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By James A. Schneider

The evolution of the American Petroleum Institute (API) design method for axial capacity of driven piles in siliceous sands is explored, and complemented with an overview of how changes in offshore site investigation practice have increased the level of knowledge with respect to vertical variability of soil characteristics. Increased use of the cone penetration test (CPT) provides near continuous profiles of soil type and strength which can be used in calculation methods that address variation in local shaft friction rather than the API method which seems to have initially been based on observations of average shaft friction in relatively uniform sand deposits. Development of a formulation for CPT correlations to axial pile capacity in sand is discussed, along with implications to existing factors of safety used in routine design.

Jan 1, 2006

By M McLean

This paper deals with change strategies on brownfield and greenfield sites in extractive industries. It draws upon contemporary experiences across Australian, Indonesia and Papua New Guinea (PNG). Change strategies can be used when owners of an extractive industry operation want to optimise their resource. This paper draws upon many tried and proven theories and practices, including the findings of the Tavistock Institute (Trist, Emmery, Bamford, Jaques), as well as the concepts of Adult Learning espoused by Malcolm Knowles and is supported by learnings of Australian based management consultants. This paper reviews a range of approaches that have succeeded in the integration of systems, machines and people, with the key corporate objectives of: increasing productivity; decreasing cost; improving on-time delivery performance and achieving long-term survival. Such integration needs to be measured to show the outcomes from the change strategies and the authors have worked within many measurement regimes and metrics but for the most part, found that JaquesÆ set of metrics being æquality, quantity, resources and timeÆ has gained currency across many Australian operations. This paper contends that investing money in machines alone without a commensurate investment into the people side is counter-productive. Further, if there is not an understanding of processes, ie stable and capable, core and support processes, then all that new technologies will do, is to make what is done badly, only quicker. Recent interventions for the most part, have been cognisant of this balanced approach towards change management. The change strategies described are across extractive industry implementations, using a number of tools and techniques drawn from Continuous Improvement and Six SigmaÖ (registered trade and service mark of Motorola Corporation, USA).

Jan 1, 2006

Pyrometallurgy has played a very important role in southern Africa for at least four centuries. It continues to do so, and recent years have seen many exciting developments in pyrometallurgical technology. The wonderfully diverse rich mineral deposits in this area of the world have provided some unique opportunities for industrial processes to be established. The ?Southern African Pyrometallurgy 2006? conference was set up to showcase southern African pyrometallurgical operations, and to provide a forum for the exchange of ideas between people working at various types of smelters. Papers have been obtained from a wide variety of pyrometallurgical plants in southern Africa. These descriptions of plant operations (as well as some history, and highlights of current work) will provide useful reference information for some time to come. Contributions are also included from universities, research organizations, and engineering companies, so that the full spectrum of pyrometallurgical activities can be covered. The plant descriptions will be published on a website, where they can be updated as and when required, with the eventual goal of having a description of every smelter in the region. The conference venue was selected to be the 'Cradle of Humankind' world heritage area, about 40 km from Johannesburg. Not only does this keep the conference within easy reach of the city and yet far enough out into the countryside to allow people to focus on the conference, it is also within easy reach of many pyrometallurgical plants. There is a particular significance to the choice of location, in that the Swartkrans area close to the Sterkfontein Caves is the site of the earliest evidence of the deliberate controlled use of fire by human beings (about 1.3 million years ago), and this is obviously a necessary precursor to pyrometallurgy. The area also lends itself to a very wide range of outdoor, social, and cultural activities to supplement the technical content of the programme. It is hoped that activities such as a hot air balloon safari and visits to the world-renowned Sterkfontein Caves and Wonder Cave will help to make the conference a memorable one for those able to attend. I trust that the ongoing value of the papers and presentations will make all the hard work of the many contributors most worthwhile.

Jan 1, 2006

By S. B. Kang

Magnesium has poor ductility at temperatures lower than 225°C and, as a result, Mg alloy sheets are produced via fairly complex thermomechanical processes consisting of numerous sequential steps of hot (warm) rolling with low reduction and intermediate recrystallization annealing operations. In context of the present study, a simple technology for the fabrication of magnesium sheets by hot (warm) rolling was applied to various magnesium alloys. The misch metal addition in those AZ alloys was done to evaluate the deformation behavior. Tensile tests were carried out for those AZ alloys after applying different heat treatments. The precipitation of ß phase (Mg17Al12 phase) induced different microstructures with various cooling method from solution treatment temperature, and also with various annealing treatment temperatures.

