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By M. E. Rossi

Reconciliation of production information is critical to evaluating the effectiveness of the predictive models, and to allow for optimization of mining operations. Whether mining open pit or underground, mine-to-mill reconciliations can be one of management's better tools to perform proper accounting, and a very useful evaluation and optimization tool. This paper proposes a set of criteria and objectives for a typical reconciliation program; also presents a stepwise, logic approach to performing reconciliations, and discusses the benefits and costs associated with the up-keeping of the information. It also highlights some of the potential pitfalls involved, and methods used to avoid collecting misleading information. These issues are illustrated with an example of a model-to-mine-to-mill reconciliation program being implemented at an operating mine; the program involves multiple predictive models (Long-term and Short-term block models), different open pit and underground mines, stockpiling, and at least 23 different mill streams. This paper presents the initial results of the program implemented at Minera Michilla S.A.

Jan 1, 1999

By J. A. Madonna

Independent prospectors and small to large-scale exploration company personnel have requested, and are in need of, guidance in geochemical field sample collection methods which will provide the most reliable results during chemical analysis. In cooperation with analytical laboratories, experienced geochemical exploration scientists and mining companies a systematic collection procedure has been developed. The procedure consists of collecting uncontaminated, water, sediment and rock chip samples of the appropriate quantity and/or dimensions to meet the needs of analysis.

Jan 1, 1999

By Garry W. Stevenson

Data from many case histories reporting tunnel boring machine penetration rates in rock with unconfined compressive strengths greater than 70 MPa (10,000psi) are summarized. The case history data are useful for comparing estimated penetration rates with historic performance in similar rock types, particularly in granitic and metamorphic rocks. TBM exhibit higher penetration rates in sedimentary rocks than in granitic and metamorphic rocks. Data for the two groups of rocks are summarized separately.

Jan 1, 1999

By P. Eger

In 1991, LTV Steel Mining Company decided to close an open pit taconite mine in northeastern Minnesota, using a passive treatment approach consisting of limiting infiltration into the stockpiles and wetland treatment to remove metals. Over 50 million metric tons of sulfide-containing waste had been stockpiled adjacent to the mine during its 30 years of operation. Drainage from the stockpiles contained elevated levels of copper, nickel, cobalt and zinc. Nickel is the major trace metal in the drainages, and prior to closure annual median concentrations ranged from 1.5-50 mg/L. Copper, cobalt and zinc are also present but are generally less than 5% of the nickel values. Median pH ranges from 5.0 to 7.5, but most of the stockpile drainages have pH greater than 6.5. Based on the chemical composition of each stockpile, a cover material was selected. The higher the potential a stockpile had to produce acid drainage, the lower the permeability of the capping material required. Covers ranged from overburden soil removed at the mine to a flexible plastic liner. Predictions of the reduction in infiltration ranged from 40% for the native soil to over 90% for the plastic liner. Five constructed wetlands have been installed since 1992, and have removed 60-90% of the nickel in the drainages. Total capital costs for all the infiltration reduction and wetlands exceeded $6.5 million, but maintenance costs are less than 1 % of those for an active treatment plant. Since mine drainage problems can continue for over a hundred years, the lower annual operating costs should pay for the construction of the wetland treatment systems within seven years.

Jan 1, 1999

By C. Lupi

In 1996 the Italian Agency for Environmental Protection (ANPA) has initiated a study of the environmental impact of the industrial sector of steel produced by Electric Arc Furnace (EAF). Within the framework of this study a hydrometallurgical process to treat EAF dusts was considered and developed. The paper describes the zinc and lead recovery from fumes coming from carbon steel production. The zinc extraction consists in acidic leaching followed by SX-EW steps. The leaching sludge containing lead sulfates was treated to obtain pure lead salt and inert solid residue. The whole process, that minimizes effluents by recycling the main liquid streams, has been developed to obtain marketable products. The solid waste, containing spinels, was subjected to elution tests in order to verify its compatibility with environmental regulation. The process, that has been set-up and tested in the laboratories of the University of Rome, will be transferred and studied on a pilot plant in order to assess its industrial and economical feasibility.

