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By Michael J. Lord, Richard H. O. Wagner

"The technologies used in the mineral processing of ores are being increasingly applied to the identification and remediation of metal contaminated industrial, military and landfill sites. The objective of mineral processing treatment of contaminated site material is to restore the value of the land and to concentrate the contaminants into a very small volume of separated material which, depending upon its nature, can be further processed, marketed, or sent to a landfill. A systematic characterisation of the site material is first undertaken. Bench and pilot testing follows to evaluate criteria for metal separation. The testing may examine one or more physical or physico-chemical reprocessing methods, singly or in combination, for the remediation of the test samples. These mineral processing tests determine the % metal removal fiom the soil and the contaminants concentrated from the medium. The usefulness of mineral processing testing for site remediation flowsheet design and execution is illustrated by the case studies presented. This paper will present the test results of three case studies: an industrial site decontamination, the cleanup of a small arms firing range, and the reclamation of property within a landfill.INTRODUCTIONEnvironmental legislation and our society’s quest for a cleaner environment has led to the application of mineral processing expertise and technology for industrial site decontamination, military site cleanup and landfill reclamation. Although the required level of decontamination varies between jurisdictions, a site becomes a candidate for decontamination once the contaminant concentrations are found to exceed the Canadian Council of Ministers of the Environment (CCME) Interim Remediation Criteria for soil (decommissioning guidelines) or applicable provincial guidelines. The objective of mineral processing treatment of contaminated site material is to restore the value of the land and to concentrate the contaminants into a very small volume of separated material which, depending upon its nature, can be further processed, marketed or disposed of in a landfill"

Jan 1, 1999

By R. R. Bhappu

The metallurgical processing industry is in the midst of a hydrometallurgical revolution with mining companies looking for low cost, energy efficient and environmentally friendly technologies for processing sulfide ores and concentrates. The Intec Copper Process is one of the most advanced of these technologies and has the potential to greatly change the way copper concentrates are treated in the future. Specifically, the Intec process has the ability to be built on a small scale and at mine sites while being much more economic than conventional smelting. Intec Copper has constructed a I tonne of copper per day demonstration plant in Sydney, Australia designed to verify metallurgical and operational performance. This paper will describe the process in more detail and provide preliminary results of the process based on the plant's performance. It will also compare the Intec Copper Process with a few of the competing technologies and evaluate the relative economic merits of Intec.

Jan 1, 1999

By André Pomerleau, Michel Grégoire, René del Villar

"The operation of industrial flotation columns requires the control of at least two variables, the interface position and the bias rate, by manipulation of some appropriate operating variables. Problems arise due to the reliability of existing methods of measuring the bias (i.e bias = tailings water - feed water), a situation which has often forced the industry to disregard this control loop. Moreover, when using such a measuring approach, the identification of the process dynamics is impossible. A second problem arises from the possible interaction between both control loops that might call for the use of a more complex multivariable control strategy.Recent work done at Lava1 University has demonstrated the feasibility of an independent sensor for bias, which models the relation between the conductivity profile across the interface and the bias value using a neural network algorithm. A 250 cm height, 5.25 cm diameter Plexiglas laboratory column was equipped with a series of conductivity electrodes in its uppermost part (across the interface) to measure both interface position and bias rate. Using such equipment, the flotation column dynamics were identified. The results thus obtained permitted the design and implementation of a distributed PI control strategy, where bias was associated to wash water rate and froth depth to tails rate. Both PI controllers were tuned using a frequency-response tuning method. Results of both identification and process control are presented and discussed.INTRODUCTIONFlotation columns are used for the separation of valuable minerals from a carrier gangue. Typically, this device is a tall (9 to 14 m height) cylinder (1 to 3 m in diameter) although other cross sectional shapes are also used. Finely ground ore is fed as a pulp at about 2 m from the top of the column, and pressurized air is introduced through a sparger at the bottom. If the pulp has been properly conditioned with adequate chemical reagents (collectors and modifiers), the valuable mineral particles falling by gravity will attach themselves to the rising air bubbles, and the air-particle aggregates will rise to the top of the column where they overflow as a stream called the concentrate. The gangue particles,, that do not attach to the air bubbles, fall down the column being withdrawn at its bottom in a stream called the tails.A particular characteristic of flotation columns is the addition of a fine spray of water at the top. As the water flows down through the froth zone, it washes out the entrained gangue particles from the mineralized bubbles, thus improving the quality of the concentrate recovered at the top. As a result of its cleaning action, this water stream is called the wash water and the upper zone, the cleaning zone. In order to ensure a downward flow of wash water, a proper water balance must be kept in the froth zone, otherwise the water added at the top might shortcircuit to the concentrate without performing any cleaning action. This net downward flow of water inside the froth zone is called the bias and represents an important operating variable of a flotation column."