Jan 1, 2006

By J Knoblauch, D, P J. J Strobos, C Foggo

The Sally Malay Project is located 120 km north of Halls Creek in the eastern Kimberley region. Since commissioning, ongoing improvements on the plant have resulted in recoveries now greatly exceeding the initial design targets. The continual optimisation endeavours of the Sally Malay metallurgy department included an automation project that was done in close collaboration with Mintek. In this team effort, several problem areas were addressed and the FloatStar advance control system was successfully commissioned to stabilise and optimise the flotation circuit. The remote location of the Kimberley Nickel Mines operation, fly-in, fly-out roster and the current mining boom makes the acquisition of experienced flotation staff difficult. The implementation of an automated flotation control system reduces this burden and contributes to the training of inexperienced staff. This paper illustrates not only the process control improvements achieved as a result of the installation of the FloatStarÖ advanced control system, but also how it has assisted operational personnel with their understanding of the process.

Jan 1, 2006

By N. Sauret-Szczepanski, G. Patry, S. Gauthier, G. Potvin, C. Munger

Adsorption/thermal desorption with sorbent cartridges and analytical method using gas chromatography coupled to mass spectrometry (GC/MS) was developed for the determination of tetrafluoromethane (CF4) and hexafluoroethane (C2F6) emitted from primary aluminum smelters. A customized cartridge was built like a packed column with a stainless steel tube filled with a specific resin. The optimization of adsorption and desorption parameters was carried out to support the PFC sampling for all aluminum production technologies. The proposed method showed good linearity for concentrations ranging from 10 to 500 ppbv for CF4 and from 5 to 500 ppbv for C2F6 with correlation coefficients above 0.999. In certain conditions, the detection limits of the analytical method reached 0.3 ppbv for CF4 and 0.15 ppbv for C2F6- Using this methodology, a field campaign was carried out using a sequential sampler allowing the simultaneous sampling of PFC with cartridges and sampling bags. The results showed no significant difference (t-test) between the two sampling technologies and no breakthrough was observed from the cartridges .

Jan 1, 2006

By Ross McClelland

This paper provides a technical overview on the installation and commissioning of the Ausmelt lead smelting, slag reduction and slag cleaning operations at the HZL Chanderiya site in India. It also discusses theoretical concepts behind the process practices currently in place at HZL.

Jan 1, 2006

By Eiji Kojima

In this research, dynamic and static load tests were performed on permanent foundation piles which had a pile length of 30 m, 800 mm in outer diameter and 15 mm in wall thickness. In this site the dynamic horizontal load test on a smaller test pile, 12 m in length, 500 mm in outer diameter and 12 mm in wall thickness, was also carried out. The static horizontal load versus horizontal displacement derived from the dynamic load test conformed well to that measured in the conventional static horizontal load test of the pile with 800 mm diameter. Then an attempt was made to predict the horizontal load displacement of the pile with 800 mm diameter based on the results of the dynamic horizontal load test of the pile with smaller diameter of 500 mm.

Jan 1, 2006

By J Kinal, I Mitchell

Many flotation plants use pH to adjust the pulp chemistry of their system to achieve optimum separation. For example, in a sequential lead/zinc circuit the pH during sphalerite flotation is increased to 10.5 or greater to depress galena and pyrite, thereby improving selectivity for sphalerite. However, maintaining a pulp at a particular pH value does not necessarily provide the operator with an abundance of information regarding the chemistry changes occurring within a plant. This paper provides the reader with a number of pulp chemical observations in several plants, showing that the same trends are noted over time; however, the magnitude of the measured values do change. Further, the changes in magnitude are invariably associated with a change in mineralogy. Thus, is measuring pH enough? Can the Eh, dissolved oxygen and temperature be measured at the industrial scale reliably? And, are these measurements useful?

Jan 1, 2006

By Peter O. Wilkinson

Ascot Racecourse in the UK is a major international venue for horseracing. The racecourse is being redeveloped to provide entirely new public facilities. The development includes the construction of a new grandstand. A site investigation was earned out comprising mainly cone penetration testing. The site is underlain by the Bagshot Formation, comprising predominately cohesionless deposits of medium dense becoming dense, silty fine to medium sand, containing occasional layers of clay. Shallow foundations would present uncertainty regarding total and differential movement; hence a piled foundation solution was chosen using a continuous flight auger (CFA) piling system. The possibility that piles may found either directly on or within the influence of cohesive material suggested uncertainty regarding toe resistance. In order to measure shaft friction, an instrumented preliminary test pile was undertaken. The results were compared to published correlations of cone and shaft resistance. This approach resulted in a net saving in terms of pile length which resulted in optimum value engineering and hence a cost saving to the client.

