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By R. A. Franks, G. F. Friel, J. C. Edwards, A. C. Smith

An evaluation of a nuisance-emissions-discriminating smart mine fire sensor system was made in an operating coal mine. These field evaluations were conducted to determine the sensor system's ability to discern nuisance emissions, such as diesel exhaust, emissions from flame cutting and welding operations or hydrogen gas from a charging station, from real fires and to compare the number of falsely reported fire alarms generated between the sensor system and a standard carbon monoxide (CO) monitor. The sensor system's ability to operate successfully in the working environment of an operating coal mine was also evaluated. The smart mine fire sensor system consisted of four sensors whose data outputs were fused with the use of a neural-network-type computer program. Long-term trials were conducted in a haulage way, a belt entry, and a track entry. The system functioned successfully in the belt entry, in accordance with its developmental goals, where the sensor system even discriminated events not anticipated during development. It was not totally effective in the haulage way and track entry, though, due to a combination of significant diurnal air temperature variations, dust, and mechanically induced vibrations. Also, deteriorating rib conditions contributed to operational problems in the haulage way evaluation. In general, the smart mine fire sensor provided nuisance emissions discrimination and was shown to be a viable new approach for mine atmospheric monitoring, enhancing miner safety. This paper describes the in-mine evaluation of the smart mine fire sensor system and discusses recommendations for improving the system.

By R. C. W. Webber

Mining up to depths of 5 000 m would be a world first and, accordingly, no previous experience in the determination of acceptable heat stress limits, criteria or indices is wholly applicable. However, some South African gold mines are already operating at depths beyond 3000 m and much of the knowledge gained in reaching and working at such depths will be helpful in making adequate provision for acceptable environmental control at the greater depths being contemplated. Accordingly, it is necessary to take cognisance of the industry?s experience in deep-level mining and of standards and regulations already established in South Africa and elsewhere in order to ensure acceptable working conditions and control standards, that compare favourably and defensibly with those in other mining industries. The local and international use of heat stress limits, criteria and indices were investigated as it was necessary to determine to what extent any other indices, limits or criteria would be applicable to South African deep mine conditions. In addition, it was necessary to establish whether there was a single heat stress index that could be used for South African ultra deep mining conditions. It was found that an appropriate combination of heat stress indices would be required in planning for and ultimately controlling thermal conditions in ultra-deep mining. The depths being contemplated and the concomitant potential heat hazard present too great a risk for reliance on a single environmental component of heat stress, such as wet-bulb temperature at present in common use locally. The study recommends that a heat stress index, preferably Air Cooling Power (ACP), be used to design an ultra deep mine?s ventilation system and that wet-bulb temperature be used to monitor and control the system once it is implemented.

Jan 1, 2003

By I. Ewart, E. Roux

Skorpion Zinc operates a solvent extraction/electrowinning zinc plant producing over 150 000 t/a of special high grade (SHG) zinc (>99.995% Zn). In the current flow sheet copper and cadmium are cemented from the neutral leach solution using zinc powder, to prevent galvanic corrosion of plant equipment and build-up of copper in plant solutions. This process is effective but unfortunately consumes expensive zinc dust and produces a low value copper product. The EMEW® (Electrometals electrowinning) technology of Electrometals Technologies Ltd. uses a rapid flow of electrolyte through a cylindrical cell to deposit copper or other metals from dilute solution (less than 1 g/L) [1]. The copper can be deposited as powder or may be harvested as a tubular cathode product. The advantage of the use of EMEW® technology at Skorpion Zinc will be to eliminate the use of expensive zinc dust and to produce a high value copper product for sale. Following extensive bench test work, a piloting campaign was carried out at Skorpion Zinc. The tests demonstrated the ability of the EMEW® cell to effectively remove copper from solution through direct electrowinning at lower operating cost than cementation. Keywords: Skorpion Zinc, copper, cementation, direct electrowinning, EMEW®