Jan 1, 1999

By J. E. Dutrizac, J. B. Sunstrum

"Lead was among the first metals known to man, and there are indications that lead was produced by the reductive smelting of galena in the mountains surrounding the Black Sea as early as 3000 B. C .(1). The early metallurgists soon discovered that silver could be recovered from lead bullion by cupellation techniques, and that the litharge product of the cupellation process could be reduced to give silver-free lead metal. By the Graeco-Roman era, lead-silver ores were being extensively exploited for both their silver and lead contents. Although silver was always of prime concern, a number of industrial uses existed for lead that included piping and sheeting. Subsequently, lead metallurgical practice developed steadily in different parts of the world, and was a relatively mature technology by the time of the European colonization of North America. In the United States, lead was produced on a small scale as early as 1720, and by 1800, the extensive Pb-Zn deposits of Missouri-Kansas and the upper Mississippi Valley were being developed(2). Many of the early American lead ores were low in silver, and seemed to have been worked primarily for their lead contents. Major uses of lead at the time included bullets, pipe and sheeting. During the period 1860-1890, the silver-rich galena ores of the western United States were exploited, and a number of lead smelters were operated. Although all the smelters produced lead metal, the recuperation of the associated silver and gold values was generally of prime concern. In Canada, lead deposits are abundant, and galenarich outcrops frequently attracted the attention of the early explorers and prospectors. In fact, the first record of a Canadian ore deposit seems to have been the observation of an argentiferous galena vein near Lake Temiscamingue in 17 41(3). The presence of silver-bearing lead deposits naturally attracted the attention of the mining community, and many outcrops were worked throughout the country. Because of the problems associated with transporting lead concentrates to existing American or overseas smelters, attention soon shifted to the establishment of local lead smelting facilities. The purpose of this article is to examine those early smelting efforts and to try to identify the first ""successful"" Canadian lead smelter."

Jan 1, 1999

By S. C. Tadolini, J. M. Goris, J. L. Gallagher

Cable supports offer several advantages over traditional secondary support methods by enhancing stress redistribution to pillars and gob areas, minimizing or eliminating timbers and cribs that reduce ventilation, eradicating material-handling injuries related to placement of crib supports, and providing a cost-effective alternative to secondary support. The U.S. Bureau of Mines (USBM), researching alternatives to traditional roof support methods, designed and installed high-strength cable supports to improve the stability of longwall gate road entries in a western U.S. coal mine. With the cooperation of industry, methods were developed to install and evaluate cable supports in a tailgate area using traditional resin cartridges. The cable-bolted areas successfully maintained roof support throughout the developed entries. Cable supports have replaced wood cribbing as secondary support in the bleeder entry system and have minimized or eliminated the use of cribbing in the longwall tailgate entries. This paper describes the theory, application, and advantages of cable supports and presents some mine measurements made to assess the cable performance during the retreat process of longwall mining.

Jan 1, 1999

By A. A. Smithen

There is an increasing awareness of the importance of including an assessment of environmental liabilities in the preparation of bankable feasibility documents. This means that environmental assessments of proposed, existing and decommissioned mine sites have to be undertaken for the purposes of quantifying environmental liabilities and assessing potential risks. This paper examines the need for considering environmental liabilities before describing the approach adopted in undertaking due diligence studies for the preparation of bankable feasibility documents and some of the difficulties experienced. Finally, some concluding remarks are made and the implications for the mining industry are discussed.

