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Cost reduction programs can focus on total cost or unit cost, but unit cost is usually the principal objective. The production cost per unit is: [Unit cost = Total cost Production volume] Consequently, any activity that reduces the total cost or increases the production volume will reduce the unit cost. Production volume is increased by (1) maximizing the availability of the production equipment and (2) maximizing equipment performance during periods of operation. Most operations managers routinely focus on volume because the factors influencing volume are generally well understood and congruent with the managers' technical skills. In fact, production volume (as a percentage of maximum achievable capacity) is widely recognized as one of the most significant measures of operational performance.

Jan 1, 1999

The arbitration process, and its drawbacks: Any time you have taken part in a major arbitration, and the decision, when it comes out, is not what you thought it would be (which is bound to happen occasionally), the normal reaction is something like æthe arbitrator got it wrongÆ. Again normally, when you have cooled down a bit, and you look in more detail at the decision, you can see, probably, æwhere he got it wrongÆ (it is only male arbitrators who get it wrong). Ultimately, when reason prevails, and you reflect on it, you can see that what really happened was that you failed to get the arbitrator to see what you were getting at in the point or points concerned. This is doubly frustrating, when you consider what has been involved in getting to this point, having been through it all at least twice. An alternative to this process may be the dispute review board.

Jan 1, 1999

By Sue Xue, Carl C. Nesbitt

A project was completed which investigated the efficacy of recycling lead or lead monoxide from various fire assay wastes including crucibles, cupels and slag. The scope of the project was to determine optimal hydrometallurgical parameters so that direct separation and recovery of lead salts was economically feasible. A process was developed from the study which could use either acetic acid or nitric acid as a leachant, followed by several precipitation processes which could directly recover litharge (PbO) or other lead salts, such as lead carbonate or lead sulfate. The economics of the process is discussed. Analytical equipment such as the atomic absorption spectrophotometer and x-ray diffractometer supplied much of the information required for the study. However some novel analytical approaches using these instruments had to be developed to help in the determination of leaching kinetics and process quality control which are discussed.

Jan 1, 1999

By J. M. A. Geldenhuis

This work is concerned with studying possible reactions in the ilmenite furnace which may control the product quality of both slag and metal. Two different approaches were followed: comparing actual furnace slag compositions with the calculated equilibrium values and using commercial oxygen probes to measure the effective partial oxygen pressure in the slag and metal. It appears from a comparison of actual furnace slag compositions (in terms of the distribution coefficient of vanadium) with equilibrium values, that the TiO1.5-TiO2reaction may fix the effective partial oxygen pressure for the vanadium reaction. This possibility was tested using commercial oxygen probes (traditionally applied during steelmaking) to measure the effective oxygen partial pressure of both the slag and liquid iron in Iscor?s 3MVA pilot plant ilmenite furnace. From these measurements, it appears that commercial oxygen probes containing zirconia solid electrolytes can be used to measure the effective oxygen potential of both the slag and liquid iron. This oxygen activity correlates well with the FeO content of the slag. The results, furthermore, clearly illustrate that equilibrium conditions are not attained in the ilmenite furnace during the production of high titania slags, since the effective oxygen potential of slag and metal differ substantially.

Jan 1, 1999

By M. Pourkani, M. Karga, Samid Banis, Andre Laplante, G. Langari-Zadeh

"The Sarcheshmeh mine processes 40,000 t/d of ore grading 0.9% Cu and 0.035% Mo. Grinding is effected in single stage ball mills using 80 mm forged steel balls, with an average consumption of 850 g/t. One of its 5 m diameter, 8 m length ball mills was emptied to measure the ball size distribution. The broken balls were first separated from the total charge, and the remaining balls classified into five size intervals of +7O mm, -70 +60 mm, -60+50 mm, -50+40 mm, -40 mm.The charge was composed of 280,534 balls (excluding broken balls) with a total mass of 305,180 kg. It was found that 4.0 % of the balls were broken; the size distribution of the charge was also markedly different from the desired one, in particular for the small-sized balls. For instance, 9% of the balls were expected to measure 2.54 to 3.18 cm in diameter, but none was found. On the other hand, the amount of top size balls was 30% higher than expected. The radial hardness of balls, which was determined by cutting the balls in halves, showed that the hardness sharply drops when the balls become smaller than 65 mm. The unexpected ball size distribution was attributed to the rapid change in the balls radial hardness. Based on the measured ball size distribution, a new ball make-up charge which uses 80% of 80 mm and 20% of 60 mm balls instead of 100% of 80 mm was proposed and implemented. The effect of the new ball make-up procedure in terms of ball consumption and grinding efficiency is being investigated."

