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By M Paakkunainen

Sampling is often the most critical part in process analysis. When the mean of a continuous lot, such as a process stream within a given time interval, is estimated by calculating the mean of several samples, the uncertainty of the estimated mean depends usually on the sampling strategy. Three different strategies can be used: systematic, stratified or random sample selection. The standard deviation of the lot mean is different for these methods so that systematic sampling usually gives the smallest and random sampling the largest standard deviation. Pierre Gy developed a method where the sampling errors of one-dimensional lots for these three strategies can be estimated from a variogram, which is calculated from a variographic experiment, ie from a set of one-dimensional time series measurements with fixed sampling interval. While variogram is an excellent tool for characterising and displaying the variability of autocorrelated processes as function of time, the sampling error estimation from it is quite laborious, however. In this work an alternative method for estimating the sampling errors was developed. The process is divided into strata of equal sizes, varying the length of strata similarly to variographic analysis. For stratified sampling the standard deviation estimates are obtained by analysis of variance and for systematic sampling by fitting a linear regression line to each stratum and calculating the residual variances. By pooling the individual variance estimates the variance estimates that are corrected for autocorrelation are obtained. The new method was tested with simulated and real data sets having periodic, random and/or drift fluctuations. For stationary processes the results agreed well with the results of the GyÆs variographic method. The method can probably be generalised to estimate the sampling variance of higher-dimensional lots.

Jan 1, 2005

By C J. Adams, H J. Campbell, T Popham, A Goodall

Pounamu is a MSori collective term for semi-precious stone scientifically referred to as nephrite, semi-nephrite, jade or bowenite (tangiwai) that is composed predominantly of metamorphic tremolite in a felted, fibrous texture. It is Aotearoa/New ZealandÆs icon mineral material. Ownership and management of this important taonga (treasure) has been vested in Te Rnnanga o NgSi Tahu as part of a Treaty of Waitangi settlement process. Increasing demand from the tourist, jewellery, fashion and sculpture industries, as well as cultural renaissance, has placed pressure on the pounamu resource. This had led to nephrite importation, allegations that foreign material is being marketed falsely as New Zealand pounamu, and wider concerns over the potential for exploitation/over-use and theft of genuine pounamu.   Research is underway to characterise different pounamu source regions by defining their ægenetic fingerprintÆ. The geological age and radiogenic isotopic composition of Aotearoa/New Zealand pounamu is distinguished from other nephrite jade occurrences overseas, due to relatively young cooling ages. Strontium isotope ratios distinguish pounamu from different source areas within Aotearoa/New Zealand (whakapapa), with signatures reflecting the host terrane rocks (their family) and their position in a sequence of metamorphic events (their generation). The research will provide a tool for archaeological research, trademark and resource protection.   Mineral resource assessments normally aim to define the total volume/tonnage present, which is generally assumed to be finite, applying drilling and geostatistical modelling. Pounamu resource assessment requires a different approach, as its intrinsic value is insufficient to warrant modern exploration methods (eg drilling, geophysics). Pounamu is only known to occur at a restricted few in-situ (hard-rock) localities. It is primarily found in transported (alluvial) detrital river and glacial outwash deposits, where collectable material has short term variability due to erosion and transport processes. A new methodology is being developed aiming to define: +        the total resource present, +        the relative rate of change in the availability of that resource through erosion and other geological processes, +        active areas where new material is likely to be exposed (eg by erosion), and +        appropriate extraction rates for sustainable use. The methodology will provide a holistic overview of the resource in different regions of Aotearoa/New Zealand, and may be applicable to other transient or restricted natural resources that occur within geologically active environments (eg supplies of driftwood on beaches).

Jan 1, 2005

By R. K. Filip

"Steel bearing piles have long been used to carry high compressive, tensile and lateral loads. Such piles are most commonly tubular or ""H"" profile and are typically installed using percussive techniques. The noise and vibration associated with such installation techniques tends to preclude the use of steel bearing piles in urban and other sensitive areas.This paper describes the design and construction of an innovative new road bridge in Milton Keynes, UK. The steel bearing piles were required to continue out of the ground to form the bridge columns and abutments and then be cast directly into the soffit of the reinforced concrete bridge deck. This project was to be the first time in the UK, that this form of bridge design had been used.The paper shows how new installation techniques allowed the designers to use these high capacity steel elements in a sensitive urban environment without the use of percussive or vibratory installation techniques. Finally the paper shows how these quiet and vibration-less installation techniques can be extended to other applications.A UNIQUE BRIDGE SUPPORTED ON ""BOXED SHEET PILES""CONCEPT HISTORYThere are over 700 bridges in Milton Keynes. Concrete is the dominant construction material, most are single span with massive parallel wing wall retaining abutments. All have a certain uniformity of aesthetic design. Pell Frischmann Consultants Ltd (PFC) proposed to the client, English Partnerships (EP), that an ""integral bridge"" with a slender open appearance would be an appropriate aesthetic form for a new highways bridge, within the district of Westcroft (figure 1). The concept required that the bearing piles be continued up out of the ground to form the bridge columns and abutments. Four rows with four piles in each row were suggested. Each would then be cast directly into the reinforced concrete bridge deck forming a moment connection (figure 2). This concept meant that a single continuous steel structural member would replace traditional reinforced concrete bored piles, pile caps and piers. This member would carry vertical and lateral loads. The conceptual design was intended to meet the following client requirements:"