Jan 1, 1999

By Belinda F. Arbogast

Reclaimed mine sites have been evaluated so that the public, industry, and land planners may recognize there are innovative designs available for consideration and use. People tend to see cropland, range, and road cuts as a necessary part of their everyday life, not as disturbed areas despite their high visibility. Mining also generates a disturbed landscape, unfortunately one that many consider waste until reclaimed by human beings. The development of mining provides an economic base and use of a natural resource to improve the quality of human life. Equally important is a sensitivity to the geologic origin and natural pattern of the land. Wisely shaping our environment requires a design plan and product that responds to a site's physiography, ecology, function, artistic form, and public perception. An examination of selected sites for their landscape design suggested nine approaches for mining reclamation. The oldest design approach around is nature itself. Humans may sometimes do more damage going into an area in the attempt to repair it. Given enough geologic time, a small-site area, and stable adjacent ecosystems, disturbed areas recover without mankind's input. Visual screens and buffer zones conceal the facility in a camouflage approach. Typically, earth berms, fences, and plantings are used to disguise the mining facility. Restoration approaches the best land use as restoring to its original condition. Rehabilitation targets social or economic benefits by reusing the site for public amenities, most often in urban centers with large populations. A mitigation approach attempts to protect the environment and return mined areas to use with scientific input. The reuse of cement, building rubble, and macadam meets only about 10% of the demand for aggregate. Recognizing the limited supply of mineral resources and encouraging recycling efforts are steps in a renewable resource approach. An educative design approach effectively communicates mining information through outreach, land stewardship, and community service. Mine sites used for art show a celebration of beauty and experience-abstract geology. The last design approach combines art and science in a human-nature ecosystem termed integration. With environmental concerns, an operating or reclaimed mine site can no longer be considered isolated from its surroundings. Site analysis of mine works needs to go beyond site-specific information and relate to the regional context of the greater landscape. Understanding design approach can turn undesirable features (mines and pits) into something perceived as desirable by the public.

Jan 1, 1999

By Mark Colwell

This paper summarizes the results of a research project whose goal was to provide the Australian coal industry with a chain pillar design methodology readily usable by colliery staff. The project was primarily funded by the Australian Coal Association Research Program and further supported by several Australian longwall operations. The starting point or basis of the project was the Analysis of Longwall Pillar Stability (ALPS) methodology. ALPS was chosen because of its operational focus; it uses tailgate performance as the determining chain pillar design criterion rather than simply pillar stability. Furthermore, ALPS recognizes that several geotechnical and design factors, including (but not limited to) chain pillar stability, affect that performance. There are some geotechnical and mine layout differences between United States and Australian coalfields that required investigation and, therefore, calibration before the full benefits offered by the ALPS methodology could be realized in Australia. Ultimately, case history data were collected from 19 longwall mines representing approximately 60% of all Australian longwall operations. In addition, six monitoring sites incorporated an array of hydraulic stress cells to measure the change in vertical stress throughout the various phases of the longwall extraction cycle. The sites also incorporated extensometers to monitor roof and rib performance in response to the retreating longwall face. The study found strong relationships between the tailgate stability factor, the Coal Mine Roof Rating, and the installed level of primary support. The final outcome of the project is a chain pillar design methodology called Analysis of Longwall Tailgate Serviceability (ALTS). Guidelines for using ALTS are provided.

