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By Francis S. Kendorski

Rock reinforcement has been in widespread use and generally has been accepted in underground mining and tunneling since the 1950s. The first rock reinforcement technologies employed were mechanical anchors such as split wedges or expansion shells with 5/8-inch-diameter steel bolts. Failures occurred in weak strata which provided poor anchorage or in ground with corrosive waters. Friction rock fixtures consisting of relatively thin-walled tubes have been in use for about 15 to 20 years. While generally performing adequately, longevity problems have developed from corrosion in water bearing ground Longevity of rock reinforcement is much enhanced with grouted bolts. Portland-cement-grouted rock reinforcement has been in use since the mid-1950s, primarily in funneling and other civil engineering underground construction. Tests of decades-old installations have revealed few problems except in ground with aggressive waters. Polyester-resin-grouted rock reinforcement was introduced in the United states to musing in the late 1960s and to tunneling in the early 1970s. Experience from 30 years of resin-grouted bolt installations and field tests have identified longevity problems associated with degradation of steel reinforcing bars, but in generally unusual situations. Improvements continue in resin chemistries, packaging, corrosion protection, grout quantities, and mixing and distribution in the drilled hole to achieve long-term performance. Specific case histories cited with resin- or Portland-cement-grouted rock reinforcement longevity or performance problems, upon close examination, reveal that the causes of the problems were qualify control procedures being inadequate and not in accordance with good practice. Manufacturers' recommendations and engineering specifications, if followed in the field, and with competent inspection and supervision, would have prevented must, if not all, reported longevity or performance difficulties.

Jan 1, 2000

By Harry Siewert, Tom Milner, Jack Stickney

"LocationThe Gibraltar mine is located in central British Columbia (NTS 93B/9W), 362 km north of Vancouver. Access is provided by 20 km of paved road from McLeese Lake, which lies 45 km north of Williams Lake on Highway 97. Latitude and longitude of the mine are 52° 30' and 122° 16', respectively.The total area of the McLeese Lake site is approximately 1700 ha (4200 acres). This includes the orebodies, dumps, surface drainage collection system, plant site, roads and tailings ponds.Brief Description of OperationOre is mined by open pit methods and is concentrated using conventional crushing, grinding and flotation processes. Copper and molybdenum flotation occurs at an average rate of 40 000 tons per day. Tailing is discharged to an impoundment area and the water recycled as process water. Additional copper is extracted from the waste dumps using sulphuric acid as a leach solution followed by solvent extraction and electrowinning.HistoryExploration by Gibraltar began in 1964, continuing until late 1970, at which time it was announced that the property would go into production. Construction started in early 1971, with initial production in March 1972. Target capacity of 30 000 tons per day was achieved by the end of March and is currently at 40 000 tons per day.Ore reserves as of January 1, 1998 were 184 384 000 tons grading 0.31% Cu and 0.010% MoS2."

Jan 1, 2000

By Mamoru Kuwahara, Tomohito Taki, Masamichi Sano

"Theoretical basis and experimental results on ultrasonic separation of dispersed inclusions from molten metal are outlined. Transitional formation of an ultrasonic standing ·wave field in a liquid bath is numerically predicted based .on the wave equations. Numerical solution of the equation of motion of a fine particle in a standing wave field indicates that the inertia term can be neglected during conventional ultrasonic separation of fine particles: Analytical solutions for the position at which particles are coagulated the minimum power for separation, and the ultrasonic separation time are derived to incorporate such key process parameters as the density difference and the acoustic energy density exerted. Cold model experiments have been carried out to observe ·transitional coagulation of polystyrene particles in an aqueous sugar solution with the incidence of standing ultrasonic plane wave. Experimental results agree well with the theoretical predictions.IntroductionDespite of recent progress of fundamental and applied researches in metallurgical systems, advanced materials· with less inclusions and better properties may demand more innovative processing in a: molten state. It may be realized by applying electromagnetic and/or ultrasonic external fields to the systems. The present authors1)·2) have been proposing : new methods of ultrasonic processing of materials based on such phenomena as acoustic streaming, acoustic radiation pressure on dispersed phase in a standing wave field, and the cavitation in liquid associated with use of high-intensity ultrasound and so on. Taking account of common physical natures between ultrasound and sound wave, we call such · a processing assisted by acoustic wave as ""sonoprocessing"". This report ·deals with some theoretical and technological aspects on the ultrasonic separation of fine particles from liquid, which could become an important operation to produce clean materials. Fundamental theory and ·supporting experimental results will be given below to give an insight into the liquid metal sonoprocessing."