Jan 1, 1999

By M. M. Carpenter

Specialty chemicals are widely used in the industrial minerals process industry for many different purposes including beneficiation, filtration, flocculation, dispersion and biological control. Optimal use of such chemicals can confer benefits both in terms of cost efficiency and end product attributes. In this paper we will review recent progress in the fundamental understanding of mineral additive interactions and present data which show how optimization can lead to improved products.

Jan 1, 1999

By D. Brunner, G. R. Baiden, H. J. Yazici

System simulation is an increasingly popular technique for analyzing and improving existing as well as newly designed underground mining operations. An engineering firm that specializes in simulation helped a major metals producer build a long-range planning model of an existing underground mine. Subsequently the team adapted this model to assess technology alternatives in the design of a new mine. The two models differ in the level of detail used for modeling the development process. This paper discusses the differences in approach between the models along with the experiences gained and challenges faced during the construction and use of the models.

Jan 1, 1999

By Chen Zhang

Polycrystalline Ti-rich NiTi thin films have been deposited from a single NiTi target using a DC magnetron sputtering system. Free standing film was obtained by using a single crystal silicon substrate. Thickness ofthe thin films is controlled at around 12 pm. In this investigation, the effect of deposition temperature on the microstructure and transformation temperatures of the thin films is studied. Influence of post heat treatment temperatures on the properties of the thin films is also investigated. Transformation temperatures of the thin films are determined by differential scanning calorimetry (DSC). The surface microstructure of the thin films is studied using a scanning electron microscope (SEM), and the crystallinity is determined using x-ray diffractometry. It is found that the thin film deposited on a hot substrate is crystalline even when the substrate temperature is as low as 300°C, while the normal crystallization temperature for an amorphous thin film is around 500°C. The microstructure of the film deposited on a hot substrate shows a very fine grain size. The grain size increases with increasing substrate temperature during deposition. The effect of post deposition heat treatment on grain size is minimal.

Jan 1, 1999

By Patrick Doig, Ross Webb

The Bradshaw Section 5A Interceptor involves the construction of two miles of 108-inch, finished diameter tunnel in dry soils. Excavation is generally by Lovat TBM with ribs and lagging support. The tunnel is beneath a recreational parkway and stringent measures have been enacted to preserve the parkway and minimize disruption to the neighborhood. Apart from these constraints, the project would have been unremarkable but for the intervention of CalOSHA and the local fire department who ordered extraordinary fire protection measures. The paper discusses the cause and effect of these measures and comments on the potential repercussions for other projects.

Jan 1, 1999

A laboratory size solvent extraction apparatus has been constructed, which incorp- orates three stages of countercurrent extraction, followed by two stages of counter- current stripping. The model uses a gravity flow system from one stage to another and air lift pumps to recirculate organic and aqueous phases. A novel pump/mixer system is used to transfer solutions from the mixer compartments to the settler compartments. The model has proven valuable in the teaching of solvent extraction principles.

Jan 1, 1999

By M. Manrique, E. E. Vidal, I. Accorsi, P. R. Taylor

Various pyrometallurgical methods for treating ilmenite and zircon concentrates are reviewed. Laboratory experiments using a thermal plasma reactor were performed to evaluate the conversions of ilmenite to TiC or TiC-Fe and zircon to ZrC or ZrC-SiC. Results are examined and possible processing routes are identified.

Jan 1, 1999

By Mark Jolly

"Over the last ten years or so many man hours have been dedicated to developing methods for simulating shape casting processes. The majority of the methods developed have been devised by a combination of computer, mathematics and materials specialists often with limited knowledge of foundries and foundrymen. As a result of this it would appear that although there are many software packages for the foundryman to use there still exist fundamental misunderstandings as to their usefulness and suitability within the foundry.The paper aims to identify how well current software packages perform. The relationships between physical phenomena, practical defects and software capabilities are presented. Some discussion of the use of criteria functions is also presented. Finally issues arising from the postprocessing of results are discussed as the presentation of the results to the lay-person in simulation techniques is possibly one of the most important aspects in influencing the adoption of this type of software in the foundry community."

