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By C. Carrasco

Caletones Smelter, Division El Teniente of Codelco Chile, has used Teniente Converter (TC) as the only smelting unit since November 2000. The modernization project considered the shutdown of the last reverberatory furnace, the installation of the fourth Teniente Slag Cleaning Furnace, the installation of a new fluidized bed dryer and the modification of the concentrate injection system into TC. The modernization project and related investments allowed for the increase of the smelting capacity up to 1.25 million t of concentrate annually.Next stage of the smelter expansion in the year 2004 considered the increase of the smelting capacity up to 1.44 million t/year. The expansion required technology modernization and the installation of the new equipment, such as concentrate injection system, oxygen plant, fluidized bed dryer and storage bin. Currently the annual smelting capacity is about 1.35 million t of copper concentrate, being limited by sulphuric acid plant treatment capacity. This paper presents the technology and production evolution in the Caletones Smelter in the years 2000 - 2006, demonstrating the potential of development and competitiveness of Teniente Converter as world-wide recognized smelting/converting reactor.

Jan 1, 2007

By E. J. McLean

Gold mineralisation at Bendigo is exclusively associated with quartz reefs, commonly found within or near anticlinal fold hinges. The gold is typically coarse grained (0.5 mm to 5 mm), free milling and displays a complex, nuggetty distribution within the veins. This ore is highly amenable to gravity recovery processes. As the Bendigo operation is not permitted to treat whole ore by a cyanide leach/CIL circuit, the flow sheet is more complex than conventional gold recovery circuits. Primary gold recovery is from a gravity circuit closing the grinding circuit to a bulk gravity concentrate and from a flotation circuit treating cyclone overflow to a bulk float concentrate. The plant capacity is relatively low by current gold industry standards at 600 000 tpa. Re-establishing gold production at Bendigo has presented several challenging, and sometimes competing, issues in process design and operation. The mine, process plant, associated services and infrastructure are at Kangaroo Flat, a low density, semi-rural zone in the southern urbanisation of the Bendigo metropolitan area. One of the main processing challenges during the design was the competing comminution requirement to avoid over-grinding, which would flatten or smear the characteristic nugget gold and hinder effective gravity gold recovery, whilst also providing sufficiently well liberated particles that would respond well to flotation. Important, non-metallurgical challenges were to minimise impacts on the local community from noise, dust, air emissions, visual impact, water egress and off-site traffic.

Jan 1, 2007

Several industrial-scale HydroFloat separators have recently been installed at Mosaic?s South Fort Meade beneficiation plant for the purpose of improving phosphate recovery and throughput capacity. This technology was implemented after numerous laboratory, bench-scale and on-site, pilot-scale test campaigns. The results from this detailed test work provided sufficient justification for the complete retrofit of the existing coarse and ultra-coarse flotation cells. Data indicate that the metallurgical results obtained with the full-scale separators are consistent with that obtained during both the bench- and pilot-scale evaluations. The benefits, theory of operation and commissioning of the equipment are also discussed.

Jan 1, 2007

By Brian Hart, Roger St. C. Smart, James Francis, Mark Biesinger

"There are a number of challenges involved with the surface analyses of different mineral phases from process streams in a flotation facility. The first of course is to collect samples that are representative of the process and to ensure that they remain in a pristine condition prior to introduction into the instrument. In mineral processing, sample collection from the different streams is done on site and preservation involves simply removing oxygen from the sample by bubbling nitrogen or argon gas through the sample and snap freezing with dry ice.The second challenge in studying the surface chemistry of specific minerals is to find reliable methods of mineral phase recognition. In surface analysis of mineral particles confident mineral selection can be difficult with many multi-metal minerals (e.g. chalcopyrite, pyrite, sphalerite) and with precipitated, adsorbed, reacted and contaminant species in the outermost molecular layers.In this paper we show that principal components analysis (PCA) of ToF-SIMS data provides improvement in phase recognition, particle selection and associated variations in surface species. We will demonstrate, with specific examples, that this technique can be utilized to differentiate surface chemical factors promoting (hydrophobic species) or inhibiting (hydrophilic species) flotation.Species recognition based on the PCA method in a study of Cu transfer between chalcopyrite, pyrite and sphalerite mineral mixture clearly identified a statistical difference in copper intensities between the sphalerite and pyrite phases. A similar ToF-SIMS/PCA based study applied to concentrate and tails samples collected from the Inco Matte Concentrator demonstrated extensive CuOH and NiOH transfer between the chalcocite and heazlewoodite minerals. The statistical analysis has been able to confirm some mechanisms and deny others proposed to control recovery and selectivity giving more focus on the control factors.The ToF-SIMS PCA statistical analysis has elucidated differences in surface chemistries which illustrate the discriminating depressant action of adherent aluminosilicate (gangue) fine particles and adsorbed ions on the surface of sphalerite grains. In the flotation test concentrates, HIC conditioning resulted in the removal of these gangue fines thereby improving surface collector attachment efficiency, promoting a greater recovery of sphalerite."