Jan 1, 2000

The Kunwarara magnesite deposit is the largest known magnesite (MgCO3) deposit in Australia. It is located under black soil plains to the north of Rockhampton in Queensland. The deposit consists of magnesite nodules set in a fine-grained sandstone, siltstone and mudstone matrix. The magnesite is derived from weathering of serpentinite in adjacent hills and transport of magnesium in solution to a Tertiary/Quaternary river system. The magnesium has come out of solution in the active river system, and combined with atmospheric and biogenic CO2 to form magnesite nodules. The magnesite can be very pure with certain varieties up to 98 per cent MgO (LOI free). The deposit has been mined since 1991 and processed into magnesia (MgO) which is sold into refractory, agricultural and other markets. The geologist is an integral part of the small mine technical team. The role of the geologist includes characterisation of the ore through drilling and bulk sampling, supervision of geological aspects of mining and assistance in the optimisation of ore processing.

Jan 1, 2000

By G P. J Dijkema, M A. Reuter

From a material cycles perspective all processes are interconnected and consequently a process can never be evaluated as an isolated and independent unit. This also holds true for the evaluated co-incineration options. Environmental and sustainability issues for example, such as raw material and energy utilisation or air pollution, are a resultant of the whole system of industrial activities. It is therefore important, not to optimise a single process or industrial activity, but rather the whole system. Although engineering procedures for the design of individual industrial units are well developed, the problem of determining the best arrangement of these interconnected units is often far more difficult. Regulation that manages the arrangement of the units for waste processing is still under construction. In the evaluation of co-incineration, analogous principle from process control can be used: feedforward control. This principle includes the determination of which outlets can be used for all process outputs, hence avoidance of any æunusableÆ products or wastes possibly arising from co-incineration. To establish the extent, to which produced wastes are usable, a system overview is necessary, in addition to in-depth information on the subsystems, which produce and can consume wastes. Material cycles modelling can be used as the basis for a tool that supports the development of a suitable playing field. It should provide overview of the system and in-depth information on its subsystems. This tool then represents an attempt to bridge the gap between æholisticÆ industrial ecology and process engineering.

Jan 1, 2000

By D R. Swinbourne

In the recent past a number of smelting plants were commissioned in India to supply the rising demand by domestic steelworks for manganese-based ferroalloys, and they enjoyed cheap electric power and readily available high-grade manganese ore. Presently, the cost of electric power is much higher than in some neighbouring countries, there continues to be poor transport infrastructure and the prices of high-grade manganese ore have increased. Additionally, the Indian Government has opened its economy to the outside world, resulting in the import duties on ferroalloys being drastically reduced. In this paper the current situation in India will be detailed, the electric arc furnace and blast furnace smelting methods for ferroalloys compared and proposals for the construction of a new ferromanganese blast furnace in India outlined. The future of ferroalloy smelters in India will be assessed and actions which could be taken to improve their position discussed.

Jan 1, 2000

By K. Saikiran, A. R. Nalla

Longwall management, regular shield maintenance, and evaluation of ground control problems can be performed using real-time shield monitoring program. Based on real-time shield pressure data, evaluation of intensity and interval of periodic weighting, estimation of time-dependent pressure increase and the effects of geologic anomalies can be obtained. In this study, full-face shield pressure data of over 457 m (1,500 feet) of face advancement is analyzed to evaluate shield response in the presence of surface lineaments, floor undulations, and multiple main roofs. Shield pressure increase due to web cutting is also correlated with setting pressure during periodic weighting and normal time. In addition, time-dependent pressure increase rate on Sundays and holidays is also correlated with time average pressure and the location of previous periodic weighting.

Jan 1, 2000

By Kirstin Girdner, Tom BoBo, Brian Norton, John Kemeny

Split Engineering is a truly customer oriented company dedicated to providing quantified fragmentation information of the highest integrity to enable process management and control. Technical decisions, blasting costs, operational efficiency and productivity and equipment performance can all be related to optimum fragmentation. In the past, the lack of an easy, non-disruptive, economical measuring technique has meant that, in most cases, rock fragmentation has not been defined in quantitative terms. Now, the Split-Desktop@ software provides an economical alternative to manual sampling and screening and an objective measure rather than subjective qualitative estimates. This workshop will present the latest features of the Split-Desktop@ software and show users how to quickly get quantifiable results from their blast fragmentation. A step-by-step demonstration will display the software’s flexibility, user-friendly options, and ease of use. Outlining where other mines have benefited from using the Split-Desktop@ software will provide insight to a wide range of software uses and potential applications like creating a database of geologic zone specific post-blast fragmentation information, underground draw point monitoring, stockpile, leach pile, and waste dump size measurement and monitoring, as well as many other applications.

