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Mill liners provide the wear-resistant surface within grinding mills, they also impart motion to the mill charge, ie the grinding process, by providing the key between the charge and mill shell, and, at the discharge end, they remove the ground contents of the mill. As semi-autogenous grinding (SAG) mills have grown in size the process aspects of liner design and their impact on mill performance have become particularly important. While feedback from practical experience is critical to good mill liner design, increasingly sophisticated computer-based tools are being developed to assist in mill liner design.

Jan 1, 2007

By Ann Barron

Even though you think your company’s safety program is the best it can be, equipment, processes, supplies, surroundings and people do not always behave or react as expected. Consequently, needless accidents occur each year at quarries, construction sites, surface mines, and other locations where explosives are used. While blasting accidents account for only a small portion of the total accidents reported, the severity rate for blasting accidents is higher than for any other accident category.

Jan 1, 2007

By C. Yu, N. Topliffe, H. Song, W. Yu

The water separation pump is a highly effective alternative for medium pressure (1.6?6.4 MPa) slurry pumping requirements and has been widely used in industry since it was invented in the 1980s. The water separation pump is powered by a single or multi-stage clean water centrifugal pump. The water separation pump combines the advantage of high flow centrifugal pumps with the high pressure capability of reciprocating pumps. The clean water pressure is exchanged to slurry kinetic energy through the separating chamber, the principle component of the water diaphragm pump. Currently in its the third generation, the separation chamber uses a ball and flexible water seat that provides a true separation mechanism and can completely isolate the two fluids with near zero water loss.

Jan 1, 2007

By K. Blaski

his paper reports an investigation aimed at optimizing the compaction of granulated hard-metal powder for the production of cutting tool inserts. The optimal compaction is that which yields optimal shrinkage during sintering, i.e. minimum porosity in the sintered part. Extensive compaction tests on 23 different hard-metal powders have been carried out and have shown that the ideal ?green density? of a hard-metal compact, i.e. the density after compaction, increases linearly with the apparent density of the powder. On the basis of this result, an equation has been derived, which allows one to predict the optimal shrinkage that a hard-metal compact undergoes during sintering once the following data are known: the required sintered density, the volatile content of the powder and the apparent density of the powder. Since these data are available to the tooling designer, this equation allows one to design tooling for the compaction of hard-metal, which leads to optimal shrinkage

Jan 1, 2007

By J. S. Edwards

The ISASMELT? process is recognized worldwide as a modem, flexible, environmentally-friendly and low capital cost smelting technology. Due to the inherent simplicity, and the advanced process control that has been developed, personnel become competent within weeks of being introduced to the ISASMELT? technology. This compares with the years required to become proficient with alternative technologies. Copper smelters in Australia, USA, India, China, Peru and Zambia have installed ISASMELT? technology under licence from Xstrata Technology. In the secondary copper business, plants in Belgium and Germany are processing copper and/or lead materials in ISASMELT? furnaces in a two stage process. In a single furnace smelting is followed by converting. Both plants have exceeded design capacities and are continuously improving their performance. The next evolutionary step for the technology is the implementation of the continuous copper converting process on a commercial scale. The present work describes the design status of the continuous converting process - ISACONVERT?.

Jan 1, 2007

By E. Jackson

This paper describes highlights of the Placer Dome MiniMole project - the development and testing of a robotic machine for mining narrow ore veins. A prototype hydraulically controlled robotic machine was built and tested. The machine provided a platform for testing numerous cutters in the field. Other cutters, e.g. undercutting devices, were tested in the lab. Extensive analyses were done on specific energies and cutter penetration. Three sets of quarry trials were done, then the machine was tested in an underground mine. Rock UCS values varied from 180 MPa to 230 MPa. The paper includes lessons learned and recommendations based on the project findings.

Jan 1, 2007

By L. Contretras

This study has as an objective to analyze and to propose actions to improve the quantity and quality of the graduate education in the area of mining industry, specifically of mining engineers, metallurgists, geologists, to satisfy the expectations of professionals in the mining industry. Included are an analysis of the present scenario and the future demands in countries like Chile and proposed plans for the Establishment of Educational Initiatives, country policies and market forecast, vis-a-vis the experience of Australia, South Africa, United Kingdom, Canada and the United States of America.

Jan 1, 2007

By P. J. Brereton-Stiles, C. J. Hockaday, I. J. Barker, M. S. Rennie

This paper reports on studies that have been done on the electrical conduction in silicon, ferro silicon, and charge chrome furnaces. A system has been developed that can distinguish between normal resistive conduction and arcing, and this was used to quantify in particular the relative amount of arcing that takes place in these furnaces. It was found that silicon and ferro silicon behave similarly and exhibit a relatively large amount of arcing. Charge chrome on the other hand exhibits considerably less arcing, and the extent of this arcing is highly correlated with the tapping of the furnace. The arcing measurements can also be used online in the control of the furnace, both for the electrodes and electrical circuit, and for the raw materials.

