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By A. K. Mukhopadhyay, B. Sikdar, V. P. Arora

Introduction During the past several years, persistent concerns about an economic slowdown in India have tempered capital-expan¬sion plans. This has encouraged companies to find methods of increasing the capacity of existing production equipment. One of the more cost-effective methods of increasing produc¬tion capacity without major capital investment is to improve equipment maintenance to prevent needless machine down¬time. This can have a significant financial impact because of reduced maintenance costs and increased machine availabil¬ity. The maintenance program employs different techniques, but the analysis of the vibration behavior of machine compo¬nents to assess their condition was found to be the most accurate technique for monitoring various machine disorders. A dragline that handles overburden in open pit mines is one of the more capital-intensive pieces of production equip¬ment. It is imperative that the machine be run at its optimum capacity under the prevailing environmental conditions. Condition monitoring of the various components of the dragline through vibration analysis not only improves the machines availability but also ensures a long operation time free from sudden failure. This paper describes the application of vibration monitor¬ing and analysis techniques to assess the components of a W2000 dragline. The paper reveals that condition monitoring through vibration analysis can be as valuable in failure prevention as it is in failure analysis. Finally, the paper presents an approach to a knowledge-based expert system to the quick and correct diagnosis of mechanical faults in a dragline. Equipment A dragline is an intermittent-discharge-type excavator having a long boom at one end. Unlike other excavators, the bucket is not rigidly held by the frame structure. In favorable geomining conditions, the intensive operation of these exca¬vators is the least-expensive means of overburden removal. The basic working elements of this equipment are the hoist system, the crowd and retract system, the wing mechanism and the propel mechanism. The walking dragline is accepted as the most economical machine for stripping overburden at depths of up to 60 m (200 ft). They are electrically powered and the various motions are effected by individual drives. The Ward-Leonard system is used to provide the optimum flexibility in controlling different dc-drive motors. To mini¬mize the cost of mineral extraction, the largest such machine in India has a 24-m3 (850-cu ft) bucket with a boom length of 96 m (315 ft). Draglines are very costly, and considerable financial penal¬ties may arise from sudden stoppages due to component fail¬ures. Thus, operational reliability is of the greatest importance. Active measures are now being taken to minimize downtime by adopting condition-based maintenance techniques. Though a number of techniques come under this scheme, it has been observed that assessing the health of the dragline by measuring vibration is the best method of determining the dynamic behavior of its various rotating components to avoid any catastrophic failure. Based on criticality, the vibration-behav¬ior of the following components are studied: • motor-generator unit, • exciter unit, • hoist motor-gearbox unit, • hoist drum-gearbox unit, • drag motor-gearbox unit, • drag drum-gearbox unit and • swing motor unit The approach Increases in the vibration levels in different subsystems of the dragline were observed due to the presence of faults such as unbalance, misalignment, looseness and bad bearings. A vibration behavior study included the measurement of vibra¬tion level, trend analysis of time-domain vibration signals and vibration frequency analysis at bearing points of the components. A vibration meter, a vibration analyzer and a data collector are used. Vibration-level measurement. When the dragline was assembled and put into operation for the first time, vibration data were collected to generate baseline data for the equip¬ment (based on International Standard ISO 2372). After¬wards, the vibration levels were recorded regularly using a vibration meter. The measurements were taken at all bearing

Jan 1, 2000

By J. T. Gepford, K. A. Prisbrey, T. Scott, M. Spangler

Using neural networks for plant control is challenging. The objective was to show how to make a neural network effective, even with noise, lag times, and unmeasured disturbances in the plant. The procedure was to evaluate the neural network in a laboratory flotation vision system and in a plant refractory gold autoclave system. Although the resulting neural network easily conquered simple laboratory data, the noisy plant data was much more difficult, and adaptive linear models were equally effective. We concluded that the neural network needs support by combining it with other tools found in the best control packages.

