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By H. Bilgin, Sedat Esen

In this paper, the ground vibrations induced by blasting for stripping work at Sekkoy Open Cast Coal Mine belonging to TKI Yenikoy Lignite Mine (YLI) are investigated and the procedures for monitoring and control of ground vibrations are presented. Ground vibration measurements are conducted in the direction of Turkish Electricity Authorities’ Yenikoy Establishment and social facilities because of the complaints and annoyance arising from this site. Forty ground vibration records are taken in this direction and the vibrations are measured in transverse, vertical, longitudinal components together with peak vector sum. After then the scaled distance relationship is determined at 95% confidence value. Further, Fast Fourier Transform analyses are carried out to determine dominant frequencies for both ground and the structures and amplification factors. When the records taken at four different structures together with the ground are evaluated, it is observed that one of the apartment buildings is amplified the amplitude of longitudinal component 4.3 times. The maximum allowable amount of explosive that can be fired safely at this mine is calculated and recommended on. In the determination of safe amount, 95% confidence line, USBM RI8507 and OSMRE criteria, the dominant frequencies of both ground and the structure, amplification factor and the human response are taken into account.

Jan 1, 2001

By Lon Santis

Although unproven, it is suspected that there have been eleven locations since 1988 where explosive generated carbon monoxide (CO) gas moved through the earth and accumulated in nearby underground enclosed spaces. This paper summarizes the incidents, which involved about 30 suspected or medically verified CO poisonings and 1 fatality. Ten incidents occurred in residences and one occurred in a manhole. Although practically nothing is known about the mechanism behind the suspected gas migration, review of the incidents and available information indicates there are certain warning signs and a successful remediation technique available. In each case, overburden heavily confined the explosive in the blasts, preventing release of explosive-generated gases to the atmosphere. All the blasts were in residential areas, and none were excavated immediately. Where the distance from the blast was recorded, 5 of the blasts were within 20 to 50 feet (ft) (6 to 15 meters [m]) of the underground enclosed spaces, 3 were 100 to 150 ft (30 to 46 m) away, and 1 was 400 to 500 ft (120 to 150 m) away. Investigators often identified suspected pathways from the blast site into the underground enclosed spaces. One technique appeared successful at quickly correcting an existing condition. This technique involved applying negative pressure to the earth and removing the CO from the ground surrounding the underground enclosed space.

Jan 1, 2001

By Alexander Malahoff

The study of why and how life survives in the Extreme environment is a major frontier of science today. Extremophiles are organisms that require extreme environment including high temperature, pH, pressure and salt concentration, or low temperature, pH, nutrient concentration, or water availability. Their common habitats are geothermal vents, pools, lakes and craters of active volcanic regions, such as those of New Zealand, Japan, Kamchatka, Yellowstone USA or the hydrothermal vents of the ocean ridges and submarine volcanoes. These settings are accessible by foot, boat, helicopter, or submersibles. This presentation examines the geology, chemistry of geothermal sites of New Zealand, including the active volcano, White Island, Yellowstone, the submarine volcano Loihi in Hawaii, and sections of the mid-ocean ridges. Designing process and construction of Extremophilic sampling and bioreactor systems used in the study of Extremophiles will be discussed. The driving force behind the research of extremophiles is not only the fundamental science, but also biotechnological potential associated with these microorganisms and their cellular products. The University of Hawaii?s Marine Bioproducts and Engineering Center (MarBEC) is laying the foundations for such new industries.

Jan 1, 2001

By D Stow, M Edmondson

Lemington coal mine is operating in an environmentally sensitive area in the Hunter Valley, NSW, Australia. Late in 1999 the southern pit was developed using a series of box cut blasts. After the initial development the area would have been free dug due to the soft, well-jointed nature of the deposit. However, it was decided to trial drill and blast to determine if shovel productivity could be improved to enable an overall mining cost reduction. The initial trial blast results were less than satisfactory with both environmental issues occurring and the desired shovel productivity not being achieved. An audit of the blasts indicated that wet ground and the presence of soft clay inter-bedded with harder rock caused the poor blast results. Also, water-affected explosive product combined with explosive energy loss into soft ground led to flat spots and tight digging in the hard band areas, resulting in the lower dig rates. Lemington Mine and Orica Explosives developed a plan to match the rock with the appropriate explosive type and energy. This resulted in a number of blasts over a six-month period using a new non fuming explosive product, æNovaliteÆ. The results have been excellent with the environmental issues being totally resolved and dig rates improved, enabling reductions in mining costs. This has allowed the mine to continue with their exemplary record of environmental management whilst achieving operational efficiencies.