Jan 1, 2005

By D. P. Roberts

This paper reviews the use of crush pillars on mines in the Bushveld Complex and the Witwatersrand Supergroup. Stress measurements were undertaken in order to determine the residual strength of these crush pillars. The results from these stress measurements are compared with previous attempts to determine the residual strength of crush pillars using back analysis. It is concluded that the residual strength of such crush pillars lies in a band between 13 MPa and 25MPa. Using the data from the stress measurements, as well as published and unpublished data, a stress-strain curve for a crush pillar with a width-to-height ratio of 2:1 is proposed. Where further work is required, this is indicated in the text.

Jan 1, 2005

By Jisheng Han

Interaction effect exists when two or more neighboring seams are mined. The mining activity in one seam causes stress redistribution and strata movement in both the roof and floor. When the thickness of interburden between two neighboring seams is small, some hazardous situations like roof cutters, roof falls, floor heave and rib spalling in one seam may be encountered due to the effect of the mining activity in the other seam. An investigation about roof cutters, roof falls and floor heave was conducted in a West Virginia mine to study the interaction of multi-seam mining. The mine is mining the Sewickley Seam, which is about 90 ft above the Pittsburgh Seam which was mined in the 1960's using room and pillar method. The roof falls and other stability anomalies of entries observed underground in the Sewickley Seam were found closely related to the location of barrier pillars and gas well pillars left in the Pittsburgh Seam. Then numerical modeling was carried out to check the interaction between these two seams of mining. It was found through the modeling results that in the areas where pillaring operation was conducted in the Pittsburgh Seam, the stress concentrated less in the Sewickley Seam while near the edge of the gas well pillars and barrier pillars, high stress concentration was observed. It was concluded that under the geological conditions of the study mine, the entries stability would be affected by the lower seam mining activity, especially above or around the edges of pillars.

Jan 1, 2005

By Mark Ioli, Debra Struhsacker

In September 2004, Gale Norton, U.S. Secretary of the Interior, presented the Manhattan Mine with a U.S. Bureau of Land Management’s 2004 Hardrock Mineral Environmental Award. The Manhattan Mine is a sustainable development showcase. The reclamation accomplishments at this Nevada gold mine demonstrate how modern reclamation techniques can restore an old mining district into an aesthetically pleasing landscape that can support multiple and sustainable uses. In a collaborative effort that relied on substantial community involvement, Round Mountain Gold Corp.(RMGC) has improved the environment and eliminated a number of public hazards associated with old, unsafe mining features. RMGC’s community collaboration, innovative engineering, creative reclamation design and corporate commitment to environmental excellence show what Secretary Norton’s 4 Cs Initiative looks like on the ground and inaction.

Jan 1, 2005

By John J. Sammarco

Computer-related accidents have caused injuries and fatalities in mining as well as other industries. Normal accident theory (NAT) explains that some accidents are inevitable because of system complexity. NAT is a classic argument in organizational sociology although it has been criticized as having imprecise definitions and lacking criteria for quantifying complexity. These limitations are addressed by a unique approach that recasts this organizational theory into an engineering-based methodology to quantify NAT complexities of computer-based systems. In this approach complexity is categorized as external or internal. External complexity is defined by the external behavior of a system, and is quantified by these dependent variables: system predictability, observability, and usability. Dependent variable data contain the perceptions of 32 subjects running simulations of a system. The system?s internal complexity is characterized by modeling system-level requirements with the software cost reduction (SCR) formal method. Model attributes are quantified using 15 graph-theoretical metrics?the independent variables. Five of 15 metrics are correlated with the dependent variables as evidenced by structure correlations exceeding 0.25, with standard errors <0.10 and a 95% confidence interval. The results also show that the system predictability, observability, and usability decreased as NAT complexities increased. This research takes a step forward in operationalizing NAT for computerized systems. The research benefits mining and other industries as well.

Jan 1, 2005

By M. D. Vance, G. R. Corbett, S. D. Butt

Surface wave imaging is a relatively new seismic technique that generates subsurface depth images without having to drill boreholes into the ground, and is rapidly becoming a standard tool in non-destructive geotechnical characterization. This paper presents a case study of the application of these surface wave techniques to image shallow abandoned mine workings at the Montague Gold Mines district near Dartmouth, Nova Scotia. This district has numerous steeply dipping narrow vein workings from historical mining activity, and has actively subsiding and collapsing crown pillars. Due to the rugged conditions at the site and the relative narrowness of the openings (often less than 1 m), a surface seismic system was developed that had improved portability and lateral resolution over other available seismic imaging systems. Seismic surveys were conducted over two sites where independent evidence indicated the presence of shallow mine workings. At one site, a comparative gravity survey was also conducted. The seismic data was processed to generate velocity vs depth images. Overall, the velocity images show vertical zones of zero velocity in the same lateral positions where historical mapping, current subsidence and gravity surveys indicate the presence of steeply dipping workings. Further, the velocity sections are consistent with the thickness of the till cover at each site and the possible weakening of crown pillars at one of the sites.