Jan 1, 2000

By M. Josick Comarmond, Paul L. Brown, Greg P. Timms, A. Ian M. Ritchie, John W. Bennett

Geochemical kinetic models have only become available in recent years and their utilisation in the prediction of effluent chemistry from sulfidic waste rock piles is even more recent. The models used to date, however, have incorporated some questionable assumptions. This paper shows how geochemical, mineralogical and physical field data have been coupled to remove some ill-founded assumptions in the construction of a geochemical kinetic model. Further, the paper discusses a comparison between the observed effluent chemistry from a waste rock dump at the Rum Jungle copper/uranium mine in northern Australia with model predictions. In general, there is good agreement between the two, although an anomalous result is discussed.

Jan 1, 2000

By William R. Yernberg

The Fifth International Conference on acid rock drainage (ICARD 2000) was held May 21-24, 2000, in Denver, CO. The three-day conference consisted of about 150 oral presentations and poster sessions that described the state-of-the-art of acid-rock-drainage (ARD) science and technology. The conference also featured a trade show. It included representatives from consulting companies and government agencies with interests in ARD, as well as other environmental issues related to mining. The conference also included field trips to ARD treatment sites and short courses on acid rock drainage issues. ICARD 2000 was planned and promoted by the ICARD 2000 Organizing Committee and the Society for Mining, Metallurgy, and Exploration, Inc. (SME). Financial support was provided by Barrick Gold, BHP Copper, Homestake Mining, Noranda, Phelps Dodge, PlacerDome, the US Bureau of Land Management, the USEnvironmental Protection Agency and the US Geological Survey. Since the original ICARD was held in Roros, Norway, in 1988, knowledge has improved of the behavior of mine wastes as have methods of environmental mitigation. The ICARD 2000 presented the latest advancements in the field of acid drainage.

Jan 1, 2000

By R. C. Ford, J. Kelsey, S. A. Pierce, M. D. Ankeny

Evaluation of acid drainage risk from spent (leached) ore in arid climatic zones consists of two components: (1) whether residual and secondary minerals will release acid and metals when exposed to rainfall, and (2) whether ambient rainfall is likely to infiltrate, and eventually impact surface or ground water resources. The risk of acid drainage from spent ore at the El Abra on-off copper leach pad operation was evaluated using conventional geochemical methods and unsaturated flow models. Although geochemical testing indicated poor quality water would result from any seepage, unsaturated flow modeling demonstrated that infiltration and seepage were unlikely given the arid climatic conditions. Modeling further demonstrated that the residual moisture content of the spent ore when it is removed from the leach pad controls the risk of seepage. To further reduce the risk of seepage, operational controls were developed and implemented at the El Abra site.

Jan 1, 2000

By David Brown, Glen Hall, Ken DeVos, Frank Barone

Dredging and Flooding was completed on the Falconbridge Limited "New Tailings Area" in the period from 1996 through 1998, as part of their site closure measures. Part of the decision making process and closure planning was water quality prediction, including oxidation and diffusion modelling. The purpose of this modeling was to define the potential water quality that would result during and after dredging. A significant body of research on the geochemistry and oxidation kinetics of this site had been compiled. The results of the modeling provide practical insight on the potential water quality that may be expected. Water quality in the pond has steadily improved since flooding was completed with the exception of short term peaks during spring runoff. Aquatic vegetation is appearing through natural recovery and transplanting of local species, and colonies of minnows are now observed in the ponds.

Jan 1, 2000

By G. Bryant, P. Ziemkiewicz

Acid mine drainage (AMD) from both abandoned surface and underground mines is a serious problem. The flow of water and changes in quality over time from abandoned mines is important in determining remediation strategies. Acid mine drainage from surface mines is estimated to last for 10-20 years, while estimates of acid drainage from underground mines vary from 10- 100s of years. Fifteen underground mine discharges in West Virginia were studied to compare water quality changes between 1968 and 1999 to see if our data are consistent with other studies. Each of the discharges were categorized into one of three groups: undisturbed since 1968, affected by surface mining since 1968, and reclaimed. Comparing water quality between 1968 and 1999, the discharges in the undisturbed category showed a 35 to 95% improvement in acid concentration and a 40 to 99% reduction in iron concentration. The discharges affected by surface mining showed the most dramatic improvement. For acidity, iron, and aluminum, the percent improvements were all above 44%, and in most cases in the 70 to 99% range. In the reclaimed category, one of the four discharges declined in water quality. Discharge 82 showed a 76% increase in acidity, and iron and aluminum concentrations worsened by 58 and 96%. However, discharges 15 and 74 improved in water quality with a 94% acid load improvement and a 95% iron load improvement at both sites.

