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By W. Beres, M. Bielawski

Recent research on the development of erosion resistant coatings has been directed to the finite element modelling of the behavior of coating and substrate, and their interface under the impact of eroding particles. The approach presented in this paper is based on advanced computer simulation techniques using ABAQUS/Explicit to investigate stress and strain at the surface and at the coating/substrate interface of multilayer coatings under single particle impact. It was found previously that solid particle erosion mechanisms are predominantly governed by the kinetic energy of the impacting particles. However, recent modelling efforts revealed that effects of various material models could be also significant. Therefore, different material models representing relevant coating and substrate properties were investigated and the effects of these models on the coating/substrate response were studied. Particularly, differences between elastic, elastic-plastic and brittle cracking model responses were assessed.

Jan 1, 2006

By K. Ronald Chapman, Claus Ludwig, Doug Jenevein

"In the spring of 2005 Schnabel Foundation Company completed a $15.2 million Design/Build subcontract to underpin 11 structures, and provide 202,800 square feet of earth retention for the Reno Transportation Rail Access Corridor (ReTRAC) project in Reno, Nevada. Schnabel’s work was part of a Design/Build contract to depress a railroad alignment through downtown Reno. The depressed section was 2.2 miles long, 54 ft wide, and up to 35 ft deep (3.5 km long, 16.5m wide and up to 10.7m deep). The trench structure was required to be watertight. SUBCONTRACT WORK OVERVIEWEleven buildings along the track alignment required underpinning. Three types of underpinning were used, designated Type 1, Type 2 and Type 3.At four buildings the trench retaining walls were to be located directly under the exterior footings. This alignment eliminated traditional underpinning and cut-off wall techniques that could normally be used to support structures. Type 1 underpinning was used at these buildings. This underpinning system consisted of a combination of permeation grouting, hand-dug piers, and permanent tiebacks. This underpinning system became the new watertight trench walls.Five buildings were located a few feet behind the trench walls, and their exterior walls were supported by continuous footings. Type 2 micropile/pile cap underpinning (patent pending) was used to support these buildings.The remaining two buildings were also located a few feet behind the trench walls, but they had column footings along the exterior walls. At these structures traditional micropile underpinning was provided through the existing footings. This is described as Type 3 underpinning.Temporary earth retention was required on both sides of the trench along most of the alignment. This shoring supported frontage roads, private property and surcharge from the temporary railroad shoofly running parallel to one side of the trench.SUBSURFACE CONDITIONSThe soil along the trench alignment consisted of river outwash deposits. The top 2 to 18 feet (0.6m to 5.5m) generally consisted of flood plain silt and sand deposits, or fine-grained fills. These fine-grained soils are underlain by the Tahoe Outwash Formation which consists of interbedded layers of sand; sand and gravel; and sand, gravel, cobbles and boulders. Some of these layers encountered during construction consisted of 30 to 50 percent cobbles and boulders, with some boulders up to eight feet in diameter.A major challenge to the design and construction of the trench structures and the underpinning was the ground water table which was 10 feet (3m) above subgrade in the deepest portions of the trench. Based on specification restrictions, temporary and permanent dewatering was not feasible. As a result, the selected design and construction methods had to consider three water conditions: the anticipated groundwater level during construction (CGW), the groundwater level for permanent design (DGW), and an additional special design condition with water at street grade."

