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The general types of industrial behaviour of liberated valuable sulfide minerals in the 0 - 10 ¦m size fraction are described and tests to explore on site at a concentrator the general nature of any deficient behaviour are discussed. In addition, the general types of behaviour of the gangue minerals in this size fraction are also described in terms of their mechanisms for recovery. These behaviours are also discussed in terms of the type of grinding device and grinding environment in which they were produced and the target grinding product size. Major recent improvements in the industrial capabilities of grinding devices are discussed.Present difficulties in characterisation of particles in the 0 - 10 ¦m range are described and desirable improvements for the future are outlined. Further, desirable improvements for industrial processing of valuable minerals in this size range are discussed along with some remedial actions.

Jan 1, 2005

By M. A. Golozar

Partially stabilized zirconia (PSZ) has been proven to be an excellent candidate as a thermal barrier coating (TBC) for hot sections in, for instance, heat or internal engines and gas turbine parts. The main functions of these coatings are reduction of heat losses, reduction of fuel consumption, increasing efficiency, and extending durability and life. One of the main problems involved is wear behavior in the development of such coatings for these applications. Using air plasma spraying (APS) technique, conventional and nanostructured 8 wt % yttria partially stabilized zirconia (Y-PSZ) coatings were deposited on austenitic stainless steel (AISI 304) disc-shaped substrates. The coated substrates were subjected to pin-on-disc wear tests, using 10 mm silicon nitride and zirconia balls as the pin. The coefficient of friction was recorded in real time. The weight loss of coated substrates was measured. Coatings were characterized before and after being subjected to wear testing by various techniques including optical microscopy, scanning electron microscopy (SEM), energy dispersive X-ray spectrometry (EDX) and X-ray diffraction (XRD). Effects of various experimental parameters such as wear distance, test temperature, and counterface material were also investigated. Results obtained revealed that, regardless of experimental conditions applied, the nanostructured zirconia coating shows better wear and tribological properties than those of the conventional one.

Jan 1, 2005

By Paul J. Lewis

Estimation of the axial side shear resistance of drilled shaft rock sockets is directly related to the unconfined compressive strength of the bedrock. Commonly, the mean unconfined compressive strength value is calculated from a range of laboratory test results and is used to estimate the side shear of the bedrock. This paper presents the results from a full scale axial load test performed on an 8.5-feet-diameter drilled shaft rock socket, and compares measured side shear values to estimated values for two different rock strata. Measured side shear values correlated well with the design value calculated for the "strong" rock stratum, but did not correlate well with the design value calculated for the "weak" rock stratum. The mean unconfined compressive strength was used to calculate the side shear in both strata, but review of the laboratory data indicates that this value may not have been appropriate for the weak stratum due to a large variation in the laboratory test results. Also included in this paper is a discussion of the subsurface conditions, the laboratory test results, and the methodology used to design the drilled shaft rock sockets for axial and lateral resistance.

Jan 1, 2005

By Michael S. Wieland

Toxic fume concentrations from industrial mining explosives depend somewhat upon the type of rock (or other strata) confinement. Though traditional detonation theory disregards this influence, the work principal from thermodynamics reveals it, when the violent interactions that transpire within the rock blast are taken into proper account. Resolution of the work principle technique requires total thermodynamic equilibrium under constraint, so the nonequilibrium dynamics is rendered in that way, using an old trick from theoretical mechanics that revises the representation of forces. The rock pressure reduces to a four-component sum: the rock compressive strength and natural atmospheric pressure, as reckoned quasi-statically, and the gravitational influence and reversed inertial resistance, as reckoned dynamically. Tabulated specie concentrations and graphical trends reveal the dependency upon rock pressure, rock temperature and the fuel-oil percentage in ammonium nitrate mixtures (ANFO), used to illustrate the model. Rigid-wall test chambers have notable ullage (residual space), where rapid expansion influences the reaction quenching, yielding a fume spectrum unlike that for rock confinement; reported rock tests are therefore used for comparisons. For the thermodynamic regime where quenching occurs, seven concentrations are resolved, including carbon monoxide (CO) and total nitrogen oxides (NOX). Their trends yield inferences regarding the way unwanted charge desensitization from transitory hole-to-hole wave impact in conjunction with reduced rock pressure can yield nasty toxic fumes, the dark rusty cloud phenomenon!