Jan 1, 2007

By J. A. Bakken, M. Tangstad, P. A. Eidem

In the submerged arc production of ferromanganese, sillicomanganese and ferrochromium, the coke bed characteristics play an important role. The basic mechanisms of electric current conduction in the coke be dare not yet fully understood, but important parameters are the material resistivity of coke and the contact resistance between the coke particles. Preliminary tests indicate that the contact resistance is of great importance to the bulk resistance of the coke bed. An apparatus measuring the material resistivity and contact resistance of carbon materials has been developed. Both graphite and industrial coke have been tested. The material resistivity tests were performed on single particles to ensure that the effects of pores and cracks were included and the contact resistances were excluded. Two geometries were tested to obtain the contribution of the contact resistance to the total resistance of two connecting particles. The tests were performed in an inert atmosphere at temperatures and current levels found in industrial submerged arc furnaces. The results show that the method has a satisfactory reproducibility. It was found that the contact resistance is about 10 times higher than the resistance of the material when two particles are in perfect contact and that the resistivity of SSAB coke is more than 10 times higher than that of the graphite at room temperature, but with increasing temperature the difference decreases. For SSAB coke the general trend is that both the resistivity and the contact resistance decrease with increasing temperature.

Jan 1, 2007

By A. Golshani, M. Oda, K. Suzuki, T. Takemura

Anisotropic behaviours of OhshimaOshima granite were investigated by carrying out uniaxial compression tests, together with observations of microcracks under an optical microscope. The elastic modulus tensor of Oshima granite at 10 per cent strength,E10, were calculated using theoretically formulation of elastic modulus tensor in terms of the second-rank crack tensor for pre-existing open microcracks. Furthermore, with the assumption of orthorhombic elasticity, the nine moduli of Oshima granite E10were determined by uniaxial compression test. Twenty-onemoduli of samples, calculated without assuming any symmetry, also showed orthorhombic features. Direction of the symmetry axes agreed well with the orientation of preexisting cracks. Comparison of crack tensor-based formulation results with the experimentally determined one show that the anisotropy of elasticity of Oshima granite is caused by pre-existing open microcracks, not by pre-existing healed microcracks and also crack tensor formulation can be used, as a first-order approximation at least, to describe the anisotropy of Oshima granite induced by pre-existing open microcracks. ZUSAMMENFASSUNG: Das anisotrope Verhalten des Oshima-Granits wurde mit Hilfe voneinachsigen Kompressionstests und durch die Betrachtung von Mikrorissen unter einem optischenLichtmikroskop untersucht. Das Elastizitätsmodul von Oshima-Granit bei 10 Prozent Kraft E10wurde berechnet, indem man die Formulierung des Elastizitätsmodultensors, ausgedrückt alsRisstensor zweiter Ordnung theoretisch auf bereits existierende Mikrorisse angewandt hat.Außerdem wurden die neun Module des Oshima-Granits unter der Annahme orthorhombischerElastizität E10mit einem einachsigen Kompressionstest bestimmt. Einundzwanzig Stichproben,die ohne die Annahme irgendeiner Symmetrie genommen wurden, zeigten ebenfallsorthorhombische Merkmale. Die Richtung der Symmetrieachsen stimmte mit der Orientierungbereits vorhandener Risse überein. Der Vergleich der Ergebnisse der auf dem Risstensorbasierenden Formulierung mit der experimentell bestimmten Formulierung zeigt, dass dieAnisotropie der Elastizität von Oshima-Granit von bereits vorhandenen offenen Mikrorissenverursacht wird, und nicht von vorhandenen vernarbten Mikrorissen, und dass dieRisstensorformulierung auch zumindest für eine Annäherung erster Ordnung benutzt werdenkann, um die durch vorhandene offene Mikrorisse induzierte Anisotropie des Oshima-Granits zubeschreiben. RESUME: Les comportements anisotropes du granit d’Oshima ont été étudiés en réalisant destests de compression simple, et en observant les microfissures au microscope optique. Le tenseurdu module d’élasticité du granit d’Oshima sous une résistance de 10 pourcents, E10, a été calculéen se servant de la formule théorique du tenseur de module d’élasticité basé sur le tenseur defissures de second ordre des microfissures ouvertes préexistantes. En outre, sur base del’hypothèse de l’élasticité orthorhombique, les neuf modules du granit d’Oshima ont étédéterminés par des tests de compression simple. Vingt et un modules d’échantillons, calculés endehors de toute hypothèse de symétrie, ont aussi montré des caractéristiques orthorhombiques. Ladirection des axes de symétrie correspondait bien à l’orientation des fissures préexistantes. Lacomparaison des résultats de la formule basée sur le tenseur de fissures avec les résultatsdéterminés expérimentalement montrent que l’anisotropie de l’élasticité du granit d’Oshimaprovient des microfissures ouvertes préexistantes, et non de microfissures préexistantes referméeset que la formule du tenseur de fissures peut servir, au moins comme première approximation, àdécrire l’anisotropie du granit d’Oshima marqué par des microfissures ouvertes préexistantes.