Jan 1, 1999

By P Worsey, B Lane

The recommended maximum explosive weight for boulder blasting using internal charges is 0.15 kg/m 3 (Olofsson, 1988). Normally this charge results in excessive scattering and flyrock, creating increased liability for the operator, especially in congested areas. An alternative technique using smaller explosive charges is being developed at the University of Missouri-Rolla (UMR). It is designed to reduce boulder scatter, flyrock and fumes and allows shooting in close proximity, using common blasting products. The method comprises drilling a hole into the top of the boulder, inserting a small primer, filling the hole with water and shooting it. The hole is drilled approximately two thirds into the boulder and the charge (10 g/m 3 ) is placed half way into the hole filled with water. Upon initiation the primer produces a small volume of gas at extremely high pressure which acts upon the surrounding (relatively incompressible) water. The water transmits this pressure to the surrounding blasthole, hydraulically fracturing the rock. As the fractures propagate and the boulder expands a rapid increase in the blasthole volume occurs. Because of the small charge the gas pressure quickly dissipates reducing rock movement, resulting in a fractured boulder with minimal material leaving the immediate vicinity. The current work includes both laboratory and field testing programs. The laboratory program is focussed on determining optimum parameters at reduced scale using concrete cubes. The field program focuses on determining a minimum powder factor and includes shooting smaller boulders up to 1 m 3 underground and 1.5 to 5 m 3 boulders in a surface quarry. In both cases the boulders were obtained as oversize from regular production blasts.

Jan 1, 1999

By Bob Thomas

The roof drill operator productivity can be enhanced by the introduction of control technology The operators control station can be improved by considering human factors such as handle forces and control location. The smaller electrical controls can be located much easier than the traditional hands on valves. The operators control can he improved by using processors with programmable subroutines that assist the operator in the decision making process. For example to increase feed rate - to slow rotation - to avoid clogged steels - etc. The overall affect is to improve drilling and bolting consistency. The control system uses a dedicated processor packaged as an intrinsically safe control station. The roof drill operator is assisted in the drilling; arid bolting by a closed loop feedback system. The processor monitors the drilling parameters such as feed force, feed rate, rotation torque, RPM, drill position, and vacuum condition Based on the drilling parameters the processor executes pre-determined condition statements intended to enhance drilling The drill operator has an active display to alert him to the real time machine status. For example if the feed were to slow or delay due to a high vacuum level the display would show "high vacuum". The dedicated processor is available on the arm feed style machines, The prototype machines used programmable logic controllers to develop the feedback relations. The ability to record drilling parameters was extremely helpful in this development project. The extended use of the recording feature will aid operators in mapping the mine roofs Interpreting the recorded drilling parameters can reveal a void in the top or hard competent drilling The prototype machines also showed the importance of vacuum monitoring This feature is extremely valuable in softer materials, The benefits of the control system range from efficient use of the consumable bolting materials to uniform operator performance.

Jan 1, 1999

Hong Kong continues to display a remarkable enthusiasm for undertaking ambitious tunnelling schemes despite apparent recessions in the Asian economy. This paper provides an outline of tunnel projects currently under construction, those recently tendered and a glimpse of the extent of forthcoming projects which, according to Government sources, carry a price tag of HK$ 200B. Committed works will cost about HK$ 15B and involve a variety of TBM and drill and blast tunnels. These include the recently tendered works for KCRCÆs West Rail and MTRCÆs Tseung Kwan O railway extension, together with five no retendered TBM drives for the Strategic Sewage Disposal Scheme (SSDS) following forfeiture of the works by the Campenon Bernard-Maeda JV in mid-1997. The JV claimed unreasonable specifications leading to unacceptable levels of water inflow and dangerous working conditions. Key technical issues that are now arising in Hong Kong are:the general use of design and build contracts for bored tunnel contracts;a trend to accept TBM options for relatively short drives in urban areas;the use of æfixed-priceÆ contracts which in the current competitive market, can encourage tenderers to take contractors to take very high risks; andthe difficulty of predicting and managing water inflows in rock tunnels.This paper also includes a new empirical method of predicting water inflows in rock tunnels, and makes recommendations for managing these on-site.