Jan 1, 2006

By Gift Makusha, Dave Minney

Anglo Coal South Africa mines coal for both the domestic and export market using open cast and strip mining methods. To establish a mine, a process is set in place to gather ever increasing amounts of geological and metallurgical data to confirm a proven reserve. Increasingly, geotechnical data are also included in this process to confirm that reserve is easily and safely mineable. The mine design process is an iterative one using a combination of numerical modelling and empirical data to arrive at a mining layout that is both, practical, productive and safe. In South Africa it is a legal requirement to compile a code of practice to combat rock fall and slope instability accidents and these have to be revised annually, reinforcing the iterative process of continual improvement. To ensure best practise occurs, all Anglo Coal operations are subjected to annual 2nd party audits and ad hoc 3rd party audit by independent consultants. This paper attempts to explain the process described above in a concise, but understandable manner. 1.0 GEOLOGICAL SETTING The Ecca sediments date from the Permian period and the coal deposits were formed in glaciated valleys on a basement of Dolomite, Ryolite or Granophyre rock types. The sediments overlying the coal deposits are typically flat lying and multiple bedded. The sediments consist of mudstones, shales and sandstones and are generally capable of forming stable highwalls given the time that they must stand up for. Anglo Coal extracts coal from the Witbank, Highveld and Vereeniging coalfields. The Witbank coalfields contain five seams numbered from the base upwards, 1 to 5 Seam; Highveld coalfield the 2 and 4 Seam and the Vereening area the seams are described as Top, Middle and Bottom seams. Coal deposited over the basement Dolomite formation display very erratic dips, as contemporaneous subsidence occurred in some instances over sinkholes that were forming, resulting in local thickening of the coal deposit and resulting in strata that dips toward the centre of the sinkhole.

Jan 1, 2006

By C Hedemann, N Silveste, H Davis, C J. Moran

For nearly two decades water scientists have been debating the need to use appropriate models for the questions being asked and the data available. This paper puts forward a rationale for a hierarchical framework for water balance modelling as it applies to mine sites. The hierarchy is based on the complexity of models and their data requirements. Scientific models are the most complex and require the most data; next is engineering models, then systems models and the simplest representations are given by conceptual models. A position is put forward that systems models have a range of uses that the others do not provide. A systems model, called SiteMiser, is described and its calibration illustrated. The model is applied to seven coal mines from the Northern Bowen Basin in Central Queensland. Currently, there is little relationship between total water use and coal production. This relationship is not any stronger when fresh (raw) water is compared to reused water. Leading practice water use levels are simulated for all sites. The simulation results demonstrate that there is considerable opportunity to reduce water consumption and, in particular, to import less fresh (raw) water to the sites.

Jan 1, 2006

By J. L. Huisman

Bio(hydro)metallurgy is the latest development in the ongoing search for efficient and economic metal winning processes. In addition to bioleaching, other biotechnology-based applications are becoming more and more accepted. In this paper the THIOMET process for general effluent treatment is described. With this process, it is possible to produce sulfide on-site and on-demand and to use the sulfide to precipitate metals, even selectively when required. The process is ideally suited as a treatment to remove metals after, for example, an acid regeneration process. Another process is proposed that deals with stainless steel pickling bleeds. Such effluents typically contain nitrate, iron, nickel, chromium(VI) and other species. This one process handles these compounds, as well as other metals.

