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By J. S. Stickling, P. J. Whittaker, N. O. Lotter

"Assessment of opportunities to improve mineral processing performance in existing concentrators and in describing undeveloped orebodies is key to improving the business case of a mining company. This assessment has traditionally been performed using the distinct and separate inputs from mineral processing and mineral science.More recently, process mineralogy has been used to integrate these two disciplines. This trend has been driven by the need to develop and process more challenging ore deposits, and has been assisted by the availability of modern automated instruments. Together with the acquisition of a QemSCAN (quantitative evaluation of materials by scanning electron microscope) from CSIRO in Australia, and with the use of a supporting SEM with EDX/WDX capabilities and an XRD, the development of process mineralogy at Falconbridge commenced in 1997.The sampling challenges in presenting a QemSCAN with representative sample material at the polished section level are significant, but have been effectively addressed. The full description of this aspect is beyond the scope of this paper.It is shown that, by use of this approach, the set nature of an orebody can be best exploited with selected flowsheet changes in a concentrator which address the generic characteristics of the orebody. In this way, the flowsheet provides a process that more effectively fits the mineral processing requirements of the ore. This leads to clear and tangible improvements in grade and recovery."

Jan 1, 2002

By S. Culp, P. Metcalfe

Web technologies and the Internet have revolutionized the computer industry. The Web browser technologies have also moved to portable devices such as Personal Digital Assistants (PDAs) and mobile phones. This paper looks at how to implement a Web Server solution and addresses some of the inherent advantages in the technology. It will also look at some examples of how plant productivity can be managed with a Web Server approach.

Jan 1, 2002

By S. C. A. Franca, M. T. Millqvist, A. B. Luz

Laboratory experiments were performed on a Brazilian diatomite from Bahia State to produce an industrial product for use as a filter aid. Bench and pilot plant tests were conducted consisting of: diatomite desegregation, organic matter and clay removal, filtration, drying and calcination. Calcination temperature and sodium carbonate addition influenced diatomite particle size distribution. Optimum filtration rates for calcined products were obtained at 900°C and 47 min. residence time with 3% (w/w) of sodium carbonate addition, and resultant products met specifications imposed on filter aids.

Jan 1, 2002

By H. Zhu

Coal desulphurization by flotation is often difficult due to the surface oxidation of coal pyrite. Scanning electron microscope (SEM) and X-ray diffraction (XRD) were adopted to obtain detailed information about the surface oxidation of pyrite. Fresh pyrite surfaces were found to be hydrophilic, and to turn hydrophobic after initial oxidation, with oxidized products such as polysulphide FeSx and free sulphur. The oxidized products on the pyrite surface were reduced by an electrochemical method, returning the surfaces to a hydrophilic state and thus increasing the separating efficiency of coal from pyrite by flotation. Key words: surface oxidation, pyrite, SEM, XRD pattern, electrochemical modification.

Jan 1, 2002

By Kul Bhushan

This paper presents the results of lateral load tests on 0.61-m to 1.27-m (24 to 50-inch) diameter drilled and cast-in-place piers in San Diego area residual/formational soils. The test piers were installed and tested in the following soils: Decomposed Granitic Rock (Ktd), Stadium Conglomerate (Tst), and Friars Formation (Tf). Lateral loads of up to 845 KN (190 kip) were applied to the piers in residual granitic soils, and loads up to 1780 KN (400 kip) were applied to the piers in Stadium Conglomerate and Friars Formation. The tests were conducted by jacking against adjacent piers and monitoring the lateral load and lateral deflection at the ground line. Test results indicate that ultimate lateral pile capacities of up to 1800 KN (400 kip) can be obtained for 0.61 m (24-inch) drilled piers with penetration of 3 to 6 m (10 to 20 ft) in the residual/formational soils tested. Lateral load analyses using p-y curves for very dense sand significantly overestimate the observed lateral deflections. For lateral load analyses using dense sand p-y curves, p-multipliers that increase the lateral soil stiffness (p-y curves) by 2 to 8 times are required to match the load-deflection behavior measured in the test piles. When applied to the dense sand p-y curves, the p-multipliers provide a more accurate prediction of load-deflection behavior in the residual/formational soils, and can result in shorter required pier penetration and significant savings in foundation cost.