Jan 1, 1999

By Michael L. Wayman

Archaeological and ethnographic work during the last century has shown clearly that metals have played a small but important role in prehistoric Arctic cultures. For at least the past several millenia both iron and copper have been used in the North, primarily for blades, projectile points, knives, awls, engraving tools, fishhooks, scrapers and axes. In addition they were used for joining purposes as staples and rivets. It is of great interest to enquire into the origins of these metals. In this connection one begins with the observation that to date there has been no clear evidence for the smelting or melting of metals in the Arctic prior to the arrival of Europeans. This can be explained partly by the absence of traditional pyrotechnologies such as the high-temperature firing of ceramics and the heat treatment of bone and wood. Another factor which surely inhibited the development of smelting/ melting operations is the relative absence of wood in the region. The production of charcoal for smelting requires large quantities of wood, to the extent that the desertification of a number of areas in the Old World is believed by some to have been at least partly caused by charcoal production. In the North this was obviously not possible. Thus the Arctic peoples were restricted to using native (naturally occurring) metals and metals obtained by various direct and indirect forms of contact with areas of the world where smelting was practiced. Both of these sources were important in the case of iron; we know that meteoritic iron, telluric (native) iron and smelted wrought iron were all used in the Arctic. These three types of iron will be considered in tum.

Jan 1, 1999

By D P. Yang, Yang R. G

The laws of throwing and heaping of engineering blast are important for making use of throwing and heaping of thrown body to form certain shape, such as building dams by directional blast. The article is to apply Ballistic theory of single thrown body to take the throwing course of thrown body as the movement of particle system, and then delimit the total of thrown body into units of thrown bodies, and regard the heaping shape of single thrown body as a perfect triangle, and found a quantitative relation between macro-geometry parameters of perfect triangle and designed parameters of explosives. The theory has been adopted in blast practice and gotten good effects.

Jan 1, 1999

By Greg Hodges

Sand-and-gravel aggregates have become the number-one, nonmetallic-mineral resource in the world. Surficial aggregate deposits of economic size are becoming increasingly rare in most parts of Canada. In southern Saskatchewan, this is especially true, and detection and delineation of intertill sand-and-gravel deposits with airborne electromagnetic (EM) surveys have proven very successful. Airborne and ground geophysical surveys detect such deposits by their resistivity contrast relative to the surrounding clay-rich soils. Dighem helicopter-borne electromagnetic surveys map soil variations over a large area quickly and cost effectively, greatly reducing the cost of detecting and mapping deposits compared with traditional methods (air-photo interpretation, ground EM, and drilling.). The multiple-frequency EM system used by Dighem can map variations both horizontally and vertically. Magnetic data collected simultaneously are useful in mapping bedrock geology. Both resistivity and bedrock maps aid in the important task of reducing drilling costs and person-hours in the field. The results of the survey are presented as maps of ground resistivity, which are relatively easy to interpret. These maps are produced in the field at the time of the survey, making quick follow-up of the survey possible. Airborne EM surveys can map the extent and depth of aggregate deposits more effectively than is practical from the ground. Since aggregate deposits can vary tremendously in a very short distance (<300 m) large-area EM maps can show both local area variability and also help develop intertill trends. A test survey for the Saskatchewan Highways and Transportation Department over a 3-km by 5-km area mapped all the known deposits as well as some unknown deposits, subsequently proven by drilling. The test-survey data show that the method not only detected the deposits, but also gave an estimate of the shape (volume) of each of the deposits. Comparison of the data to drill sections shows excellent correlation. Theoretical modelling demonstrates that the multifrequency system can discriminate sand and gravel from bedrock ridges. Since the successful test work, about 725 km2 of ground have been surveyed, resulting in the discovery of four new deposits, which can be used immediately, resulting in significant savings for the Saskatchewan government and taxpayer.