Jan 1, 2006

By R C. Schodde

The future of any mining company depends on maintaining and growing its access to high-quality mineral resources. Often the true size of a given resource is not fully recognised until after mining has commenced. Also, the strong desire to increase production puts pressure to expand the resource base of the mine to get maximum value out of the capital employed. This, plus diminishing M&A opportunities and declining world-class greenfield discovery rates, makes brownfields exploration a high priority activity in any operating company. For the success and long-term survival of the company it is critical that this is done well. The primary aim of brownfields exploration is to find or acquire new deposits within economic transport distance of an existing mine that will add materially to shareholder value through: mine or capacity expansion, displacement of lower-margin ore from the mine plan, preserving and extending the mine life, and ensuring potential value is understood in order to maximise potential future mine development or exit. A number of strategic principles are important in any program designed to achieve these aims: understanding the life of mine (LOM) production profile and the related key drivers for exploration, understanding the dynamic nature of the brownfields search space, understanding and measuring depletion of the brownfields search space, understanding the potential of the near-mine region, investing in exploration technology to expand the search space, and investing in a basic geological understanding of the ore-environment. Examination of the LOM profile will highlight critical issues facing development plans for the mine including future grade and throughput issues, key technology requirements or innovations and scenarios for increased production. Exploration targets in the brownfields program should address these key issues. Often it is as æsimpleÆ as keeping mine development sufficiently far ahead of extraction to allow time for the various phases of exploration and resource assessment drilling. Because of the low additional capital costs required, expansion of the brownfields search space is strongly leveraged to: metal prices, development of new markets, incremental operating cost reductions, strategic changes in downstream requirements in integrated businesses, depletion of higher unit-value ores, and new technologies (both extraction and exploration). Therefore the brownfields search space is likely to incrementally expand through time and must be regularly reviewed. This is also important as any given search space will be progressively exhausted, resulting in smaller and higher cost discoveries. It is therefore important to monitor and critically review sustained trends of increasing brownfields discovery cost. The first wave of discoveries in any camp are usually empirically driven and do not need a strong geological understanding. However, an improved geological understanding is critical to making the next generation of hidden discoveries. To illustrate these points, a case study was carried out on the exploration and development history of the Kambalda nickel camp. Over a period of 40 years, more than 40 deposits were found containing over 1.7 million tonnes of nickel metal. Efficient mines need to maintain reserves for operating flexibility. Consequently, the company needs to clearly understand the global resource in order to maximise its full potential. In addition, understanding the full brownfields potential earlier in the development of a deposit rather than later, creates optionality through the flexibility that this understanding brings to future development choices. To ensure best practice in attaining this aim, the roles and responsibilities of the exploration team and the mine operation should be clearly understood. It is important for the explorers and the operators to have shared views about what needs to be done. Typically, mine operators would be accountable for identifying future resource requirements to support the life-of-mine production schedule whilst explorers would be accountable to ensure best-practice assessment of brownfields exploration opportunities. This would include an assessment of the global undiscovered endowment in the regional near-mine area. The balance between brownfield exploration drilling and resources to reserve conversion will need to be decided to ensure efficient operations are maintained. Both need to agree the optimum level of brownfields funding taking into account: urgency to replace or grow reserves, and quality of opportunities (relative to those elsewhere). The ultimate cost of ignoring the full brownfields potential of an operating asset can be significant, ranging from inefficient and poorly planned operations, lost opportunity cost and resultant value through under-utilised resources and, in the worst case, early exit from the asset at the bottom of the commodity cycle û leaving behind huge amounts of shareholder value.

Jan 1, 2006

By S. Amira

The corrosion behavior of high pressure die-cast and thixocast AXJ530 magnesium alloys has been investigated in 0.05M NaC1 solution at pH 6.0 using potentiodynamic polarization tests, electrochemical noise (EN) technique, electro-chemical impedance spectroscopy (EIS) and scanning reference electrode technique (SRET). The behavior of die-cast and thixocast specimens were compared using each of these techniques and the results discussed. Further tests have been carried out with die-cast AZ91D alloy to better compare and interpret the results. Experiments indicate that the thixocast specimens of AXJ530 alloy have a better corrosion resistance than those of die cast alloy in neutral solution.

Jan 1, 2006

The following paper outlines the types of employment immediately available to graduates following their university degree, a discussion on mine manager requirements, mentions career advancement and time frames to achieve this as well as providing some key information regarding student vacation work. The author hopes to educate present graduates, as well as inform students of characteristics to develop the most opportunities in life.

Jan 1, 2006

By Tianjiao Luo

Some literatures discussed on how to recycle the various reagent, but the discussion on how to reuse the waste liquid directly is very little. How to reuse the waste liquid directly was researched in this paper. Firstly, the waste liquid should be filtrated to remove the impurity; then some quantity of H2O2 solution was dripped into the waste liquid to pretreat it; finally, CuSO4solution was added into the treated waste liquid and the pH was adjusted to about 12, then some HCHO solution was added into the waste liquid, in which the treated carbon fiber can be plated. The morphology and composition of coatings were investigated by means of Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDS), the deposition rate was mensurated by the way of dissolution. The results indicated that, the plating effect was basically identical with new plating solution, and the solution is stable, and the plating rate is still about 0.8µm/h, and the copper coating is even and combines closely with carbon fiber. According to this way, the waste liquid can be reuse 5~7 times.