Jan 1, 2005

Following GyÆs earlier proposals for the use of StudentÆs t-test, a simplified, effective method and philosophy are proposed to test for maximum tolerable bias in data sets as well as in sampling devices. The philosophy of testing is particularly emphasised to derive important practical implications in terms of decision-making and risk control. Conclusions are offered which should equally matter to manufacturers and users of sampling equipment.

Jan 1, 2005

By Pramod C. Thakur

Floor gas emissions on wide longwall faces are common occurrences in the Northern and Central Appalachian basins. It creates unsafe working conditions on the face and results in very costly production delays. This paper discusses various methods of mitigating the floor gas emissions including hydrofracing of underlying strata, use of cross-measure boreholes and specifically completed gob wells.

Jan 1, 2005

By Stephen C. Tadolini, Thomas M. Barczak

Western mines have had limited choices for standing support. Wood cribs were often too soft and unstable. The introduction of the Can support in the early 1990’s provided a very effective alternative and remains the dominant form of tailgate support. Water-filled prestressing cells are now used to cap the Can and preload it to provide an active roof load. The Cluster Prop, consisting of three timber wedge props bundled together, provides more capacity than an equivalent sized Can support and improves transport efficiency. However, the Cluster Prop is less stable and does not maintain a consistent load throughout its loading profile. Pumpable roof supports are another alternative support, but they have not been proven in high deformation environments. Alternative supports are also being used in longwall recovery operations. These include the Rocprop and Omni Prop, which are extendable support systems. They also provide active roof loading which can be beneficial in these applications. Specialty supports, such as the Sand Prop and Spider Prop, have also been introduced into western longwall operations. This paper compares the performance characteristics of these various support systems.

Jan 1, 2005

By Dale S. Preece, Matthew A. Reisenmay, Avione Northcutt

The ability to simulate the explosive effects of land mines on military vehicles is a valuable capability in the defense community. The current competency levels of such simulations, however, are in need of improvement. Experiments have been conducted to measure the explosive induced impulse of a land mine on a steel plate placed above the explosive charge. The purpose of this paper is to report the findings of a variety of simulation tests conducted in order to correctly predict the empirical impulse data gathered in corresponding experiments. The computer hydrocode, AUTODYN v5.0.01 (Century Dynamics, 2003), is the simulation code used to simulate, and process the results. The experimental data has not been made available to allow computer analysts to exercise their codes on the problem without the temptation to tweak parameters in order to match computer code predictions with experimental results

Jan 1, 2005

By C Kocsis, G Baiden, Y Bissiri

CANMET-MMSL and Penguin Automation Systems Inc have been exploring how process simulation and ventilation modelling software, when combined, can be used to optimise hard-rock/metal mine ventilation systems. In combination, it is anticipated that this methodology will facilitate the exploration of mine design options that affect ventilation requirements and ultimately cost. Such integrated mine design could limit, and possibly reverse, the drivers that under current practices would generally dictate increased ventilation, power consumption, cost and greenhouse gas emissions. It is believed that the mining industry needs such process models to develop better business cases. For example, the implementation of optimised ventilation systems will undoubtedly require significant investment and mines are often reluctant to try such conservational measures unless they can be proven cost-effective. In general, Canadian hard-rock mines know their ventilation systems are providing too much air and consuming power unnecessarily. This is because their systems are designed to provide maximum production flexibility, based upon peak demand, which may be at some future time, and operated continuously at that level regardless of actual need. Simplistic analyses have shown electrical energy savings can range from 30 per cent through to 90 per cent (Hardcastle, Gangal and Leung, 1998). These savings depend upon such factors as the intensity and continuity of the production schedule as opposed to non-productive time. Where these savings occur is also important, if limited to either the primary or auxiliary ventilation systems, they could be negligible in a mineÆs total energy consumption. The problem these mines face is determining what level of ventilation is required in real-time and then the relative benefits. Such parameters as varying electricity costs, heating fuel options, different design criteria and their complex inter-relationship can effect the selection of an optimal system, depending on whether energy, environment or cost is the prime driver. The use of process simulators in underground mining is in its infancy; to date they have been used to show the benefits over the life of a mine under different mining methods, such as a comparison of tele-remote mining from surface against conventional manned operation (Baiden, 2000). This ongoing development advances the use of such simulators into a new and potentially important area, namely modelling the life-cycle ventilation requirements of a mine. This paper shows how such a life-cycle analysis as opposed to peak demand can provide the basis for optimising the design of ventilation systems and their control.