Jan 1, 1999

By S. J. Kohut

Until recently SX-EW technology has only been used to produce conventional cathode for the cyclical commodity marketplace. Unlike electrorefining, SX-EW lends itself to the integration with the downstream manufacturing technologies for direct mine site production of value added products. The integration of SX-EW and downstream manufacturing results in the elimination of redundant process steps, the cost savings, and the access to value added product markets which can buffer the producer from swings in the cathode market. SX-EW production of copper powder and powder-based products has been demonstrated at the pilot plant level. The SX-EW process has been successfully redesigned to meet the more specific demands of engineered products. Challenges include the solution purity, the cell ventilation, the high current density operation and the product handling. Successful demonstration of mine site production of value added SX- EW products opens up new non-commodity marketplaces to the mining industry.

Jan 1, 1999

By C. J. Newman

The new Kennecott Utah Copper smelter, started in 1995, was designed to be the cleanest smelter environmentally in the world. The plant is operating at production rates above the original design capacity. Copper concentrate is smelted in an Outokumpu flash smelting furnace. Matte is granulated and processed using Kennecott-Outokumpu flash converting. Copper anodes are processed in a modernized copper refinery using the Kidd Process while anode slimes are processed for precious metals recovery using a unique hydro-metallurgical process. To allow the production of high quality cathode, using modem smelting and converting technology to minimize emissions, impurity control had to be carefully addressed. All process bleed streams from the smelter and refinery are treated in a hydro-metallurgical plant to fix impurities in a stable form, allow for the rejection of impurities as required and recover valuable metals. Special technology was developed for the copper refinery to ensure production of high quality cathode from anodes containing high levels of impurities. The smelter routinely achieves a sulfur capture in excess of 99.9% which is equal to less than 2 kg of SO2 per tonne of copper produced. This paper describes the design of the smelter and refinery and includes recent production and emission data and modifications carried out to allow operation at above the original design rates. It emphasizes the unique features required to achieve environmental and quality goals and compares environmental performance data to that published on other smelting operations. The processing of intermediate streams, the management of recycled materials and the impurity control strategy will be covered in detail.

Jan 1, 1999

By C. A. Young, J. D. Miller

Adsorption isotherms previously determined by in-situ Fourier transform infrared/internal reflection spectroscopy (FT-IR/IRS) for oleate adsorption at calcite and fluorite surfaces near pH 9 and at various temperatures are compared. Results indicate that, at both mineral surfaces, chemisorption occurs at equilibrium concentrations below approximately l x l0-5 M oleate while calcium dioleate surface precipitation occurs at higher equilibrium oleate concentrations. The extent of chemisorption at the calcite surface is 3 to 5 times less than that at the fluorite surface while the extent of calcium dioleate surface precipitation on calcite is nearly a magnitude larger than that on fluorite. However, for both minerals, surface precipitation decreases with increasing chemisorption. Contact angle measurements and flotation recoveries show the hydrophobicity of fluorite to be greater than that of calcite at each of the temperatures and oleate concentrations studied. Significant differences are noted only in the chemisorption region. Unlike calcite, the hydrophobicity of fluorite was sensitive to the presence of oxygen in the system. Multichannel Laser Raman Spectroscopy (MLRS) showed this behavior was caused by the double-bond reactivity of adjacent chemisorbed oleate molecules and subsequent formation of an epoxide/polyether complex at the fluorite surface. Such a reaction product could not be detected at the calcite surface. These differences in adsorption density, hydrophobicity, and polymerization behavior are discussed in terms of the intrinsic surface properties of the minerals.