Jan 1, 2001

By M Fahey

Large volumes of tailings are produced annually by the goldmining industry of Western Australia. This material ishydraulically discharged into large storage facilities usingsub-aerial deposition methods. Much of the gold comes fromhighly weathered rock, resulting in tailings with significant claycontents. Consolidation of these materials can be very slow,particularly if occurring under the effects of self-weight alone.To optimise the consolidation behaviour of the tailings, disposalstrategies can take advantage of the effects of evaporation byallowing each tailings layer to dry before the next layer isdeposited. In the last 20 years, much of the gold processing inWestern Australia has utilised saline groundwater. As the salinetailings dry, the surface will develop a thin salt crust. Laboratorytests have shown that these crusts can drastically reduce thesurface evaporation, adversely affecting the behaviour of thestorage. This problem has been the focus of an extensive researchprogramme, with the objective of obtaining a fullerunderstanding of the mechanisms controlling the coupledconsolidation and evaporation behaviour of saline gold tailings.Part of this study involved site investigations of a wide range ofstorages to ascertain their current states. Methods of gainingaccess to the tailings following deposition were developed.In situ testing and high quality sampling were conducted on each storage and samples returned to the laboratory for analysis. These investigations have enabled full characterisation of the storages to be accomplished. Examples of data are shown herein and the implications of the results are discussed.

Jan 1, 2001

By Randolph R. Dreher, Michael L. Schreder

"In recent years, FFE Minerals has designed, installed and commissioned several large grinding mill circuits. This paper discusses the issues related to the erection and commissioning of large grinding mill circuits. The three circuits discussed are Collahuasi in Chile, Minera Los Pelambres in Chile, and Century Zinc in Australia. These circuits include large SAG and ball mills with both gear and gearless drive arrangements, as well as, both trunnion and shell supported mills. Aspects of these features are discussed with respect to their impact on installation and commissioning. While the normal challenges of mill erection and start-up were experienced, there were also a few unexpected challenges encountered partly due to the large scale of the equipment. An overview of the equipment and design ratings of these circuits is also provided.COLLAHUASIOverviewThe Collahuasi mills were started-up in November of 1998. The site is located in the Andes Mountains at an elevation of 4300 meters. The grinding circuit includes two lines featuring one SAG mill and one ball mill for each line. The circuit features a recycle conveyor around the SAG mills with provision for adding a pebble crusher in the future. The design tonnage of the grinding plant is 60,000 MTPD with an ore BWI of 10.5 kWh/MT.The SAG mills are 32’ x 15’ (1 3’ EGL) with 10,800 HP drives. The drive arrangements are dual pinion through pneumatic clutches. The mills are driven by low speed synchronous motors with CCV variable speed drives. The SAG mills are trunnion supported and use hydrostatic lubrication. Feed to the SAG mills is via a rock-box type feed chute on a cart. The mills discharge on to trommel screens with a bucket wheel to remove the oversize.The ball mills are 22’ x 36.5’ (36’ EGL) with 12,500 HP drives. The drive arrangements are dual pinion through pneumatic clutches. The fixed speed mills are driven by low speed synchronous motors with GE Quadramatic load sharing drives. The ball mills are shell-supported and feature multi-pad bearings with hydrodynamic lubrication. The mills are fed via a rubber lined sump box with feed spout on a cart. The ball mills also discharge on to trommel screens. Twenty-six inch (26”) diameter hydrocyclones are in closed circuit with the ball mills."