Jan 1, 2003

By Hans Korfmacher

Product take-back regulations implemented in Europe have presented significant challenges to the consumer electronic product and battery industries. Initially companies established single compliance organizations within individual Member States. These programs met business needs but were inefficient and costly. They were protected from pressures of marketplace competition and could not leverage economies of scale. In order to address these problems P&G, Hewlett Packard, Sony and Electrolux conceived a pan-European compliance organization to collect waste electronic equipment Europe-wide. This organization, called the European Recycling Platform (ERP), operates in competition with existing national compliance systems. Since 2005 ERP has collected 800,000+ tons of waste electronic products and delivered millions of dollars in cost savings. This presentation reviews the steps needed to establish successful competitive collection organizations that provide sustainable recycling at the lowest cost.

Jan 1, 2010

The Small Pebble Process for Reducing Ball and Power Consumption in Secondary Grinding Ball mills are used widely for secondary grinding. A mixture of ball sizes can be used to optimise grinding efficiency, but the use of balls smaller than about 30 mm in diameter is not normally viable, particularly when alloy steel is required. Preliminary testing of the grinding efficiency of various combinations of 40 mm steel balls and crushed stone in the size range 7 to 25 mm was carried out in a 300 mm diameter mill, which has accurate power measurement.The primary interest was to assess the potential benefit of adding small pebbles (from a primary circuit crusher or mill) to a secondary ball mill, to reduce ball consumption and to improve grinding efficiency. The optimum proportion of pebbles was found to be about 25 per cent by volume. This mixture produced about the same amount of fines as balls alone, but with lower power consumption, due to the lower density of the pebbles. The net result was a 12 per cent saving in power and a 25 per cent saving in ball consumption. The production of fines was partly due to pebble wear. The use of portions of 15 mm balls, (ceramic and steel), was also tested for comparison. A few batch pilot-scale tests were conducted in a 1.2 m diameter, 0.31 m long mill to test the viability of the pebbles at a larger scale. The pilot-scale tests confirmed the reduction in power and that the rate of production of fines was the same as that obtained with balls. The same residence time was used and this implies that pebbles can be added to an existing full-scale ball mill, with no loss in capacity. Samples of secondary mill feed and pebbles were obtained from a copper mine and the steady-state consumption of pebbles was determined by locked-cycle laboratory-scale tests. These tests demonstrated that mill power could be reduced by up 13 per cent and that the consumption of 40 mm balls could be reduced by up to 38 per cent, while maintaining the same throughput and product size. The rate of pebble addition was about 4 per cent of the primary circuit feed rate. Application has been made for patent protection.

Sep 13, 2010

By M. M. D. S. Vemba

Paper written on project work carried out in partial fulfilment of B.Sc. Eng (Mining Engineering) degree Engineering refers to the application of mathematics and other sciences to logically develop solutions to problems. However, in opencast mining, due to the randomness of operations, the use of mathematics is often neglected. Instead, practices that have proven successful elsewhere tend to apply. At the other end of the scale, mathematical models have been developed to identify and quantify all the operational parameters involved in the loading and haulage of ore. These are then used to optimize the operation. Optimization in this context, refers to the reduction of cost through effective utilization of the available time and resources. Considering these mathematical models, the loading and transport system at SMC (Catoca Mining Society) will be assessed with a view to its optimization. The discussion will be introduced by considering the mine background and other general information, which will highlight the main operational variables.