Jan 1, 1999

The Cadia Mine is located 25kms South West of Orange in the central west of New South Wales (NSW), Australia (Figure 1). Orange is a major regional centre with a population of 35,000 people. Cadia has a history of mining and exploration dating back to 1851 and shortly after the first Australian gold rush at Ophir, north of Orange. Newcrest Mining commenced an exploration program at Cadia Hill in 1992. This identified a substantial zone of copper and gold mineralization. Subsequent resource definition drilling defined an orebody with a mineable reserve of 200 million tonnes of ore with an average gold grade of 0.74g/t and 0.17\ copper. A full feasibility study commenced in 1994, approvals to proceed with development were granted in September 1996 and the processing plant was commissioned in July 1998. The project came in on budget at A$440 million and on time, 24 months from design to construction. The estimated operating cost at the time of commissioning was A$8.85/t of mill feed.

Jan 1, 1999

By J. E. Dutrizac, J. B. O'Reilly

"Zinc is a relatively abundant element which occurs as both high-grade sulphide ores {sphalerite ZnS) and oxide ores which the ancients collectively termed ""calamine"" (smithsonite ZnC03 and/ or hemimorphite Zn4Si201(0H)2 - H20 and/ or hydrozincite Zn5(C03) 2(0H)6). Although oxidic zinc is readily reduced by carbon, the process becomes thermodynamically viable only at - 1000°C, and at this temperature the zinc is released as a vapour (B.P. 907°C). Casual cooling of the vapour results in its re-oxidation by excess combustion air or even the carbon monoxide product of the reduction reaction. ZnO + C = C09,, + Zn vapom Only fairly rapid quenching of the zinc vapour and the isolation of the reduction products from the combustion gases will yield metallic zinc; these conditions were not produced deliberately until the advent of distillation technology. Until quite recently, the principal use of zinc was in brass manufacture; galvanized iron was not discovered until the 19th century and zinc casting alloys are a relatively recent invention. As will be seen, brass could be produced without recourse to a pure zinc intermediary, and the discovery of brass preceded that of zinc by many centuries. The purpose of this paper is to outline the discovery and early development of both zinc and brass with special reference to the European scene."

Jan 1, 1999

By F. McGravie, S. T. Solinski, W. W. Robertson

During this, the Centennial year of the discovery of the Hall-Heroult process, it seems appropriate to review some of the developments which have taken place in Canada and to explain why it has become an important world centre for the production of primary aluminum. For many years after it was recognized that the element aluminum existed, scientists were frustrated in their efforts to isolate it. In the early 1800s H. C. Oersted and Frederick Woehler prepared small quantities sufficient to measure some of the physical properties. A quasi-commercial process involving reduction with metallic sodium was developed by the French scientist H. St. Claire Deville in 1855 but the cost was very high ($30. 00 per kg). It was not until 1886 that Charles Martin Hall in the United States and P.L.T. Heroult in France, more or less simultaneously but completely independently, discovered the process which is essentially that in use today. Some of the early pioneers in the industry quickly recognized the potential of the hydro-electric resources in Canada as economic energy suppliers for aluminum production. The first commercial production in Canada was in Shawinigan, Quebec in 1901, only 15 years after the process was discovered. Subsequently operating plants were established at nine different locations in Canada (Quebec and British Columbia) (Table 1). Operations continue today in all locations except one (La Tuque). The table shows present plant capacity which for the older plants was reached in an evolutionary manner including replacement of obsolete capacity or upgrading and modernization of existing designs.

Jan 1, 1999

By G. H. Blackwell

Open pit mine management must ensure that sufficient trucks are available and are being used effectively for production, and that operating costs are under continued control and review for improvements. This paper describes methods for estimating truck fleet requirements which have been used effectively at large- and medium-sized open pit mining operations. Applied to commonly available data, multiple regression analyses can indicate when mine plans should be revised toward optimizing the number of trucks required. Prediction of major cost items for budgetary purposes is addressed, along with an example of how readily available production data can be used to reduce costs systematically.