Jan 1, 2000

This is a sampling of the papers presented at the conference, the proceedings can be bought from the SAIMM The technique reported here involves measuring the air pressures generated within sealed boreholes located behind blasts. Results from twelve free face blasts in competent rock environments a represented. There were no instances of high pressure gas penetration, even at distances corresponding to less than one blast burden. Rapidly generated underpressures were measured in most holes, with the magnitudes of the peak pressures decreasing with distance behind the blasts. It has been proposed that the under pressures are the result of new volume created due to crack formation and overall rock mass dilation. The experimental evidence is consistent with this, including a correspondence of the onset times of the peak underpressures with the nominal firing times of the nearest blastholes. New post-blast cracks were observed when using borehole video cameras in the monitoring holes. A calculation of new volume produced within the monitoring holes is proposed as an indicator of damage. While the data exhibit considerable scatter, there is a power function dependence on scaled distance, which resembles that of typical vibration data. The data also lie within the normally quoted vibration regimes for rock damage and are consistent with measured extents of damage. It is concluded that this technique may provide an inexpensive and practical comparative measure of near-field rock damage due to blasting. It is further concluded that gas penetration is not a common phenomenon. Damage appears to be mainly attributable to the nearest blastholes and the control of charge mass in perimeter blastholes is emphasized for damage minimization.

Jan 1, 2000

By C. Allen

A series of zinc chloride electrowinning tests was carried out in a laboratory scale cell to evaluate the effect of temperature, current density, electrolyte composition, gas sparging and additives on the performance of the cell with respect to current efficiency, voltage, specific energy consumption and deposit morphology. The anode material was DSA for chlorine evolution and the cathode was made of aluminum. At 400 A/m2 current density, a current efficiency of 90.9%, a voltage of 3.4 V and an energy consumption of 2.78 kWh/kg were observed. Air sparging was found beneficial but was not pursued for health and safety reasons. Various additives in the same chemical family as tetrabutyl ammonium chloride (TBAC1) were tested. Both TBAC1 and tetrabutyl ammonium bromide were found to be equally effective. Attempts to carry out the electrolysis at 1200 A/m2 were not as successful.

Jan 1, 2000

By M. Krishna, Jayagopal Uchi1, Shanta Sastry, B. M. Satish

"A well-considered composite of ZA-27 reinforced with weight percentage 0, 2, 4, and 6% of alwninite particulate has been made by compocasting technique. The elastic properties of ZA- 27 /alwniniute particulate composite were determined by using U1M. The results showed that the modulus of elasticity and UTS of the composite gradually increases with increase in the wt.% of reinforcement. However, the overall ductility decreased monotonically with an increase in reinforcement. The results of these tests· as well as the predictions of several model~ for composite strengthening available in the literature were compared with experimental results. The data observed from Young's modulus by measurements studies were compared with theoretical results predicted by Eshelby model.IntroductionMetal matrix composites (MMCs) have received increasing attention in _the recent decades as engineering materials. The introduction of a ceramic reinforcement into a metal matrix produces a composite material resulting in an attractive combination of physical and mechanical properties that cannot be obtained with monolithic alloys. Particulate reinf9rced MMCs among the discontinuously reinforced MMCs have attracted quite a lot of attention both in the industrial sectors and the academic communities. There is an increasing need for knowledge about the processing techniques and mechanical behavior of particulate MMCs in view of their production getting enhanced and their commercial applications becoming wider [I]. Interest in particulate reinforced MMCs is mainly due to easy availability of particles and economical processing techniqu"