Jan 1, 2007

By Holger Witthaus

There is more than a century of experience in multiple seam mining in Germany. In several mines up to 20 seams had been excavated within the last decades. Due to the nature of the deposit and the history of technical development the older panels cause a complex stress distribution for the lower seams and the current longwalls in descending order of mining. The depth of the longwalls reaches up to 4000 ft. This causes a maximum vertical stress that reaches between 30 and appr. 60 MPa. To handle these conditions several support systems are applied for roadway heading. A central knowledge management system for ground control is used for design and dimensioning of support within the DSK. This paper gives an overview to the nature of German multiple seam mining and the solutions in matters of panel layout and support design. It describes the full lifecycle for roadways in the seam starting with the geological and geotechnical evaluation, the basics of roadway deformation in great depth, the development of planning tools and standards for German coal mines, the range of alternative of support systems and roadheading techniques, as well as the reinforcement measures and the processing of support at the T-junction of the face entry. This paper uses exemplary descriptions that are consolidated in a specialized reference book ?Gebirgsbeherrschung von Flözstrecken? ? ?Ground Control in Roadways? which summarizes the standards of ground control based on the development of the past 25 years in German coal mines.

Jan 1, 2007

By J. Baklík, V. Rak, W. Kolarcík, Z. Franc

The paper deals with hydraulic transport of thin and dense slurries. Based on mathematical modelling of three-phase flow, dynamic properties of the systems for pumping of thin slurry are solved. Theoretical calculations were experimentally verified both at the testing hall and in real operation. For thin slurry (e.g. bauxite slurry), a three-chamber hydrohoist with float is used. Dense slurry (e.g. ash and water) is transported from the power plant to a deposit site by means of a three-chamber hydrohoist with sealed separator (piston).

Jan 1, 2007

Traditionally, the term ætotal systemÆ design applied to comminution conjures images of a design that addresses the usual business and operational drivers, including health, safety and environment (HSE), capital cost, operating cost, throughput and product size. In terms of the physical process, the mine to customer type studies also exemplifies an approach that satisfies a normal ætotal systemsÆ approach. As an industry there are drivers that are forcing a re-consideration of what we regard as our total system. This modification of drivers will require changes in approach and implementation to provide the best solutions. Some of the major changes that impact the drivers are shortage of skilled personnel, changing social attitudes to remote mine site work, greenhouse gas emissions (GHGE), quality of available orebodies and geographical location of new mine sites. One approach to the challenges presented by the changing business environment is to expand the system envelope around comminution to ensure that comminution, in its widest sense, helps to meet the new realities. Background to the new drivers and constraints is provided and some of the appropriate responses are examined in relation to the impact on the total system.

Jan 1, 2007

By R. Niechcial

As populations grow and industry expands, the limited fresh water resources available are increasingly under stress. This situation creates conflict between communities and industry; and the sustainability of both is threatened. The symbiotic relationship between community and industry highlights the need to develop innovative solutions to these water shortages. The sea may hold the key to providing the resource to permit the development of industry, the sustainability of communities, and the protection of the dwindling legacy water resources around the world. Desalination technologies have developed to where it is now economically viable to create industrial and potable water quality from seawater. Nowhere is this development more important than in the arid region of Northern Chile, where high copper prices have encouraged a boom in mine development.