Jan 1, 1999

By Dolf Gielen

This paper discusses the results of a Western European energy and materials systems engineering study that analyses the impact of greenhouse gas (GHG) emission reduction on the future of the steel and aluminum industry. he technology selection will be significantly affected by future CO2 policies. The avail- ability of C02 removal and storage technology and the social acceptance of this strategy for GHG emission reduction is of key importance for the strategy selection. The use of coal based smelting reduction technologies is optimal in case of weak C02 policies or in case of strong C02 policies and low CO2 removal and storage costs. The selection of CCF or Corex technology depends on the penalty regime. However, if C02 removal proves to be problematic, CCF development fails and strong C02 policies are introduced, the gas based DRI production processes will become more attractive. In both cases, the energy efficiency of the iron and steel industry will further increase in the next decades. The impact of GHG emission reduction on aluminum prices and aluminum use can be significant. However contrary to common notions the aluminum production will be positively affected by GHG emission reduction, notwithstanding the currently high emissions in aluminum production. A combination of emission mitigation in production and significant GHG emission reduction effects further down the product chain cause this effect. A significant potential exists for improved materials efficiency. This potential is generally neglected in energy efficiency and CO2 reduction studies. However improved steel qualities are of similar importance for C02 emission reduction as increased energy efficiency. It remains to see if this potential will be used to its full extent in the next decades. Model calculations indicate that the impact of C02 policies on the competition with other materials will be limited. Greenhouse gas emission mitigation will have much more impact on materials production and waste handling than on materials consumption.

Jan 1, 1999

By John Frostiak, Lloyd Buckingham, Kenneth G. Thomas, Luis Wilson

"The El Indio roasting facility associated with El Indio Mine in Central Chile has operated since 1981. It is a facility developed to remove arsenic and antimony from gold bearing enargite/pyrite flotation concentrates.The three installed roasters are Nichols Herreschoff units each with 14 hearths and measuring 4.85 metres diameter. Hearths are rabbled by central shaft driven rabble arms. Product is progressively heated to 750°C under neutral to reducing atmospheric conditions to drive off labile sulphur, arsenic and antimony.Ancillary equipment includes skip hoist feed arrangements, water cooled screw conveyors for transporting and cooling calcine, gas cyclones, post combustion chambers, heat exchangers, electrostatic precipitators, bag houses, gas scrubbers and packaging facilities .Operating practices, history, mineralogy and results are reviewed. The improvements to arsenic and antimony extraction, ambiental conditions and environmental achievements are discussed.INTRODUCTIONHistoryThe El Indio property lies in the El Indio belt, a copper, gold and silver area approximately 175 km long by 10 km wide. The property is located in the Andes Mountains of the central part of Chile at latitude 30"" South and 160 km from the sea-side city of La Serena. Plant location is at 3850 meters above sea level.The property currently consists of two underground mines feeding the El Indio plant and an open pit feeding the newer Tambo leach plant. The property has been controlled by a succession of owners (St. Joe Minerals, Fluor, Bond Gold International and Lac Minerals Ltd.) before acquisition by Barrick Gold Corporation in 1994."

Jan 1, 1999

By Weber P, Sneyd S

The total world steel production in 1998 amounted to approximately 780 000 000 t. The share of electric steelmaking was in the range of 35 per cent and is expected to increase further to over 40 per cent of the world's production within the next ten years. As electric steelmaking is primarily based on the use of scrap and as it is progressing more and more into higher steel grades the need for low-residual metallics will become increasingly important. Consequently, the demand for scrap substitute material will increase, reflected in the world wide spate of interest for DRI (Direct Reduced Iron) and HBI (Hot Briquetted Iron). The increased significance of DRI/HBI as a substitute for steel scrap has obviously emanated also from its comparatively lower and more predictable costs per ton and definable chemistry. In 1998 already 37 million tons of DRI/HBI were globally produced.

Jan 1, 1999

By Fogarty J. G H

Ausmelt Technology has a unique capability of removing the impurities, phosphorus and sulphur, from the feed materials to the process. Sulphur is removed to the gas phase almost completely because of the interactions of ore and coal in the reaction region at the top surface of the slag bath. Phosphorus is removed to the slag phase, with both basic and higher, controlled iron oxide levels in slag being achieved in the process. The significance of these features of the process relate to the production of pig iron with very low levels of these impurities for the further processing to steel, and to the treatment of high phosphorus and high sulphur raw materials. The marketability of pig iron and the raw materials are discussed in relation to this feature of Auslron.