Jan 1, 2000

By Christopher F. Gleeson, Roger D. Thomas

"Abstract - Wawa has long been a center of mineral exploration activity and diamonds have been reported in the area since the 1930s. However, diamond exploration did not begin in the area in earnest until 1991. In 1993, Sandor Surmacz and Marcelle Hauseux of Saminex began a prospecting program in the area which culminated in their discovery of the "Sandor" diamond occurrence in an outcrop on the east side of the Trans-Canada Highway. They subsequently optioned the property to Spider Resources Inc. who obtained the necessary exploration permits from Algoma Central Corporation and undertook an exploration program. The diamonds at the "Sandor" diamond occurrence are hosted in the matrix of a spessartite dike composed of actinolite, biotite, and albite. Of the 64 similar dikes that have been sampled and analyzed to date, eight have been found to contain a total of 231 diamonds. Most of the diamonds are of high quality, although they are small.The dikes are non-magnetic and do not have any other geophysical characteristic that can be used to differentiate them from the adjacent country rock. All of the dikes discovered to date have been found by prospecting or by geological mapping by the Ontario Geological Survey. The dikes do not contain pyrope garnet or chrome diopside, two of the commonly used kimberlite indicator minerals. Instead, low Mg, high Cr, Zn-rich chromite, and ilmenites of variable composition, some of which lie within the field of kimberlitic Mg-ilmenite compositions, characterize the diamondiferous dikes. A regional-scale till sampling program for heavy minerals, and geochemical analysis of the <0.177 mm fraction, was used to further define the areas of occurrence of the spessartite dikes and to indicate additional areas for diamond prospecting. Heavy minerals in till that were most useful include: actinolite, chromite, and ilmenite. Geochemical analyses of the dikes show them to contain elevated concentrations of Ni and Cr and to be enriched in Ba, Co, V, Ca, Fe, and Mg relative to the surrounding rocks. Elevated concentrations of Ni and Cr in till occur overlying and down-ice of known lamprophyre dikes."

Jan 1, 2000

By S. R. Rao, J. A. Finch, E. El-Ammouri, K. Ngoviky, P. A. Disten

Sludges produced by lime treatment of acid mine drainage (AMD) can contain significant quantities of base metals which represent both a potential hazard and a loss of values. A new technique for metal recovery from sludge is proposed by combining selective acid leaching and adsorption of metal ions by activated silica sol. The process is demonstrated on two AMD sludges, one containing primarily nickel and the second zinc. They were first treated with sulphuric acid (pH 3.5) to selectively leach the target metals and then activated silica sol was added to the leach solution to adsorb the nickel and zinc. Thickening and centrifuging gave about 90 percent rejection of the input volume to effluent. The adsorbed metals were redissolved by strong acid into a concentrated solution relative to the feed and the silica sol was recycled.

Jan 1, 2000

Drilling underground can be a hazardous undertaking in many circumstances. Raiseboring and boxhole boring underground could form an integral part of the block caving production methodology and getting the right mix of technical capability, ergonomics and economical viability has been the goal of many machine manufacturers. With the introduction of the Terratec Universal Boring Machine concept, flexibility of raiseboring, downreaming and boxholing has been enhanced by the introduction of a single machine that will perform all three processes. In addition to its technical flexibility, additional safety features have been introduced that will eliminate many sources of injury by mechanising most of the operational procedures. Together with the one-man remote operation, this machine design addresses and solves many of the safety issues. This paper outlines the machine concept, details its safety features and shows the techno-economic advantages for use in the block caving environment. Block caving is a distinct caving method applied mostly to large massive orebodies because of the inherent low costs and high production capabilities. Areas of sufficient size are mined by undercutting so that the mass above will cave naturally. Extraction of the caved ore at the bottom of the ore column causes the caving action to continue upward until all of the ore above the undercut level is broken into sizes suitable for handling (Figure 1).

Jan 1, 2000

A substantial proportion of current and historic West Coast gold production comes from deposits situated around the margins of æice ageÆ glaciers. Gold has been eroded and transported by glacial ice then deposited in till and outwash gravel. The interplay between fluvial and glacial processes, climate, basement geology, tectonic uplift, sediment supply and sea level dictates many aspects of the development of the West Coast landscape. The way in which the external forcing factors interact is crucial in determining the gold content of placer deposits in this region. The following is an outline of some of the factors that influence the gold distribution in vicinity of glacial margins.

Jan 1, 2000

By D. Morin, J. Villeneuve, S. Foucher

The development of new processes has to follow "best practice" rules in order to be technically and economically as efficient as possible. However, innovations, new process routes and new rules are continuously emerging to minimize financial risk and maximize environmental compliance. Process simulation, which offers a complete overview of the flowsheet, makes it possible to cope with this new challenge-minimizing waste production and water consumption. Furthermore, simulation provides an estimate, at the early stage, of the cost of alternative technical routes. Four examples involving biotechnological circuits are presented, both at the design and commissioning stages.

