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By G. Buchan

This paper discusses the design of long panels for longwall mining at Twentymile Coal Company (TCC) from conception to implementation. The case study of the long panels at Twentymile includes extensive mine plan reengineering in the early 1990's to world record production months in 1996 and 1997. The obstacles of subsidence engineering, environmental regulations, conveyance, ventilation, equipment design, and continuous miner (CM) development timing had to be overcome to successfully begin longwall production within a 4 year time frame. The background and some detail for each of these areas listed will be discussed to show how the coordination of many facets must be pulled together to implement a successful long panel mine plan.

Jan 1, 1998

By Ernst Raphael

Mechanical drives of belt conveyor drives have experienced a huge amount of improvements concerning technology, manufacture and product structure that reduced investment and maintenance cost significantly. Most of these improvements were of technological nature in the'70s and '80s of this century; whereas, the present decade requires products that meet technical excellence as well as commercial advantages such as quick delivery, low cost and reliable spare parts supply. The best approach to meet these requirements is a highly modular and standardized system of reliable components that cover all demands a conveyor drive might require.

Jan 1, 1998

By Akira Yazawa

In the field of pyrometallurgy, the equilibrium evaluation has recently become easy by use of thermodynamic software, but it is strongly desired to estimate the amounts of non-equilibrium minor components to simulate practical processes. However, simple physico-chemical technique can not be applied to evaluate practical non-equilibrium components for many reasons. As an engineering solution for postulated equilibrium system, the activity coefficient is modified and introduced as the simulation parameter referred to as the "adjustment coefficient." This modified thermodynamic calculations were adopted to various sulfide roasting processes where many solid phases are participating and the system is not necessarily in equilibrium. Successful simulation was realized by assigning suitable adjustment coefficients for minor components which form a pseudo solid solution in the calcine. Some examples from sulfation roasting and dearsenizing roasting were discussed. In the smelting system, the loss of copper in slag is caused by equilibrium and non- equilibrium reasons, that is, chemical dissolution and entrainment of copper in slag. The total copper content of slag was simulated by use of the adjustment coefficient for entrained copper.

Jan 1, 1998

By Kirsi M. Riihilahti

The oxidation characteristics of solid copper matte particles under simulated Kennecott-Outokumpu Flash Converting conditions are presented. The effects of feed matte grade, matte particle size, oxygen-to-matte mass ratio, oxygen content of the process gas and temperature on the particle oxidation rate, quality of conversion, particle size change and particle morphology were determined. The converting quality was highest (~68) with the 58% copper matte at 1100°C. At similar conditions, the 72% copper matte was more likely to produce copper oxides and leave unoxidized particles rather than directly produce sulfur dioxide at 1100°C, resulting in an average converting quality of 55. The quality of conversion was poorest for the 72% matte at 920°C (~45); the sulfur removal was extremely low even with a relatively high degree of oxidation. Fragmentation of the particles was significant in all cases with the 72% matte. A higher O2/matte .ratio and higher temperature, in general, resulted in increased fragmentation while oxygen enrichment had no significant effect. With the 58% matte, particle size was found to increase for the finest fractions rather than to decrease due to particle expansion.

Jan 1, 1998

Hydraulic backfill is generally retained in stopes using permeable barricades. Mitchell et al (1975), Mitchell (1992) and Grice (1989) have shown that under normal drainage conditions, barricades experience low levels of loading. Cowling et al (1988) have also shown that barricades are susceptible to piping failures if excess water has ponded on the upper backfill surface and if leakage of backfill from the barricades has occurred. During 1997, six hydraulic backfill barricades failed in four different Australian mines. Fortunately, in each case, the quantity of backfill slurry released was small, and no injuries to personnel nor damage occurred. Detailed investigation of two of the incidents showed that the primary cause of failure could be attributed to the delivery of excess quantities of transport water from the low-density slurry. For each of the incidents investigated there was evidence of the development of piping failures, which resulted in hydrostatic loading conditions on the barricades from the ponded water on the upper backfill surface. The circular failure surfaces in the barricades were characteristic of the application of point loading conditions. This paper discusses the circumstances that led to these incidents and analyses the modes of failure. The standards for the safe operating of hydraulic backfill systems are reviewed along with requirements for ongoing management and control. The design requirements of barricade construction are analysed and some appropriate guidelines introduced.

