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By W. S. Steinberg

In 1963, the full-scale engineering study for the development of an iron, steel, and vanadium plant was initiated. This was the birth of Evraz Highveld and its process flow as it is known today. Highveld started out as a steelworks that produced steel and vanadium-bearing slag from a titaniferous magnetite iron ore mined from its own mine site near Steelpoort. The process utilized co-current rotary kilns for prereduction, and submerged-arc furnaces for the production of pig iron with approximately 1.15% vanadium. Because of various technical challenges that the submerged-arc furnaces experienced over the years, a decision was taken in 2004 to convert the furnaces to open slag bath (OSB) operation, in order to enable the maximum production of iron and vanadium while improving the control over operational parameters. The conversion proved to be highly successful and, since 2005, three furnaces have been converted to OSB operation. The fourth furnace will be converted in the first half of 2011. The conversion to OSB furnaces not only yields higher vanadium recovery to the metal at the iron plant, but also improves the overall throughput of the steel plant. This is the result of the higher carbon content of the liquid iron from the OSB furnaces, eliminating the need for anthracite addition to the shaking ladle process. This reduces the blowing time by approximately 60%. The conversion of the furnaces to OSB configuration is seen as an enabling technology change and a prerequisite to the implementation of other plant improvements that are envisaged. The long-term vision of EHSV is to convert five furnaces to OSB mode, and permanently decommission the two remaining submerged-arc furnaces. This will allow EHSV to maintain current steel and vanadium production but at a significantly improved overall efficiency.

Jan 1, 2011

By A. Tohn, L. May, Adham. K.

The path from process conception to commercial implementation poses significant technical, economic, and sometimes political challenges for every project team. Solving the technical challenges typically distinguishes successful projects from those that fail. Here, the authors provide an outline for technical success based on lessons learned from years of experience in process design and R&D. Challenges faced by new technology developers, with regard to design and definition, are described. Experience-based methods to avoid missteps are shared. Special emphasis is placed on the selection of viable unit operations, definition of known and unknown parameters, experimental screening of options, and piloting for scalable design information. Use of computational models to define, assist, and interpret the pilot operations and results are described. Furthermore, the value of active collaboration amongst the design, research, and owner team is demonstrated.

Jan 1, 2011

By Hideaki Kitajima, Ryo Sakamoto, Katsuya Sasaki, Maehata Hidehiko

The Electric Discharge Impulse Crushing System (EDICS) is a technology for carrying out crushing by using electrical power and nitromethane. It is designed for construction tasks such as splitting of concrete and rocks.The EDICS consists of an electric discharge generator that supplies a high-voltage high-current pulse, a cartridge that generates power by using electric discharge energy, and cables that connect the electric discharge generator and the cartridge. The cartridge contains a thin metal wire that evaporates because of the electric discharge energy and a nitromethane that reacts with this evaporated metal wire. The cartridge can be used to generate a high pressure on the order of gigapascals within a time interval of several hundred microseconds, and crushing power equivalent to that generated by explosives is generated during this period. In recent years, the EDICS has been widely used in Japan because of its good performance and favorable characteristics.

Jan 1, 2011

By P. Gautier

Current feedstock in the aluminum hot forging processes can be used in the cast or extruded forms. The microstructural variation between as-cast and extruded materials could result in different mechanical properties and corrosion resistance for hot-forged products. Corrosion performances were examined for forged parts produced by two AA6082 feedstocks at different conditions using the following corrosion tests: open circuit potential, anodic polarization, salt spray exposure and corrosion fatigue. With the help of optical and scanning electron microscopes, metallographical investigations were carried out on cast-forged and extruded-forged materials before and after corrosion. The corrosion behavior of both materials was compared in both as-forged and aged tempers. Results show that there is no significant difference in the corrosion performance for final cast-forged and extruded-forged products.

Jan 1, 2011

By Jinsheng Chen

For underground openings, many factors can cause roof failure and thus roof falls. The most common factors related to Mother Nature are weak roof lithology, geological structures, and an abnormal in-situ stress field. Theoretically, any underground opening can be successfully supported under any geological and mining conditions if the opening width is limited and the roof supporting system is well designed. However, roof control cost must be taken into account. In practice, to minimize the roof control cost, different roof control plans have to be considered to take care of the uncertainty or variation in geological and mining conditions. For most underground mines, it is unsafe or economically unrealistic to use one fixed roof control plan for the entire mine. Therefore, local, abnormal geological and mining conditions must be identified and a site- or area-specific roof control plan must be employed. This study tries to identify the major factors that have significant impact on entry roof stability by analyzing the historical roof fall data at Rofomex mine. Finally, the appropriate roof control plans or roof bolting systems for different geological and mining conditions are recommended.