Jan 1, 2006

This paper reports the advances made during the development of underground mine fill technology from circa 1960 to the present and, in particular, indicates where increased input from process plant metallurgists û mainly milling, but also smelting û can contribute to further advances. Fill types pertinent to the discussion are partially deslimed, partially dewatered mill tailings fill (uncemented, cemented) and paste fill. Pertinent process plant includes hydrocyclones, thickeners, filters, elutriation tanks, holding tanks, mixing mills, pumps and pipes. Control instrumentation is a critical component of each of the process plant units. The impact of smelter practice on filling is not considered in this paper, except to note that some smelter slags are, or have the potential to be, active pozzolans and when ground to the specific surface area of Portland cement can act as partial Portland cement replacements, a factor of economic and operating significance when Portland cement supply lines are considerable and/or tenuous. The important role of process plant metallurgists has long been recognised, with Thomas, Nantel and Notley (1979) including them as one of the many categories of professionals with contributions to make. With the ever increasing sophistication of mine fill practice and its ever increasing acceptance as an essential component of the mining/ milling/waste disposal process, the scope for contributions by the modern breed of highly educated, specifically trained process plant metallurgists is becoming ever increasingly obvious.

Jan 1, 2006

Young professionals are riding the current wave of high demand for their services and relatively little competition for placements. The attraction and retention of quality incumbents has therefore become a significant strategic issue for companies in our industry. Money is important, but poorly structured career development and lack of learning opportunities can discourage the highest paid professionals from being enthusiastic and striving for excellence. This will inevitably lead to the search for a new position. Important factors at play include the young professionalÆs lack of understanding of career pathways and poor quality, or lack of, structured on-the-job training and professional development. Too often young and not so young professionals are faced with the reality that fabulous looking (and paying) jobs can be quickly reduced to the monotony of repetitive tasks in an isolating environment. While it is the responsibility of the incumbent to manage their own career and professional development, without experience, how is anyone meant to understand the importance of their roles and the options for career development? Mentoring is therefore essential to the strategic plans of every organisation and the strategic plans of every professional. Mentors will accelerate learning, guide decision making and develop both competency and confidence as they share their experience, both technical and regarding the machinations of a particular discipline, within our industry. Mentors need not be from the same organisation as the mentee and in some cases this may be a distinct advantage. This paper discusses mentoring as an opportunity for young professionals and mentors to initiate and maintain a supportive relationship, the responsibility of management to get mentoring right and the responsibility of young professionals to demand the opportunity for professional development through mentoring.

Jan 1, 2006

By S Harris, A Bossilkov

The Kwinana (Western Australia) and Gladstone (Queensland) industrial areas are among the few dozens of heavy industrial areas globally that demonstrate significant levels of regional resource synergies. Such synergies are also referred to as æindustrial ecologyÆ or æindustrial symbiosisÆ. Fundamentally they involve the exchange of by-products or sharing of utilities between companies in close geographic proximity to achieve competitive advantage and environmental benefit. A concerted research effort is currently underway to foster greater realisation of regional resource synergies in minerals processing intensive regions, in Australia and internationally. This paper summarises current insights from the foundation research into engineering tools and technologies and enabling mechanisms for regional resource synergy developments. Regional resource synergy developments were reviewed for 16 international and two Australian regions. It was found that Kwinana and Gladstone compare favourably with the well-regarded international examples of regional synergy development. Given the fairly strong evidence that self-organisation is critical for regional synergy developments, an implementation model has been proposed that captures entry points for synergy developments at the level of platform (industry collaboration), process (developing synergy opportunities) and project (assessing and implementing specific synergies). It was also found that regional synergies have so far developed in the absence of specific methods for identification and screening of synergy opportunities. Moreover, very limited attention has been paid to the associated technological and engineering challenges. The current technical research effort therefore targets: the development of a toolset for the identification and development of potential synergy opportunities; and assessment of technology needs and opportunities for regional synergies involving water, energy and materials recovery and reuse.