Jan 1, 2002

By Donald A. Bruce

The construction of major structures in karstic limestone terrains poses difficult problems to designer and contractor alike. This reflects the inherent variability of such conditions, and also the significant impacts caused by the construction processes themselves. Three case histories are provided of recent projects in the United States: the sealing of a major inflow into a quarry, the improvement of a highly loaded bridge pier foundation, and the installation of high capacity micropiles. Emphasis is placed on problem assessment and execution verification.

Jan 1, 2002

This article updates the status of fatalities occurring in both coal and metal/nonmetal mines from January through December of 2001. Based on preliminary accident reports, as of December 31, 2001, seventy-two fatalities have occurred at coal and metal/ nonmetal mining operations. During this period, forty-two fatalities occurred at coal operations and thirty fatalities occurred at metal/nonmetal operations. Ignition or explosion of gas or dust and fall of roof were the most frequent accident classifications in coal and powered haulage fatalities were the most frequent accident classification in metal/nonmetal.

Jan 1, 2002

By Anthony D. Hammond

The use of geographic information systems (GIS) as a tool to analyze and display data is gathering momentum in the mining industry. Of particular interest is the capability of GIS to link spatial features and tabular data. The application of GIS in underground mining discussed here concentrates on four technical areas. They are land ownership and mineral claims, exploration management, production and mine safety.

Jan 1, 2002

By R. Laplante, P. Radziszewski, P. De Ciccio

"Predicting the effect of wear can lead to improved control strategies that can possibly minimize the risk of catastrophic failure due to wear while maximizing useable life. In the field of geological exploration, diamond drill rod wear illustrates just such a case. Wear conditions vary with geological formations and compositions. The objective of this paper is to determine a general relationship, based in theory and practice, that will approximate drill rod wear and therefore predict remaining drill rod life in the context of Canadian, Australian and South American drilling campaigns. Simulation results allow the definition of simple graphical tools that permit the estimation of the potential drill depth remaining on a given drill rod string. IntroductionWear, in many industrial processes, is an undesired phenomenon for which enormous efforts are made to control, if not eliminate. However, wear, in many other cases, is an intrinsic phenomenon of the given process. In such cases, predicting the effect of wear can lead to improved control strategies that can possibly minimize the risk of catastrophic failure due to wear while maximizing useable life. In the field of geological exploration, diamond drill rod wear illustrates just such a case where abrasive conditions vary with geological formations and compositions.A number of studies have been published on drill rod wear especially with regards to the petroleum industry over the last thirty years (Lewis, 1968; Rollins, 1968; Smith, 1978; White 1978; Rowe and Wilson, 1981; Cheng, 1982; Eustes, 1986; Dudman et al., 1989; Besaisow et al., 1990). Of these, most studies covered management techniques (Rollins, 1968; Smith, 1978; White, 1978; Rowe and Wilson, 1981; Besaisow et al., 1990) and some described case histories (Cheng, 1982; Eustes, 1986; Dudman et al., 1989). However, little (Lewis, 1968) was presented that could aid in predicting wear in the particular case of diamond drilling in the metal mining industry.The objective of this paper is to determine a general relationship, based in theory and practice, that will approximate diamond drill rod wear and therefore predict remaining drill rod life in the context of Canadian, Australian and South American diamond drilling campaigns."

