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By E. R. Bauer

The trend in underground room-and-pillar coal mining is to employ remote-control continuous mining machines and extended cuts, 12 m (40 ft) deep or more. This system of coal extraction, adopted by over 435 mines, can create additional worker-safety hazards. To address the ground control and worker-positioning hazards, a combination of statistical analyses and numerical modeling was conducted. Initially, the reported roof-fall incidents and fatalities were reviewed to delineate the ground-control hazards. Then, the application of the Coal Mine Roof Rating (CMRR) for estimating safe extended-cut depths was evaluated. Finally, computer modeling to predict roof displacements during extended-cut mining was completed. The paper describes the results of these studies and their impact on the safety of extended-cut mining.

Jan 1, 1999

By Keith A. Heasley

Historically, the surface subsidence over underground coal mines has been predicted using empirical profile or influence functions which have little or no connection to the actual mechanics of the subsidence. Without a mechanistic basis, establishing the exact site-specific parameters to use in these empirical methods has been problematic. A practical subsidence predictive method based on mechanics has the appealing capability of allowing the determination of site-specific parameters from fundamental properties of the overburden with minimal field calibration work. This paper presents several case studies where a mechanics-based, boundary-element program is used to back-calculate the surface subsidence associated with various panels at several Northern Appalachian coal mines. The program used in this case study is called LAMODEL, and it incorporates a frictionless, laminated overburden into a general purpose displacement-discontinuity code primarily designed for calculating the stresses and displacements in coal mines or other thin scam or vein type deposits. In this paper, the program is used to calculate both the underground convergence and the resulting surface subsidence at five longwall panels and a room-and-pillar section. The fitted subsidence from the model is compared with the field measurements and analyzed. The results from the case studies in this paper demonstrate that the laminated model with calibrated properties can easily provide moderately accurate subsidence predictions and is fairly flexible for fitting measured subsidence. However, additional subsidence predictive case studies arc recommended in order to ultimately evaluate the potential of the laminated overburden model for practical subsidence prediction

Jan 1, 1999

By John Loop, W. A. Gibbins, Donald D. Hogarth

"Introduction Background The Frobisher voyages of 1577 and 1578 were organized by the Cathay Company for the express purpose of finding and mining gold ore. Since publication of the Baffm expedition of Charles Francis Hallill, the location of Kodlunarn or Countess of Warwick Island, the headquarters of Frobisher's third (1578) voyage, and focal point of the largest Arctic voyage of all time, has been known to the world. Through Hall we also know the location of the Countess of Warwick Mine on Kodlunarn Island. However, the exact locations of the other mines are not known. Of the ""ore"" we know little. Pieces of the original ""black stone"", once as large as ""a half-penny loaf' have now disappeared altogether. Specimens collected at random from the repository of shipments in England and from loose rock on Kodlunarn Island were termed, respectively, ""hornblende pyroxenite"" and ""amphibolite"" and from a locale about 200 yards from Kodlunarn as (hornblende) ""pyroxenite""121. However, it is uncertain whether these specimens are representative of Kodlunarn or of the other mines, although Blackadar131 notes that, in the northern trench of Kodlunarn, biotite gneiss contains lenses and bands of amphibolite. The ""gold"" itself is even less well defined. It has long been accepted that gold was virtually absent in Frobisher's ore. The ""gold"" has been termed pyrite, biotite and both biotite and pyrite together. Even t h e word "" marquesset"" , which appears and reappears in contemporary descriptions, is nebulous and is defined as ""a stone participating in the nature of some metal, yet in so small quantity, that the metal cannot be melted from it"" (0.E.D., definition of 1616)."