Jan 1, 1998

By Tuneo Funahashi

Sumitomo Shisaka Works has been treating EAF(Electric Arc Furnace) dust to recover zinc and lead in the Waelz Kiln process. Since its commencement of operation in 1977, many technical improvements have been successfully made to increase the production capacity and the zinc recovery rate. The EAF dust charge to the Waelz Kiln was increased from 35,000tly to 120,00OtIy, and the production of zinc oxide now amounts to 40,000tly. The zinc content in the clinker was decreased from 5% to less than I%, by the optimization of the kiln heat pattern with no accretion trouble. And the clinker has become more a valuable raw material for steel making. This paper describes the above progress ofthe SMM Waelz Kiln process operation at the Shisaka Works.

Jan 1, 1998

By C. Waddell

PDMI mines five different grades of ore. Shovel operators were experiencing problems differentiating one material type from another. In 1997 PDMI decided to try GPS ore control to aid operators in identifying material boundaries. Computer generated ore control maps and GPS data defining the shovels' position is fed to a computer on board the shovel. A monitor, located near the shovel operator, displays material types, their boundaries, and the shovels' position and movement in relation to the mining face. This information has reduced errors in material identification by 50%.

Jan 1, 1998

By F. J. Sotillo

The objective of this investigation was to determine the feasibility of using a high-pressure roll mill (HPRM) to improve the separation efficiency of dolomite from apatite in downstream operations when treating high-dolomitic pebbles. High-dolomite samples from four phosphate mines were used for the test program. The research work plan included sample characterization studies; INSTRON tests to develop preliminary crushing data; high-pressure roll mill evaluations to determine crushing parameters, such as feed rates, rolls speed and gap, and applied torque, pressure and energy; and screen, microscopy, and flotation studies to assess dolomitelapatite separation efficiency. The results of the HPRM tests show that commercial products for all four mines can be obtained. Recoveries of 74-82% of the P2O5 and rejections of 46-83% of the MgO were reported with an specific energy consumption of 0.2-0.5 of that of a laboratory rod mill.

Jan 1, 1998

By D. Eugene Rannels, Sarah E. Dunsmore, Cara Martinez-Williams, Yu-Chen Lee

"Dunsmore, Sarah E., Yu-Chen Lee, Cara Martinez Williams, and D. Eugene Rannels. Synthesis of fibronectin and laminin by type II pulmonary epithelial cells. Am. J. Physiol. 270 (Lung Cell. Mol. Physiol. 14): L215-L223, 1996.Previous investigations demonstrated that type II pulmonary epithelial cells regulate extracellular matrix deposition as a function of time in primary culture. In those studies, the matrix fraction was analyzed as a whole. The present work focused on two components of the type II cell matrix, fibronectin and laminin. These glycoproteins have differing effects on differentiation of type II cells in primary culture. Fibronectin synthesis was quantitated between day 1 and day 6 in the cells, matrix, and medium; laminin synthesis was quantitated only in the cells. Although total fibronectin synthesis was regulated as a function of time in culture, reaching its greatest value on day 2, the average proportion of newly synthesized fibronectin in the cells (35%), medium (50%), and matrix (15%) remained constant over a 6-day interval. Between day 2 and day 6, the relative abundance of fibronectin messenger RNA increased 6.5-fold. Rates of cellular laminin synthesis did not vary with time in culture. These results support a role for differential regulation of fibronectin and laminin synthesis to determine the composition of the type II cell extracellular matrix. INTERACTIONS BETWEEN THE pulmonary epithelium and alveolar basement membrane may play a role in the physiology and pathophysiology of the lung. Pulmonary epithelial cells and the alveolar basement membrane form one component of the blood-gas diffusion barrier. Integrity of this barrier is crucial to normal lung function. Specific domains of alveolar basement membrane components have been proposed to determine localization of type I and type II pulmonary epithelial cells during lung growth and development, as well as during repair of the alveolar surface after injury (13). In the injured lung, the extent of damage to the epithelium and the underlying basement membrane is thought to be a key factor to determine subsequent repair or fibrotic scarring (3)."