Jan 1, 2002

By J. Andrew Cornier, Mike Cooper

"Upon successful completion of the AG/SAG Mill project (Cooper et al., 2001) the Brunswick Mine concentrator was configured with single line processing through the AG/SAG mill, followed by two parallel ball mill and flotation circuits. The Stage Grinding project was undertaken to utilize a pre-flotation stage on the AG/SAG mill primary cyclone overflow and simplify the flowsheet by consolidating the two ball mill and flotation circuits, resulting in single line processing fi-om AG/SAG mill to final concentrate. Concurrently, the reclaim water supply capacity was increased to enable flotation cleaning at lower percent solids.Benefits from the Stage Grinding project include revenue enhancement from increased zinc grade and recovery combined with additional lead recovery. Further benefits included a reduction in the number of process pumps, reduction in loss associated with spillage to sumps and process simplification through efficient use of equipment layout.The Stage Grinding project was implemented in six phases over a period of seven months in 2000. Each phase was commissioned during scheduled concentrator shopdays with minimal additional downtime required. One year after project approval the Stage Grinding project was completed at a total cost of $1 1.8 million.INTRODUCTIONThe Noranda Inc. Brunswick Mine, located near Bathurst, New Brunswick, is one of the world’s largest leadzinc mines. Milling of ore began in 1964 from the No. 12 orebody, with an expansion in 1966 to accommodate ore fkom the No. 6 open pit located several kilometers away. In 1980 the pit was exhausted and the concentrator rationalized to accept a design feed rate of 10,500 tomes per day from the No. 12 mine. In excess of 100 million tomes have been milled to date, representing over three-quarters of the known reserve. The concentrator employs differential froth flotation to produce lead, zinc, copper and leauzinc bulk concentrates. The ore is massive sulphide, with approximately 20% valuable minerals, 60% pyrite and 20% silicates."

Jan 1, 2002

By R. D. Hull

Paper written on project work carried out in partial fulfilment of B.Sc. (Eng.) (Mining) degree As a partial fulfilment for the degree of B.Sc. (Eng) (mining) at the University of the Witwatersrand, a dissertation was to be completed in the mining industry. This was done at Finsch mine, with the purpose of determining the best solution to the required secondary breaking problem. In order to complete the study of the secondary blasting method available for use in the new block 4, cave mining method at Finsch mine the following problem statement was identified and solved ?The methods currently in use, for the secondary breaking of oversize rocks at their source in the current production levels, are to be investigated, and their applicability to the new block 4mining project determined?. To effectively achieve this problem statement above; time was spent researching and investigating, in depth, the methods that are currently in use at both Finsch and Koffiefontein mines; so as to gain practical knowledge of these. The methods were identified and independently evaluated, taking into consideration factors such as costs of the equipment, time to break oversize rocks, advantages, disadvantages, safety and labour requirements, etc. This in turn then allowed for a direct comparison between the methods and the decision as to the best to apply to the new block 4 production level. The methods that were investigated included: ?Concussion blasting, where concussion bombs and lay-on charges are used to break hang-ups and boulders. ?Drill and blast methods, where holes are drilled in large rocks and charged manually with explosives. ?Emulsion secondary blasting, which is a new project in use at Koffiefontein mine from African Explosives Limited. ?The Ro-BustTM breaking system, a hydro-fracturing breaking system. Once all the methods had been evaluated and compared it was found that the Ro-BustTM Breaking system was the most applicable for the breaking of boulders, with, the Emulsion Blasting System being used for hang-ups. Further information and the more in-depth version of this report, is stored in the resource centre at De Beers?Finsch Mineand the School of Mining Engineering WITS University.`

Jan 1, 2002

By Martin Nevens

"In 1998, the Iron Ore Company of Canada initiated an aggressive program to improve the performance of its Carol Lake Concentrator located in Labrador City, Newfoundland. This program was termed the Concentrator Upgrade Program. The Concentrator Upgrade Program was a group of initiatives developed with the common goal of improving the overall process and operations of the IOCC Carol Lake Concentrator. The main goal of the program was to increase the annual production capacity of the concentrator from 18.0 million tomes to 21.6 million tomes. This gain in capacity was to be done mainly through improvements in process iron recovery. The target iron recovery value was 80+% versus a historical value of 70%. This improvement in iron recovery would translate to a natural weight recovery improvement from 44% to 50%.The Concentrator Upgrade Program provided the first opportunity in 30 years to make fimdamental changes to the concentrator flowsheet. To accomplish this, several pilot plants were built to evaluate new circuits. AAer 2 years, a new flowsheet was selected for the primary gravity separation circuit and the magnetite circuit. The centrepiece of the new flowsheet was the introduction of Hindered Settling Separators to the metallurgical process.The Concentrator Upgrade Program has since proceeded into detailed engineering and, as of February 2001, construction. The first one of IOCC’s 3 primary AG Mills (Mill 11) has been converted to the new flowsheet at the time of writing and is in the throes of commissioning. This paper will review the flowsheet development program in the pilot plant for the gravity separation circuit and examine the overall benefits to the operation of the IOCC Carol Lake Concentrator."