Jan 1, 2006

By A Sadri, S Smith

In the metal and mineral industry, different empirical techniques are used to estimate the remaining thickness of the lining within an operating furnace. The disadvantage and costly factor when using these methods is that production needs to be halted. Hatch has developed an accurate and reliable technique based on stress wave propagation principles to determine the condition of the remaining lining whilst the furnace remains online and operational.The technique involves test data collected and compiled to generate 3D imagery used to assist operators and maintenance planning personnel with valuable information showing areas of metal penetration in the lining, remaining lining thickness, exact location of voids, cracks, poor contacts and deterioration due to chemical attack. In this paper, the principals of the AU-E technique will be explained both theoretically and practically. In addition, the use of ultrasound technology for determining the condition of copper cooling elements will be briefly addressed.

Jan 1, 2006

AustraliaÆs current interest in renewable energy is based on a desire to reduce the countryÆs greenhouse gas emissions. Wood from sustainable sources offers a unique opportunity to combine greenhouse gas benefits with other significant environmental and social benefits, including salinity mitigation, carbon sequestration, soil replenishment and rural industry. The challenge is to make renewable energy from wood in a cost competitive manner, so that this broad range of benefits may be best realised. Bioenergy and carbon products are of great interest as new, commercial forestry products that can drive large-scale environmental tree planting:In Western Australia, Enecon has worked with Western Power Corporation to build the first full-scale plant for integrated processing of mallee eucalypts, to produce activated carbon, renewable power and eucalyptus oil. It is intended that this plant is the first of a number of such plants to help catalyse environmental tree planting in Western Australia. New technologies being developed overseas may provide competitive bioenergy in areas where traditional markets for wood do not exist. For example, pyrolysis converts wood into a bio-oil that may be transported to remote sites for power generation in gas turbines. Pyrolysis also produces wood char. Pyrolysis and wood-to-ethanol technologies, coupled with short rotation coppicing trees, offer the long-term prospect of large-scale production of renewable fuels around the country.

Jan 1, 2006

By T Baumgartl, D Mulligan, R Haymont

Mining at the Mt Leyshon Gold Mine in semi-arid north Queensland stopped in 2002. Newmont Australia has recently initiated a thorough post-closure water management study of the site by revisiting the existing information and conducting new water-related investigations. The focus of this paper, which is the first publication on post-closure environmental management of the site, is an overview of the site water quality in view of the sources and spatial distribution of polluted mine water, and also the performance of cover systems in controlling water flux though mine wastes. Since the mine closed the rehabilitation of waste rock dumps and tailings dams have significantly improved water quality in the surface receiving waters. However, the Scats Stockpile, the Heap Leach and Old Plant areas, which can potentially produce acidic waters, enriched with heavy metals and arsenic, are the top management priority. Modelling of the potential transport of contaminants in groundwater needs further investigations. A detailed examination of the waters in seepage sumps showed high concentrations of manganese, cobalt, nickel and selenium, which were previously overlooked. The study also showed distinctive chemical signatures for waters at different locations: the waters draining from scats, supergene materials and waste rocks have distinctly lower pH and higher concentrations of dissolved iron, sulfate, heavy metals, Mg, Mn, U, Se and As. While, the tailings sumps are more alkaline, and are enriched in Na and Cl. The southern tailing sump is characteristically As rich. The waters draining from the supergene materials have higher Cu concentrations. Assessment of the cover monitoring systems showed that although covers pass the design criteria, automated recording of data may ignore any failure of the monitoring system. Recalibration of the moisture sensors not only showed realistic moisture values compared to rainfall data but also showed that the permanently installed system records values that are higher than those of the mobile system. Event-driven recording of data overlooks infiltration events. Besides, with a higher time resolution (daily measurements) the breakthroughs could be clearly detected. Modelling of the water balance in covers is underway and an example is given here. Newmont is currently reviewing water management options and is willing to share the lessons learned.