Jan 1, 1999

By D. Kump

The Bullfrog Mine is an underground gold mine that uses the underhand-cut-and-fill mining method. The portal was established on June 18, 1991. Mining is expected to be completed by the summer of 1999. This paper starts by discussing what it took to get from nothing to 2000 tons-per-day backfill, and ends with a hindsight commentary on things that did and did not help.

Jan 1, 1999

By A J. Burchell

The introduction reviews the tunnelling carried out in Singapore since the early 1980s. Between 1983 and 1990, Phases 1 and 2 of the mass rapid transit system were constructed. These included some 20 km of bored and cut and cover tunnels together with 18 underground stations. Some particular points of interest in this massive project are briefly commented upon. Reference is also made to other underground or underwater schemes undertaken during this period such as the proposed large caverns project and the submerged tunnel to Pulau Seraya. A description of the subsurface works, now under construction in Singapore, follows. This includes an all underground North-East railway line 20 km long with 16 stations. At a budget of US$ 3 billion, this is a major civil engineering undertaking. Another project is the extension of the railway to Changi Airport which involves 3.5 km of twin tube tunnelling together with a major underground station which is fully integrated into the airport terminals. An on-going program of further major railway extensions over the next 10 to 15 years is in place and an outline is given of some of the most important underground sectors. Other proposed projects such as the underground roads system and the deep level sewers are briefly described. Together they demonstrate the very significant volume of underground construction scheduled for the next century in Singapore.

Jan 1, 1999

By Chidchai Loyprasert, R. A. Stoehr

"A computer model has been developed to predict grain structures in alloys solidified under unidirectional flow using a combination of three techniques -- solution of the equations for flow of an incompressible fluid bounded by curved surfaces by the SOLA-SURF algorithm, calculation of heat flow by a finite difference method, and simulation of grain formation by a two-dimensional cellular automaton (CA) model. The changing rigid surface has been taken into account. Heterogeneous and homogeneous nucleation are considered, and the growth kinetics of a dendrite tip are evaluated by the Kurz-Giovanola-Trivedi (KGT) model. These calculations were applied to solidification of an Al-4.5% Cu alloy flowing over a chill on the bottom of a channel, a system for which experimental results were available. Using a variety of flow rates and superheats, agreement between the computed and experimental results were very good including transitions between columnar and equiaxed grains, the aspect ratio of the grains, and the inclination of the grains to the flow.IntroductionModeling of casting and solidification processes has developed over the years along two distinct tracks: (1.) modeling of macroscopic heat transfer and fluid flow for design purposes, and (2.) modeling of microscopic processes such as nucleation and growth in order to improve the scientific understanding of the phenomena involved. The present work is an attempt to combine the macroscopic and microscopic approaches for the solidification of an alloy flowing over a chill. The specific case chosen is that of an aluminum-4.5 % copper alloy flowing linearly over a water-cooled copper chill for which experimental results were available over a range of flow rates and superheats. For the macroscopic calculations, the SOLA-SURF algorithm for solution of the twodimensional fluid flow equations was combined with the finite difference method (FDM) for calculating heat transfer. For the microscopic calculations, heterogeneous and homogeneous nucleation were considered, and the growth kinetics at the dendrite tips were evaluated. The cellular automaton (CA) technique was used to apply the microscopic kinetics to the temperature and .flow conditions."

Jan 1, 1999

Maximizing margins in competitive markets demands superior productivity. Unfortunately, management systems developed early this century for other industries often drive counterproductive behaviors choking mining productivity. Many executives and managers waste valuable time and effort relying on simply training and communicating to improve managerial practices and attitudes. In covering practical human behaviour, the paper explains why this fails -and explains how to use systems to successfully drive improved managerial practices and attitudes. It highlights use of modern performance Measurement, Analysis and Reporting systems to drive behaviors and improve margins -without capital investment -and make executive and managerial work easier and more effective.

Jan 1, 1999