Jan 1, 1998

By W. A. Crosby

The ability of open pit mines to steepen overall final wall angles allows significant cost reductions as a result of reduced waste movement requirements. Final wall angles are principally controlled by three factors: geological conditions; hydrological conditions; and wall control blasting practices. The first of these factors is not controllable by the mine operator, the second can be influenced to some degree, but the last one certainly can be controlled, hence the current interest in final wall blasting practice at many mining companies. This paper discusses common blasting techniques employed to steepen final pit walls and outlines the attractiveness of moving from small hole high cost systems to the use of full size production drills as a means of reducing wall control blast costs. Attempts to make this change have been limited at many mines by the physical size of the drills and their inability to reverse drill. In the past, pres pi it, pre-shear or trim holes have had to be drilled vertically, at considerable distance from the upper bench toe, with the result that inter-berm face stability is reduced and final wall angles have to be made somewhat more shallow than desirable. The paper concludes with a description of how these problems can be overcome by utilizing the new Bucyrus 39R which has the capability of drilling at a ?15 degree angle underneath the machine. It is concluded that the resulting wall control blast designs will offer large mines improved final wall angles with resulting significant overall cost reductions.

Jan 1, 1998

By W. Irwin

Global warming hitherto viewed as a distant threat to the environment, is now the subject of fierce goo-political debate. The debate centres around the time frame required to achieve environmental compliance, and the cost implications of meeting that objective. Since coal is the fuel of choice for power generation, the priority objective of energy producers is the pursuit of environmental protection measures that allow coal to be burned without any attendant negative impact on the environment. From an environmental point of view, public attention is today firmly focused on the impact that all industrial activity has on the environment, and coal is singled out from other fossil fuels as being the product of an inefficient smokestack industry. Despite coal's poor public image it is unrealistic to suggest as some do, that use of this fossil fuel as a primary energy source should be drastically curtailed. Coal which already generates about 35% of the world's electricity is continuing to increase its share of this rapidly expanding market, and to argue against its use is flying in the face of reality. However, changes are required in the way coal is used in some of the new clean coal technologies, since many include advanced methods of combustion. Indeed changes in the way coal is used is a vital link to the future of coal as a primary source of energy, and increased coal utilization will be directly linked to changes in its use. Discussion of various issues that affect coal utilization are the focus of this paper.

Jan 1, 1998

By A. Mayton

The prolonged exposure of equipment operators to shock and whole-body vibration (WBY) is linked to cumulative back, neck, and abdominal disorders. In low-coal mines, space restrictions make seat suspensions difficult to use in isolating operators from shock and WBY. Researchers at NIOSH, Pittsburgh Research Laboratory, are responding to these issues by investigating viscoelastic foams. For the full-load case. an ergonomic seat with viscoelastic foams isolated the shuttle car operator from shock at 15Hz. Researchers used results from additional foam testing with an analytical model to identify viscoelastic foams that provide shock isolation at a frequency below 5 Hz.