Jan 1, 2007

By T. Lindstad, S. Gaal, S. Hansen, S. Prytz

The SINTEF SiO-reactivity test, developed by Tuset and Raaness in the 1970?s, is a recognised method of characterising the ?reactivity? of carbonaceous reactants, used in the ferrosilicon and silicon metal industries. Recently, the test has been updated, which has resulted in the development of an extended and improved SINTEF SiO reactivity test. This has included updating the test reactor, control system, data-logging, handling and preparation of carbonaceous materials to be tested and measurement procedure. The scientific basis has been re-assessed, resulting in a new interpretation of the test results. The repeatability of the test has improved significantly, especially through system automation. In the ?old? test, the kinetics of the reaction: SiO(g) + 2C(s) = SiC(s) + CO(g) for a specific carbonaceous material was characterised solely by the ?R10? parameter, the volume of SiO(g) which passes un-reacted through the coke-bed as the concentration of CO in the outlet gas decreases from 18 to 10%. As both the kinetics and obtainable conversion of SiO to SiC for a reductant is of importance to the ferroalloy producer, the new SINTEF SiO reactivity test ranks carbon materials both according to degree of conversion and reaction rate. From research carried out on the test in the past couple of years at SINTEF and NTNU, it has also become clear that some of the reactions taking place in the test reactor are more complex than previously assumed. As an example, it was previously assumed that the condensation reaction of SiO gas in the condensation chamber of the test reactor can be described as: 2 SiO(g) = Si(l,s) + SiO2(s). However, it has been established that the side-reaction: CO(g) + 2Si(l) = SiC(s) + SiO(g) causes approximately 10% of the total volume of CO to react to SiC and SiO2 in the condensation chamber. This means that some back-reaction i.e., the reverse SiO-generator reaction 3SiO(g) + CO(g) = 2SiO2 + SiC also takes place in the condensation chamber. In the new SINTEF test, the %CO versus time curves are therefore corrected in order to describe the effect of the reaction between SiO(g) and C(s) studied i.e., SiO(g) + 2C(s) = SiC(s) + CO(g). A correction-formula for this purpose is presented.

Jan 1, 2007

By A. V. Tarasov

There are still a number of copper smelters in the world using the roasting and smelting process flow diagram for treating sulphide raw materials. The technical, economic and environmental performance indicators of such operations are inferior to the respective indicators of advanced processes. First of all with respect to copper and sulphur recovery: 95% and 75% as compared with 98% and over 90%, respectively. Based on the studies of the single-stage smelting process to produce white metal and blister copper conducted during recent years an analysis of the feasibility of roastingsmelting technology improvement was carried out in the Gintsvetmet Institute to substantially increase the copper and sulphur recoveries. On the basis of this analysis, it was proposed to modernize the technology and equipment within the framework of the existing process flow-sheet. The proposed modernization implies an increase in the roasting temperature; higher desulphurization degree in the process of roasting; a number of modifications in the roaster design depending on the particular conditions of a given operation; addition of lime flux to the feed charge to roasting; and transition to combined calcium-silicate smelting slags. The metallurgical and energy computations made have indicated that the proposed modifications of the technology will improve the copper and sulphur recovery up to 98% and 90%, respectively. The required capital investments have been estimated using as an example a particular copper smelter, the payback period determined taking into consideration additional output, fuel saving and a reduction in fines for sulphur emissions. For comparison, the capital cost of a smelter modernization is given for change-over to basically new autogenous Ausmelt, Outokumpu and V anyukov smelting technologies.

Jan 1, 2007

By I J. Holland

Located in North West Queensland, XstrataÆs Mount Isa Copper Operations (MICO) is one of the largest underground mines in Australia with annual production exceeding six million tonnes of ore with average copper grades of three per cent. As at 30 June 2006, the Ore Reserve inventory totalled 87 Mt, with annual diamond drilling planned at >40 000 m in order to convert existing resources and test and define exploration targets. The role of the geology department within MICO is to collect, interpret and communicate relevant geological information to ensure the optimal extraction of ore. Routine underground inspections across multiple ore sources are undertaken and the information derived is then distributed to a range of professionals, operational personnel and management. The information is a æreal-timeÆ geological view for the stakeholders. Ongoing data collection and interpretation has developed a strong geological input to all mine planning processes within MICO. This has created strong synergies between mine planning professionals and a throughput benefit has been seen all the way to the concentrator. The MICO geological framework also provides avenues for a geological focus away from short-term production requirements, and as a result significant orebody scale observations and patterns have been realised that have led to an increase in the accuracy of geological and resource models. This has provided practical benefits for short-term scheduling and production, whilst enabling the realisation of long-term benefits that have a strong potential to increase the volume and value of the MICO resource. This paper will discuss the various mine geology contributions at MICO and illustrate some examples where mine geological input from graduate level has added significant value to the MICO business.