Jan 1, 2002

By J. P. D. Strydom

The transmission of excessive vibration to the human body can cause physical stress that may result in crippling pain or permanent disability. Rock drills are known to transmit high levels of vibration that are difficult to attenuate through conventional approaches to vibration isolation. However, it can be shown that once the ISO frequency weighting has been applied, most of the vibratory effect of the rock drill?s motion is concentrated at the drill?s operating frequency. This observation opens the way for utilizing a concept known as vibration absorption, aimed at attenuating the rock drill?s vibration. In essence this entails using the inertia of a secondary vibratory system to counteract the motion of the handle. This article documents an investigation into the use of such an absorber for attenuating rock drill vibration and demonstrates the feasibility of such an approach. A mathematical model of such an absorbing handle was developed and used for design studies. Based on these investigations an experimental prototype model was manufactured and tested. A significant reduction in vibration levels could be achieved.

Jan 1, 2002

By Heikki Jalkanen

The mineralogical composition and morphology of solidified copper smelting and converting slags are of some interest from slag cleaning (by froth flotation), impurity elimination, and environmental points of view. Properties result from both the state of molten slag before solidification and processes taking place during solidification and cooling. In solidification and cooling, copper and sulfur dissolved in molten slag are .precipitating substantially from the silicate phase. Even in water quenching of slag, dissolved copper is pushed out of the solution in the form of finely divided precipitate. Elements present in the raw materials are distributed in a distinct manner between the solidified slag and non-silicate solidification products. Arsenic, antimony, and tin are strongly accumulated in copper precipitate, but not the other metallic constituents common in copper concentrates. Smelting and converting slags differ remarkably on their mineralogical composition and morphology although resulting principally of same chemical processes. Converter slags are more inhomogenous; they often contain solid particles and copper content is .as a rule higher than in matte smelting slags. The final copper content of converter slags was observed to be in a distinct manner dependent on iron oxide - silica ratio. Slag forming, solidification, and precipitation phenomena are discussed on the basis of mineralogical and morphology analysis of smelter slags and laboratory scale experiments.

Jan 1, 2002

By Gyimah Kasali

Rapid Load Testing was performed as part of an extensive drilled pier testing program for the University of California Berkeley Capital Improvement Program. The purpose of the program was to: (1) Verify the axial compressive design capacity values for the planned 24" piers, and to estimate the capacity of the existing 30" CIDH piers, and (2) To evaluate the seismic performance of the proposed drilled shafts. The Fundex PLT was used since the loading period of the PLT is very similar to the period of a seismic event, making it an ideal tool to model the pier response to seismic events. "Performance-based design" of structures subject to seismic loads has been of particular interest to UC Berkeley Seismic Review Committee and the Pacific Earthquake Engineering Research Center. The comparison of static tests to Rapid Load testing also provided valuable correlations. The program represents one of the most comprehensive drilled pier test programs on the West Coast. The testing program consisted of Rapid Load Testing using the Fundex PLT on 6 drilled piers. Rapid Load Tests were followed by conventional static compression and tension tests on selected piers, followed by another cycle of rapid load tests on the statically tested piers. The piers featured extensive instrumentation to allow detailed interpretation of the test result. Correlations were drawn to compare static load test result to that of the PLT in the particular soil profile, and the PLT also provided the data to analyze the ultimate seismic capacity of the piers. The load test results indicate that the ratio of interpreted failure load from the PLT data to the corresponding load from the static load test data is about 1.2 to 1.3 for the clayey soils underlying the test site. The results also indicate that the PLT offers an economical approach to defining the stiffness of drilled pier foundations subjected to seismic loads for use in performance-based design.