Jan 1, 2007

By A. G. Mattes

This paper presents an overview of passive, engineered, biologically-based anaerobic bioreactor (ABR) treatment systems of the sort that can be used to remove dissolved copper from mine wastewaters. The paper begins with a brief history of the origins of this treatment technology and continues with a discussion of principles of engineered wetlands (EWs, advanced kinds of constructed wetlands, CWs) and the use of vertical sub-surface flow (VSSF) varieties that contain pulp & paper biosolids as the reactive medium for EW cells. A brief outline of a procedural methodology used in evaluating the potential for biological treatment on a site-specific basis is also included. An introduction to the microbiology of passive biologically-based treatment systems is followed by some recent research results in the general area of wetlands and ABR research. The paper concludes with a brief discussion of several sites known by the authors to have successfully (or not) demonstrated the potential of this treatment option.

Jan 1, 2007

By John E. Lens

Driving bridge foundation piles into glacio-fluvial sands and gravels and glacial tills brought surprisingly longer than predicted driving lengths on several recent projects in Vermont. In some instances, piles drove more than 40 feet past refusal depths predicted from Standard Penetration Resistances from borings terminating in glacial till. Overall, piles developed substantially less skin friction than predicted using common capacity formulas and drove as much as 80 feet longer than predicted in the moderate to dense gravelly and cobbly soils. These piles were driven for one to five span highway bridges within narrow valleys with bedrock ranging from 80 to over 200 feet deep. Piles were for both conventional and integral abutment bridges. H-piles were used for a variety of reasons including lower unit cost, better availability, and better ability to drive through cobbly soils in upper strata. Dynamic testing was used to evaluate capacity, including skin friction and end bearing capacity. In order to develop better pile length and capacity predictions for future projects, VTrans and one of their geotechnical consultants are collaborating to develop criteria for improved pile capacity predictions in these river valleys. We are doing this by evaluating driving and dynamic testing data from four projects in comparison with the Federal Highway Administration (FHWA) DRIVEN pile design software, and methods from Myerhof (1976) and Tomlinson (1981). Our overall objective is to provide a basis for choosing appropriate pile types and reliably estimating pile lengths for projects in this terrain. Bridge foundation design projects in other mountainous terrain share similar design and construction challenges to those encountered in these Vermont projects. These include: difficult exploration drill rig access requiring smaller rigs with limited capability to drill through cobbles and boulders deep enough to reach bedrock; limited experience with displacement piles as alternatives to H-piles in this geology; and relatively greater variability in soil stratigraphy between foundations at these sites as a consequence of the relatively high energy depositional environment in mountainous terrain. This paper presents the case history summaries of the pile driving, results of the ?back analysis? capacity evaluations, examples of solutions employed on these projects to address the lower capacities achieved, and resulting pile capacity design guidelines and prediction criteria for these geologic conditions based on data from these projects.

Jan 1, 2007

This paper presents recent advancements in the MillMapper software technology, developed and used for thickness gauging of liners of cylindrical grinding mills used for mineral comminution. MillMapper uses calibrated laser scanner data captured inside a mill to determine thickness at several million points on all liner surfaces with millimetre accuracy. The paper is structured as follows. First, a review of the technology and its numerous advantages over existing techniques and the value it adds to operations are presented. These are followed by discussion of recently-implemented innovations, including improved visualisation and inspection tools, automatic ball charge volume measurement and automatic mill liner volume/weight measurement. Results from its application at several sites in Australia are presented throughout.

Jan 1, 2007

By Rick Frechette, Bryan Ulrich

Representatives from several mining operations in three western states left their mines behind for a day in February to discuss with their peers the issue of water. The event was Knight Piésold and Co.’s Roundtable 2007, held in Elko, NV. It was third such event put on by the company. The issue this year was site-wide water considerations.