Jan 1, 2001

By R. Tyreman, G. Ritson

"The Red Lake Mine is situated in Balmer Township, Red Lake area in northwestern Ontario. It is an underground mine that has been in production since 1948. The property was originally known as the Dickensen Mine and was shut down in 1996.A feasibility study was carried out in 1998 and it was determined that a new mill should be constructed with a throughput rate of 600 stpd. The life-of-mine average gold grade was projected to be 1.35 oz/t with gold predominantly associated with arsenopyrite and pyrite. Metallurgical testwork indicated that the optimal flowsheet for gold recovery would include an autoclave for oxidation with a carbon circuit for adsorption. To limit capital cost and establish cashflow, the mill was constructed without an autoclave. The recovery by gravity and cyanidation was projected to be 83%. A flotation plant was constructed at the tail end of the circuit to recover the additional gold associated with sulphides from the leach circuit tailings. This material is being stockpiled onsite for future oxidation treatment.Detailed engineering was started in early 1999 and the first gold was poured in August 2000. One feature of the project was the use of Contact Lake equipment from Cameco’s Contact Lake project. The entire mill was purchased and equipment re-used where possible. The capital cost for the process facilities was C$3 1.5 million."

Jan 1, 2001

By Peter Radziszewski

"Comminition process costs, which typically represent an important contribution to mining operating costs, can themselves be divided roughly between energy and liner /charge wear. As such, developing the ability of predicting mill wear will allow a more accurate estimation of wear costs and therefore their control. In this paper and based on the possibility of estimating energy dissipated in impact and abrasion by using a discrete element charge motion model for mill charge motion simulation, media wear will be investigated principally as a function of three wear mechanisms : impact, abrasion and corrosion. Experimental results will be used to identify a total media wear model. Model results will be compared with real mill data from three operating Australian mines. These preliminary results show for the cases tested that the overall average error, as compared with the observed cases, is 0 % with a standard deviation of 66.1 %. Results from the Bond abrasion index tests, for the same cases investigated, give an overall error of 73 % and a standard deviation of 192.5 %. Further work is in progress to improve test procedure, validity and confidence.INTRODUCTIONComminition process costs, which typically represent an important contribution to mining operating costs, can themselves be divided roughly between energy and line / charge wear. In Greenfield situations where the estimation of operating costs is critical in determining project feasibility, the level of confidence in such estimates becomes quite important. With regards to media wear, the Bond abrasion test currently serves as the standard media wear prediction device. However, as shown [l, 21 test results once compared with actual wear rates can vary greatly. Figure 1 shows test results as compared with 15 cases. Average error over this data is 73 % with a standard deviation of 192.5 %. As such, developing the ability of more accurately predicting mill wear will allow greater confidence in wear cost estimation and therefore their control."

Jan 1, 2001

By Gerhard Meyer

A new instrument for the determination of iron., zinc, calcium, and other metals independently directly in the fumes emitted from steelmaking processes is described. Based on the well- accepted method of X-ray fluorescence, the instrument can detect numerous metals simultaneously in the fume as well as report their concentration on a mass per unit time basis real time to a control room computer. The instrument mounts on the wall of the fume duct and can., via a small opening, directly view the hot exhaust plum inside the duct. The concentration of metal in the fume over time has been shown to change dramatically depending on process variables. Variables such as oxygen flow rate, lance height and nozzle configuration., slag condition., and episodic scrap addition can affect the presence of metal particles and fume in the exhaust. An analysis response time of 6 seconds enables better control of the steelmaking process thereby conserving primary resources and reducing environmental impact.