Jan 1, 2007

In June, 1,334 underground construction and tunneling professionals gathered in Toronto, Ontario for the 2007 Rapid Excavation and Tunneling Conference (RETC). This biennial event, sponsored by SME, is one of the global underground construction industry?s major events. And this year?s RETC was the first one that included the new Underground Construction Association. [ ] (UCA) of SME. In addition, the conference?s exhibit attracted 125 equipment and service providers. The next Rapid Excavation and Tunneling Conference is set for June 14-17, 2009 at Caesar?s Palace, Las Vegas, NV.

Jan 1, 2007

With the increased variability of today's large-scale mining operations, consistent flotation performance is important to improving and sustaining overall recovery through the circuit. The Newcrest Telfer Mine has implemented advanced process control technology to obtain stable level operation and consistent mass pull in the copper rougher and scavenger flotation circuits. The final result has been an overall reduction in variability, which impacts on both copper and gold recovery. This paper describes the methodology and implementation of the improvements in control at the Newcrest Telfer Mine as being an essential part of the business for minerals processing.

Jan 1, 2007

By D. M. Bastidas

The reduction of copper sulfide and copper oxides originated during artificial tarnishing of copper was studied using potentiodynamic potential/current density experiments. Six copper surface treatments were considered: mechanical polishing; indoor exposure for 7 days; chemical etching in 1.6 M nitric acid; chemical etching and heating at 160°C; and chemical etching and dipping in a 9x10-4 M or 0.9 M potassium sulfide (1(25) solution at 70°C. Cuprite (Cu20) and chalcocite (Cu2S) were the main compounds formed. A linear relationship with the square root of the scan rate (v) was obtained by plotting the potentiodynamic potential/current density for the tarnish dissolution processes. A relationship between potential and current density cathodic peaks was not obtained, according to Müller's model, showing a proportionality factor with the dimensions of a resistance.

Jan 1, 2007

The development of 3D multi-parametric models facilitate the provision of resource information well in advance of the mining face. Using the model, one can evaluate mining areas not only for grade and tonnage predictions but also for predictions of rock mass quality. Blast design and milling requirements can be derived from the rock mass quality predictions. This information can be used for overall mine planning and evaluation, costing, production optimization and slope design. This allows the full range of mining activities and costs to be interconnected, thereby lowering costs and improving efficiencies through the application of the multi-parametric model. Feasibility studies for new projects require an expected budget expenditure estimate to within 5% of actual costs. This level of accuracy is expected by mining companies and investors but cannot be achieved without a sound knowledge of the rock mass variability. By developing a 3D multi-parametric model as part of the feasibility study and using the same geological model exploration boreholes, a significantly better understanding of the rock mass conditions can be obtained. This rock mass information can be used for equipment selection, economic pit layouts, processing plant design, underground mining layouts and support requirements, to name but a few design parameters that depend on rock mass conditions. The initiative at Anglo Platinums, Potgietersrust Platinum Ltd.?s (PPRust) operation, has delivered significant results showing improvements across the mine to mill value chain. These include increased loading rates, reduced electricity and crushing consumables, as well as higher plant throughput. The ore reserve model has gained international acceptance as an invaluable tool for a mining operation. Certainly most financial organizations will not invest in a mining project that does not have an ore reserve model. There is the potential for multi-parametric models to be recognized as vital tools in the mining process, as is the case with ore reserve models.

Jan 1, 2007

By M. Sanchez

In the last decades, the Chilean copper mining and metallurgical industry have had to modify their technological processes to meet the environmental regulations implemented by the Chilean government, and also to support the pressure of the public opinion. Thus, air quality standards for sulfur dioxide and particulate matter (primary and secondary), plans for reducing emission of arsenic by the Chilean copper smelters, effluents discharge limits, among others regulations were applied by the environmental agency. Additionally, agreements on cleaner production were carried out by mining sector and government. Now, a draft law on mine closure, and another on environmental mining wastes (abandoned mines) are being discussed by the authorities and the mining sector. In the context, production and environmental impacts in different ways to produce copper in the Chilean mining industry are reviewed and regulatory tendencies as well as abatement technologies today used are exposed and discussed in this presentation. Pyro, hydro and electrometallurgical processes employed and their current effluent and contaminants are presented showing various alternatives of treatment in the copper industry. An update of regulations established in Chile vis a vis copper production, with an especial attention to mine closure are also presented.