Jan 1, 1999

By Eirik Sundvor, Hany Doss, Peter Vogt, Kathleen Crane

"Abstract - In 1989-1990, the SeaMARC II side-looking sonar (11 to 12 kHz) and swath bathymetric system imaged more than 80 000 km2 of the seafloor in the Norwegian-Greenland Sea and southern Arctic Ocean. One of our main goals was to investigate the highly oblique (115°) junction between the Mohns and Knipovich ridges, and to determine, using new morphotectonic data, whether or not this junction is stable or in a state of readjustment. These findings are presented in this paper.Along the northern Mohns Ridge, we observed a highly segmented rift valley undisturbed by transform faults. In contrast to the elevated Reykjanes Ridge, the Mohns Ridge is dominated by deep en echelon fault-bounded troughs, which are bordered by high rift valley volcanoes. These segment boundaries are interpreted to be sites of recent to present volcanic activity, based on their high acoustic reflectivity. The northwestern flank of the Mohns Ridge is marked by shallow quasi-linear ridges parallel to the present orientation of the Mohns Ridge. The orientation and geographic position of these ridges suggest that they were formed at the Mohns Ridge. Only in the northernmost cases are some of these off-axial ridges non-linear. The degree of the non-linearities increases slightly with proximity to the Mohns-Knipovich bend. In addition, because no transform fault was detected between the Mohns and Knipovich ridges, we conclude that the Knipovich Ridge must be obliquely spreading to the NW-SE."

Jan 1, 1999

By David Davison, Richard Johnson

Metal-oxidant blends are ordinarily unsuitable as diiect replacements for explosives, because the reaction occurs too slowly. Oxide coatings protect metals, preventing or delaying reaction. By contrast, the electrically-activated reactive composites described below are configured as metal fibers or foils in close proximity to oxidants, with continuous electrical paths from one end to the other. By quickly vaporizing the metal component with an electrical pulse, a reactive composite will be activated, and the reaction will occur rapidly.

Jan 1, 1999

A thermochemical model is developed to study the two-stage smelting reduction process for ironmaking without post-combustion. Steady-state multi-material and heat balance equations are solved simultaneously to study the effect of metallisation, slag basicity, coal rank and heat loss on consumption rates of coal, ore, flux and oxygen and production rate of slag to produce hot metal of a given composition, tapped at a given temperature. The model is applied to the commercial data for a COREX-plant producing a wide range of hot metal compositions, tapped at different temperatures. The computed rates of coal, slag, flux, ore and oxygen were found to be close to the reported ones, but an exact match could not be obtained. It is found that a four per cent change in metallisation brings changes the coal rate by five per cent, flux rate by six per cent, slag rate by eight per cent and oxygen rate by 13 per cent, while a ten per cent change in basicity changes the coal rate by ten per cent, flux rate by 13 per cent and oxygen rate by 22 per cent. Further, it is found that an increase in metallisation decreases the coal rate and export gas. At a given per cent metallisation, the coal rate and the export gas are lowest for anthracite compared to all other types of coal.

Jan 1, 1999

By E. F. Schnitzer, S. R. Mamoyac, P. J. Wampler

During 1996 and 1997, Oregon experienced flooding on a scale not seen in many years. Some gravel pits located near rivers experienced erosion and, in several cases, breaches between the gravel pit and the river. Initial evaluation of several sites that experienced breaches indicates that impacts to the river system are complex and vary significantly from site to site. The impacts to the adjacent river system may be viewed as both positive and negative. Several floodplain-mining sites in Oregon located in areas of historic river flow have reverted to active riverbed. In many cases, state and federal fisheries biologists and university researchers see the resulting increase in channel complexity and habitat as favorable. The Oregon Department of Geology and Mineral Industries – Mined Land Reclamation Program (DOGAMI-MLR) is performing additional studies of the impacts to the off-channel areas that resulted from the 1996 floods. More data is needed to make sound floodplain decisions regarding mining.

Jan 1, 1999

By Y. K. Yen, J. D. Miller, C. L. Lin

The image-based On-line Particle Size Analyzer (OPSA)system has been developed at the University of Utah to measure particle size distributions under plant conditions where overlapped and segregated particles are being transported on a moving belt conveyor. Evaluation of the OPSA system at several plant sites has been completed. The results show a consistent agreement between the particle size distributions obtained from the OPSA system and those obtained from laboratory screen analysis of belt samples. These results and the stable performance of the OPSA system during the field tests suggest that continuous quality control of crushed products is possible using the OPSA system.