Jan 1, 2001

By Graham Holmes, John Starkey

"The Kinross Kubaka Project is a gold mine located in the Russian Far East. The grinding circuit, comprised of a 6.1 m diameter x 2.74 m long SAG mill and a 4.1 m diameter x 5.5 m long secondary ball mill in closed circuit with cyclones, was built using SAG Power Index and Bond Ball Mill Work Index testing to determine the grinding energy requirements. Extremely cold climatic conditions and the need to keep heated space and capital costs to a minimum, dictated a grinding circuit with no in-circuit crusher and no conveyors external to the mill. High energy requirements for both the SAG mill and the ball mill were correctly predicted and have allowed grinding production tonnage forecasts to be met. Design test data and production results are given.INTRODUCTIONIn 1995 Davy International Canada, now Kvaerner Metals E & C, was commissioned as the Engineer and Project Manager for the Omolon Gold Mining Company, to design and construct a gold extraction plant for the Kubaka gold deposit, located in the Russian Far East. This deposit had been studied extensively in Russia during the exploration phase and a Feasibility Study was completed in 1993 by Kilborn who visited the site twice during that year to inspect facilities and to take metallurgical test samples. More samples were taken in 1995 to check ore hardness variability, as part of the final design program by Davy.The client’s objective in designing the Kubaka grinding circuit was to achieve design tonnage at all times, even when milling the hardest ore zones in the deposit. Since the samples taken in 1993 were taken as composite samples, it was necessary to take additional samples in 1995 to determine the extent of the variability. Six samples were sent to Canada for SAG Power Index (SPI) testing. Five of these were combined as a composite open pit sample, while the sixth sample was taken from the site adits as a composite sample to represent undergound ore. These two composite samples were tested to determine the MacPherson Autogenous Work Index for comparison with the SPI values."

Jan 1, 2001

By Thierry Bernard, Philippe Dozohne

May 13th, in the back country of Nice @arice) collapsed a complete piece of mountain, cutting the RN 2085 and destroying a part of Valabfre’s viaduct. The fist inspections of the site showed that materials had broken loose from surrounding cliffs, The geologists discovered that a block of several thousands of m3 remained suspended in cliff and that it presented a risk raised of gliding. Decision to destroy it by blasting in one blast was there taken by the French department’s council of the Maritime Alps. A race against the clock engaged. Indeed, the RN on 2085 is the main axis connecting the village of Saint Etienne de Tinee and the resort station of ISOLA in the centre of Nice

Jan 1, 2001

By E. Contestabile, B. von Rosen

On August 5th, 1998, a tractor-trailer carrying approximately 18,000 kg of blasting explosives, struck a rock face on the side of the road near the town of Walden, Ontario. Eye-witness accounts of the incident state that there was an intense fire for approximately 30 minutes before the detonation. The detonation caused severe damage to the tractor-trailer, shifted the pavement and caused blast damage to the rock face. A rock fragment was recovered almost 2.5 km from ground zero and a 70 kg piece of an axle assembly was recovered over 1 km from the site. Windows were cracked at distances of almost 3 km.

Jan 1, 2001

By S Bhandari

This paper is a step in the direction of developing a computer model of the near source dispersal of suspended particulate matter (SPM) in planetary boundary layer (PBL). Since Surface Mine blasting is done during daytime, study of daytime dispersion in convective boundary layer (CBL) is relevant to the mining engineers. The scope of this paper covers dispersal after the blast in any type of PBL ie stable, convective and neutral but only under weak wind condition. Mathematical analysis of the dispersion of vertical dust column has been carried out during weak wind conditions in a tropical meteorological environment. It is noted that dust concentration reaches its maximum value some distance away from the point of blast, immediately after the blast (t*=1) and thereafter rapidly decreases. After a short interval from the time of blast at t*=11 the dust concentration shows linear decrease in concentration with distance. Dust concentration also rapidly drops during the interval t*=1 to t*=11, thereafter, rate of drop is nearly the same at any distance from the point of blast.

Jan 1, 2001

The risks faced by organisations are part of a risk continuum. They can be evaluated in terms of hazard, uncertainty and opportunity as well as by the degree of influence they have on conformance, operating performance and strategic objectives. This paper discusses the application of risk management techniques for mitigating blasting hazards, reducing blasting output variability, and implementing blast improvement opportunities. Effective risk management practices can identify and evaluate risks across all levels of the continuum and can deliver realistic assessments of the likelihood and impact of risks on the companyÆs safety and business objectives. This paper does not attempt to present technical details about blasting, rather it aims to provide enough blasting context and examples so that the practical benefits of applying the risk management process to blasting can be fully appreciated. The topics discussed include: explosive management plan; statistical process control; quality blasting, rock-on-ground; Blast Management; Mine to Mill optimisation; and blasting information systems. The concept of a blasting risk management system employing a continuous improvement loop is also introduced. On reflection the insights presented should be extremely useful for observing and understanding which risk face has management focus at a mine site or for a blast site.

