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By H. K. Taylor, B. Denby, L. D. Smith

Contributions by H.K. Taylor and G.A. Davis discuss the three papers published in Transactions IMM A, vols. 103 and 104, with responses by Smith and Dowd

Dec 1, 1995

By W. R. Paterson, W. Morton, D. B. Cameron

The Massbal II computer simulation program has been used to develop a general framework for the building of thermochemical models of metallurgical processes. The framework allows the rapid, simple construction of complex models of process equipment for use in flowsheet design, planning and plant operation. Application of the program to model the iron-making blast furnace and a flash smelting process is described

Apr 1, 1991

By H. S. Sichel, W. J. Kleingeld, C. E. Dohm

A model of ore value distributions is presented that is the culmination of a statistical approach rather than simply a model that has been successfully applied to the evaluation of ore reserves. Detailed geological and physical observations based on large sampling data sets have been used to support the statistical modelling. Fundamental to the modelling process is the concept that the occurrence of a given grade value in space is a function not only of the presence of the mineral but also of the fact that it is associated with a specific trapping mechanism. The concepts have been specifically applied to gold mineralisation

Aug 1, 1995

By S Colak, M Tunc, C Celik, M. M. Kocakerim

The most important parameters affecting the solubility of ulexite (sodium calcium borate) in H2SO4 were found to be reaction temperature and solid:liquid ratio, in that order. Dissolution increased with increase in temperature and stirring speed and with decrease in solid:liquid ratio, particle size and acid concentration, the last effect as a result of decreased precipitation of CaSO4 on unreacted particles. Optimum conditions, in which around 99.5% of the ulexite could be dissolved, were a reaction temperature of 60 degrees C, a solid:liquid ratio of 1:8 g/ml, an acid concentration of 8 mol/l, particle size smaller than 425 micrometres, a stirring speed of 52.33/s, a reaction time of 1 800 s, a calcining time of 3 600 s and a calcining temperature of 170 degrees C. These conditions, determined by the Taguchi method, are reproducible in a commercial production environment

Jun 21, 1905

By A Cox

It has been demonstrated that all the cadmium from spent batteries, typically 4 g per battery, can be recovered by burning polyvinyl chloride waste to yield hydrogen chloride; this reacts to produce volatile calcium chloride, which can then be condensed and collected in a separate reactor. Alternatively, chlorine may be used to chlorinate the cadmium with equal efficiency. There is also a prospect of using very low concentrations of these gases, less than 1%, to effect the separation. The Cd was recovered more quickly when exposed to sustained, controlled flow rates of chlorinating gases, whereas when PVC was burnt most of the gas was produced in a very short time, not allowing complete reaction. This problem can be overcome by recirculation of the gas into the reactor. The technology is efficient and clean and the equipment used is simple, enhancing the prospects for a pilot-scale version of the process

Jun 21, 1905

By A. C. Apling, N. B. Barrett

Roadstone production requires the generation of non-flaky material, as outlined in British Standard 812 section 105.1; with respect to this criterion, a mathematical model of a cone crusher must be able to predict the flakiness index of a particular size range as determined by the relationship between thickness and nominal size. The Whiten cone crusher model utilises breakage and classification functions to predict a product particle size distribution only, so a shape function has been proposed that is based on a phenomenological approach, taking into account the transfer between flaky and non-flaky material at each stage of breakage. The results of laboratory tests to determine material breakage characteristics and of examination of pilot-scale test products illustrate the method's potential

Apr 1, 1995

By J Kokado, N Hatta, S Yabushita

A theoretical model is described for prediction of the capacity of fines from porous ores, such as cokes and sintered ores, to be removed by a pneumatic, horizontal-type classifier prior to charging into a blast furnace. First, the influence of variation in the apparent density and drag coefficient of porous ores on removal efficiency is analysed from a stochastic standpoint. The effect on efficiency of collisions between particles in the classifying region is then examined analytically in relation to the ratio of the mass flow rates of particles and air (the loading ratio). Finally, a theoretical model is constructed that takes these factors into account. Theoretical and experimental results are compared and classifying efficiency is discussed from both experimental and theoretical viewpoints.