Jan 1, 2004

By Garry Johansen, Andrew McCallum, Sandy Gray, Gary Patrick, Jennifer Abols

"The authors challenge the traditional thinking that whole ore cyanidation followed by Carbon in Pulp (CIP) or Carbon in Leach (CIL) should be applied as a standard process in the majority of gold processing flowsheets. The concept of whole ore leaching by using cyanide can result in unnecessary environmental and capital risk. Alternative, currently available technologies can be used to provide the desired level of gold recovery at a much lower installed cost and less impact on the environment. Gravity concentration, alone or in conjunction with flotation, can produce a gold bearing concentrate that can then be fed directly to a batch or continuous intensive cyanidation unit.The InLine Leach Reactor (ILR) is an intensive cyanidation unit developed by Gekko Systems of Australia. Advantages of this technology include significantly reduced capital outlays for greenfield plants or plant upgrades and increased investor returns. Reduction of onsite cyanide and carbon inventories improves plant safety, materials handling and site security. By using direct electrowinning to treat the gold bearing solutions produced by the ILR, the need for a conventional carbon stripping circuit is removed. Potential also exists to increase grind size – saving energy, further reducing capital and operating costs and decreasing the environmental impact of a mill. Detoxification of cyanide before the release of solution to the tailings dam can minimise tailings disposal and containment requirements.When used in the right application the proposed process will have little or no impact on gold recovery and may actually increase recovery for complex ores. Areas applicable to this type of treatment include: plants in environmentally sensitive regions, lower tonnage higher grade deposits, coarse gold deposits, and preg robbing ores - some of which may not currently be economically feasible using standard processes and flowsheets. We have provided three examples of such projects, where an alternative to whole ore leach and CIP or CIL has delivered these benefits."

Jan 1, 2003

By D. R. Tesarik

Researchers from the National Institute for Occupational Safety and Health (NIOSH)1 and engineers from Placer Dome, Inc.2, conducted an underground rockfill span test at the Turquoise Ridge Mine near Golconda, Nevada, USA with the purpose of improving safety and increasing productivity by using a bulk mining method instead of drift and fill. A rockfill sill was constructed by mining and backfilling six adjacent, parallel drifts and then undercutting the sill with a 13.7 m (45 ft) wide and 30.5 m (100 ft) long room. Displacement measurements from vertical borehole extensometers installed in the mine roof and rockfill indicated that the sill remained stable with a maximum vertical deformation of less than 5 mm (0.2 in). These results were confirmed by visual observations and calculations from a validated three-dimensional numeric model of the sill. The numeric model was also used to simulate load on the sill produced by dislodged roof material in the shape of a 11.0 m- (36 ft-) high triangular prism with base measurements equal to those of the sill. Failure in the bottom third of the sill occurred with this additional load.

May 1, 2007

By R. A. Franks, J. C. Edwards, L. Yuan

To determine the critical air velocity for preventing smoke rollback, diesel-fuel fire experiments were conducted in the National Institute for Occupational Safety and Health’s (NIOSH) Pittsburgh Research Laboratory’s Safety Research Coal Mine. Such information is necessary for preplanning and implementation of ventilation changes during mine fire fighting and rescue operations. The fire intensity varied from 50 to 300 kW depending on the fuel tray area. Airflow in the 2-m- (6.6-ft-) high, 2.9-m- (9.5-ft-) wide coal mine entry was regulated during the course of each experiment. The airflow was measured upwind from the fire as an average over the entry cross-section with an ultrasonic airflow sensor and was recorded dynamically with a mine monitoring system. The extent of smoke reversal was monitored with light-obscuration monitors, ionization smoke sensors and visual observations. Experimental results for the critical air velocity for smoke reversal as a function of fire intensity compared very well with model predictions based upon a computational fluid dynamics fire dynamics simulator.

By P. K. Naik, B. Das

Flotation studies were carried out to recover carbon values from blast furnace flue dust containing ~30.34% carbon, 4.6% volatile matter (VM), and 65.03% ash. The variables chosen for the experiments were dispersant (sodium hexametaphosphate), pH, collector (diesel oil), and frother (MIBC). The experiments were designed according to a 24 full factorial design method and regression equations for the recovery of carbon and product grade were determined from the data. Experiments were performed to optimize recovery and grade using the steepest ascent method. The maximum recovery of carbon was 90.0% with a concentration of 56.5%, whereas the maximum obtainable grade of carbon was 66.35% with 50.45% recovery.