Jan 1, 2006

By C. O. Aksoy, P. M. Ozfirat, M. K. Ozfirat, C. Tatar, C. Pamukcu

"Temporal and other factors contributing to the occurrence of occupational accidents at an underground coal mine in Turkey between 1992 and 2000 have been analyzed. The time period of the study spanned the transition from hand-worked mining methods (1992 to 1996) to hand-worked mining methods and mechanized mining methods (1997 to 2000).The mine selected for the study employed an average of 5,835 men per year on three separate eight-hour production shifts for 302 d/y (Sundays are not worked, and there are 11 holiday days per year). Production on an annual basis averaged 190,000 tons per year between 1992 and 1996, and 300,000 tons per year between 1997 and 2000.The purpose of the study was to determine which, if any, of the factors studied contributed to the occurrence of accidents so that the mine could take the necessary steps to reduce the risk to the workforce. Regression analysis was used to determine the strength of the relationship between each factor studied and the number of occupational accidents.The strongest relationships observed were between the age of the employee, the day of the week, and the total yearly labour."

Jan 1, 2006

By William R. Yernberg

The Society of Economic Geologists (SEG) held its biennial conference May 14 through 16, 2006, in Keystone, CO. SEG is an international organization with about 3,500 individual members with interests in economic geology. The 2006 SEG conference theme was “Wealth creation in the minerals industry — integrating science, business and education.” The conference exceeded expectations with 705 participants, including 102 students, from 44 countries. The conference featured 30 oral presentations, 24 professional posters and more than 70 student posters. The conference also included a trade show with 50 vendors, numerous field trips, workshops and social activities.

Jan 1, 2006

By M. B. Greyver

The results of laboratory tests on iron precipitation from non-decopperized nickel anolyte are discussed. The parameters (pH, oxygen consumption and stirring speed) for iron precipitation from the anolyte, using the oxygen in the air, were determined. In the experiments conducted under optimized conditions, the residual concentration of iron in the anolyte after precipitation was 0.7-2.7 mg/L, and the copper and nickel losses to the solid phase were 0.05-0.07% and 0.05-0.16%, respectively. The filtration ability of the iron slurry obtained was 2 to 5 times higher as compared to that after chlorine oxidation and oxyhydrolysis. The leaching of the non-ferrous metals from the iron cake made using the separate nickel anolyte purification process was possible by dissolution in sulphuric acid. It was established that after cobalt precipitation from the copper- and iron-depleted anolyte, the precipitates obtained had lower ratios of Fe:Co and Ni:Co.

Jan 1, 2006

By Steve Kral

The mining industry in northern Ontario is known mostly for its huge nickel deposits. Inco’s and Falconbridge’s nickel mines in the Sudbury Basin are the best known. And with nickel prices being what they are, interest in the region continues. And how. Inco and Falconbridge want to merge. Teck Cominco wants Inco, but without Falconbridge. Xstrata made a hostile bid for Falconbridge, which Falconbridge rejected. And, in June, Phelps Dodge trumped them all when it made an approximately US$40-billion friendly offer for Inco and Falconbridge in a two-part deal.

Jan 1, 2006

Accurate hematite solubility data are required to construct predictive solution chemistry models for complex hydrometallurgical solutions. These data are useful in understanding Fe(III) speciation and precipitation in a variety of hydrometallurgical processes. Hematite solubility data were generated in 10 to 70 g/L H2SO4 solutions and at temperatures from 130 to 270°C, using specially modified titanium autoclaves. These measurements represent an improvement over previous experimental data because of better in-situ filtration of the sample aliquots, the approach to equilibrium via hematite dissolution, and the inhibition of Fe(III) reduction on titanium surfaces. Fe(III) reduction was particularly studied to evaluate the inflationary effect of Fe(II) on hematite solubility measurements. Chromate was found to reliably inhibit Fe(III) reduction on titanium. Finally, the generated hematite solubility data were used to construct a solution chemistry model using the OLI software.

Jan 1, 2006