Jan 1, 2001

By S. Kim Juniper

The discovery of chemosynthetic-based ecosystems at hydrothermal vents in the deep ocean was arguably one of the most important findings in biological science in the latter half of the 20th century. More than 100 vent fields have been documented along the 60,000 km global mid-ocean ridge system. Over 500 new animal species, over 80% of which are endemic to the vents, have been described from this environment. Unusual, highly evolved symbioses between invertebrates and chemolithautotrophic bacteria are common at vents, producing concentrations of biomass that rival the most productive ecosystems on Earth. Hydrothermal vents ecosystems, because of their very limited area and the presence of endemic species, are highly vulnerable to human disturbance. Mining for polymetallic sulphide deposits poses the greatest future physical threat to hydrothermal vents and their biological communities. However, there is more immediate concern about the impact of concentrated scientific research activities. Some sites have been revisited by several research expeditions per year for more than a decade. As vent sites become the focus of intensive, long-term research, oversight organizations are discussing mitigative measures to avoid significant loss of habitat or oversampling of populations. Canada recently became the first national jurisdiction to set aside a hydrothermal vent site as a Marine Protected Area.

Jan 1, 2001

By Remo Grandori

The Umiray Angat 13,2 km long tunnel in Philippines have been bored through extremely variable and difficult ground conditions including a number of special events. In particular the following adverse conditions were found: faults in decomposed ground, high temperature rocks, extremely rapid and important convergence phenomena, water inflows up to 800 litres per second. The special El Nino climatic conditions caused a long dry season and lower the level of the lake that was granting the access by barge to the site under the minimum navigable level. Many equipment have had therefore to be transported to site by a 10 ton capacity helicopter, after having been partially dismounted. For the same reason most of the tunnel drive have been bored servicing the site by 1 ton capacity helicopters to transport materials, spares and personnel. In order to overcome the above geological and logistic problems several innovation were introduced and tested in this project. Despite all that difficulties the 13,2 km of tunnel were bored in about 24 months, with a global average of 500 m/month.

Jan 1, 2001

By Callie Covert

This paper describes the application and results of a more efficient method of breaking boulders using dynamite and water. This method is being used for the disposal of boulders that result from pinnacle and cap rock remaining after blasting on highways and job sites. This method is a faster and less expensive use of dynamite to reduce oversized boulders than the conventional rock hammer. The problem with excessive fly rock has been substantially reduced when using this technique over traditional methods.

Jan 1, 2001

By M Spiteri, S Woth, J Caratti, K Henley

Blasting is an essentially violent process aimed to disrupt and loosen rock for productive excavation and downstream processing. Dilution of the orebody to some extent is the inevitable result, particularly in narrow vein gold mines. A small change in gold recovery is usually a strong lever on revenue generation. As a result blast designs are carefully engineered to both minimise and control the direction of rock movement. Traditionally blast designs in gold mines have used the minimum powder factor that will still permit rock excavation. This now conflicts with the recent industry trend to optimise the total process flowsheet from the mine to the mill. Numerous mines have achieved success in reducing total mining cost by increasing powder factors. Not only is explosive energy cheaper than mechanical comminution energy requirements, the increased blasting effect may deliver benefits across all downstream processes of digging, hauling, crushing and milling. Kalgoorlie Consolidated Gold Mines (KCGM) Fimiston operation is the largest gold mine in Australia, located in the heart of the Kalgoorlie Goldfields. Blast dilution has been reduced at KCGM by managing location of blast boundaries and by firing along strike to choked faces. Significant economies of scale have resulted from application of a bulk mining methods. The bench height of 10 m is the largest in the Western Australian Goldfields, and is typically mined in a single pass with large face shovels. Recent increases in production rates in both the mine and mill has been partly attributed to a 30 per cent increase in powder factor. KCGM then examined the benefit of a further 18 per cent increase in powder factor to 1.0 kg/BCM. A concern though was the impact of very high powder factors resulting in excessive blast movement and subsequently ore dilution. This was the subject of a project conducted with Orica Explosives. OricaÆsDMC(Distinct Motion Code) blast model was applied to understand the effect of not just further increases in powder factor but also blast geometry and explosive type. The modeling work demonstrated that high powder factors may be applied with minimal increase in ore dilution provided the combination of blast geometry and explosive type is optimised. These results are currently being implemented to achieve further reductions in total mining costs without a significant impact on recovery.