Jan 1, 2005

By P. J. Remington

Field measurements utilizing a seat pad accelerometer were made on 61 surface coal mining machines in order to quantify the vibration levels experienced by the operators. Those data were combined with information on the statistics of the operating times of those machines in order to compare the operator's vibration exposure to the criteria in ISO 2631, ?A Guide for the Evaluation of Human Exposure to Whole Body Vibration.? The comparison showed that about ha]f of all surface coal mining machine operators can be expected to be exposed to vibration exceeding the fatigue decreased proficiency criterion, whereas only on the order of 15% would be expected to experience vibration exceeding the exposure limit. Detailed exposure statistics are presented and the implications of the results are discussed.

Jan 1, 1983

By Benjamin Smith Lyman

THE importance of topography to geology is so commonly underrated as to deserve to be pointed out again and again. The relation of topography to the different branches of geology may be seen best by a glance at them all. Geology is well understood to consist of the observation of facts about rocks as materials of the earth (geognosy), and the explanation of those facts (geognosy). The facts to observe are : I. GEOMETRICAL, as (1) structure, including the dip and strike at different points, the size, shape, and position of basins and saddles; (2) vertical section, that is, the thickness of rock groups and of their parts ; (3) horizontal or geographical position. 11. PHYSICAL, such as texture, whether sedimentary or crystalline ; and, if crystalline, whether granitic, porphyritic, amygdaloidal, globular, or concretionary ; whether compact or granular; coarse or fine; pervious or impervious; hard or soft; firm or tender; with cleavage or without ; massive or thin ; the microscopic structure ; also whether magnetic or not ; soluble or insoluble ; fusible or infusible ; and the constituent minerals. 111. CHEMICAL that is, the composition of the rocks and of their minerals and their affinities. IV. PALAENTOLOGICAL, as what kind of fossils are in the rocks,

The geological features of the destructive plate margins of the southwest Pacific favour the formation of porphyry type deposits. The major controlling factor favouring the formation of gold-rich deposits of this type is a dense crust. This results in shallow intrusion of large magma bodies beneath andesite stratovolcanoes. Where the intrusives have near vertical sides, the comparatively low temperature of transfer of volatiles from the solidifying melt favours the partitioning of gold into bubbles of volatiles. They reduce the viscosity and density of the melt, resulting in the upward movement of a mineralised melt. With the drop of pressure with upward movement the bubbles separate into a two phase mixture, triggering freezing of the mineralised melt and the formation of a gold mineralised stockwork.

Jan 1, 1995

By Stephen C. Tadolini

The International Ground Control Conference in Mining has always provided an open forum for the publication, presentation, discussion, and often heated debate on roof bolting systems mostly with attention to how, when, and why they work. During the last 24 Conferences at least 170 papers have been presented by International Experts on these ?simple? devices that range in length from 30-inches to 20 ft and from 5/8 to 2 inches in diameter. Roof bolts are primarily mechanically anchored, glued, cemented, or driven. Bolts are placed vertically, angled, or tied together with special fixtures (trusses and slings). They have been termed active, passive, stick-slip, and several other descriptive acronyms or mining slang expressions. This retrospective paper will present the changes in bolt types and usage, point out some of the biggest myths and hail the most significant advances (according to the authors? opinions of course).