Jan 1, 1999

By H. V. Scotland III

Lafarge Corporation's Texas Quarry, in Baltimore MD, achieved a substantial expansion of pit reserves by removing an inactive underground mine. The day lighting program, designed, and completed in 1997, open pit mined more than 400 meters of room and pillar workings which were originally developed to recover high brightness Calcium Carbonate. The project proved to be a challenge throughout its course as the pit plan was modified and successful daylighting techniques were developed to remove the mine without adversely affecting the safety of the operation, quality of the stone recovered, or negatively impacting the surrounding community. The design parameters and techniques developed and implemented at Texas may prove of interest to other operators as they are faced with daylighting opportunities. This article will detail the challenges we faced and the solutions which made the project a success.

Jan 1, 1999

By Joram M. Amir

During recent years, the integrity testing of piles has made considerable progress. With the availability of portable and powerful computers, practically all integrity testing equipment is now digital. Using sophisticated software for data acquisition and analysis, today's testing systems can provide owners with important information regarding both the length and integrity of piles and drilled shafts. This sophistication carries a price: Very few clients, including experienced engineers, do understand the strange-looking graphs adorning the reports they get. In fact, most of them will never ask, some because they are too busy to care and others because they are ashamed to show their ignorance. This situation is well exploited by a few shrewd operators of test equipment. Facing strong competition and falling revenues, they simplify their task and cut their expenses by the following means: 1. Using old equipment until it falls apart, and then some, 2. Hiring under-qualified personnel, 3. Staying on site as little as possible, 4. Eliminating the analysis and evaluation stage altogether, 5. Confirming as-made lengths and reporting no defects.

Jan 1, 1999

By Mark Sherman, M. Dennis, Raj Rajamani

"The two Alumbrera 36ft (10.97m)dia. SAG mills were sized, using the FDW ""Grindpower 'I program, to treat an average of 1852 tph each. This paper describes how modelling of the shell lifter design, using the Millsoft program, identified milling inefficiencies caused by poor charge motion. This explained the ""as built"" circuit's inability to achieve the throughput rates predcted by the circuit's designer. Use of the Millsoft program to design a new, dramatically different lifter configuration, in conjunction with a different approach to variable speed drive utilization, has resulted in an improved charge motion and a 30% increase in hard ore milling rates. The new lifter design has allowed the designer's predicted average throughput rates to be achieved.IntroductionThe Alumbrera project grinding circuit consists of two 36ft dia. X 17ft EGL, 13 500 kW, variable speed, gearless drive SAG mills coupled to four 20ft dia. X 30ft EGL, 6 000 kW fixed speed, gear driven, ball mills. The circuit is configured as two identical grinding aisles, each consisting of one SAG mill and two ball mills. No pebble crushing circuit was installed due to the expected absence of a critical size fraction in the first years of production. However, the grinding circuit layout does incorporate space for a pebble crushing retrofit. At present, only about 5% - 10% of the new mill feed reports as trommel oversize and is recycled back to each SAG mill using a water cannon.The circuit was designed to be ball mill limited and to treat the four major Alumbrera ore types at rates varying between 68 000 tpd, and 89 750 tpd, depending on ore hardness. Average throughput rate, and hence nominal design rate, for the grinding circuit was 80 000 tpd (1 852tph per line at 90% availability)."

Jan 1, 1999

By S. Ng, Peter Stapleton, Paul Mankowski, J. Spence, R. Siy

"Syncrude has developed a low energy extraction process for the recovery of bitumen from oil sand. This new process operates at a temperature of 25 °C, resulting in substantially lower energy costs and lower capital costs, especially for the thermal energy generation equipment. The process will be used in Syncrude’s Aurora Mine, which is scheduled for startup in mid 2000. The flowsheet for Low Energy Extraction includes hydraulic transport of oil sand slurry, and bitumen separation using collector and frother chemicals and air as process aids. A number of flow sheet innovations and optimizations have been included, resulting in the next generation of extraction technology. Experimental pilot plant results, engineering progress to date and areas of ongoing work will be discussed. SUMMARYThe Low Energy Extraction Process has been successfully developed for commercial implementation at Aurora. The 1996 100 tonne hour Field Pilot demonstrated that the bitumen recovery target could be met with an 11.1% grade oil sand. However, pilot plant bitumen recoveries for a lower grade oil sand were not acceptable. The subsequent flowsheet optimization study led to a new flowsheet for Low Energy Extraction, which includes a primary separation vessel, a flotation circuit for PSV middlings, and the use of middlings displacement in the PSV cone bottom with flotation underflow. A test program conducted in 1997 showed that the new flowsheet could significantly improve the bitumen recoveries for lower grade oil sands. Engineering work on process scale-up led to selection of a 30 meter diameter PSV, with a tangential feedwell. The successful development and commercialization of Low Energy Extraction for the Aurora Mine Project is a major enabling step in the Syncrude 21 program. The low energy requirements of this process allow Syncrude to develop the Aurora leases more cost effectively. The use of this process results in major capital cost savings, predominantly in the thermal energy infrastructure and also provides long term operating cost advantages for Syncrude."