Jan 1, 2011

By Steven A. Fechner

In 1984 the Bureau of Mines cunducted mineral investigations of specific sites within the Yentna Mining District. One hundred eight placer and rock samples were taken. Reconnaissance placer samples were collected from drainages in the Talkeetna, Susitna, and Yentna River basins. The highest placer gold values were found in the historic placer gold producing creeks of the Cache-Peters Creek area. Samples taken from an outcrop in the Middle Fork of Iron Creek in the Talkeetna Mountains contained previously unreported high lead, zinc, and silver values.

Jan 1, 2011

By Kenneth G. Thomas

Since approximately 2003 we have witnessed the unprecedented escalation in commodity prices. Coupled with economic chaos following the 2008 economic downturn this has caused difficulties in controlling schedule, capital costs and operating costs for mining projects. Once again escalation has returned to commodity prices fuelled by growth in the BRIC countries especially China and Brazil. This is further exasperated by the missing generation of skilled technical personnel not graduating from universities in the 1980s and 1990s owing to depressed commodity prices. This paper examines the six tenets for successful project implementation.

Jan 1, 2011

By Mike Ghassemi

It is clear that precise overground and under-ground mapping is an important factor for all designers. Due to rapid changes in underground construction, tunnel designers are increasingly in need of updating project information. This article explains the latest techniques for detecting under-ground utilities as well as underground mapping. Global Positioning System (GPS) is a very ac-curate and popular navigation and mapping system that has been used extensively above ground, but is not used for underground mapping as signals are not strong enough to pass through ground or water. Most underground techniques were developed for military applications during the first and second world wars. Later, the techniques became public. For example, ground penetrating radar was developed for the military in 1970 to be used for locating tunnels under the demilitarized zone between North and South Korea. Later, the same technique was used for detecting unexploded ordinance such as plastic land mines.

Jan 1, 2011

By D. Lopez, D. L. Doerr, T. J. Drake

Automated scanning electron microscopy has been widely used in recent years for gold and other precious metals characterization. However, application of this technology is resource intensive and in most instances needs specialized technical personnel to process the samples and information. Newmont Metallurgical Services (NMS) has recently acquired an ASPEX SEM. The ASPEX SEM offers some significant benefits/improvements in sample preparation and sample processing time. NMS and ASPEX have been working together to develop an approach utilizing this technology for the minerals processing industry and specifically for gold characterization.

Jan 1, 2011

By K. Bunney, R. Pleysier

The deportment of a suite of elements through representative gold ore processing unit operations in cyanidation has been investigated. Chromium and lead are not soluble in alkaline cyanide solutions. Arsenic, antimony, cobalt, molybdenum, selenium, tellurium and vanadium are soluble, but typically do not adsorb onto activated carbon to any appreciable extent. Silver, copper, cadmium, mercury, nickel and zinc to varying extents report along with the gold to the carbon eluate. Cadmium, mercury and zinc can report to the carbon regeneration kiln off-gases. Strontium is soluble and adsorbs on carbon where it remgins.

Jan 1, 2011

By R. Barthel, O. Nitzsche, J. Pateiro Fernández, T. Cramer

The Hong Gai coal field in northeast Vietnam has been the main coal mining area of Vietnam for more than 150 years. Anthracite coal is produced from several open pit and underground mines situated close to the UNESCO world natural heritage site Ha Long Bay. The mining-induced environmental impacts such as dust emissions, acid mine drainage, and visual impairments due to waste dumps resulted in severe conflicts of interests regarding future land use and the protection of the world natural heritage site Ha Long Bay. Within the RAME project (Research Association Mining and Environment in Vietnam), Brenk Systemplanung is contributing to an improved environmental and sustainable planning in Vietnam's mining industry and the reduction of environmental impacts on Ha Long Bay by developing suitable and sustainable technology and planning measures (e.g. for dump construction/rehabilitation, predictive modelling, and/or monitoring) for Vietnam's leading coal producer.

Jan 1, 2011

By W. A. Wright

The use and abuse of social media restate common employee relations issues. Business solutions to these issues require advanced preparation. Employers should establish and enforce social media policies to guide their reactions to employees? social media posts that reflect on the employer and its business.

