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By F. Nelson

RJB Mining is the largest coal producer in the UK. In January 1995 the Company acquired the Central North and Central South Regions of British Coal consisting of: ? 15 operating collieries -including capital equipment ? 2 care and maintenance mines ? 16 operating Opencast sites ? Interest in 26 prospective and 46 potential Opencast sites ? Approximately 417 million tonnes of proven and probable reserves and considerable mineral resource ? 9 million tonnes of coal stocks ? Long term contracts to supply approximately 90 million tonnes of coal to National Power and PowerGen to the period of 3 March 1998 ?Approximately 7,600 employees and 4,500 mining contractual labour. Up to the acquisition RJB Mining had the capacity to produce 14 million tonnes of saleable output with an approximate 1,500 strong workforce.

Jan 1, 1998

By C. M. Jones

The training program developed at Sierrita over the last twelve months has led to several significant improvements in both safety performance and productivity. Our most easily quantified results have been in truck productivity, where we have also experienced a 6% decrease in truck cycle times. We feel this is due to increased skill levels and awareness on the part of our operators due to our new training effort. The cycle time improvement has resulted in an increase in Truck productivity of 6%. Costs associated with productivity training have been $160,300. This includes program development and execution costs, as well as lost productivity during the training itself. These costs are offset by $1,400,000 in savings directly attributable to the increased skill levels of our technicians due to our training effort. As such, this represents a solid, high return investment at Sierrita.

Jan 1, 1998

Laboratory tests were conducted to evaluate the silica collection efficiency of flooded-bed scrubbers with six different filter panel designs and at two operating velocities. Test results indicated that reductions in filter density negatively impacted respirable dust collection. Silica collection efficiency for the least dense filter was as much as 33 % lower than the collection efficiency of the densest filter. At the low operating velocity, the least dense filter allowed over 40% of the respirable silica dust in the scrubber intake air to pass through the unit, where it would be discharged back into the mine environment. Operation of the scrubber at the higher test air velocity increased silica collection efficiency, regardless of the filter panel tested. The density of the filter panels also impacted the quantity of air that is moved through the scrubber, with higher density filters reducing scrubber airflow. For each filter, the relationship between dust collection efficiency and air moving capacity must be considered to determine overall effectiveness for specific mine applications.

Jan 1, 1998

By N. Kanari

Kinetics of the carbochlorination of Cr2O3 has been studied with C12+CO gas mixtures between 500 °C to 900 °C using thermogravimetric analysis. The apparent activation energy is about 100 kJ/mol. Mathematical fitting of the experimental data suggests that the shrinking sphere model is the most adequate to describe the carbochlorination mechanism of chromium oxide and that is controlled by the chemical reaction. In the temperature range of 550 "C to 800 OC, the reaction order is about 1.34 and is independent of temperature. Changing the C12+CO content from 15 pct to 100 pct increases the reaction rate and does not affect the reaction mechanism. Similarly, changing the ratio of C12/(Cl2+CO) from 0.125 to 0.857 do not modify the carbochlorination mechanism of Cr203. In these conditions, the reaction rate passes through a maximum when using a chlorinating gas mixture having a Cl2/(C12+CO) ratio of about 0.5.

Jan 1, 1998

By R. M. Enick

A novel liquid-liquid separation for the recovery of free or liberated gold from mixtures of fine particles was evaluated. The separation, conducted at ambient temperature and a pressure of about 1000 psi a, was based on the difference in wettability of precious metals and minerals. Contact angle results indicated that in the presence of water and liquid CO2, gold, platinum and silver had intermediate wettability. Minerals such as quartz and magnetite, however, were hydrophilic. Therefore fine gold particles. -325 mesh, that were mixed with water and liquid CO2 dispersed in the CO2 or agglomerated at the H2O-CO2 interface while the minerals tended to remain in the aqueous phase. Best results were obtained when these fine gold particles were liberated, were not agglomerated in slimes, were not adhering to minerals, and were not coated with minerals.