Jan 1, 2007

The basic make-up of the majority of currently produced bulk explosives has changed little in the last 20 years. These explosives would be described as mature in a life cycle analysis. Therefore these explosive products and the practical rules for their use are well understood and well established. In recent years there has been interest in low density explosives, predominantly due to ammonium nitrate shortages and the associated increase in the cost of explosives. In the use of low density explosives some of the practical rules for the more commonly used bulk explosives do not apply. Therefore a shift in the thinking among users is required. At a number of mines low density explosives have been trialled or are being used, utilising the practical rules that apply to bulk explosive products. This has led to poor blast results in many situations. These poor blast results have often then led to a reduction in the use of low density explosives at the mine. This reduction does not acknowledge the advantages that can be gained from this product in the area of reduced cost of mining. This paper looks at low density explosives and discusses how and why these products work. Included in the paper are some practical ideas and examples of how low density explosives can be effectively used at the mine site.

Jan 1, 2007

By J. P. Sancho, J. M. Duart, J. I. Verdeja, J. O. García

Following a short review of the history of rails used in the transport of passengers and goods, this paper describes the process for rail fabrication, rail structure, and properties, and summarizes the fatigue test curves carried out on rails used today. Also reported is the process for “continuous rail” production using aluminothermic welding via the introduction of weld metal in onsite casting, as a homogeneous melt. Weld characteristics of aluminothermic welding using different preheating procedures—fusion zone, heat-affected zone, microstructure, hardness, slow bend test, and fatigue test resistance (Wöhler curves)—are related to preheating and welding procedures of 700, 900, and 1,100 MPA rail grades. The Locati method is preferred over the staircase method for ascertaining the fatigue limit due to its simplicity. Macrographic and metallographic inspection of broken specimens reveals the reliability of welding techniques and the good metallurgical quality of welds.

Jan 1, 2007

By D Thornton, B Smith, S Demey

Mine to Mill (MTM) optimisation, a total systems approach to the reduction of energy and cost in mining and mineral processing operations, is well-established technology. However, successful applications of MTM optimisation have been largely confined to gold, copper and lead/zinc semi autogenous grinding (SAG) operations, where the goals of tweaking the blast design to increase fines and hence throughput through the mill have been relatively easy to meet. The application of MTM optimisation in a more demanding environment, like that of a multi-stage crushing and screening aggregate operation, was conceived as part of a Department of Energy (DOE) initiative in 2004, aiming to reduce the energy consumption in the US aggregates industry. Two quarries operated by the Luck Stone Corporation of Richmond, Virginia, were selected for the demonstration sites. Dealing with ore variability and a requirement to maintain a fixed feed size distribution to the tertiary plant, whilst still aiming to increase yields of saleable products, presented some unique challenges. Despite these variables, the implementation of the MTM approach at Luck StoneÆs aggregate plant in Pittsboro, North Carolina, has led to a tangible improvement in productivity, particularly in the primary and secondary plants. The successful outcome was dependent upon several key factors, including reliable blasting and processing models, careful analysis of the rock conditions and plant configuration, understanding and buy-in from the Luck Stone operations staff, excellent collaboration with Virginia Tech staff and students, and long-term monitoring made possible through comprehensive PLC logging. This paper presents a review of the work conducted at the Pittsboro quarry and highlights the key reasons behind the successful implementation of the MTM approach in a complex plant environment.

Jan 1, 2007

By Rajesh A. Vaidya

A large scale piling work is undertaken in India for an important fast track industrial project. Thousands of solid square precast concrete piles are driven to depths of around 50m. Soils encountered are of alluvial origin with very soft clays varying in thickness from 10 to 18m at the top followed by medium dense to dense and occasionally very dense sand, stiff clay and finally dense to very dense sand layer as the founding layer. Recent site grading with around 4 metres thick hydraulically filled river sand necessitated driving the piles to the bottom sand layer to avoid problems on account of negative skin friction and to achieve optimum pile capacity. A process approach suggested by Bell et al (2002) to promote better understanding of the pile behaviour, pile capacity, and parameters assumed at design stage for static capacity and for wave equation analysis is followed with an aim to bring in effective economy in terms of pile length and pile installation speed. Soil investigation work is also undertaken in stages to cut down pile wastage. A judicious combination of PDA and static pile load tests is followed. Pile Driving Analyser (PDA) tests at end of driving and also at various stages of recovery of pile capacity are carried out to understand the pore pressure dissipation phenomenon. The paper attempts to present some of the valuable experiences that would go to establish precast pile as a very effective alternative to driven cast-in-situ piles and bored piles which are very common in this part of the world despite their limitations in terms of economy, speed and certain geotechnical aspects.