Jan 1, 2000

By Y. Moriya, Y. Sadayoshi, Y. Nonogaki, Y. Takeda

"Preparation and growth processes of CaF2 on Si(111) and of . InxGa1-x,As islands on CaF2 by molecular beam epitaxy (MBE) are described. It was found that first of all the Si(111) surface treatment process to obtain the 7x7 reconstructed structure was necessary to ensure the cleanness of the surface and to grow a flat and high quality CaF2 on it. Growth of InxGa11-x,As islands on CaF2 was tried by droplet heteroepitaxy using the same MBE reactor. In,GaxGa1-xAs islands were successfully grown epitaxially, and the size and density of the islands dependent on the In composition were investigated.IntroductionThough semiconductor/semiconductor heterostructures are widely used for many device applications, small band off-sets of the conduction bands and the valence bands restrict the utilization of the intra-subband transitions to far-infrared regions. With InAs as the quantum well and fluorides as the barrier layers, we can design three-electronic-level systems in the infrared region, which is the low loss transmission window of the silica optical fibers. To realize those structures, we have grown InxGa1-xAs islands on CaF2 thin films that were epitaxially formed on Si(111) substrates by molecular beam epitaxy. By the droplet heteroepitaxy that we invented, the InxGa1-xAs islands with height of -10 nm have been obtained successfully. Optimum processing to obtain atomically smooth surfaces of Si and CaF2 and high quality InxGa1-xAs islands is reported.ExperimentsMBEMachineCaF2 was grown on Si(111) and InxGa1-xAs islands were grown on CaF2 successively by MBE. The MBE machine consisted of a growth (or reactor) chamber and a loading chamber. The reactor chamber was equipped with Ga, In, As and Er metal source cells and CaF2 and BaF2 source cells. Cell materials were P-BN for Ga, In and As metals, and were graphite for CaF 2, BaF 2 and Er to avoid reaction with BN cells. The electron gun and screen were attached to the reactor to observe the RHEED pattern during the substrate surface treatment and the growth of CaF2 and InxGa1-xAs islands. The substrate manipulator was designed to heat up the Si substrate up to 1,200°C for the surface cleaning. The QMS was also equipped to analyze the residual gas species in the reactor chamber. The base pressure of the reactor chamber was 2-5x10-11 Torr, being pumped by ion pump and the liquid nitrogen shroud"

Jan 1, 2000

By Robert De Saro, Willis Bateman, Ramesh Jain

A Vertical Floatation Melter (VFM) has been developed (sponsored by DOE) which simultaneously decoats and melts organic laden scrap in a single unit. Scrap aluminum is fed into the top of the VFM where it falls through a cone. Hot gases flow upwards through the cone, imposing a variable drag force on the scrap. Equilibrium is reached in which the scrap weight equals the drag force and the scrap becomes suspended. The gases strip off and vaporize the organics. Next, the scrap reaches a liquid state, taking on a more aerodynamic teardrop shape, allowing it to fall into a holding furnace. Heat transfer coefficients are 10 times higher than that of a conventional furnace, allowing rapid melting at a low gas temperature. Typical energy use is well under 2,324 joules/g (1,000 Btu/lbm) with a metal yield from 92 to 98%. This paper reports on the operation and data of a 453 kg/hr (1,000 pph) pilot-scale VFM.

Jan 1, 2000

By I. J. Duckworth

During the last twenty years computers have be-come widely used to assist with the simulation and design of large scale, primary ventilation systems. However, to date there are few computer programs available to help with the modeling of auxiliary ventilation in dead-end headings or tunnels. This paper presents the results of the first year of a research and programming study dedicated to the development of a user-friendly duct simulation tool. Included is a literature review that summarises publications on duct leakage and resistance, on previous programs developed for the simulation of airflow in ducts, and case studies on extended ductlines in mines and tunnels. The methodology behind the development of Ductsim, a Windows based simulation program is presented.

Jan 1, 2000

By Mick O'Meara

Metal Organic Chemical Vapour Deposition (MOCVD) is used in the production of computer circuit boards and metal shapes in nickel, gold, copper, cobalt, etc. All varieties of .MOCVD use the decomposition of a vapour of organometallic compounds to produce different forms of ultra-pure metals, or alloys. CVD Manufacturing's proprietary MOCVD process has been adapted and developed to produce commercially ultra-pure metal shapes, metal powders, and metal foams. Therefore, it is a purification process. The typical process has three steps. First, a volatile metal organic compound is produced from volumetrically contaminated metals, metal oxides, etc. Typical feed materials are metal powders, ores, concentrates, or a slurry of metals and contaminants. Secondly, the volatile. metal organic compound is purified by fractional distillation. Thirdly, the purified metal organic compound is decomposed into different forms of ultra-pure metals, such as net shapes, powders, or metal foams. A mixture of metals can be purified either by the selective production of volatile materials, or a separation can be achieved during the second step, in the fractional distillation stage. The purification and recycling of metals by the MOCVD process will be discussed, particularly with regard to nickel, aluminum, gold, the platinum group and other metals.

Jan 1, 2000