Jan 1, 1999

By R Milton, D Hake, H Sprague

The North Western Sewer tunnel extends over 11.5 km in the North Western suburbs of Melbourne.The $253 million tunnel project provides a critical link in the Melbourne Sewer Network. The existing sewers fail to service the increasing demands of the growing population of the North West regions of Melbourne. This project will protect the environment and improve the standards of service of the existing system. This paper concentrates on Section three of this project, consisting of the final 4 km of the Contract, three access shafts and a cut and cover section of tunnel.Transfield Tunnelling as Head Contractor constructed the tunnel for Melbourne Water Corporation, with Enetech Streamline, formally Streamline Australia, a trading arm of Melbourne Water acting as Superintendent.Excavation of Section three of this project commenced in September 1994 and project completion is scheduled for October 1998. The tunnel passes below the residential suburb of Essendon, through some of the most challenging ground conditions ever attempted to be tunnelled in Australia.

Jan 1, 1999

By Les Gutzwiller

Fan applications in the mining industry have changed during the last 70 years. In 1922, J.R. Robinson authored a technical volume entitled Practical Mine Ventilation. At that time, atmospheric control had only recently shifted from natural to mechanical. The large, mechanical draft fans that were used then were centrifugal. The fans ran at low speeds, about300 rpm. Most were steam-engine driven. In the late 1920s and early 1930s, mines became larger, increasing the pressure and volume requirements of the fan equipment. Axial fans were designed to run at much higher speeds (710 to 880 rpm) and were driven by electric motors. They were also smaller and less expensive to install than the cumbersome centrifugal units. However, changes in mining have resulted in progressively higher static-pressure requirements. So centrifugal fans are once again proving to be a good choice.

Jan 1, 1999

By Kazuaki Mita

There are various intermetallic compounds in the Zn-Fe system. We synthesized them at about 673K. A specimen was examined chemically and X-ray diffraction was applied to ensure the formation of intermetallic compounds. Material containing two phases was placed in a Knudsen type effusion cell and the mass spectrum studied to evaluate the vapor pressure of zinc. The thermodynamic properties of intermetallics was then evaluated through measured intensity.

Jan 1, 1999

By C. M. Acuña

At the Chuquicamata Division of Codelco-Chile high arsenic concentrates are produced, which at the smelter are processed via the Outokumpu Flash Furnace and Teniente Converters to obtain copper mattes. In the case of the Teniente Converters the production of matte grade near white metal composition is a common practice since the eighties and provided in the pyrometallurgical route no appropiate measures are taken, penalties have to be paid because of arsenic content in the anodes. During smelting huge volume of slag is produced and elimination of arsenic by slagging at this step is not economically attractive. Although during fire refining is possible to eliminate arsenic by use of mixtures of calcium and sodium carbonates this alternative is expensive, takes long process time and decreases the lifetime of the refractory lining. In spite of these facts a reasonably way to control arsenic in metal, and therefore in the anode, is taking, action in the converting step. The effects of oxygen and arsenic content in metal, arsenic in white metal and basicity index of the slag upon the distribution coefficient of arsenic between metal and slag were investigated at pilot and industrial levels. The best results are obtained for metals around 7,000 ppm oxygen and 0.3 basicity index slag, which results in a 5.7 distribution coefficient for a 5,800 - 7,100 ppm arsenic content in white metal, 18%-24% CaO slag at 1473 - 1523K. Furthermore, no significant/visible refractory wear has been realized.

Jan 1, 1999

By Dinah O. Shumway

California's annual production of >11 million tons of cement, at a value of over $640 million, comes from eight companies, which operate 11 plants. Cement is California's second most important mineral commodity, representing 25% of its total annual mineral production. Although most of the cement produced is consumed within the state, current export locales include the Pacific Northwest, Nevada, Arizona, Utah, and New Mexico. An enumeration of the components required to produce cement is deceptively simple: calcium oxide (65%), silica (20%), alumina (4-5%), iron (3-4%), and calcium sulfate (4%) as a retardant admixture. The last, and most expensive, ingredient in cement manufacture is energy. Detrimental materials in cement mixes include excess .magnesium, alkalis, heavy metals, sulfur, and other volatiles. Each of the 11 cement plants in California requires a unique chemical solution of combined raw materials to produce a uniform product: portland cement. The geologist proposing solutions for the additive raw materials in cement manufacture must have a thorough knowledge of a particular cement plant's needs. In the California cement market, keeping the costs of additive raw materials down is one way to also stay competitive, and using a combination of natural and waste materials as additive raw materials allows cement producers to stay competitive.

Jan 1, 1999