Jan 1, 2000

By O. A. Paulson, D. D. Runnells, D. P. Dupon, K. J. Bruxvoort

Background groundwater quality is often used to drive remediation programs at sites with waters that have been affected by mining activities. In the past, these levels were sometimes chosen without rigorous statistical and geochemical analysis. A probability-distribution approach was used at the Sweetwater Uranium Project to separate a large set of geochemical data into populations that represent contribu¬tions from different sources. Natural background populations were identified for major ions, metals and radionuclides, and these were submitted to the US Nuclear Regulatory Commis¬sion (NRC) to modify the extent of a corrective-action pro¬gram and to establish control limits for future monitoring.

Jan 1, 2000

By C. F. Barter, H. G. Kreis, D. S. Weber

Before and during in situ mining at the Santa Cruz In Situ Copper Mining Research Project test site, hydraulic testing was conducted at injection and recovery test wells to characterize patterns of fluid movement in the 5-spot well field. Testing included borehole spinner flow meter surveys, single-well and multiple-well injection and recovery tests, straddle packer injection tests, and bromide pulse tracer tests. Results of hydraulic testing for determination of fluid flow regimes were used to modify well and mining zone hydraulics for the purpose of increasing fluid migration in flow pathways of the mining zone with higher copper grade.

Jan 1, 2000

By G. Karahalios

Industrial minerals have always enjoyed an important share in the technological growth of any country in the world. Today, extraction and trading of industrial minerals has expanded, but is also subject to stricter environmental guidelines. This paper presents the current status as well as the growth potential in the exploitation of industrial minerals in the countries of the south eastern European region, i.e. Albania, Bosnia-Herzegovina, Bulgaria, Croatia, F.Y.R.O.M., Greece, Italy, Serbia and Montenegro, Slovenia and Turkey. More specifically, annual production figures per country are presented for1992-1998. These figures are compared to each other and, where applicable, to world production figures. Trading of industrial minerals from these countries to Europe and the world and its effect to the local economies is also evaluated were such data is available.

Jan 1, 2000

By W. J. Spat

Political risk is an integral part of the mining business in northern Andean countries. Peru, Ecuador, Colombia and Venezuela all have a higher than average political risk compared with other South American countries. Successful operations require good political-risk information, a thorough political-risk-management plan and a strategy to deal with political-risk perception on the part of the investing public. Colombia is perceived as about the riskiest place in the world to do business. A selection of recent headlines reads: “Colombia on the brink” (Economist, 1998), “Colombia’s ship of state is sinking” (Insight on the News, 1998), or simply “Bad news” (US Catholic, 1998). The World’s Most Dangerous Places rates Colombia as “currently the most dangerous place in the Western Hemisphere, and perhaps the world” (Aral and Pelton,1998). And many prospective investors and analysts say to Greystar Resources: “Yes, we love your results, but Colombia?”

Jan 1, 2000

By D. Harris, M. Osterberg

This paper examines the economics of acquiring mineral exploration rights by royalty-rate bidding when the royalty basis does not provide for full cost recovery. Bidding takes place prior to exploration and the documentation of actual tonnage and grade. Consequently, it increases considerably the risk to exploration capital when the fraction of cost recovered is small and the product price exhibits large fluctuations. Price and grade risk are demonstrated on a 360-Mt (400-million-st) porphyry copper deposit by Monte Carlo simulation of discounted-cash-flow analysis. Copper price is modeled as a stochastic price process, and costs are based on US Bureau of Mines cost models. When both grade and price risk are considered, the probability for a negative NPV is 0.54, given a royalty rate of 5% applied to a basis that allows the recovery of costs up to 50% of product price. Investment risk could be considerably reduced by defining the royalty basis to allow greater cost recovery. Although such a basis would require society to share in the risk, society would benefit from greater resource development.