Jan 1, 1999

By Langdon T. Mitchell, Karl Ingmarsson

The title is not referring to jewelry; nor is it about diamond core drilling. This article is instead about an emerging application for diamonds, hard rock percussive drilling with diamond drill bits. Diamond’s outstanding wear resistance has long been taken advantage of in core drilling. However, until now diamond has been less successful in hard rock production drilling in the mining and quarry industry.

Jan 1, 1999

By Mike Smith, George Chung

"A 23 million dollar Flotation Plant has been commissioned at the Iron Ore Company of Canada in 1998. Nine OK-50 cells &re used to float silica in this 1,400 tomes per hour plant. The paper details project development, construction and operating results. This plant gives IOC the capability to produce not only high quality blast furnace pellets of varying silica, CaO and MgO levels, but also a high iron, DR grade pellet. The first activity was simply to sit down with the suppliers, Outokumpu, Wemco. GL&V and Svedala, to discuss applications and share experiences. We learnt what each supplier had to offer, what features would particularly suit this application, what options were offered, what were the materials of construction, how the equipment is maintained, which wear parts require replacement, etc., etc. We tried to learn as much about the equipment as the suppliers themselves knew. Then we tried to learn more: we contacted users and asked about any weak points, which options were worth incorporating and which items were not. We then discussed these points with the suppliers and established how potential problems might be overcome."

Jan 1, 1999

By M. M. Hajdasinki

A project's rates of return (RORs)1, be it the internal rates return (IRRs) or one of the many IRR surrogates, frequently needs to be approximated. The success and efficiency an ROR- approximation procedure depend on the quality the approximation-initiating parameters, such as bounds or seed values (guesses). The existing approximation procedures commonly use bounds and guesses suggested by intuition rather than supported by mathematical considerations. This paper presents three mathematically founded ROR-bounding and eleven ROR-guessing approaches and examines their suitability by using examples of typical project cash-flowpatterns (CFPs). The calculated bounds and guesses not only improve the approximation efficiency, but also allow the process of the ROR discovery to be automated, thereby making it more convenient and reliable.

Jan 1, 1999

By D. L. Stevens

Following an in-depth scenario and strategic planning exercise in 1997, Noranda's mine production goal was set at 500,000 tonnes per year of both copper and zinc metal within five years. There had been no recent discoveries, reserves were shrinking and things had to be done differently and quickly. Change is now continual in our program but here is what we did first: Combined the exploration and business development groups Formed teams to search for and respond to opportunity Made our geologists more business minded and our engineers more optimistic Went global Set clear thresholds, farmed out the marginal properties, fast tracked the others Focused reconnaissance exploration where we had a clear competitive advantage Became a "flexible" partner to both juniors and seniors Is it working? A number of successes, near successes, and outright failures are discussed. The main result is a much higher rate of opportunity flux which is essential for success in the mining industry.