Jan 1, 2005

By Jeffrey D. Winterton

Keywords: Copper, ion exchange, sulfonic acid, bis-picolylamine, ion exchange modeling, ion exchange kinetics As part of an investigation into the feasibility of using ion exchange resins to recover copper from aqueous waste streams generated during the manufacturing of semiconductor devices, the uptake of copper onto two ion exchange resins was investigated. The resins studied were DOWEX G-26, a standard gel type sulfonic acid resin, and DOWEX M4195, a macroporous chelating resin with a bis-picolylamine functional group. The equilibrium and kinetic behavior of the uptake of copper were investigated over a range of copper concentrations with constant sulfate concentration and different levels of acidity. The homogeneous structure of the G-26 resin yields equilibrium relationships that fit the Langmuir equation, and equilibration times of less than 30 minutes. The uptake behavior of M4195 is complicated by the need to absorb co-ions to maintain electroneutrality, resulting in uptake profiles that change character with increasing copper concentrations, and extended equilibration times.

Jan 1, 2005

By S KandT

The FalTmT iron ore deposits are located in the so-called æBirrimianÆ volcano-sedimentary complex that extends in a general NE-SW direction across eastern Senegal and part of Mali and Guinea. The rocks underwent folding and greenschist facies metamorphism, as well as various events of granitoid emplacement. The deposits form part of the DialT-DalTma Series of the Birrimian Supergroup and were subjected to contact metamorphism. The Fe-mineralisation occurs as primary magnetite within the metamorphic aureole. Supergene oxidation (martitisation) of this mineralisation produced the hematite-rich iron deposits that can be seen as prominent hills across the plains of this south-eastern corner of Senegal. BRGM of France and Miferso (SociTtT des Mines de Fer du STnTgal-Oriental) have conducted several phases of prospecting since 1957. Their aim was to delineate the hematite deposits and to assess the grade, beneficiation characteristics and marketability of the iron ore. A feasibility study by Fluor Daniel was completed in 1992. Results indicated that, at the time, the resource could not compete in the international arena in terms of size and accessibility. The growing iron ore market and additional available resources in the area now challenge the 1992 feasibility study results and put the old kid back on the iron ore block. The project faces some mining challenges, such as the amount of magnetite in the hematite product that will be acceptable to the market. Previous project evaluations only considered the secondary hematite deposits as economically viable. It is therefore important to accurately delineate the magnetite/hematite contact zone to optimise the resource tonnage. Project logistic constraints also exist in terms of railway access and harbour facilities. The resource is, however, well situated for the European iron ore market and aims to find a place in the rapidly expanding iron ore seaborne trade.

Jan 1, 2005

By R. M. S. Häggblad

The article deals with stabilisation and regeneration of Ce02 and Ce02/Zr02 based Pt water gas shift catalysts, subject to high initial deactivation. The reaction gas species effect on the catalyst deactivation was investigated by H2-TPR. Activity measurements enabled the effect of different promoters, some added to the Ce02 based catalysts and some to the Ce02/Zr02 based Pt catalysts, to be investigated. The catalysts were also characterised by BET and CO-TPR. Deactivated catalysts activity was restored by using various regeneration methods. Of the two selected carriers the Ce02/Zr02 based Pt catalyst showed the highest resilience to deactivation. For the two different carriers, Ce02 and Ce02/Zr02, Wand Re were the best promoters when the catalyst was subject to deactivation. Experiments with Hr TPR indicate a fast initial change in the platinum oxides concentration and composition. The CO-TPR was used to make conclusions about the various regeneration effects of water and oxygen on the catalyst. Finally it is suggested that not one deactivation mechanism is possible and which mechanism that dominates is dependant on the catalyst and the reaction gas composition.

Jan 1, 2005

By C J. Noack, P B. Ganza

The concept of large trucks underground has been around for some time. While the road train concept is gaining momentum, there are underground mining applications where these trucks have not been suitable. Unfortunately few of the ægreenfieldsÆ projects that are most suited to the road train concept have come æon lineÆ since the underground road train was first introduced to Australia in 2001 so that the trucks have generally been adapted to existing operations. As at December 2004, there were 17 road trains operating underground in Australia, one being rebuilt and one under construction. This paper addresses the necessity for the mining industry to have an integrated ore transport system that starts at the underground load haul dump unit (LHD) in the stope production area and finishes at the crusher feed at the processing plant. Chute and orepass designs are investigated, as well as feeders to determine the best load and haul system for large-scale trucking. The paper also discusses potential developments in the large truck scene. The paper highlights the cost and productivity gains by introducing large trucks and associated integrated ore transport systems underground. While 400 vertical metres was seen as the limit of vertical hauling in the 1970s, one kilometre is a common discussion point for trucking limits today. In real terms the cost of underground trucking (including ownership costs) has decreased from $1.50 - $2.00/t.km in the mid-1990s to $1.00 - $1.20/t.km at present.