Jan 1, 2000

By S. N. Groudev

A process for the combined chemico-biological removal of iron present as oxide minerals in different mineral raw materials (quartz sands, kaolins, clays, etc.) was developed. In the process, mineral raw materials are leached at about 90 °C with lixiviant containing microbially produced oxalic and hydrochloric acids. The leaching is carried out in mechanically stirred acid-resistant reactors for periods of from 1 to 6 hours, depending on the iron content and the forms of iron in the raw materials being leached. The iron contents of some sands treated by this method were lowered from levels that were in the range of 0.035% to 0.088% Fe2O3 to less than 0.012% Fe2O3, making them suitable for the preparation of high-quality glass. The iron contents of different kaolins were lowered from levels that were in the range of 0.65% to 1.49% Fe2O3 to levels in the range of 0.44% to 0.75% Fe2O3. As a result, the whiteness was increased from values of 55% to 87% to values of 86% to 92%. The iron content of clay was lowered from 6.25% Fe2O3 to 1.85% Fe2O3, and this increased the “fireproofness" of the clay from 1,670°C to 1,750°C. A similar process was used for the leaching of aluminum from aluminosilicates, mainly clays and kaolins. However, in this case, the microbial fermentation fluid containing citric acid was acidified by means of sulfuric or hydrochloric acid or by means of different mixtures of mineral acids. For enhancing aluminum solubilization, the aluminosilicates were heated before leaching at 600° to 650°C for 1 to 2 hours. Over 90% of the aluminum present in different clays and kaolins were leached within 3 to 6 hours. "Silicate " bacteria related to the species Bacillus circulans were used to leach silicon from low-grade bauxite ores containing aluminosilicates as impurities. The bacterial action was connected with the degradation of the mineral structures (by means of microbial metabolites such as organic acids and exopolysaccharides), as well as with the selective separation of the rich-in-aluminum fine fractions, which were retained by the mucilaginous capsules of the bacteria. The solid residues after treatment were characterized by higher values of alumina and silicon module (A1203: SiO2 ratio), and they were suitable for processing by means of the Bayer process for recovering aluminum. The bending strength and other ceramic properties of kaolins were improved by contact with well-developed cultures of "silicate" bacteria. The improvement was caused mainly by bacterial metabolites (exopolysaccharides) that acted as resins during drying.

Jan 1, 2000

By Hugo T. Dummett

I would like to share some observations about the mining business and place the ongoing discussion in the context of our changed world. The mining industry practices its trade in a universe defined by prices, laws and governments. Prices, as in what the industry is paid for what it produces, and the costs of goods and services. Laws that have to be transparent and fair. And governments that the industry prefers to be stable and supportive of the industry, and certainly not corrupt. However, the day-to-day realities of the mining business in 2000 are not what they were 10 years ago. Several events have occurred that have resulted in a less populated workplace that is obliged to work much smarter and faster. These include real declining prices for most mineral commodities; low and diminishing returns to company shareholders; massive restructuring of the industry through mergers, partnerships and alliances; gold’s changed role from reserve currency to just another commodity; the growing importance of native title and the startling imperatives of “sustainable development.” In addition, the “borderless world” now means that resource companies will need to pass the test of being responsible corporate guests who respect and enhance the social, moral and societal values of their host countries.

Jan 1, 2000

By J. M. Mutmansky, Aiping Wang

This paper outlines the patterns of methane emission in both longwall and room-and-pillar operations and discusses the effects that these patterns have on the decision as to whether the methane is most economically handled by ventilation alone or by means of a methane-drainage system in addition to ventilation. The costs of handling the methane in the ventilation system and the costs of implementing the methane-drainage system are discussed, as well as the costs related to the production of coal. The important issues of production slowdowns and gasouts are also discussed, as well as the proper response of mine management to such a situation. Suggestions concerning the keeping of production records related to methane problems are made, and the justification for more intensive economic analysis of coalbed methane extraction and utilization is discussed