Dec 1, 1993

By P. S. Heyns, M. Heyns

A computer model has been developed of mine hoisting systems in deep South African gold mines. Particular attention was paid to the contribution of different modelling assumptions for the guides and guide-roller assemblies. Objective functions indicative of guide-roller tyre endurance, slipper-plate forces and perceived vibration levels were introduced to quantify dynamic performance. These objective functions were used to compare models. It was found that the choice of guide and guide-roller models did not influence the forces on the guide rollers significantly for typical shaft and conveyance characteristics at typical levels of viscous damping coefficients. The rigid and finite-element guide models gave the same results as those of the effective-stiffness guide model, and while the latter is suitable for simulation for design purposes, the finite-element model should be used for unusual guide geometries

Jun 19, 1905

By P. A. Davies

Paper presented at the conference: Risk assessment in the extractive industries, held in Exeter, UK, 23-24 March 1994, and first published London: IMM, 1994, preprint volume, 11pp., 15 refs. Hazards such as vibration, dust emission and fragment projection can result in an area called the Danger Zone being set around a blasting site. Traditionally Danger Zones have been set solely on the basis of consequences (e.g. based on the maximum distance of rock projection or expected ground vibration plus a defined safety margin). Advances in risk assessment and its growing acceptance as a safety management tool have led to the setting of Danger Zones based on both consequences and frequency of occurrence. This allows distances to be optimised on the basis of acceptable risk levels rather than the potential consequences of infrequent events. The setting of a flyrock Danger Zone is used to demonstrate a risk-based approach compared with a traditional consequence approach

Aug 1, 1995

By D. M. Evans, D. L. Buchanan

Paper presented at the IAGOD international symposium on mineralisation related to mafic and ultramafic rocks, held in Orleans, France, 1-3 September 1993. The Zinca area was chosen as a suitable location for an investigation of the weathering and secondary dispersion of platinum group metals from the Zone. It was concluded that platinum is immobile while within weathered rock, its mineral phases tending to alter from primary sulphides and tellurides to secondary Pt-Fe alloys. Palladium is variably mobile in weathered rock. In stream sediments Pt occurs mainly as small, dense, discrete particles, giving rise to a nugget effect, whereas Pd probably occurs as much finer particles or chemically adsorbed on to a suitable substrate. Pt shows a rapid decrease in sediments downstream from mineralisation, whereas Pd has a much slower downstream decay

Apr 1, 1994

By R. A. Halatchev

A risk model for assessment of the uncertainty in the forecasts of the planned profit is developed. It is based on the selling price of the metal recovered from the ore and the production per shift of the excavators. These two critical variables characterise the economic and technical aspects of the mining venture. Time-series methodology is used to describe the behaviour of the economic variable, which improves the adequacy of the modelling. A hypothetical open-pit gold mine is used to illustrate the application of the model. Results obtained show that the model is a good alternative to sensitivity analysis in taking account of the stochastic character of the price of the metal recovered from the excavated ore and the production per shift of the excavators used. The model can be extended by the inclusion of new variables that have a probabilistic nature

Dec 1, 1996

By G. D. Schena, M Zanin

A numerical approach is presented for predicting the liberation of phases during comminution, with direct calculation of a liberation spectrum giving the fraction of the particulate system in each narrow size-composition class. The numerical model uses a Poisson flat process for stochastic generation of the non-convex three-dimensional Poisson polyhedral textures and the system of fractures that give rise to convex fragments. With this numerical approach, there is no need to assume random uniform isotopic fracture (lack of selective liberation); only computational geometry primitives are exploited for the derivation. The agreement with relationships obtained previously under the random uniform isotopic fracture hypothesis demonstrates that the approach is capable of deriving full liberation spectra directly. Both volumetric and superficial composition can be calculated

Jun 21, 1905

By B. Gazea, A. Kontopoulos, A. Kourtis, K. Adam

Static tests give a measure of the balance between acid-producing and acid-neutralising mineral components in a material, while kinetic tests determine acid generation and neutralisation over a long period. Drill-core samples from the amphibolite and gneiss host rocks of the Stratoni lead-zinc sulphide deposit in Greece and mine/mill waste samples from Stratoni and Olympias were examined by the standard acid base accounting, BCR and net acid production tests. Mineralogical data on the materials and resulting residues were used to illustrate the differences between the methods and establish their ranges of applicability. BCR seems to simulate most closely the conditions prevailing during generation of acid mine drainage but is time-consuming and requires elaborate equipment. Acid base accounting is suggested for standard screening; net acid production might be used in the field or for solids with less than 10% S

Jun 19, 1905

By M. K. Abd El-Rahman

A complete chemical analysis of the waste showed that it contains 15.64% P2O5; X-ray diffraction analysis revealed that it is composed mainly of francolite, calcite, pyrite, quartz and dolomite. The phosphate values were recovered and the settling rate of the wastes enhanced by the use of hydrocyclone and flocculation techniques. The hydrocyclone produced an underflow enriched in phosphate and an overflow enriched in clays. The former represented 39.8% by weight of the phosphatic clay waste and assayed 26% P2O5 at a recovery of 66.36%. The results of flocculation of the phosphatic clay waste showed that both the degree and rate of settling were increased and that the process water could be recycled. The settling rate was 37 times greater when anionic polyacrylamide A130 was used