Jan 1, 2006

By G K. N Subasinghe

Metallurgists operating Knelson Concentrators (KC) often rely on manufacturerÆs recommendations for selecting operating parameters, such as fluidising water flow rate and cycle time. Recent studies have shown that these parameters are not only dependent on the machine parameters but also on the feed characteristics, such as size distribution of the gold and gangue particles and the composition of its constituent minerals. It is known that a particle entering a KC initially traverses a circular path within the bowl. For a particle to maintain a given orbit, the required centripetal force must be supplied by external means. It has been argued that this centripetal force, which is dependent on the mass of the particle, its radial position and the rotational speed of the bowl, is provided by the fluid drag force created by inwardly moving fluidising water and the BagnoldÆs force created by the particle/particle collisions. Depending on the fluidising water flow rate, one of two situations can occur where the porosity of the bed increases or decreases, which influences the amount of material retained within the bowl. The amount of material of a given size and density retained in the bowl is thus dependent on the extent of the centripetal force provided. Based on the above concept, a criterion that can be used to predict the amount of material recovered in the bowl has been derived and validated by experimental data. It may also be construed that this criterion demarcates the transition of the bed from a packed-bed state to a fluidised state. By identifying the transition values for the different constituent mineral particles in the feed, it is possible to estimate the optimal fluidising water flow rate that would maximise gold recovery while minimising gangue recovery. In addition, the kinetics of gangue displacement by incoming heavy mineral particles were also studied using synthetic mineral mixtures. The experimental data suggests that this process follows first order kinetics and that the build-up of heavy mineral reaches a maximum. A model has been proposed to predict the optimal batch cycle time for a KC in terms of the feed characteristics and machine operating parameters.

Jan 1, 2006

Mother Nature controls, technical professionals model and miners decide. Decisions to explore, mine and mill. Mine decisions, mine design, planning and scheduling are subject to the quality of models û geological models, geotechnical models, resource models, density models. The closer these models are to reality, the more accurate the predicted outcome. So why is it we delegate the modelling tasks to the most junior and least experienced people? If we insist on this, we need to support them û to provide them with æexperience acceleratorsÆ. Technical mentoring is the most effective way to provide the right information at the right time. When this information (read skills) is supplied at the right time we can inject experience into the quality of our modelling and into our decision- making processes. The objective of this paper is to share those behaviours and manners that foster relationships and create frameworks for skills and experience transfer. Central to this is an understanding of how adults learn, an understanding of the basic rules of mentoring etiquette, and the three keys to building meaningful mentoring relationships. An understanding of adult learning processes and styles provides a structure within which a mentor can understand the learnerÆs perspective. Understanding the world from the learnerÆs point is critical to selecting the right language to engage, teach and transfer skills. Basic rules of mentoring etiquette like timeliness, respect and trust need to be brought into the consciousness so they can be agreed on and monitored to prevent conflicts in cultural and generational norms between the mentor and the learner.Meaningful relationships hinge on the three behaviours: truly listening, rather than just hearing; understanding the technical issues within the WIIFM (whatÆs in it for me?) question; and facilitative behaviour. Stronger and more meaningful technical mentoring relationships within our industry will bridge the generational gap and ensure we can capture and capitalise on the wealth of grey hair experience and develop an informed group of young decision-makers.

Jan 1, 2006

By Mark R. Svinkin

Regulations are needed to keep construction vibrations in tolerable limits. The existing regulations were developed for low-rise residential structures, but they are incorrectly used for different super and underground structures. The existing regulations cannot prevent most of harmful vibration effects on sensitive devices, people and structures from construction and industrial vibration sources. It is important to determine the areas of application of the existing regulations and bring attention to the necessity of measurement of the structural responses for assessment of vibration effects on structures. For multi-story residential, commercial and industrial buildings, the frequency-independent safe limit of 51 mm/s (2 in./s) can be chosen for the peak particle velocity of structural, not ground, vibrations. Specifications for construction operations with dynamic sources have to consider specifics of each construction site. Preventive measures can be used to mitigate harmful vibration effects on various structures and settlements in sand and clay soils.

Jan 1, 2006

By D. Brazier, W. Laing, D. Nixon

Keywords: Pyrometallurgy, furnace, smelter, copper, Palabora The Palabora copper smelter has operated for the past 38 years, treating concentrates produced at the mine site. Palabora has reduced captive material by almost 40 per cent with the transition from a large open-cast to a smaller underground mine. The smelter and refinery complex was designed to treat 120 kt contained copper units per annum, with the underground only supplying 70 per cent of the feed. The agreed strategy was to import enough concentrates to maximise production and reduce operational unit costs. This transition has presented the Palabora management with new challenges both in technical and financial aspects.