Jan 1, 1998

Exploration requires substantial capital, and is an extremely risky business (only 1 in 100 prospects ever becomes a mine). The average lead time, that is the time between discovery and production, varies from around two years for a gold mine, to 15 years for a lead/zinc mine. Since it takes years to find, prove and develop most ore bodies, exploration must be carried out years ahead of the depletion of existing deposits. Investors in exploration are exposed to risk for long periods before knowing whether they will receive a return on the funds invested. The risk, high-cost, uncertainty and long lead times involved in exploration make it an aspect of commerce that most managers and investors find difficult to rationalise or understand. Nevertheless, it is a given that the long-term survival of the mining sector depends on discovery of new mineral deposits, however the immediacy of the need to find or acquire new mineral deposits in order to compete and prosper in the industry is less well understood. This paper examines the commercial realities which underlie exploration for new mineral deposits. The first and foremost reason for exploration is to maintain or increase depleting ore reserves which are the asset base of mining, but there are other compelling commercial reasons for exploring, and these are: to maintain return on investment, to achieve growth or create wealth through discoveries which lead tonew mining ventures, to remain competitive in the industry, to diversify, and to control raw material source for mineral processing and/ormarketing ventures. Exploration is necessary for survival of the industry, and also for survival of organisations competing in the industry. The organisations which discover the best orebodies are in the best position to compete, and mining organisations which fail to find or acquire new mineral deposits rapidly become uncompetitive and unable to maintain return on shareholdersÆ investment.

Jan 1, 1998

By Wenxian Zhu, Xuema Li, Patrick R. Taylor

"Experiments were performed in a non-transferred arc, thermal plasma flow reactor to investigate the synthesis of ultra fine boron nitride (BN) powder from the reaction system of boron oxide (Bz03), methane (CH4), ammonia (NH3) and hydrogen (H2). Argon (Ar) and nitrogen (N2) were used as plasma gases. The thermodynamics and kinetics of the synthesis reactions were examined and a chemical reaction mechanism was proposed. The powders produced under certain operating conditions had high purity and good conversions. All the products were extremely fine powders (< 30nm) and were uniform in size distribution. The powder products were analyzed by chemical and physical characterization. The effects of the reaction variables on the conversions from B203 to BN and the purity of the products were investigated.IntroductionIn the past few decades, boron nitride (BN) has attracted a great deal of interest because of its excellent thermal, chemical and electrical properties (1-4) It has a high thermal stability and thermal conductivity. Chemically, it is very stable and is not wetted by most molten metals and slag. It is also an excellent low loss insulator. Since hexagonal boron nitride (h-BN) is light in weight, strong and easily fabricated, it has applications in a variety of specialized high temperature areas, such as a high temperature lubricant, crucibles for molten metals, thermocouple protection tubes, break rings for horizontal continuous casting of steel, and friction reducing coatings. In cubic form, boron nitride is one of the hardest materials known, second only to diamond, and it is an excellent material for tools in which the use of carbon based materials is limited by oxidation or reaction with metals."

Jan 1, 1998

By P. Clifford

FIPR-sponsored research will playa critical role in enhancing the competitiveness of the Florida phosphate industry as ore grade declines and environmental restrictions tighten. FIPR&apos;s program seeks to improve surface mining and pipeline transportation while reducing the energy cost for pumping phosphate matrix. The development of a reliable on-line analyzer and a modern process control strategy will result in improved processing efficiency. Significant improvement in overall efficiency will also be realized as the industry adopts column flotation technology. Economic acidulation of high-Insol rock will allow the industry to adopt simplified flotation flowsheets thereby reducing operating costs. Various applications of phosphogypsum would save the industry millions of dollars in constructing and closing gypsum stacks.

Jan 1, 1998

By G. L. Black

Choosing a mining method for an underground ore body is a complicated and often iterative process. Advances in technology give the design team an overwhelming array of possibilities for methods and equipment. Hecla&apos;s recent discovery of the deep Gold Hunter ore body has given the staff at the Lucky Friday Mine the exciting challenge of determining the optimum mining method. Taking an ore body from prospect to production requires traditional resource characterization, including drilling, delineating and modeling. Developing the mining plan is an evolving process, changing with each new piece of information as the project progresses through exploration and development.

Jan 1, 1998

By Jan M. Andersson

This paper will discuss the background information about rock cutting tools used for soft ground excavation, their history and evolution. A brief review of the current state of the art manufacturing technology will be presented and some parameters related to the material used in the drag and conical type pick cutters and their impact on their life and performance will be explained In addition, the selection procedures for choosing the right bit for excavation of a particular geological formation will be reviewed A set of guidelines will be provided for initial selection of the tools for various machines and rock formations. The methods for estimation of the tool life in various materials and the influencing parameters along with limitations of the rock cutting tools will be discussed as well.