Jun 21, 1905

By A. S. W. Kurny, M. Z. Huq

Bangladesh ilmenite is partially altered, containing pseudorutile, rutile and haematite as well as the predominant ilmenite phase. A typical analysis is 39.45% TiO2, 24.19% FeO and 33.0% Fe2O3. Reduction of the ilmenite by charcoal was found to involve two major reactions: conversion of pseudorutile into ilmenite and rutile, and change of ilmenite into metallic iron and rutile. The first, which was much the faster reaction, was responsible for an initial increase in ilmenite content with reduction time at lower temperatures. Apart from these two major reactions, rutile was reduced to lower oxides at 1 100 degrees C with a consequent decrease in its XRD peak height

Jun 19, 1905

By J. Konnerup-Madsen, T. Unlu, H. Stendal

Paper presented at the conference Economic geology in Europe and beyond II, models for mineral deposits in sedimentary basins, held in Keyworth, UK, 13-14 April 1994. The region includes the Deveci siderite/goethite deposit and the Hasancelebi, Karakuz and Kuluncak magnetite/goethite deposits; Deveci is the only mine in operation. The area consists of a serpentine-gabbro complex overlain by a volcano-sedimentary sequence hosting the iron ores. At least three generations of hydrothermal alteration have affected all rock types except the latest trachytic dykes. The Deveci deposits occur in a pyroclastic volcano-sedimentary sequence with shales and carbonates equivalent to the main mafic sequence, whereas the other three deposits formed contemporaneously with the intrusion of trachytic dykes. The deposits are of the volcanic-exhalative type, with syngenetic siderite in pillow lavas or stratiform layers the primary and main Fe-bearing mineral. In the west hydrothermal alteration has replaced siderite in pillow lavas with magnetite or has remobilised sideritic iron into magnetite veins

Apr 1, 1995

A production drill rig at a site in Sweden was equipped with a monitoring system to estimate production statistics. Drill running times, drill hole depths, penetration rate, rotation speed, thrust, air percussive pressure and torque pressure were recorded for every 10 mm of hole length for a period of 5 months. Operational activities (rock penetration, tube handling, moving and set-up time) accounted for almost 62% of the time consumed, the remaining 38% being different types of stoppage. Drilling itself, as opposed to handling, took less than 24% of the total time. The results give an indication of how the overall drilling capacity can be increased and which activity should be emphasised. The impacts of automation, new developments and reorganisation on production can also be predicted. Average production was found to be around 100 m/day, but varied between 50 and 160 m/d. The company's specification for the drill rig, before purchase, was that an average production rate of 130 m/d be attained over two consecutive months of drilling - a rate which monitoring shows will not be achieved

Jun 19, 1905

By R. Allington, G. Walton

The approach has been applied with success to the restoration of chalk workings in southern England, and research and trials relating to restoration blasting and the replication of limestone dale landforms have been undertaken. An essential prerequisite for application of the technique is rigorous geomorphological analysis of the locality to ensure that final quarry landforms are consistent with the local geomorphological and landscape setting. It is always important to ensure compatibility of the final landform with the intended after-use, and to achieve this it is also essential that such restoration schemes have a sound geotechnical basis. A disadvantage of the approach is that final slopes tend to be flatter, especially in weaker strata where natural slopes are not steep; the implications for reserves may be unacceptable, particularly in quarry extensions

Aug 1, 1994

By D. C. Kaliampakos, A. K. Moutsatsou, J. K. Skotaras

The wastes from marble extraction in the Thasos- Kavalla-Drama region of northeastern Greece could be utilised as a new source of high-quality white carbonate fillers for the European market. Large deposits, satisfactory properties, acceptable processing costs and environmental benefits are among the factors that would have a positive bearing on a proposal for their use in this way. DTH, the waste arising from dolomitic marble quarrying operations on the island of Thasos, appears to be the more suitable material than DA waste from Nikissiani on the mainland because of the lower cost of primary grinding and the higher production rate of ultrafines with a mean particle size of 5 micrometres (the optimum size for filler properties in the case of both DTH and DA), its superior whiteness, the benefits that such use would bring to a very severe and complex environmental problem and the lower transport cost

Jun 18, 1905

By Y. Ichihara, H. Matsumoto, K. Itakura, H. Eguchi, G. Deguchi, K. Sato

Mechanical data from a rockbolt drilling machine, such as torque, thrust, revolution and stroke, are useful for understanding the geological and geomechanical conditions around roadways and hence selecting the optimum bolt type and density. Laboratory experiments showed that the level of torque or thrust reflects differences in rock type, with separation of strata and cracks appearing as a specific pattern. Algorithms of neural networks based on adaptive resonance theory and back-propagation were used to extract the pattern and estimate the location of discontinuities. For field testing in an underground coal mine, a prototype data acquisition system was attached to a portable drilling machine. Several sets of logging data from one locality were combined to construct a two-dimensional model of the strata, from which the slope angles of discontinuity faces could be estimated

Jun 19, 1905