Jan 1, 1999

By Jr. Pickering

Kaolin is mined from extensive sedimentary formations in the eastern Amazon River Basin of Brazil. Production began about 25 years ago from 30 meter thick beds of ultra-fine particle clay of superior viscosity along the Jari River north of the Amazon. Operated by CADAM S.A., capacity now exceeds 750,000 tonnes per year ot high glossing paper coating kaolin product. South of the Amazon on the Capim River are two new operations: Para Pigmentos S.A. and Rio Capim Caulim S.A. The purity , and large coarse plate-shaped particles of these Capim kaolins support production of superior brightness and whiteness paper coating and filling grades. Annual capacities are reported to be 150,000 to 300,000 tonnes each, with expansions planned. Most of Amazon area kaolin production is shipped to western European, Asian, and North American markets.

Jan 1, 1999

By Dale T. Peters

Conductivity, both electrical and thermal, are attributes accounting for about 70% of the applications of copper and its alloys. This paper presents results of on-going research into two new applications that depend on copper's excellent conductivity. The Copper Development Association (CDA), together with materials and motor company partners, is working toward a solution to the key problem preventing pressure die casting copper for the conductor bar/end ring structure of the induction motor rotor, i.e., lack of a durable high-temperature mold material. Work is showing that a combination of high- temperature materials and elevated temperature processing gives much improved mold life compared to die steels. Substitution of copper for aluminum in the rotor can result in a 20% decrease in electrical losses in motors consuming 35% of electrical power generated in the U.S. The second development uses the excellent thermal conductivity of several high-strength high-copper alloys to simultaneously improve productivity and part quality in the injection molding of plastic parts.

Jan 1, 1999

By James Douglas

A century ago the AIME meeting of 1899 was held at the Palace Hotel in San Francisco California in September. For his presidential address, James Douglas presented this paper which is reprinted in full with the kind permission of the AIME. It presents an interesting comparison relating to events and circumstances in the metallurgical industries at the close of last century. Being on the eve of a new century ourselves, the Editors of this volume of the COPPER 99-COBRE 99 Proceedings considered this paper would be of general interest, hence it is included here. Douglas believed in effective interchange of technical experiences and ideas. He considered the extreme secrecy surrounding the copper works at Swansea, Wales, the world center of copper only years before the time his paper was delivered, as one key reason for its decline, (and eventual closure of all copper plants there). In his paper, the pace of developments in various sectors such as transportation (railroads, the dominant means of I transportation at the time), the iron and steel and copper industries were examined, in much the same way as one might do but on the high technology of today. James Douglas was born in Quebec City, Quebec, Canada and spent his early life there. Forced to move to the United States for family and financial reasons, he went on to become a pioneer in the new Arizona copper industry, and with luck and good judgement with his interest in the new mining properties he also became very wealthy. Douglas was an accomplished mining and metallurgical engineer. He was the first President of Phelps Dodge and helped transform the small trading company of Anson Phelps and William Dodge into a mining giant.

Jan 1, 1999

By Tony Dunn

FMC Corp. achieved a significant cost reduction at its Green River, WY soda ash operations using a new proprietary solution-mining and processing technology. In phase one of the program, trona ore is dissolved, recovered and processed with the new technology. It is then fed into an existing refining plant, replacing dry mined and calcined trona ore. Phase two produces a final high-purity product. It also increases capacity by 635 kt/a (700,000 stpy). Both phases were completed under budget and ahead of schedule. This $120-million expansion project uses a new process and a new team to derive soda ash in a more cost-effective and environmentally friendly manner. The team successfully introduced solution-mining technology - with a liquid solution injected into previously mined sections of the mine. This shift in techniques signified a new era for soda ash production. The project is an example of teamwork at its best. For it to be successful, FMC had to work within several different areas inside and outside of the company. Engineers, contractors, mechanical operators and technical people were needed who could blend in with FMC's existing in-house team.

Jan 1, 1999

By Cliff Holloway

The past year has been difficult for Canada's primary industries. The mining, oil and forestry industries have been hit by low prices and a reduced demand for natural resources. Foreign competition, militant environmentalists, the breakdown of the Asian and European economies and Canada's shrinking dollar have all put additional pressures on the commodity purchaser to buy smarter. It is easy to appreciate why operations and maintenance supervisors want the best performing product. It makes good sense. The challenge is to source that quality product while staying within the budget. The bottom line (price), however, often becomes the control- ling factor, usually at the expense of quality and performance. This is short-term thinking, often with expensive consequences.