Jan 1, 2007

By C. G. Anderson

With demand and prices for copper and gold at near record high levels, coupled with a lack of readily treated orebodies, the emergence of environmentally sound hydrometallurgical treatment of enargite concentrates has become a priority. This paper will outline the application the industrially proven technologies of low pressure and temperature NSC (Nitrogen Species Catalyzed) pressure leaching and ASL (Alkaline Sulfide Leaching) for the recovery of copper and gold from enargite. Copper can be recovered as cathode metal or as a clean concentrate suitable for smelting. Gold is recovered by smelting, conventional cyanidation or alkaline sulfide hydrometallurgy. Coupled with this is the effective precipitation and stabilization of arsenic as scorodite and ferrihydrite.

Jan 1, 2007

Where space is limited, as it is throughout most of the northeastern United States, new construction either takes place high above street level, or below it. In Lower Manhattan, NY both kinds of expansion can be found in abundance. That is good news for the nearly 200 attendees at the George A. Fox Conference, presented by the Underground Construction Association (UCA) of SME at the Graduate Center, City University of New York, on Jan. 30. Among the many projects taking place in Lower Manhattan?s massive trans-formation process, are expansions to the city?s vast underground network of subways and other tunnels. ?New Yorkers either live on the ground or below it,? said keynote speaker Charles J. Maikish while explaining how an attempt to build above street level walkways never caught on in the city. Maikish is the executive director of the Lower Manhattan Construction Command Center. His job is to oversee the $22 billion project that will transform the island by 2010. From the construction of Freedom Tower at the site of the fallen World Trade Center buildings, to the expansion of the Second Avenue Subway, the extension of the East Side Access, No. 7 line, the new trans-Hudson line and numerous waterway tunnel expansions, including City Water Tunnel No. 3, the task Maikish is charged with is a huge one. He is primarily responsible for coordinating the scheduling and staging of the overall rebuilding plan, along with the day-to-day coordination of construction work down-town. He places particular focus on mitigating impacts on the environment and mobility, maintaining and improving access and alleviating congestion of any kind related to construction. At the time of the Fox Conference, there were 59 projects under way in Manhattan. All of those projects need things like concrete and steel delivered to sites in very tight working environments. And some need the equipment in even tighter spaces. ?This is not just about the recovery of Lower Manhat-tan (from the 2001 terrorist attacks) but this is a plan to restore it and to maintain its integrity,? said Maikish. ?I think that is the appropriate response to the terrorist attacks.? When Freedom Tower is completed, it will stand 541 m (1,776 ft) about the skyline. That will be a strong statement to the world about America?s strength. But it is the work that takes place much lower that was of interest to the conference attendees. On this respect, Maikish said Manhattan?s efforts below ground aim to provide relief to the city?s street level congestion and to make sure Manhattan ? already essential to the economy of the United States and the world ? stays current by upgrading the existing telecommunications and technological network while also allowing room for growth in that area.

Jan 1, 2007

By I. S. Laitinen

Outokumpu Technology has recently introduced new technology in both copper electrorefining and electrowinning. This technology includes, among other things, a new permanent cathode (Outokumpu Permanent Cathode) and new busbar technology (Outokumpu Double Contact System). The new technology has already been tested in commercial scale cells. To get a better understanding of the busbar system a multiphysical simulation model of the electrowinning and electrorefining cells was developed. A mathematical model of electrical conduction and heat transfer in a copper electrolysis cell was developed from partial differential equations. The model was expanded to a cell group including seven electrolysis cells connected electrically in series. The model was solved numerically using the finite element method (FEM). Using the model, different intercell busbar systems were simulated. Typical electrical disturbances, like loose contacts between cathodes and the main busbar and short circuits between electrodes, were included in the simulation. The results of the simulation runs with conclusions are presented in this paper.

Jan 1, 2007

By Georgene Renner, William R. Yernberg, William Gleason

American Commercial (ACI) offers a selection of ground control solutions. Beginning with steel liner plates installed in the Gratiot Avenue sewer system in Detroit, MI 1920, ACI is one of the leading designers and manufacturers of underground steel supports in North America. ACI is also a leader in fire-proofing underground structures with its Promat Fire Protection Boards. The sandwich panels have been used in many new and retrofit tunnel and underground construction projects worldwide. Ease of installation and replacement, cost effectiveness and superior performance have made this product line the premier choice of owners and designers for structural protection, fire-life safety requirements and architectural finish needs.

Jan 1, 2007