Jan 1, 1998

By D. R. Spears

Conventional round tank thickeners have been widely used in the mining industry for many years. The mining industry was well satisfied with the ability of conventional thickeners to improve minerals beneficiation operations. However, development of improved flocculants (the polyacrylamides) made possible much more rapid settling rates, since polyacrylamides produce large flocs rapidly (unlike starch or inorganics). Traditionally considered to be a slow operation if maximum underflow density was achieved, and therefore there was some justification for the expense. Thickeners required large volumes to permit sufficient time for settling. The oversize not considered a drawback but the initial capital cost was. In high rate thickeners, a bed of thickened material is allowed to build around the feedwell, even above the bottom of the feedwell. The slurry is fed directly into the bed at a velocity that allows the material to be evenly dispersed over the thickener area This more efficient use of settling area allows a higher solids throughput per unit surface area (rise rate). In this paper, high rate thickener rise rates and polymer consumption are compared.

Jan 1, 1998

By Hong Ro Lee, Seang Suk Cho, Byung Sun Chun, Chang Whan Won

"The preparation of Al203-SiC-TiC composite powders was studied by SHS process using silica (source of Si02) powder instead of Si which is expensive. And, aluminum powder was used as reducing agent of silica and charcoal activated was used as carbon source. Effects of the molar ratio in raw material mixtures and compaction pressure and initial temperature of reactant on the products and combustion process were studied. The most important variable affecting the synthesis of Al203-SiC-TiC was the molar ratio of carbon. The combustion reaction generated in powder state without preheating. But the unreactants exist in the product on all molar ratio. When the preheating temperature is over 400 °C, the combustion reaction was able to be generated in pellet state. Without preheating, the combustion reaction was possible by Ti02 addition. The optimum condition in this system was the molar ratio of Si02:Ti02:Al:C=2.5:0.5:4:3.1. INTRODUCTIONCeramics have demonstrated a capability as a cutting tool, especially in competition with WC-Co cermets (ceramic-metal composites) as inserts for metal turning and milling operation. The advantage of ceramics compared with carbides is retention of high hardness, strength, and chemical inertness to temperatures in excess of 1000 ·c . This allows use of the ceramics at much higher machining speeds than can be tolerated by carbides. However, the ceramics have lower toughness than the carbide materials, and have only been used successfully in the limited operations of turning and milling. There are several classes of cutting tools. The addition of TiC or PSZ, or both, and reinforcement with SiC overcame the poor fracture toughness and thermal-shock resistance that limited Al203 use in the past [1]."

Jan 1, 1998

For over 50 years R W Miller & Co Pty Ltd operated old coal properties abandoned by former owners as uneconomic, some of which dated back to the last century. The companyÆs ability to survive with what were relatively poor quality coal resources required a small efficient management organisation. In 1970 R W Miller was involved in negotiations with other coal companies through coal sales contracts to develop private coal areas under the provisions of the old Coal Mining Act (1906) and these efforts led to the development of Lemington colliery. At the same time development of the Ironbark colliery holding near Newcastle commenced. In 1971, R W Miller approached the New South Wales Government for a resource replacement area to prospect for coal in the Upper Hunter Valley. Authorisation No 33 was finally granted on 30 September 1975, but the company found the area was inaccessible as most of the surface was owned by the Australian Army. Later R W Miller was granted Authorisation 66 of 2167.5 hectares at Mount Thorley near Singleton on 1 November 1976. The development of this coal mining project coincided with the second OPEC oil crisis in 1978 and a short-term boom for coal resources and the unrealistic expectations generated by the boom. This paper gives a broad outline of the development of the Mount Thorley project between 1976 to 1986 including the feasibility study and the many governmental and industrial delays that resulted in a three-year time overrun in the project development period.

Jan 1, 1998