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A 1991 survey of 48 mining companies, employing more than 24 000 employees, showed that disabling injury and disease rates continue to be the most common measurements of safety management effectivness in the Australian mining industry.Of the companies surveyed, 22 claimed to be making regular safety audits. Of these only two listed the improvement of audit scores among their goals for 1991.Influenced by loss control management thinking, some managers have expanded the scope of their safety programs to include all accidental operational losses adversely affecting mine profitability.Learning from their new experience with total quality management some managers are now recognising that successful safety management outcomes depend on the effective management of program inputs. They are thus turning away from measurements of accident consequences - the failures of the management system - to measurements of management control.The new focus of safety management attention is now on corrective actions before accidents happen.

Jan 1, 1992

By Bothe C

Froth flotation processes use different surface properties of the minerals to be sorted. In an aqueous environment the hydrophobic mineral attaches selectively to air bubbles and is lifted to the surface of a separation vessel, while the tailings settle towards its bottom. Besides the surface properties, the hydrodynamic conditions play an important role. With respect to the hydrodynamics the flotation process can be divided, for simplicity, in two sub-processes. The attachment of hydrophobic particles to air bubbles, the so-called mineralisation, demands a large number of collisions and therefore high turbulences. The phase separation however needs a deterministic movement of both the particle-bubbles-aggregates and the tailings particles and therefore a quiescent flow field. The optimisation of the overall process requires a separation of both sub-processes, especially when fine particles have to be sorted. In conventional mechanically agitated flotation cells both sub-processes take place in the same turbulent volume. For this reason they suffer from a decreasing selectivity with decreasing particle size. In flotation columns the mineralisation of air bubbles and the phase separation are performed in a quiescent environment. This results in high concentrate grades and at the same time in a very slow attachment kinetics, which must, especially for fine particles, be counterbalanced by a long residence time of the slurry.

Jan 1, 1993

By Barro L

There is currently a world wide interest in coal-oil technology as the search continues for alternative energy sources to reduce the consumption of petroleum crude. An important aspect of this coal-oil technology study is to obtain information on the flow properties of coal-oil slurries. While some work has been reported on the flow behaviour of black coal-oil suspensions, very little work on brown coal-oil suspensions has been reported. In this paper flow charac- teristics of brown coal-oil suspensions for various coal concentration and temperatures have been presented. A Capillary rheometer, designed to handle settling suspension, has been used for deter- mining rheological properties. Brown coal of 0 0725 mm average particle diameter has been used in this work. The oil was a coal derived product having a boiling point range of 234¦- 319¦C, Apparent viscosity of all suspensions was found to increase on storage due to ageing. Ageing might have occurred due to physico- chemical interactions between coal and oil. Flow behaviour of some suspensions changed from Newtonian to non-Newtonian on storage.

Jan 1, 1980

The research, development and testing of a Blast Control Plug (U.S. Pat. #4,754,705) funded by the U.S. Department of Energy is described. The plug's function is to improve blasting efficiency through the enhancement of stemming effectiveness and thereby reduce drilling and blasting costs. The plug comprises a solid unit placed in the blast hole within the stemming column above the explosive. It is designed for use with back filled drill cuttings or any other suitable material The research and development program comprised the testing of the plug in small diameter holes in competent rock for both bench and crater blasting configurations and full scale field trials in multiple hole and row blasts using blast holes of from 76 to 387 mm in diameter. Test measurements included stemming displacement and velocity, face movement and extent, peak air over pressure and ground surface peak particle velocity. Data acquisition equipment included a Spin Physics SP2000 high speed video motion analysis system, and acoustic and seismic monitoring units. Substantial reductions in stemming ejection velocity or ejection elimination were achieved whilst reducing stemming length by up to 35% over conventional practice. Peak air blast pressures were also reduced by between 8 and 25 dB. A strong inverse relationship between rock face movement and stemming ejection velocity was found. The implications of the importance of stemming effectiveness in blasting and computer blast simulation is also addressed.

Jan 1, 1990

By Stump NW

Until a year ago all isotope on-stream analysis utilised flow cells similar to those designed for conventional X-ray on-stream analysis. These systems incorporated a fairly complex sampling system necessary to present a representa- tive air-free sample of the main process to the flow cell. Maintenance costs and capital costs associated with flow cells and sampling systems have been generally high. Costs can be greatly reduced and reliability greatly increased, by using isotopes incorporated in immersible on-stream analysis probes which actually dip into the main process stream eliminating the need for sampling. A bonus of other advantages associated with immersible probes includes temperature stability and ease of calibration. This paper discusses details and results of the probe systems, justifica- tion for installing on-stream analysis, comparison of conventional X-ray and isotope techniques, and a brief survey of methods of analysis using radio- isotopes in on-stream elemental determinations.