Jan 1, 2011

By S. J. Schatzel

Longwall coal mine operators in the US are required to ventilate multi-panel longwall districts but may have little or no knowledge about what happens to the ventilation air between the inlet evaluation points (IEPs), bleeder evaluation points (BEPs), and bleeder fans. The effectiveness of bleeder performance can directly influence the ability of a ventilation system to remove and dilute coal bed methane emissions. Consequently, the performance of coal mine bleeders is an important aspect of underground worker safety. U.S. coal mining stakeholders have acknowledged their belief that the T- junction split at the longwall face tailgate corner is very important in controlling the distribution of ventilation air. The percentage of air directed inby towards the bleeders and bleeder fan and outby to the submains is often not well-defined and can vary over the life of a longwall panel. To obtain direct measurements of bleeder performance, a tracer gas, sulfur hexafluoride (SF6), was released into the intake air stream along the panline of active longwall panels and in the bleeder/gob ventilation air inlets of an inactive panel. Tracer gas sampling was conducted underground using tube bundles attached to permissible vacuum pumps in the gateroads, former gateroads, and bleeders. Surface tracer gas monitoring was also conducted from operating gob boreholes and from bleeder fans. Testing was performed on multiple longwall panels which included various phases of longwall development and variable path lengths of ventilation air transport to bleeder fan installations. The applied methodology defines and describes coal bed gas pathways, rates, and volumes of movement at the bleeder/gob interfaces, and indicates flow rates for air/gas mixtures within these gobs. These findings are reported for three stages of longwall extraction using direct field-based measurements. Changes in the T-junction ventilation air distribution over the life of a longwall panel and its variable effect on panel ventilation airflow are discussed. These findings will assess the effectiveness of commonly applied ventilation strategies for improving air distribution and ventilation controls to meet statutory requirements and to achieve the desired ventilation patterns through multiple phases of longwall panel extraction.

Jan 1, 2011

By R. Rushforth

The surge of activity in the solar energy market, spurred by government incentives, has created new and more efficient solar technologies, but issues surrounding land- and water-use have backlogged the full-scale development of solar farms. This paper explores siting solar power plants on degraded or polluted lands, such as mine tailings impoundments. Historically, mining and has been integral to Arizona?s economy, but has dwindled in relevance due to urban pressures and environmental regulations. Currently, it is legal to site solar power plants on degraded or polluted lands, but the question remains whether the economics of this degraded lands solar development is more favorable than developing pristine land. Therefore, we explore economics of developing mine tailings impoundments at both the institutional and financial level. Methods of research for this paper were interviews with government regulators, environmental advocacy organizations, farmers, and mining company executives. Financial models using extant tax incentives show a positive net present value for the installation of solar power plants, even when accounting for the costs of land remediation.

Jan 1, 2011

By M. J. Collins, B. Parekh, A. Hasenbank, B. Hewitt

Newcrest Mining Limited, originally as Lihir Gold, has operated a pressure oxidation plant for the recovery of gold from refractory ore since 1997. The mine and gold plant are located on Lihir Island in Papua New Guinea. Design of the original pressure oxidation circuit was based on the results of pilot plant tests conducted by Sherritt in Fort Saskatchewan. Following a decision to expand the plant in 2008, Lihir Gold contracted Sherritt to design a new autoclave. The design exercise utilized the original pilot plant test results, commercial process results at Lihir, and an understanding of advances in autoclave technology since the original plant was built. The new Lihir autoclave will be the largest horizontal, multiple-compartment autoclave in the world. The design process for the pressure oxidation expansion is described in this paper.

Jan 1, 2011

By Tom Barczak

Early in my career, while giving a presentation on shield design for longwall mining at one of the International Conferences on Ground Control in Mining, the late Jim Scott told me that I was finally getting it, because ?I was starting to think like a rock!? Although I didn?t realize it at the time, those few words changed my career forever. At the start of my career, I did a lot of laboratory testing, taking advantage of the unique capabilities of the Mine Roof Simulator to study the performance and design characteristics of longwall shields. I had a pretty good handle on what made shields work and what made them fail, but I was still struggling with how and why they develop their in-service loads and what they were actually controlling as opposed to being passive bystanders in a world beyond their control. It became clear to me that the simplistic models of dead weight loading could not explain the behavior I saw and measured underground. The problem did not go away when I started studying standing support systems. Again, I learned much about the strength, stiffness, and stability of these supports and helped the industry develop several new support products that attempted to provide more efficient support designs. But here, too, the simplistic models of dead weight loading did not seem to fit for me. That?s when I began to incorporate the ground reaction concept as a way of integrating the support response and the ground behavior into a cohesive design methodology. The concept has its limitations, no doubt, but I believe some form of it will be the future of not only designing supports but also, in the broader sense, enhancing the engineering aspects of ground control. The paper presented at the International Conference on Ground Control last year by Esterhuizen (2010) on pillar behavior is evidence of this. Think like a rock. Jim Scott was right. It takes two to dance. You can?t dance alone and you will never understand ground control by thinking like a support! ?Dumb as a box of rocks?? I don?t think so. The answer lies in the rocks!