Jan 1, 1998

By Wenxian Zhu, Patrick R. Taylor

"The small dimensions of nano-sized materials leads to novel and enhanced mechanical and physical properties. A thermal plasma reactor has been developed to study the formation of nanometer sized metal powders. A supersonic nozzle and a powder filter were designed and built. By vaporizing coarse metal powders in the plasma flame, and quenching the metal vapors through the nozzle at the rate of 107 K/sec, nanometric sized powders have been produced. The powders were collected in an airtight secondary quench-filter system. The particle size of the product power is 5 -20 nanometers, obtained through TEM analysis. The XRD analysis showed that the powder did not oxidize after the filter was handled in an inert atmosphere glove box.IntroductionNanostructured materials have been shown to exhibit improved physical and mechanical properties compared to conventional materials with larger grain sizes (1,2). There have been several methods proposed for preparing nanometer size materials. Thermally induced vapor-phase reactions have been used to produce a variety of powders. A common feature of these processes is the rapid production and cooling of condensable reaction intermediates and products, by gas-phase reactions, leading to the formation of a large number of very small particles. Thermal plasma synthesis of ultra-fine size particles has been attracting increasing interest (3,4,9-11), because it offers many advantages, especially in refractory materials processing, compared to conventional processes: (a) thermal plasma temperatures are very high(> 5000 K); (b) the rates of chemical reaction are much faster than those encountered in conventional processes; (c) high-purity materials may be obtained using fewer processing steps by collecting the product at temperatures where the by-products are in the vapor phase; ( d) the mean particle diameter can be controlled; (e) unifom sized particles may be produced with clean surfaces (these particles are particularly suitable for pressureless sintering); and, (f) high throughput per reactor volume can be achieved. In addition, the process used for generating particles determines the degree of sintering ability of the powders, since the process dictates the morphologies, the purity and its size distribution. In the future, thermal plasma synthesis nanometer size particles may play an important role in vapor phase reaction techniques and might be expected to be one of the first full scale commercial installations in the future."

Jan 1, 1998

By N Fullelove

The Renison Bell Tin Mine on the West Coast of Tasmania has recently installed a new underground ore handling system incorporating underground crushing, conveying and hoisting facilities. Contracts for the sinking of the shaft and the development of the mine were let and managed by the operator, Renison Limited. Hardcastle & Richards was responsible for the design, procurement and construction management of the fixed plant and equipment including civil, structural, mechanical, electrical and instrumentation services. The system demonstrates worldÆs best practice in design and incorporates a state-of-the-art integrated control system allowing the entire system to be controlled by a single operator located in the underground crusher chamber. A rapid construction period was achieved, despite the difficult and constrained underground environment, without affecting the ongoing operations of the mine. The mine, which was established in the mid-1960s, had previously operated by trucking ore to the surface via a decline. Truck haulage distances and costs had increased as the mine became deeper over the years. By the 1990s it had become apparent that, in order to remain economically viable, it was necessary to reduce truck haulage distances and allow the mine to go still deeper to access orebodies such as Rendeep beneath the current workings. The Internal Shaft System achieved this by eliminating approximately 5 km of truck haulage. It allows the production rate to be increased to up to 1 Mtpa compared with a limit of 628 kt per annum by direct truck haulage to surface. The access it provides to the Rendeep ore and other deep orebodies greatly increases the amount of ore which can be economically mined.

Jan 1, 1998

By A. B. Holland-Batt

Following a relatively static period in the 1960s and 1970s when incremental development rather than innovation was the norm for gravity separation, the last 15 years has seen a number of new developments in this area. The paper briefly reviews the traditional gravity separation techniques and then examines the newer developments such as centrifugal separators. Particular emphasis has been placed on novel devices or improvements that offer either better control or improved performance.

Jan 1, 1998

By D. C. Yang

A practical and economical flowsheet has been developed and demonstrated by integrating the packed column flotation with the GranuFlow process for fine coal recovery. Orimulsion, which was used as an additive, served a dual purpose: first in the flotation and second in the dewatering and granulation steps. The test results on the coal preparation effluent sample show that Orimulsion is flexible and compatible with fuel oil and various frothers used in the packed column. Clean coal with ash contents of 3.0, 3.7, 4.3 and 5.1% were produced from a head sample of 33% ash at combustible matter recoveries of 72.4, 81.1, 87.5, and 89.2%, respectively. Other advantages include high throughput, low moisture, improved handleability, and reduced dustiness of the dewatered coal, thus providing a very significant economic Incentive for the integrated process.

Jan 1, 1998

By Xuerong Wen

The oxidation behavior of TiAl3 intermetallics was investigated as a hnction of time at 1273K in pure dry oxygen. The oxidation experiments were carried out using TGA method. The oxidation scales were analyzed using SEM, EDS and X-ray diffraction methods. The structures of oxides formed at the different oxidation times were analyzed. The mechanism of oxidation of TiAl3 intermetallics was discussed.

Jan 1, 1998

By C. A. Rowland

Comminution efficiency can be expressed in three different ways. Theoretical Efficiency: actual energy consumed, in a comminution machine compared to the theoretical energy required to make the size reduction. Operating Efficiency: compares the operating work index, calculated from production comminution machinery operating data, to the Bond Work Index from bench scale comminution tests or calculated from pilot plant operating data. Economic Efficiency: income compared to planned income. Using the Bond Work Index and operating work index, this paper explains how to determine operating efficiency.

