties and the corresponding small scale A*b and estimated Bond mill work index test results for 2m composites of the core. Core samples were petrophysically classified by means of cluster analysis. Comminution behaviour was then modeled for each cluster via multiple regression. The results suggest that prediction of the comminution behavior on the basis of petrophysics is viable at Ernest Henry.INTRODUCTIONMineral processing is the most important downstream operation for mining engineers and metallurgists since most mined materials are subjected to some type of comminution or beneficiation operation (SME, 1992). Comminution or size reduction is typically the first stage of processing. Size reduction steps (crushing and grinding) in any plant consume large amounts of energy, normally more than 50% of total energy (Weiss, 1985). Therefore, it is desirable to obtain laboratory results to design the size reduction equipment appropriately. One of the main factors that control the selection of hard-rock crushing equipment and the design of a crushing circuit is the mechanical character of the ore(s). Work index, density, abrasivity, compressive strength and clay content are essential parameters for ore characterisation (SME, 1992)."

Jan 1, 2009

By Dilip Khatri

Helical pile anchors have gained acceptance over the past sixty years. Most recently they have been commonplace in the 20th century for the power utility industry in anchoring transmission towers, equipment platforms, street lighting, telephone poles, and radio tower applications. They have a strong proven industrial track record in these industries. As the cost of conventional deep pile foundations rises, the practical benefits of helical pile anchors becomes evident as a practical alternative. Noted for their uplift capacity, helical piles demonstrate equally strong compressive capacity as a structural foundation element. This paper summarizes the history, practical benefits, and technical requirements for helical piles. Significant structural testing has been completed at various universities. The practical benefits of these tests are discussed. One case example of proven performance is presented to demonstrate the advantages and disadvantages of helical pile anchors as suitable foundation elements.

Jan 1, 2003

By Todd M. Ruff

Blind areas around construction equipment are a major contributing factor in incidents involving a piece of equipment striking a worker. In highway construction, these types of incidents result in an average of 22 deaths a year in the United States. The Spokane Research Laboratory of the National Institute for Occupational Safety and Health, in cooperation with the Washington State Department of Transportation, is evaluating methods to decrease these incidents. One such method uses devices that assist equipment operators in monitoring blind areas around the equipment to prevent collisions with workers or other objects. Several camera and sensor systems are available for this application. These systems were evaluated on various trucks used in road construction and maintenance. Tests were conducted on sanding trucks during the winter months, which allowed researchers to investigate the effectiveness and limitations of various technologies under the most extreme conditions. Tests were also conducted on dump trucks and utility vehicles during the warmer months to study the effectiveness of the systems in highway work zones. Results showed that many difficulties arise when using camera and sensor systems in cold, snowy climates. And, while the operation of these systems is more reliable during the warmer months, challenges still exist in using them on equipment in congested work areas.