Jan 1, 2001

By A. Paulin, J. Roth, S. Spaic

This experiment was carried out to see whether copper-iron ingots from Late Bronze Age hoards could have been produced by smelting ferruginous copper ores. Since ferruginous copper-ores are chalcopyritic, chalcopyritic concentrate from a present day copper mine was dead roasted in our experiment in lieu of a rich chalcopyritic ore. Charcoal was used as a reducing agent in the reduction of calcine (i.e., a product of dead-roasting), and quartz sand was used as a flux. Two separate metallic solutions, a copper-base and an iron-base alloy, were obtained as a result of two factors: the presence of carbon and the miscibility gap in the Cu-Fe-C system. The metallic melts appeared in a form of bigger or smaller droplets, enclosed by a molten slag which, during the cooling, solidified into metallic beads. The presence of both metals was noticed in the majority of the examined beads. It was therefore concluded that calcine consisted of an intimate mixture of oxides of both metals which were simultaneously reduced during the reduction process. Due to the miscibility gap in the Cu-Fe-C system, separate iron and copper regions were formed in the beads. In both regions, sulphide inclusions were found. The formed molten copper and molten iron solution were found to be saturated solutions. The metallographic analysis revealed the precipitation of iron out of copper and that of copper out of iron during the cooling and solidification of melts. The formed slag contained little iron and no copper oxide.

Jan 1, 2001

By Bernard Dallaire, Jean Cayouette, Sylvain Duchesne

"Louvicourt Mine's concentrator, located near Val d'Or, Quebec, treats an average of 4,300 tonnes of ore per day composed mainly of copper, zinc, gold and silver. An analysis of concentrator revenues and metallurgical losses shows a potential for additional gain, particularly in regards to precious metals (kustelite) where recovery is usually around 67 -70 %. The planning, installation and trial operational period of two Outokumpu SK-240 flash cells at the underflow of the primary cyclones took two years. The use of (( flash flotation )) technology has made it possible to exploit the favourable conditions at the underflow of the primary cyclones such as precious metal concentration and the presence of liberated coarse chalcopyrite. These conditions permit early flotation (fresh surfaces) of the kustelite and the liberated copper. Since the start-up of the flash cells, the metallurgical gains have turned out to be very positive with increases in metal recovery reflected in appreciable NSR gains. Also, significant savings in reagent consumption and a coarser copper concentrate have made it possible to reduce the drying cycle of the Larox filter presses since the cells were put into operation.BACKGROUNDLouvicourt Mine is operated by Aur Resources Inc. (30% ownership) on behalf of its partners Novicourt Inc. (45%, subsidiary of Noranda Inc.) and Teck Corp. (25%). The mine is located in northwestern Quebec about 600 km north of Montreal and about 25 km east of the mining town of Val d'Or. The mine commenced commercial production in July 1994.The massive sulphide ore deposit lies at depths varying between 450 m and 900 m. Mining reserves (2% Cu equi. cut-off) as of Jan. Is', 2000 are estimated at 7.5 million tonnes of ore averaging 3.4% Cu, 1.8% Zn, 28.0 g/t Ag and 0.9 g/t Au. Delineated ore reserves permit the use of a mechanized transverse blasthole mining method. The extraction order is a typical 1.3.5 mining sequence. Primary and secondary stopes are 15 m wide, 15 to 70 m long (25 m long average) and 30 m high. Backfilling for pillar recovery and regional stability is required."

Jan 1, 2001