Jan 1, 1999

By J. W. Holzenthaler

Teams continue to play a major role at the Phelps Dodge Mining Company El Paso Operations, especially during the present time of low copper prices. The El Paso Operations' teams have taken the initiative during this copper market downturn and have helped reduce operating costs significantly. Because of this, Phelps Dodge El Paso Operations has continued to grow within the team process by creating a total, non- exempt salaried workforce. In the last year alone, the El Paso Operations have implemented three major initiatives to accommodate the team process. The first was the creation of "guiding principles", a policies and procedures handbook. Second was the "zero and beyond" safety initiative. Third was team compensation. In addition, the Copper Products Company has now adopted a work-team environment, following the lead of the refinery.

Jan 1, 1999

By Tim O’Neil

More than 5,300 mining professionals from around the world attended the SME Annual Meeting and Exhibit, March 1-3 in Denver, CO. Seventy three technical sessions highlighted innovative technologies and applications for the development of mineral resources. And the exhibit featured 421 companies worldwide and 632 exhibit booths. The 1999 SME Annual Meeting had 10% international attendance. Professionals from outside the United States were guests at the first SME International Reception.

Jan 1, 1999

By Paul Mitchell, Amy Wheaton, James Rybock

Acid rock drainage (ARD) represents one of the most intractable problems faced by the non-ferrous metal and coal mining sectors, and the creation in the recent past of a number of high-level national and international initiatives reflects the growing concerns of industry, government and other stakeholder groups. ARD is certainly considered one of the most serious environmental impacts caused by mining and the industry's greatest environment-related technical challenge. Additionally, the global depletion of non-acid generating oxide ore deposits and the increasing dominance of sulphide ores means that the potential for ARD incidents will continue to increase. Once initiated, the cycle of chemically and biologically mediated and catalysed reactions leading to ARD generation is difficult to stop. While there is evidence to suggest that the degree of contamination of ARD will decrease rapidly within a relatively short timeframe (Wood et al., 1999), experience in historic mining regions of the world indicates that the problem may persist for centuries at certain sites. Current best practice in dealing with ARD puts the emphasis on prediction and prevention, planned from the outset of the operation and integrated with each phase of the mine site life cycle. The elements that constitute best practice are becoming more clearly defined and as this process of clarification continues industry will undoubtedly accelerate the process of best practice implementation, burying at last the image of mining as a despoiler and polluter of landscapes, an image based on past, rather than current, practices. However, it is equally clear that despite the best efforts of industry and regulators, many sites will continue to generate ARD during operation and following closure - in many cases, a legacy of ARD has been derived from operational and strategic decisions made decades ago, before the risks and impacts of the self-sustaining cycle of ARD generation were properly understood. Add to this ARD generation from poorly managed operations and from historic and abandoned sites, and it becomes clear that the treatment of ARD will be required for the foreseeable future to protect water quality, and ecosystem and human health.

Jan 1, 1999

By Mike Jahraus

The topic I would like to throw out for discussion this morning concerns the metallurgical solution management of operating a valley fill leach facility where ore depths approach 250 feet and deeper. We are currently beginning to experience solution transport times through our heaps on the order of 60 to 70 days as our heaps approach 250 feet. Incorporating a two-stage leach scenario, or solution enrichment, these times are nearly doubled. Concurrent with the increased solution transport times, the solution tenors being produced by our heaps are being diluted slightly as percolation occurs through the lower lifts. I feel the best way to handle these situations is to closely monitor solution application rates, and carefully manage ore stacking. Also, as heaps become deeper, metallurgical and hydrologic characteristics of the ore become inter-related, i.e. if channeling or preferential flow is taking place, lowering cross-sectional flow rates to older leach panels with help re­institute capillary flow while helping to prevent solution tenor dilution.

Jan 1, 1999