Jan 1, 2007

By H. Memarian

In the last few decades, many developing countries have tried to expand and improve upon higher education, which is acknowledged to be the leading factor for development. In this respect, develiping countries have significantly increased the number of tertiary institutions and their students. These rapid expansions, along with all the benefits, have drawbacks as well. An example is the status of mining engineering education in Iran. Presently, the number of active mining engineering departments in Iran (27) is more than the sum of similar departments in Canada, Australia, the United Kingdom, and South Africa (23 altogether). Also, the number of annual mining graduates in Iran (645) is more than the cumulative graduates of the United States, Canada, the United Kingdom, and Australia (613). The expansion of mining engineering education in Iran has coincided with the closing or merging of similar mining departments, as well as a decline in the number of interested students in the industrialized world. The present study shows that the need for development and the excessive number of high school graduates, resulting from high population growth in the early 1980s, are the two primary factors influencing the significant expansion of mining engineering education in Iran.

Jan 1, 2007

By Timothy C. Siegel

Drilled displacement piles (also known as augered cast-in-place displacement piles or augured, pressure grouted displacement piles) are installed by the displacement of soil and subsequent placement of fluid cement grout within the evacuated volume. Depending on the soil grain-size characteristics, soil behavior, in situ soil density, pile spacing, and pile diameter, the installation process can result in measurable densification and an increase in lateral stress. This paper examines the conditions prior to and following the installation of drilled displacement piles at sandy sites using the cone penetration test. The data support that the installation of drilled displacement piles results in a substantial increase in tip resistance.

Jan 1, 2007

By A Mehrani, F Zamani, A Dehghani

Vibrating screens play an important role in the dry classification circuit of Gol-e-Gohar iron ore processing plant. This circuit was designed to classify the autogenous mill discharge and produce a suitable feed, with K80 about 450 ¦m, for dry magnetic separators. Three parallel vibrating screens produce more than 50 per cent of the separatorÆs feed. The efficiency of the magnetic separator is greatly affected by feed size distribution. In this work, the JKSimMet 5.1 software was used as an analysing tool to assess the flow rates and USIM PAC3 software as the simulation tool to control and optimise the vibrating screens. Samples were collected and the circuit was mass balanced. Then the vibrating screen was simulated and adjustment parameters such as cut-point, bypass and imperfection factor were determined. The product streams of vibrating screens can also be predicted.

Jan 1, 2007

By D Ford

BHP BillitonÆs new rotary iron ore car dumper installation at Finucane Island (Port Hedland) was constructed to increase the total capacity of the port facility from 110 Mtpa to 120 Mtpa and to allow for incremental capacity increases in future. The arrangement of the dumper is similar to other car dumper installations existing on site. To construct the facility, approximately 120 000 m3 of material was excavated in six months, to a total depth of 22 m. The saline water table was nominally 6 m below ground level and the materials excavated varied depending on depth, ranging from sand to mangrove muds. There was a need to retain the sides of the excavation and limit the amount of water from entering the excavated area. This was required to allow excavation to progress and had to be maintained during construction of the permanent concrete and steel facility. The excavation was backfilled progressively as construction progressed. Various retaining wall methods were investigated with the preferred option being sheet piles secured by walers and ground anchors. Detailed electronic models were developed and assessed to complete the final design arrangement. Dewatering bores around the perimeter of the excavation removed the groundwater to intercepted sumps within the site. A strict and methodical program was developed to monitor the integrity of the temporary works and the quality of the groundwater. The works were completed on time despite the following challenges being encountered: availability of resources and equipment, movement of mobile plant on æboggyÆ materials, difficulty driving sheet piles into material at depth, drilling of ground anchors to 32 m, grouting of ground anchors, greater than expected groundwater flows, and the risk of hydrocarbons within the groundwater. The lessons learned from the use of the retention system and, in particular, the associated construction challenges overcome, provide a sound basis for similar work in this buoyant resource market. The conference paper describes the temporary works options investigated, design considerations and processes, construction methodology and challenges encountered, and the monitoring systems developed. Lessons learned are also discussed.

Jan 1, 2007