Jan 1, 1999

By M. K. Mohan

During the processing of metals like Cu, Ni, Co, large quantities of solutions, which contain co- products such as Sb, Cd, Pb etc. are generated. These solutions if processed to recover the metals help in conservation of metals as well as environment preservation. The present study was taken up to recover antimony from process solutions using zeolites. The effect of pH of the solution, time and type of zeolite viz., chabazite, mordenite, erionite and clinoptilolite on the sorption of antimony was investigated. Rate of sorption increases with pH and about 77-pct. antimony sorption was observed with chabazite at a pH of 6. Optimal conditions were established for the maximum recovery of antimony fiom process solutions. The mechanism of sorption for Sb was proposed in terms of adsorption and intraparticle diffusion. The calculated adsorption constants from Langmuir and Freundlich equations indicated that the adsorption of antimony on chabazite was strong.

Jan 1, 1999

Mine closure is a legitimate element of the mining cycle and like mine development involves technical planning, permitting, and finally construction. Closure begins with the mine&apos;s operational footprint and transforms the site so that it meets the explicit requirements of the owners and regulators. Implicitly, the closure will increasingly need to meet the requirements of other interested parties such as the local community, workforce, and future land users. Golden Cross is the first modern mine closure in New Zealand. It operated for 6 + years as a mid-size gold and silver mine winning ore from both underground and open pit sources, and processing via a carbon in leach circuit including a cyanide recovery stage prior to tailings disposal. The mine is situated in a sensitive high rainfall environment, and is complicated by the existence of a large ancient landslide underlying most of the tailings dam and waste rock embankment. The regulatory process for mine closure in New Zealand is not clearly understood by operators or regulators alike. The Golden Cross mine was permitted under the Mining Act 1971 and closed primarily under the Resource Management Act. This switch of legislation, the parallel reorganisation of many government departments, and change in societal expectations with respect to long term environmental stewardship during the life of the mine resulted in the requirements of closure being significantly different to the expectations at permitting.

Jan 1, 1999

By Mustafa Akser

Dwindling economic deposits of rutile (TiO2) prompted research on recovering it from secondary sources. One such resource is in Southwestern Turkey feldspar mining rejects that contain 5%-6% TiO2 mostly rutile. Previous studies could only upgrade the TiO2 to 36% TiO2 grade, claiming that the leftover flotation reagents on the surfaces of rutile and host minerals detrimentally affected upgrading of the rutile. As a potential remedy to this concern, a laboratory sample (from an operating feldspar mine in Milas, Turkey) was first caustic scrubbed, then air calcined at 400°C to evaporate the oily reagents. Subsequent physical separation of rutile included wet screening, gravity, magnetic, and electrostatic separation technologies. Such processes indeed improved the grade of the rutile concentrate up to 83 % TiO2 Low recovery of the TiO2 (<20%), was attributed to lack of full liberation of rutile, even at 125x44 micron range; interference with impurity minerals such as sphene and zircon; and simply the process inefficiency in upgrading the fine grains through conventional separation technologies for heavy minerals.

Jan 1, 1999

By David A. Holmes

After a century of variable government-supplied housing on their cold, windswept lands, and facing extremely limited natural resources and no timber, the Standing Rock Sioux Tribe has launched a study into alternative housing approaches for their people. Considering that they have little more than the soil and limited river aggregates under their feet, the Tribe has elected to consider adobe and earthen-wall construction. Earthen construction is no stranger to the Sioux lands. Smaller tribes, including the Mandan, Arikira, and Hidatsa, lived here among the Sioux in earthlodges for centuries. Such earthlodge structures were not unlike the Southwestern jacal style-a framework of upright branches and branches covered with mud-employed by the Anasazi about A.D. 700-900. Indeed, the Sioux people themselves evolved from earlier earthlodge dwellers. Indigenous peoples in New Mexico, Arizona, and neighboring Mexico have used earthen-wall housing for many centuries, reinforcing Sioux observations that this is today an earth-friendly, cost-effective, and practical approach. The Cheyenne River and Pine Ridge Sioux Reservations also recently have conducted studies on earthen- wall construction. This paper describes the search for and evaluation of potential raw-material resources for earthen-wall/adobe construction on the Standing Rock Reservation in North and South Dakota. Significant resources of clay/silt materials (8 million tons in the Striped Cloud clay bed) suitable as adobe binders and sand-and-gravel aggregate (2.5 million tons) that could support earthen/adobe construction have been identified throughout the Fort Yates Flat area on the Reservation. Also addressed is how adobe and rammed-earth construction could add to the diversity of reservation construction and address future Tribal housing and other building needs.

Jan 1, 1999