Jan 1, 1998

By R. Quintero

The HYL Direct Reduction Process was the first in the world to operate successfully at industrial scale. The results were so innovative and attractive that other steelmaking companies acquired licenses for the HYL Process. Now in its 40th year of commercial operation, the HYL process has evolved into a modem, highly efficient and economical technology -HYL III. The technology offers high productivity, minimum energy and water consumption, electricity co-generation, raw material flexibility, premium quality DRI/HBI, and is highly versatile for meeting the specific needs of each user. A historical review as well as recent developments and future plans are presented in this paper.

Jan 1, 1998

By V Seedwell, P H. McGuckin

The Broken Hill Proprietary Company Limited (BHP), started as a silver-lead- zinc mining company in Broken Hill, New South Wales, Australia in the 1880s. Since then it has diversified into the resource industries of steel, iron ore, coal, petroleum and copper. BHP World Minerals, is a Business Group of BHP which is one of the worldÆs largest and most diverse mineral resource enterprises. BHP supplies raw materials for steelmaking, copper concentrate and other mineral commodities to customers in more than 45 countries. BHP World Minerals has operations throughout the world - in Australia, the United States, Brazil, Zimbabwe and Canada. Commodities produced by BHP World Minerals currently include silver, lead, zinc, titanium minerals, platinum group metals and coal. The challenges in the improving performances in safety arena are common to our industry and BHP operations. This paper outlines the vision and values that have been fundamental in assisting BHP Cannington search for and implement a safety system addressing behavioural matters.

Jan 1, 1998

This paper describes the application of the Total Productive Management (TPM) technique as a performance improvement initiative for a coal mining operation. It discusses the objectives of TPM, with the driver for improved production performance being the Overall Equipment Effectiveness (OEE) of the equipment or process, and with the development of "ownership" as the behavioral approach to equipment management and continuous improvement through cross-functional and area-based teams. It illustrates the concept of equipment management as defects management.The scope for application of TPM to the coal mining industry is immense. The harshness of the operating environment can be a major generator of equipment defects, and a current paradigm in the industry accepts these defects as an unavoidable outcome defining maintenance costs in this environment. However recent benchmarking studies have highlighted that maintenance costs per operating hour in some mining operations are more than double the vendor's estimate of "best practice". The paper refers to these studies which also compare maintenance costs of fixed and mobile plant and equipment to "best practice" outcomes in comparable process industries.

Jan 1, 1998

By M. Grenon

"The presence, size, orientation, nature, and persistence of geological discontinuities dictate the behaviour of a rock mass. Block size, which is defined by discontinuity spacing, by the number of joint sets, and by the persistence of the discontinuities delineating potential blocks is an important indicator of the degree of fracturing of a rock mass. Consequently, block size is represented either explicitly or implicitly in all rock mass classification systems employed for analysis and design of surface and underground mining structures. Insitu block size distributions may provide a better means to describe the structural complexity of a rock mass. These are the distributions that would be derived if the in-situ rock mass was separated into its constitutive blocks, delineated by existing discontinuities, and each block measured. This paper presents the results of a field campaign at Louvicourt Mine aiming to characterize the rock mass using different methods for determining block size and block size distributions. IntroductionGeological structural data are used to provide input data for analysis and design methods for surface and underground structures. As the collection of structural data involves considerable investment of time and effort, it is sometimes overlooked, thus denying an important source of information for mine design. What is somewhat surprising, however, is that when structural data are available, they are not used to their full potential. Recent work has shown that data on block size have potential applications in different areas of rock engineering:• Blasting — Hudson (1993) has described the excavation process as the change of a preexisting natural block size distribution to the debris fragment size distribution (Fig. 1). Lizotte and Scoble (1994) have reviewed previous efforts on integrating site specific geological conditions into blast design. Grenon et al. (1997) provide a case study where in-situ block size distributions are compared to photogrammetric studies of blasted rock.• Rock mass classifications — Block size is used in the majority of rock mass classification systems either explicitly, as in the RMi classification system Palmstrøm (1995), or implicitly, such as in the NGI system, Barton et al. (1974)."

Jan 1, 1998

By Steven I. Baskin

Cyanides are utilized in many industrial applications including preparation of chemical intermediates, electroplating, and' mining, Cyanide has been utilized in chemical warfare operations as well Cyanide is also synthesized and found in plants and animals including man where it is thought to perform multiple functions. A variety of enzymes are known to detoxify cyanide under different conditions. These include rhodanese, 3-mercaptopyruvate-sulfur transferase, thiosulfate reductase, cystathionaseand albumin. Cyanide appears tQ exert its toxic effect primarily by inhibiting cytochrome oxidase? although other enzymes are also inhibited. Therapeutic antagonist categories to treat cyanide include methemoglobin formers such as nitrite, sulfane-sulfur donors such as thiosulfate, metal salts or complexes such as cobalt and cyanohydrin-forming compounds such as dihydroxyacetone or alpha keto-glutaric acid. Advantages and disadvantages of each category will be discussed. Newer compounds under development have been found that may allow for prophylactic therapy for cyanide poisoning with minimal side effects; In addition, portable co-oximetry devices may provide real-time measurement of cyanide in field units.