Jan 1, 2002

By Ivan Jackson Madura

The new Paradisus Coco Beach Resort in Rio Grande (PR) is located on an old swamp area, which has been filled with relatively clean to silty sands. The swampy deposits consists of organic silts, peat and loose fine to medium sand and silty sand. The project requires the placement of 1.0 to 1.5 meters of additional fill together with the construction of light structures. The need for the fill will trigger the development of settlements in the underlaying weak and compressible stratum. Furthermore, the susceptibility of the loose sand to liquefaction during an earthquake was considered. This paper describes the soil improvement by means of vibro-replacement, the purpose of which was threefold: reduction in total and differential settlement, acceleration of settlements during the surcharge period and densification of the loose sand to reduce its liquefaction potential. The predesign is presented together with relevant construction details of the preliminary trial areas from which the final column diameter and grid spacing were derived. Instrumentation together with settlement observations during the surcharge period are presented as well and compared with the initial predictions.

Jan 1, 2002

By George Hope, Brigitte Lacouture

"The Red Dog Mine has increased mill throughput for most years since startup. Although flotation equipment has been added over the last 10 years, the Red Dog metallurgical performance has been restricted by a lack of adequate flotation capacity. Two reduced tonnage trials conducted in 1997 as well as numerous SAG relines have consistently indicated the potential to significantly increase both zinc concentrate recovery and grade with additional flotation capacity. Late in 1999, a new circuit was designed with increased flotation capacity while simplifylng the current circuit, providing for three stages of dilution cleaning, and creating a retreat section. The purpose of the retreat section is to target the more complex particles and allow the chemical environment to be fine tuned for improved iron depression. In total, twentyone (21) Outokumpu OK50 mechanical flotation cells and four (4) 3.66m dia. column cells will be added to the current flotation circuit. The VIP (Value Improvement Program) Mill Optimization project is also addressing thickening, water treatment and power issues and has a total budget of $US105 M. Startup of equipment will be phased in to minimize the impact on current operations and is expected to be complete by the end of Q3-2001.INTRODUCTIONRed Dog Operations started production in November 1989. The mine is located above the arctic circle in northwest Alaska. It is linked by an 80 km road to a port-site facility where the concentrate is stored. Concentrate is shipped to markets throughout the world during the one hundred (100) days of open seas. Typical of sedimentary exhalative deposits, the metallurgy proved to be challenging and coupled with many mechanical shortcomings, the initial few years were very difficult. The start-up issues were slowly resolved and in 1998, a major grinding expansion, the PRI (Production Rate Increase) project, was completed. The project was designed to allow a 40% increase over the 1995 throughput. In 2000 mill throughput was 3,050,000 tonnes to produce a total of 960,000 and 140,000 dry tonnes of zinc and lead concentrates respectively, making Red Dog the largest zinc concentrate producer in the world. To address a shortage of flotation capacity remaining from the PRI grinding expansion, a project designated as the VIP (Value Improvement Program) Mill Optimization project was initiated. The mill optimization project is targeted to produce 1,100,000 tonnes of zinc concentrate at 56% zinc grade and 87% zinc recovery. The project will add twenty-one (21) Outokumpu OK50 (50m3) flotation cells, four (4) 3.66mO column cells and address water treatment, thickening and power generation capacities."