Jan 1, 2006

By K. Bruce Hodgins

The North American mining industry faces challenging emissions regulations in coming years with the introduction of new standards for off-road diesel engines. In order to remain competitive, industry stakeholders must invest in new technologies that are economically and environmentally sustainable. Westport Innovations Inc., of Vancouver B.C. has developed high pressure direct injection (HPDI) technology that allows diesel engines to run primarily on natural gas with no intrusive engine modifications, reduced emissions of NOx, PM, and CO2, with no loss in performance. This is accomplished through late-cycle high-pressure injection of natural gas directly into a diesel engine combustion chamber. The natural gas is injected at the end of the compression stroke. A small amount of diesel fuel is injected first to initiate combustion, followed by the main natural gas fuel injection. The diesel cycle and its operating characteristics are fully retained including high combustion efficiency, low speed torque, high-power output, no engine knock and fast response to load changes. Natural gas has not been an attractive fuel alternative in mining operations due to reduced performance associated with spark ignition engines and the added weight and space required for compressed natural gas tanks. However, liquefied natural gas (LNG) can be stored in a similar manner and volume to diesel fuel by virtue of its increased energy density over compressed natural gas. Cummins, Inc. of Columbus, Indiana and Westport have formed a joint venture, Cummins Westport Inc. (CWI), under which agreement the HPDI technology is being applied to a Cummins QSK engine series for high horsepower applications such as mine haul trucking. CWI, along with Komatsu Mining Systems, ENRG Fuels, Placer Dome, and Cortez Joint Venture are performing a feasibility study for the development and demonstration of an LNGfueled HPDI QSK engine in a large mine haul truck. The goal would be to demonstrate low emissions consistent with EPA ?Blue Sky? standards, high efficiency based on HPDI technology and good economics resulting from the high fuel consumption of 2,000+ hp trucks.

May 1, 2002

By Godwin Beene

During recent years, copper and acid production from Nkana Smelter has formed a significant proportion of ZCCM's total output, but a number of problems affecting the smelter over the last decade have only been recently overcome. This paper discusses recent developments in the smelting practice, highlighting some of the operational problems experienced and associated solutions. The smelter performance over the decade is discussed and the innovations in the smelting technology employed to sustain production in the wake of limited re-capitalization are dealt with in detail.

Jan 1, 1999

By Pakalnis Rimas, Lyndon Clark, Tom Brady

A major focus of ground control research presently being conducted by the Spokane Research Laboratory of the National Institute for Occupational Safety and Health (NIOSH) is to incorporate data on weak rock masses into existing design relationships, with an emphasis on updating the span design curve for manned entries and the overbreak curve for longhole entries. Both curves were originally developed at the University of British Columbia, Vancouver, BC. The original database has been augmented by information from mines throughout the United States, Canada, Australia, and Europe. The common factor in all these mines is the presence of a weak back and/or walls. In most cases, the ore zone is the weakest rock unit and must be stabilized so that the mineral-bearing rock can be extracted safety. The current NIOSH research attempts to provide rock mechanics tools to assist a mine operator in making economic decisions that will also ensure a safe working environment. This paper documents the Nevada database with a special emphasis on Nevada underground gold mines.

By Valentin Choquenaha Bombilla, Oscar Alvarez Muiloz

"Tintaya’s basic production line is copper concentrate, which has an important gold content. The process used is flotation; the objective of the metallurgical department is to obtain the best results in the copper recovery without neglecting the gold, using very specific reagents. Copper recoveries are considered high, nevertheless every day emphasis is placed upon increasing those recoveries. Regarding gold, optimum recoveries could not be achieved with flotation; and implementation of a gravity circuit was considered.According to microscopy studies, the coarse and very fine grains of gold in native form are lost to tails. The native gold due to its high specific gravity is concentrated at the underflow of the cyclone, remaining in the circulating load of the circuit. It reaches three times the concentration compared to the head grade entering the ball mills. This re-circulation generates very fine and laminated gold particles inside the ball mill, passing to the classification stage making a short circuit to the overflow of the cyclone.The very coarse gold particles as well as the thick flakes of gold do not react favorably to the conventional flotation process; thus studies that have included gravity separation have been conducted to increase the gold recovery. Part of the research included concentrating tables, jigs, and Knelson Concentrators. The Knelson Concentrator proved to be the best selection in terms of metallurgical performance and recoveries considering the throughput and operation conditions of the Tintaya Plant.The gravity concentration circuit with the Knelson Concentrator was commissioned in BHP Tintaya in October 1998, as per the flowsheet shown later on. Presently the global gold production surpasses any estimated expectations.Present efforts are directed towards showing the evaluation and optimization of the different parameters that govern the performance of the Knelson concentrator, as well as illustrating the difficulties and successes throughout the operating period.In the first year of operation 200 tons of gold concentrate have been produced with an average concentrate grade of 320 gramdton, having paid back in full the cost of the automated KC-XD- 48 Knelson Concentrator, the peripheral equipment, and the cost of the installation."

Jan 1, 2002