Jan 1, 2011

By Ananta L. Yennamani

Blast movement measurement (BMM) transmitters are a practical method to measure three-dimensional (3D) rock movement because of blasting. The BMM transmitters are activated, programmed and installed in specially designed drill holes prior to the blast and the BMM detector locates the transmitters after the blast. The BMM software then calculates and summarizes the 3D movement of each BMM transmitter ball. This information helps to redefine the ore and waste boundaries and enables improved ore and waste selection, resulting in a genuine step change in grade control. The BMM program was carried out at Newmont Mining Corp.?s Phoenix Mine, in northern Nevada near the town of Battle Mountain. The mine is in a historic mining district that contains gold, silver and copper. The geology of the pit consists of different formations made up of sandstone, siltstone, limestone, chert-pebble conglomerate, shale, skarn and quartzite, to name a few. Some of the rock is extremely hard and a powder factor of up to 0.5 kg/t (1 lb/st) is required to get adequate fragmentation to ensure sufficient throughput through the crusher and the mill. The result of using such a high powder factor translates into considerable blast movement and heave. This movement means that the ore/waste digging polygons estimated by the ore control engineer from sampling the initial blast holes will no longer be located in their original posi-tions. The purpose of this project was to test the measurement method and to see if locating the digging polygons in the broken muck pile and excavating to those polygons will improve grade control through the mill. Case studies (Zhang, 1994), (Taylor, 1995), (Gilbride, 1995), (Harris, 1997), (Taylor, 2003), Barrick Goldstrike (Gold-strike Mine, 2008), Ruby Hill Mine (Hilkewich, 2009), (Porcupine Mine, 2005) and (Aguirre, 2010) have shown that, by accounting for the blast movement, there is a potential to increase mineral recovery by as much as 25 percent for individual blasts for only a modest cost increase.

Jan 1, 2011

By H. D. Brenk

"The German Federation of International Mining and Mineral Resources (FAB) is a federation of German companies that are active in international mining and mining related business. The FAB presents a platform for the exchange of information about the worldwide mining commodities in the dialogue with German and foreign institutions. The expertise of the member companies in mining and related activities is based on a long term operation and consulting experience in Germany and abroad. This forms the basis for the special international competitiveness "Made in Germany". The FAB is particularly engaged in the following topics and tasks and acts as a focal point for: • international project developments with the German mining industry, • sustainable mining, consulting and equipment services, • geological and environmental technologies, • project financing and • intermediation of contracts, project enquiries, professional symposia and events. The FAB acts as a contact- and coordination site for international business partners, organizations and governmental authorities. Together with the federal government the FAB organizes bilateral working group meetings in the commodity and mining sector. Project enquiries are being distributed from the FAB among their member companies."

Jan 1, 2011

By Rustyn Sherer

Curis, the name of a new Arizona-based mineral development company, is an acronym which stands for ?Cu? (elemental symbol for copper), ?r? (recovery), ?is? (in situ, the Latin for ?in place?). The company was created specifically to advance the development of the Florence Copper Project in Florence, AZ and to pursue other next generation copper development projects in progressive jurisdictions around the world. ?We are extremely excited about this project,? said Curis Resources president and chief executive officer Michael McPhie. ?We?re here to set the standard for Greenfield in situ copper recovery (ISCR) operations in Arizona and around the world. We believe in our people, our technology and our process; and we are passionate about our commitment to environmental stewardship and community development. We?re making a long-term investment in Florence, and in Arizona.?

Jan 1, 2011

High-pressure grinding rolls (HPGR) are an accepted, but continuously expanding, comminution technology. The copper industry has a growing need to process harder ores with progressively lower grades, more challenging metallurgy and increasing demand for efficient bacterial leaching applications. This has resulted in a major focus on HPGR use in a crushing circuit. If the industry is to increase leach extraction while lowering energy costs in high-throughput hydrometallurgical operations, HPGR will be of inherent significance. The following paper summarizes test work on copper leach ores utilizing the benefits of HPGR comminution, while increasing several critical metallurgical parameters. Based on the current work and previous investigations, it was found that HPGR comminution within a crushing circuit, in specific instances, can result in 2 - >10% increases in cop-per extraction. The tested variables are crush size, rock type and copper mineralogy dependence. Various other process parameters may also be optimized.

Jan 1, 2011