Jan 1, 2005

By R. B. Nourse, R. Hundermark, B. Masters, H. Joubert

The new 30 MVA slag cleaning furnace at Waterval Smelter, Rustenburg Platinum, South Africa, has been in operation since 10 March 2003. The furnace design and operation face a number of challenges including a wide variety of feed materials and resulting bath conditions. Furnace feed varies in combinations of granulated Waterval Ausmelt Converter Slag (WACS), hot fed Peirce-Smith converter slag, concentrate and reverts. Coke is added as reductant. The resulting slag composition varies considerably and regularly. For the case feeding WACS an almost pure fayalitic slag (60%+ FeO, 30%+ SiO2) with a very low viscosity results. Due to the widely varying slag conditions, including a superheated fayalitic slag with high fluidity, a robust sidewall design is required adjacent to the slag bath. For this reason the furnace sidewall is equipped with Pyromet's MAXICOOL® high intensity copper cooling system. The design and installation of the copper coolers as well as tap holes are discussed. To cope with the variation in bath conditions and high slag superheat (350°C when tapped at 1650°C), the copper coolers are capable of removing peak sidewall heat fluxes above 500 kW/m2. Feedback is included on the performance of the Pyromet MAXICOO® copper cooling system for the first two years of operation. The paper further includes an overview on the design and performance of the tap holes, furnace shell, furnace roof and copper slag spouts.

Jan 1, 2005

By Jaime E. Sepúlveda

Semiautogenous grinding (SAG) operators have been realizing the very significant impact of fresh feed particle size distribution on the mill grinding capacity. In actual practice, this impact may be quite difficult to assess because of the natural process variability that may also involve- concurrently other critical factors such as ore hardness. Recognizing the limitations of the empirical approach, the current publication proposes the use of mathematical models and simulators to explore and assess the net effect of feed particle size only, independent of any other factors. The simulation analysis here reported provides a basis to claim that the size distribution of the particles being ground (simply characterized by a % - 2" or similar measurement) is one of the most relevant controlling variables of the overall mill performance, regardless of the SAG circuit configuration.

Jan 1, 2005

By Kevin Whipkey

How is Improvement Being Achieved ? Section Equipment ?Mine Layout/Projections ? Work Schedule ? Maintenance ? Management

Jan 1, 2005

By M Xu and, P F. Wells, A N. Kerr, Y Shields

Triethylene tetramine (TETA) has been used in combination with sodium sulfite (sulfite) for pyrrhotite depression at Clarabelle Mill since 1998. This combination has been highly successful at reducing pyrrhotite levels in the bulk (Ni/Cu) concentrate. Although highly effective, the roles of TETA and sulfite are not well understood. Treating bulk samples of the circuit feeds through the miniplant enabled the effects of circuit configuration on the performance of the pyrrhotite rejection circuits at Clarabelle to be determined. Reasons for the different performance of the non-magnetic pyrrhotite rejection circuit in the miniplant were investigated and tested in the laboratory. The effect of different grinding environments in the laboratory was examined to better understand the depressing mechanisms of TETA/sulfite. Modification of the grinding chemistry improved the selectivity of pentlandite over pyrrhotite in the presence of TETA/sulfite at current plant dosages.