Jan 1, 2006

By A Jakowetz

OxianaÆs Sepon Copper Operation (part of the combined Sepon Gold and Copper Operation) is located in Savannaket Province, in southern central Lao PDR. The site is relatively remote, being some five hours inland from the Laos/Thailand border crossing on the Mekong River. The copper processing plant was designed to treat 1.3 Mtpa ROM ore to produce 60 000 tpa of copper cathode. Commissioning of the processing plant was completed in mid March 2005 with ramp up completed in January 2006 with 5260 tonnes of cathode harvested in this month. The focus of this paper is on SeponÆs unique grinding circuit. The entire grinding circuit is operated at highly acidic conditions, adding a number of different operational issues over and above those normally associated with grinding circuits. It became evident early in the ramp up, that reaching design mill throughput of 170 dry tonnes per hour with the original design would be challenging, coupled with the realisation that ceramic grinding media consumption had been underestimated. In order to lift the overall throughput of the processing plant, a significant continuous improvement process has been implemented within the grinding circuit to lift this key unitÆs production capacity. This presentation will focus on the key areas that have been addressed in the 12 month ramp up period and highlight areas for future work. Results to date have shown this improvement process to be very successful, with throughput rates in excess of 200 tph regularly achieved.

Jan 1, 2006

By T. Takayama Filho

Votorantim Metais Zinco is a smelting facility which produces SHG zinc, zinc alloys, sulfuric acid, liquid SO2, copper sulfate, cadmium metal and silver concentrate. It is located at Juiz de Fora, Minas Gerais State, Brazil. This facility has been operating since 1980 and its current capacity is 95,000 tonnes of zinc per year, using mostly imported sulfide concentrates.The plant uses the conventional roast-leach electrowinning (RLE) process, in which iron is removed from the circuit as jarosite. The residues generated by the RLE process, which amount to about 200 t/day (dry weight), were until 10 years ago, deposited in tailing ponds having no impervious lining. More recently, jarosite and other wastes have been deposited in a properly built reservoir, but this is reaching its maximum capacity. In order to decommission these disposal operations and to reclaim the sites in an environmentally acceptable manner, Votorantim Metais concluded in 2004 a rehabilitation project for the old tailings pond and prepared detailed plans for managing the current and future disposal of jarosite-bearing residues. This paper describes the procedure for removing iron from the hydrometallurgical circuit and discusses the past and current status of the residue disposal sites, as well as the future challenges related to the environmentally acceptable handling of iron residues.

Jan 1, 2006

Case 1: A driller raised a drill rig mast into a 7200-volt overhead power line. Both he and his helper were killed. Case 2: A driller-helper was pulling a winch cable toward a stack of drill steel when the cable contacted a 12,000-volt power line. The helper was killed, and the driller at the rig controls was severely injured. [ ]

Jan 1, 2006

By I. Fafoutis

Laboratory column studies were conducted in order to assess the effectiveness of slag and red mud reactive barriers for cleaning up leachates generated at mining and waste disposal sites and loaded with copper and manganese. Solutions containing the metals of concern were prepared by dissolving the required quantities of CuSO4?5H2O and MnSO4?H2O in distilled water so that Cu concentration was 100 ppm and Mn 20 ppm. Flow rates of 25 mL.h-1 for Cu solution and 75 mL.h-1 for Mn solution were used in order to simulate aquifer water velocities of 1 ft/d and 3 ft/d respectively. Solutions were pumped upflow, in Plexiglas laboratory columns filled with each reactive medium, using peristaltic pumps. Measurements of middle and outflow column pH, redox potential, conductivity and elements concentration were performed to provide information regarding removal mechanisms for both elements and exhaustion/inactivation rates for each reactive medium. Both reactive media showed fairly good removal efficiency over the period studied. Copper was mainly removed by precipitation and formation of Cu(OH)2 while removal of manganese was due to precipitation of Mn(OH2).

Jan 1, 2006

By E. Özberk

Uranium minerals are often associated with iron minerals, and during the hydrometallurgical processing of the uranium ores, iron plays several significant roles. The presence of Fe(III) in solution promotes the oxidative acid leaching for the recovery of uranium. The control of the distribution of impurities in milling and refining is also affected by dissolved iron. When rejected from the process streams, iron usually collects other impurities and contributes to the stabilization of the wastes for final disposal. These roles of iron, as they relate to current uranium processing operations, are discussed in detail, and some broad and historical perspectives are also presented.

Jan 1, 2006

By Paul Hughes

This paper describes a focus of work presently being conducted at the Rock Mechanics Research Group at the University of British Columbia. The underhand method under consolidated fill ensures a high recovery under an engineered back that is comprised of cemented rock fill and/or cemented paste fill. This method of mining has been employed successfully in mines throughout North America as a method of mitigating exposure to the operator having to work under a seismically active ?back?. This paper reviews design methodology in the placement and analysis of sill mats with reference to site observation coupled with on going numerical and analytically derived solutions.

Jan 1, 2006