Jan 1, 1971

By Cunningham J. C

JUST prior to the war the Broken Hill South Ltd: raised, on the average, 6628 tons of ore per week, all of which was crushed and treated in the 4-section gravity mill and the slime flotation plant, for the recovery of lead concentrate carrying silver. The sandy residues from that treatment were railed to the treatment plant of the Amalgamated Zinc (De Bavay's) Ltd. for the recovery of zinc concentrate by flotation, on the joint account of both companies. Subsequent to that-since 1916-approximately 1000 tons of old dump slime were also treated weekly for the recovery of lead and silver as slime-lead concentrate.PLANT CAPACITYUnder this programme the Babcock and Wilcox boiler plant of 8 boilers was taxed to such an extent as to call for the installation of two additional boilers, each of 2690 sq. ft. of heating surface and 55 sq. ft. chain-grade area.The electric generators and the air compressors of the old powerplant were also loaded to their maximum capacity. In view of the fact that the old power-plant had been added to from time to time since 1901, and that further extension was notpossible, and as it was not, moreover, an economical arrangement, the whole question of power generation was reconsidered. The considerations that determined the installation of entirely new plant were as follows:(1) The need for more compressed air for underground work and more electric current for the extension of the slime-flotation plant for the recovery of zinc, as well as lead, as slime concentrates. Provision of additional power was also deemed advisable for the...

Jan 1, 1921

By Wooltorton B

Highwall failures in surface coal mines in Queensland occur as circular slips through weak and weathered material, or as bilinear slides on sub-horizontal surfaces and steeply dipping joints. Weak horizontal planes occur in the Permian-Tertiary unconformity or on bedding surfaces within the Permian Coal Measures. Sub-vertical movements occur along rock joints and tension cracks induced by stress relaxation after excavation. Blasting also introduces new fractures and causes movement along existing rock discontinuities. Critical factors for stability include the dip direction of potential failure surfaces, shear strength of the rocks, damage due to blasting prior to highwall excavation, groundwater conditions, the type and performance of clays on shear surfaces, and pit geometry.

Jan 1, 1981

By Colwell JB, Cronan DS

Manganese nodules cover great areas of deep ocean floor far from land, and have long been considered a major potential resource of nickel, copper, cobalt and perhaps manganese. A decade ago there was a period of intense evaluation of nodule fields, especially those lying between the Clarion and Clipperton Fracture Zones in international waters southeast of Hawaii. There, nodules are abundant and of high grade (average of 2.4% Ni+Cu+Co). The evaluation activity has since declined, but a recent agreement on lease boundaries among all interested parties may lead to a resurgence of work. Indeed, French and Japanese groups have pushed ahead with field and economic assessments.The Southwest Pacific, where there are large nodule fields in the waters of the Cook Islands and Kiribati, has seen considerable assessment of resources in the last ten years, especially through a major field programme of the Japanese Metal Mining Agency. The best prospect appears to be in the South Penrhyn Basin, in Cook Islands waters, where nodules are very abundant but of only moderate grade (1% Ni+Cu+Co). Using a cut-off of 5 kg of wet nodules per m2, Cronan (1989) and Cronan et al. (1989) have estimated the total resource to be a huge 110 million tonnes of Ni+Cu+Co.

Jan 1, 1990

By Kleine T. H

Blast design involves many engineering constraints and objectives. Some of the more important include the implementation costs, the desired fragmentation and shape of the muckpile. A spreadsheet has been developed to allow blast design options such as burden, spacing, blast hole diameter, decking and explosive type to be varied. As any option is varied the spreadsheet recalculates and graphs the expected implementation costs, fragmentation and muckpile shape in seconds.The spreadsheet extends the philosophy of simple robust fragmentation prediction (Cunningham, 1983) to include similar models for explosive detonation (with respect to explosive type, age, blast hole diameter and density) and muckpile shape (with respect to burden, spacing, charge location and weight). The new empirical models for explosive detonation and muckpile shape prediction have been calibrated successfully for one situation and are now undergoing further field trials.