Jan 1, 2005

By M, C A. RosiFre, R C. Figueiredo e Silva

Jaspilites and underlying basalt contacts of the Archaean volcano- sedimentary Grpo Parß Group, Carajßs, host giant iron mineralisation in the ~100-km long, E-W trending Carajßs fold. Preliminary, unpublished geochronological data point to a Palaeoproterozoic mineralisation event. Geochemically, jaspilites are typical volcanogenic banded iron formations. Basalts exhibit evidence of spilitic seawater interaction. Iron-associated hydrothermal alteration of mafic rocks was induced by fluid infiltration in amygdales, with development of chlorite- and hematite-dominated zones. In the case of jaspilites, iron mineralisation encompasses: partial replacement of jaspilitic microcrystalline hematite by blasts of martitic magnetite; jasper recrystallisation, producing fine-grained, hematite-free granoblastic quartz; martite recrystallisation, forming lobate¦subhedral hematite; pervasive porosity development by quartz-chert leaching; incipient cavity filling by microlamellar hematite; and advanced filling by coarser, euhedral and comb-textured, tabular- shaped hematite.Peak hydrothermal ore textures indicate typical epithermal-crust conditions, supported by preliminary fluid-inclusion calculations at 160 - 200¦C. Such temperatures and extreme fluid-to-rock ratios during alteration must have exceeded the ambient metamorphic conditions, with the infiltrating fluid relatively hot and capable of leaching SiO2. Therefore, mineralisation developed over exhumed, Archaean, brittly deformed rocks, with mineral associations representative of very low- to low-grade metamorphism. Considering that chlorite (¦talc) abounds in mafic rocks; hydrothermal albite is developed; dolomite fills veins and vugs; the typical rare-earth-element (REE) pattern of jaspilites is significantly modified in higher-grade hard hematite ores (higher LREE); pyrite, copper sulfide minerals and rare gold occur in association with carbonate-quartz-rich alteration zones, it is suggested that an alkaline, H2O-Fe-CO2 mineralising fluid dominated, also containing species like S¦Cu¦Au. Peak-mineralising conditions are likely to have resulted from a single, evolving fluid, via incipient- through advanced-stage alteration phases. The porous, high-grade soft hematite-type ore (SH), rich in microlamellar and anhedral hematite, must have derived from interaction with this relatively hot SiO2-leaching fluid, whereas the high-grade massive hard hematite-type ore (MH) developed due to closer fluid-rock temperature equilibrium conditions, attained by mineral reactions, with relative increase in the Fe/Σcations ratios allowing the precipitation of subhedral-tabular hematite that partially cements the soft-hematite ore. SH and MH hematite ore types must thus reflect intermediate and high fluid:rock ratios, respectively. Since the N5 deposit is to date understood to contain the largest amount of the MH ore, its units are interpreted as the loci of the highest fluid:rock ratios in the district. Preliminary mineralogical information regarding the S11 deposit of the Serra Sul (south range) implies higher-temperature conditions. The near-equant grain size and the granoblastic intergrain relationship, coupled with the presence of riebeckite, augitic pyroxene and garnet, suggest hornfels textures. The data collected, though still relatively sparse, permit the speculation that the immense driving force for the Carajßs world-class iron deposits was a relatively shallow, igneous-related hydrothermal system. If such a model is correct, then the Carajßs Palaeoproterozoic iron deposits could represent an end-member of the iron oxide-copper-gold hydrothermal system in the province.

Jan 1, 2005

By P. Cienfuegos, J. Loredo, J. J. Fernández, F. Pendás

This coal basin is a fore-deep basin with a lot of similarities with the Appalachian basin in the U.S.A., where throughout the 1990s, the research in coalbed methane grew rapidly due to a combination of factors, including the high prices for gas and electricity. In the Asturian Central Coal Basin 129 coal beds with thickness ranging from 0.8 to 1.5 m have been recognised in the productive carboniferous in an area bigger than 1500 km2. The maturation grade of these coals varies from the external zones of the basin where the volatile content ranges from 35%-40% to 20%-30%, to the internal zones of the basin where the volatile content ranges from 20% to 10%. In this context a sustainable exploration for fossil fuel is currently being undertaken in the most favourable areas of the basin in order to evaluate the real possibilities for coalbed methane (CBM) resources.

Jan 1, 2005

By M. E. Austin

Many numerical models for the tubular solid oxide fuel cell (SOFC) exist, with various degrees of sophistication. However, the question of what physics must be modelled, and what can be neglected has not been resolved. A parametric model is proposed and analyzed to quantify the influence of thermal phenomena such as reaction heat generation, cathode channel convective cooling, and thermal radiation with participating media. Currently, a three-dimensional model is used to simulate the conditions of an anode supported cell in the centre of a tube bundle. The interconnect and nickel foam spacers that bridge adjacent cells in series and parallel, respectively, are neglected thus enabling a domain consisting of a 45o azimuthal section of the tube. The conservation equations for mass, energy, and species transport are solved using commercial computational fluid dynamics software, and radiation heat transfer is also modelled using a Discrete Ordinates method. Finally, temperature-dependent material properties and reaction rates are used. The model predicts lower overall temperatures than models that do not include radiative heat exchange and more moderate temperature gradients than those that ignore participating media radiation. Further, different regimes are identified, from convection dominated heat transfer to radiation dominated heat transfer. The results can be used to aid in the selection of appropriate models for a given fuel cell operating regime.

Jan 1, 2005