Jan 1, 2000

By D. K. Denton, D. F. Scott, T. J. Williams

Spokane Research Center personnel have been investigating the use of seismic tomography to monitor the behavior of a rock mass, de¬tect hazardous ground conditions and assess the mechanical integrity of a rock mass affected by mining. Seismic tomography can be a valuable tool for determining relative stress in deep, >1,220-m (>4,000¬ft), underground pillars. If high¬stress areas are detected, they can be destressed prior to development or they can be avoided High-stress ar¬eas can be monitored with succes¬sive seismic surveys to determine if stress decreases to a level where de¬velopment can be initiated safely. There are several benefits to using seismic tomography to identify high stress in deep underground pillars. The technique is reliable, cost¬effective, efficient and noninvasive. Also, investigators can monitor large rock masses, as well as moni¬tor pillars during the mining cycle. By identifying areas of high stress, engineers will be able to assure that miners are working in a safer envi¬ronment.

Jan 1, 2000

By Winfield G. Wright, Greg P. Meeker, Philip L. Verplanck, Douglas B. Yager, Dana J. Bove, M. Alisa Mast

A really extensive acid sulfate-altered and mineralized rock in the southeast Red Mountains area is noted for its association with naturally occurring and mine-related acidic and metal-rich waters. Integrated geologic and aqueous geochemical studies demonstrate that the degree of metal mobilization and acid production in natural waters correlates well with the type of hydrothermally altered rock and structural features in which these water interact. Quartz-sericite-pyrite, quartz-alunite, and argillic alteration assemblages are associated with some of the most naturally acidic, high-metal waters in the study area; calcite-bearing propylitic rocks are related to the most pristine waters and buffer sulfate-rich, acidic waters produced by pyrite oxidation. Trace metals in natural waters are mostly derived from enargite, zinc-rich tetrahedrite and sphalerite. Pyrite oxidation contributes very little with respect to base-metals in these natural waters.

Jan 1, 2000

By Ignacio González, Marcos Monroy, Valerie Bertrand, Roel Cruz

Results of an electrochemical study using carbon paste electrodes of pyrite and pyrrhotite samples suggest that the mineralogical impurities associated with these minerals are the determinant factor on their reactivity under alteration systems. These results were supported by mineralogical and leachate chemistry data from leach cell tests run on these samples. Pyrite reactivity decreases in the presence of associated impurities due to a galvanic effect whereas pyrrhotite reactivity appears to be controlled by the formation of a passivating layer, which overcome impurities effect. Electrochemical responses of sulfide-bearing samples provided valuable information on the prediction of ARD generation.

Jan 1, 2000

By F. Calizaya

The PT Freeport Indonesia‘s Deep Ore Zone(DOZ) copper deposit is located in the province of Irian-Jaya, Indonesia. Currently, a block cave mine is being developed around this deposit. Production is scheduled to start in year 2000 and to ramp up to25,000 tpd by year 2003. The air quantity requirement for this mine is equal to 780 m3/s. To supply this quantity, the mine will require five centrifugal fans (one 450 and four 750 kW fans). This study summarizes the technical aspects related to the installation and commissioning of one of these fans. The fan was installed on the surface in a parallel arrangement with two others. It has a design capacity of 240 m3/s of air at 2.2 kPa of static pressure. The study presents the installation details from the underground shaft excavation and portal development through fan testing and commissioning. It also presents the results of a monitoring system that was installed to determine the fan duties.

Jan 1, 2000

By M. Tamlin

The state of the lithium mineral industry is closely linked to the performance of the glass and ceramic industries and to the overall economy. Demand for the glass/ceramic products in Europe, Asia and North America remained strong during 1999. This was due to a slight improvement in the economy during the latter half of the year. Consequently, demand for lithium minerals was firm, with a positive outlook. The major economic minerals for lithium are spodumene, petalite and lepidolite. The latter was once the primary mineral. But its importance hasdeclined since the 1960s. The lithium industry consists of two different segments: •The lithium minerals segment mines from hard-rock deposits and physically processes the material to high-grade concentrates. •The lithium chemicals and metal industry segment. The major feedstock for specialty lithium chemicals was previously high-grade spodumene ore converted to lithium carbonate. However, most lithium carbonate is now sourced from salars in North and South America.

Jan 1, 2000