Jan 1, 1992

The application of reinforcement techniques to enhance the stability of underground coal mine roadways subject to high stresses is discussed. Research conducted in the Illawarra Coal Measures has been aimed to delineate the factors which influence the behaviour of rock above roadways and the performance of the reinforcement placed. Design considerations for the reinforcement of mine roadways in the Bulli coal are based on a quantification of the rock response together with a reinforcement strategy to enhance the structural integrity of the roof strata.

Jan 1, 1986

By Lee H. G, El-Rahaiby S. K

The literature relating to reduction of sulphides by carbon using lime as sulphur-absorbent is reviewed. A stage-wise thermodynamic model is employed to evaluate the practical feasibility of the direct reduction smelting of galena (PbS) concentrates with a carbon reductant in the presence of lime; a coke-rate of 65 kg/ton Pb is predicted by the model. The experimental data on the reduction of PbS:4CaO:4C mixtures under nitrogen were correlated by means of a finite difference numerical method and the values of the intrinsic rate constant I1 were derived. The results for the uncatalysed reduction are represented satisfactorily with log I1 = 1.247(±0.522) - 5540(±610)T-1.The catalysed PbS:4CaO:4C mixtures contained 2.5 wt% of ternary (K, Li, Na)2CO3 catalyst. For the catalysed reduction it was found that log I1 = 3.981 (±0.301) -7790(±353)T-1, where I1 (in both relations) is expressed in moles.(g.C.)-1.atm-1.s -I. The catalytic enhancement faclor was found to be quite large in the 1068 to 1262°K temperature range investigated here.

Jan 1, 1991

By Kyle J. H, Browner R. E

The selective adsorption of gold cyanide by the weak base ion exchange resins, PAZ-4* and Duolite A-7*, the neutral polymeric adsorbent, Amberlite XAD7*, and the strong base resins, PAZ-8 and IRA-400+ have been studied in both low and high salinity waters, and performance compared with activated carbon. The selectivity of the neutral polymeric adsorbent and activated carbon for gold decreased in highly saline water, while the selectivity of weak and strong base resins for gold increased in highly saline water. This supports the contention that the adsorption mechanism for neutral polymeric adsorbents and activated carbon is the same. Copyright

Jan 1, 1992

By L Neems

In conjunction with Orica Explosives, Worsley Alumina have managed a program of continuous improvement to their cap rock blasting over the last two years. Blasting conditions are challenging because of the hard and shallow nature of the material. Blasting costs must be controlled and the environmental consideration of noise and dust is critical. Worsley have sought to determine the optimum balance between drilling and blasting costs and fragmentation. As the cap rock has few inherent weaknesses, loader productivity is strongly controlled by the degree of fragmentation from blasting. The optimum blasting solution is also constrained by maintaining airblast levels at the surrounding residences below 115 dBL . The major blast design parameters optimised during the program were stemming type, stemming length, powder factor and blasthole diameter. A series of carefully managed trial blasts were fired during 1997 and 1998 to quantify the effect of these parameters. Fragmentation was digitally measured using OricaÆs Powerseive G technique. Shovel productivity, airblast levels and blasting costs were also quantified. As a result of the project, Worsley now have an increased knowledge of the key parameters driving blast performance, and their consequent impact on downstream processes, the environment and total mining cost.

Jan 1, 1999

Sizing is fundamental technology for each step of ironmaking process. The progress of sizing technology has greatly contributed to the development of ironmaking technology. As the purposes of ironmaking operations diversified particularly since the oil crisis of 1973, the sizing technology made new advance- ment, as represented by pulverization of ser- pentine, dezincification and classification of secondary blast furnace dust, pulverized coal injection, size-segregated sinter charging and a coal preparation control process. These techniques are mostly characterized by the fine grinding of a given type of mineral or coal to heighten the degree of reaction con- trol. This trend is expected to continue Further.

Jan 1, 1984

By Singh RN

Monolithic packing systems have gained in popularity as a gate side packing method. However, there has been no detailed investigation to assess their underground strength behaviour. This work includes the laboratory and in situ investigation for strength behaviour determined on various monolithic packing materials namely Tekpak-XX, Hydropak-20, Hydropak-30, Astrapak-3R, Flashpak, Thyssen pack and Aquablends. A simple technique for assessing the pack strength was developed at the laboratory by using a penetrometer, of which penetration resistance can be directly correlated with the uniaxial strength of the pack. The in situ strength investigations were made on core samples obtained from three pipes inserted inside the pack, while the penetration test were made on the pack surface. The in situ results indicated that the packing material develops an inconsistent strength on various part of the pack which was mainly related to an inadequate mixing of grouts inside the pack.