Jan 1, 1998

By I. Kim, J. C. Choi, W. D. Cho

"The effect of yttrium addition on the oxidation behavior of Fe3Al intermetallic compound was investigated in the range of temperature 800 to 1100 °C in 0.2 atm 02 in terms of oxidation rate and oxide adhesion. The oxidation rate of alloys, Fe-14.3 wt% Al and Fe-14.1 wt% Al-0.3 wt% Y, was nearly identical and the parabolic rate constant calculated as a function of temperature is Kp=5128 exp[-39506(cal/mol)/RT] mg2/cm4 hr.Rapid cooling and ultrasonic stress tests were carried out to test adhesion of scale formed on the alloys. While the oxide layer formed on the Fe-Al alloy without Y was found to be fragile and detached easily during the tests, the oxide layer formed on the Fe-Al alloy containing Y was protective, dense, and adhesive. The following two mechanisms were proposed to explain the adhesion improvement of Ah03 formed on the Fe3Al containing yttrium : (1) the addition of yttrium decrease generation of growth stress in alumina scale because the preferential diffusion of yttrium through grain boundary in alumina scale prevent internal oxidation of Al, one of main causes of growth stress, and (2) the second phase formed on the oxide scales prevents crack propagation through the scales, leading to better mechanical stability of the oxide scales.IntroductionIron aluminides have attracted the attention of many researchers as a candidate for use at high temperature because of their excellent oxidation resistance due to the formation of protective alumina scale. In order to resist aggressive environments at elevated temperatures, oxide scale formed on iron-uluminum alloy must satisfy the following three requirements : (1) thermodynamic stability (2) slow growth rate (3) adherence on substrate. According to Wallwork and Hed [l], the most suitable alloys for high temperature application are Fe, Ni, and Co alloys with the protection of Si02, Cr203, and Ah03 scales. While chromium oxide can vaporize as Cr03 above 1000 °C and silicon oxide may form low melting silicate [2,3], Alz03 has a high melting point and is the most stable among the three oxides thermodynamically [6]. In this respect, iron aluminides forming alumina seem to be most suitable for use at high temperature. However, alumina scale formed on the iron aluminum alloys tends to be easily spalled during oxidation due to the combination of growth stress and thermal stress."

Jan 1, 1998

By Yuri Gelfgat

"The report presents the results of theoretical and experimental investigations of the MHD method used for production of composite materials from immiscible melts, e.g., Al-Pb, Zn-Pb, Bi-Ga and others, which, when solidified, can be presumed as ""frozen emulsions""IntroductionThe searching of the methods for controlling the phase distribution in various liquid heterogeneous media is one of urgent tasks in modem material science. The studies [1-3] have revealed that in case of electrically conducting media the influence of electromagnetic body forces on the liquid can be a rather effective mean of such a control. The current paper investigates some physical conformities governing the behaviour of binary liquid metal systems with a immiscibility region under electromagnetic processing designated to produce ingots with homogeneous structure.The main idea of the proposed method rests upon a concept that the electromagnetic forces in the melt are similar to gravity forces due to buoyancy effects in space and have a selective ability to influence the melt components dependent on their conductivity. In crossed electric E and magnetic B fields (fig.I) each component of the medium is influence by the force density f = jXB, where the current density j is determined by the conductivity a of the component j = -oE. When this force is directed parallel or non-parallel to the gravity vector, the buoyancy of suspended particles can be controlled accordingly.This phenomenon allows one to create a situation in binary system, when the sums of all mass forces (gravity and electromagnetic) affecting every component are equal, and two components are under conditions of equilibrium with respect to each other. These conditions are called quasiweightlessness, which is generated in the melt by the electromagnetic forces."

Jan 1, 1998

A case study of a systematic approach to grinding circuit steady-state optimization is presented. After overall review of the flowsheet, two circuits were prepared for detailed testing. Functional performance analysis was chosen as the primary modelling system, and on this basis a quality assurance program for data gathering was implemented. A number of circuit design and operating variables were experimented with statistical analysis of plant test results revealed relationships previously unquantifiable by any other modelling technique. Improvements in classification system and mill grinding efficiencies were demonstrated and significant energy cost savings thus realized.

Jan 1, 1998

By Bawden WF, Paynter JT

This investigation involves laboratory testing and stability analysis of paste fill at the Golden Giant Mine. Site-cast samples are tested in unconfined, confined, and consolidated-undrained triaxial compression. Pore pressures during shear and consolidation characteristics are measured to determine both drained and undrained shear strength parameters and assess the potential for undrained loading. Liquefaction potential is also considered. A limit equilibrium solution is used to obtain factors of safety against failure of the fill during mining of adjacent stopcs

Jan 1, 1998