Jan 1, 2002

By Aly M. Mohammad

The Delaware River Tramway will link civic and retail developments in Philadelphia, Pennsylvania and Camden, New Jersey. Twin 300-foot towers will anchor the cables at either side of the river. Four high capacity drilled shafts designed by the Geotechnical Department of DMJM+HARRIS support each of the towers. At the Philadelphia tower, each 6-foot diameter shaft extends 130 feet deep and terminates with a 30-foot rock socket. The shafts are situated within the footprint of an existing relieving platform, which complicates the typical construction sequence. Also, the subsurface conditions at the site provide a unique challenge in both the design and construction of the drilled shafts. During the construction of the four-drilled shafts for the Philadelphia tower, a 6000-ton Osterberg load test was performed on the first shaft to verify design assumption and confirm the shaft capacity. The results of the test were utilized to establish load transfer characteristics and develop foundation design parameters suitable for the site conditions. By doing so the Design Engineer was able to reduce the length of the rock sockets on the remaining production shafts by approximately 5 feet per shaft. As a result, the test provided a significant cost saving to the Owner by eliminating 15 feet of rock drilling from the construction costs. This paper presents a description of the unique design and construction methods adopted for the foundations, also on the Osterberg load test including equipment used, number and locations of strain gages, and interpretation of results. The results and findings presented in this paper could benefit both the design and construction industries because it provides a comparison between geotechnical design assumption and actual field measurements; which has always been a challenge particularly for rock formation.

Jan 1, 2002

By Inn-Joon Park

Major problems associated predicting soil-structure interaction behavior are based on the fact that soil is neither homogeneous nor elastic and soil properties are spatially variable. There also exist significant coupling problems between the behavior of the structure and geologic media. When designing foundation or other geotechnical structures, the load transfer between the soil and structure takes place at the contact surface. This surface is called the interface. The behaviors of interface play an important role in the load-deformation response of soil-structure interaction systems. The purpose of this study is to develop improved model for simulation of saturated sand-steel pile interface behavior based on a general concept, called the disturbed state concept (DSC), which can characterize the behavior of saturated soils under dynamic loads. In this study, the Disturbed State Concept (DSC) constitutive model is calibrated and modified for steel pile-saturated sand interface and interaction by using the continuous hardening model for relative intact (Rl) state and the critical state model for the fully adjusted (FA) part in the saturated sand material. The general formulation for implementation has been developed. Then, the DSC model with modification for interface and saturated sand is implemented in finite element program based on the generalized Biot's theory. The interface tests under one-way monotonic and two-way cyclic loading and cyclic triaxial tests are executed for defining the parameters for interface and surrounding soils. Based on these parameters, steel pile-saturated sand interface and interaction are numerically simulated using the finite element program modified in this study. The DSC predictions show improved agreement with the observed results from laboratory test.

Jan 1, 2002

By M. Mirnezami, D. Lascelles, J. A. Finch, E. El-Ammouri

"In a previous publication, the depressant action of Mg above pH 10 on Cu-activated sphalerite was described (Lascelles et al., 2001). In the present communication, a second role, aggregation is introduced.Aggregation (i.e., the tendency of particles to cluster) is measured using settling rate and turbidity converted to an aggregation index (AI) where 0 corresponds to dispersed and 1 to aggregated. Surveys of Cu and Zn flotation stages at four concentrators showed the A1 increased significantly above pH 9. The metal ions identified in the process waters, principally Ca and Mg, were tested to determine which might be responsible. The presence of Mg was found to be the most important, 50 ppm Mg having a greater impact than 500 ppm Ca fkom pH 9 to 1 1. In one plant, poor repeatability in A1 was suspected to be related to varying Mg levels; doping with Mg significantly increased AI.In both aggregation and depression, therefore, the common feature is the impact of Mg at pH > 9. Over this pH range Mg forms a range of hydroxy species, including Mg(OH)2 precipitates. Suggested aggregation and depression mechanisms associated with these precipitates are introduced. Possible problems and opportunities arising from the findings are discussed.INTRODUCTIONProcess waters in flotation circuits contain a variety of metal ions that may introduce unwanted activation or depression. Two common metal ions are calcium and magnesium. Typical concentrations are in the range 50 ppm Mg and 500 ppm Ca (Marticorena et al., 1994, Basilio et al., 1996, Negeri et al., 1997, Nesset et al., 1998)."

Jan 1, 2002