Jan 1, 1992

In dense medium processes for the beneficiation of minerals the consumption of medium (generally ferrosilicon) represents a major component of the operating cost. This provides a strong incentive for improvements in heavy medium recovery circuit design and operation. A major thrust in heavy medium plant design over the past decade has therefore been towards circuits which reduce medium losses. In this paper recent trends in plant design are examined in relation to the factors infl uencing circuit performance and medium losses. Operational details ' which have a significant effect on losses are discussed and illustrated by means of plant and pilot plant test data, with particular emphasis on the performance of wet drum magnetic separators. While the emphasis is on reducing the consumption of the high-cost ferrosilicon medium used in minerals beneficiation, most of the principles described in this paper are equally relevant to the design and operation of magnetite recovery circuits for coal preparation plants.

Jan 1, 1987

By Elliot B. J

Flash smelting is a complex and capital intensive technology. Although in use for 50 years the technology is still not well understood from a fundamental point of view and thus uncertainty is evident when significant change to the practice is necessitated. The application of effective design and process simulation tools has significant advantages when process change and improvement is required. Mathematical models have been used to simulate the processes occurring in the shafts of copper flash smelters. The present approach to flash furnace modelling differs from earlier work in that the burners were modelled in detail, the output from the burner model becoming the input to the shaft model. This paper serves as an introduction to the modelling process used to analyse the performance and provide a better understanding of the parameters applicable to the flash furnace at the Kalgoorlie Nickel Smelter.

Jan 1, 1992

By Brinkmann J. R

In the narrow stopes of South African gold mines, rockbreaking is carried out by drilling and blasting with safety fuse and igniter cord being used as the initiation system. The fuse/gniter cord system is used primarily because of its low cost, however several limitations of this method include: inaccurate delay time, unreliable firing, inflexible application to varied configurations, and the absence of dynamic interaction between holes. Alternative initiation systems that incorporate millisecond timing are being developed to overcome the limitations of fuse(tgniter cord systems. Current investigations by the Stoping Technology Division of the Chamber of Mines Research Organization (COMRO) into the effects of millisecond initiation are being conducted at a deep test site. Experimental blasts using various millisecond delays and the independent firing of holes with fuse/igniter cord are being studied in order to quantify the influence of delay time on the blasting process and to identify the best methods of applying millisecond initiation systems. The effect of design variables such as delay time, hole firing pattern, stemming, and panel layout are discussed. Blast results including throw distance and direction, muckpile profile and rock cleaning times are used in the discussion of different combinations of blasting variables.

Jan 1, 1990

By Mckenzie CK, Leach KR, Bateman KW

Modelling of industrial coal flotation based on data collected in several Central Queensland flotation plants and supplemented by laboratory data is discussed. The model is kinetic in form and provides the basis of an automatic control system. The important features of the model are, 1. a distribution of flotation rates for each species of particles corresponding to the range of particle sizes, 2. a physical restriction on the removal rate of solids in cells where froth 'overloading' occurs. In this condition the removal rate of solids is proportional to the removal rate of water, 3. enhanced particle floatability due to increasing collector addition where froth overloading does not occur, 4. a second mechanism of recovery of all particles by mechanical associ- ation with water. This mechanism is particularly important in the recovery of fine high-ash species.

Jan 1, 1978

By Hermulheim W

In the Federal Republic of Germany hard coal is mined underground only. The coal mines reach down to 1 500 m deep, recently having an average depth of 900 m. The commonly used winning system is long- wall mining with face lengths up to 250 in. The gate roads, which separate the seam into single panels, have an average length of one kilometre with a cross- section up to 20 m2. These single entries are usually supported by yielding steel arches. The installation of steel arches can hardly be mechanized. The choice of heavier support, caused by increasing depth and roadway cross-section, results in high cost for labour and material in gate roads. Furthermore, the heavy steel arch is acci- dent-prone, not only during installation but also during transportation and ship- ment. Rock bolts combined with a suitable lagging offer a way of mechanizing support work in headings. The aim is to decrease cost and to increase mine safety and pro- ductivity. Over the last ten years, 50 km of gate roads have been reinforced by a combination of rock bolts and weld mesh. Nevertheless, there are still differing opinions on the feasibility of rock bolting in gate roads. In Germany a long tradition and experience with steel arch support exists, whereas the function of an anchorage is a closed book to miners, preventing this new technique from spreading more quickly. Advantages and shortcomings of both steel arch support and rock bolting are compared. The experience with rock bolting up to now is reported. Possible improve- monts arm discussed.

Jan 1, 1986