Jan 1, 2005

By D. Caiden, C. S. Covil, P. J. Chamley

The paper describes the background to alternative delivery models, drawing on international experience, and introduces Project Alliancing/Contract Partnering, common risks and risk sharing on tunnel projects. A plea for early contractor involvement in design is made before describing some whole life design implications for tunnels. The paper concludes with four short case studies; Channel Tunnel Rail Link in the UK, Hull Waste Water Tunnel in the UK; Island West Sewage Transfer Station in Hong Kong, and the New Southern Railway in Australia.

Jan 1, 2005

By Martin Herrenknecht, Karin Bäppler

The last five years have seen a remarkable increase in tunnelling projects in both soft ground and hard rock applications. Part of the increase is a result of recent Research & Development efforts to improve Tunnel Boring Machine (TBM) adaptability, capability and reliability. This paper will review the latest innovations in the TBM industry and explain in detail the results of these innovations followed by a forecast where the technology will take the tunnelling industry in the future.

Jan 1, 2005

By K Uchino, M Inoue

Self-potential anomalies are generated by fluid pressure gradient, by temperature gradient or by chemical gradient. On the basis of this principle, a new technique is proposed to locate the fire source of spontaneous combustion of coal by the self-potential method. In order to investigate whether this method can be applied to locate the spontaneous combustion of coal in practice, surveys of self-potential distributions were undertaken in a coal waste pile undergoing spontaneous combustion. The results showed that there is a negative centre of the electrical potential distribution in the measurement area. The potential in this centre is about 140 mV lower than that in the surrounding area. Moreover, the negative centre of electrical potential distribution almost overlaps with the high temperature zone. Therefore, it is concluded that it is possible to locate the heat source by the measurement of self-potential distribution.

Jan 1, 2005

By C. Garcia, C. L. Lin

Characterization and analysis of multiphase particles and/or particulate systems (such as the packed particle bed) are of great technological importance for mineral processing applications. In general the performance of these applications depends on the statistical characteristics of particle microstructures, such as composition distribution, surface exposure of mineral grains, pore network structure, etc. For continued technological progress in the field of multiphase particulate processes, the need for quantitative spatial analysis of multiphase particles in three dimensions has increased sign6cantly. Such quantitative information must be accurate enough that the measured values can be used as parameters for simulation models, process design procedures, and control strategies. Modern 3D image-acquisition techniques, such as X-ray microtomography (XMT), offer a unique imaging capability that can produce high-resolution (a few micrometers) three-dimensional images of the internal structure of multiphase particulate samples. These three-dimensional image data present new challenges for image analysis, image processing, and visualization. Furthermore, important issues should focus on how to use the 3D information and derive new insights into the improvement, design, and operation of mineral processing processes. In this paper, utilization of XMT for characterization and analysis of leaching process involving multiphase particulate system is discussed.

Jan 1, 2005

By Lawrence Williamson, Randall J. Essex, David P. Field

As part of a $2.2 Billion bridge project that will link Indiana and Kentucky, an interchange project northeast of Louisville will require the mining of a 6-lane tunnel system about 2,000 ft long in order to cross beneath the historic Drumanard Estate. This paper will discuss preliminary engineering that has been undertaken to compare two-bore and three-bore layouts, the planning of an exploratory tunnel facility, and the potential for including a test chamber to investigate the ability of high capacity roadheaders to mine the 22,000 psi limestones.

Jan 1, 2005

By Ian Hooper, Alan Winter, Stefan Sadokierski, Craig Covil

The existing Tappan Zee Bridge was built in the late 1950s and has been working over its design traffic load for some time now. A new project, which is being jointly sponsored by the New York State Thruway Authority and Metro-North Rail Road, is looking at new alternatives to provide new road and rail crossings of the Hudson River. These include 2 to 5 mile and potentially longer tunnel crossing options that include hardrock TBM and EPBM opportunities. The paper describes the project needs and tunnel concept design work done on some of the alternatives. It also relates to the current EIS process for the project and talks about a possible double-stacked tunnel option. It also talks about the geology and environmental constraints relating to tunneling and provides and introduction to the tunnel ventilation work necessary for tunnel crossing of this magnitude. It does not report on the bridge engineering options being evaluated.

Jan 1, 2005

By K Hines

Anglo Platinum is the worldÆs largest producer of platinum group metals, and also produces large quantities of nickel, copper and cobalt at its Refining complex in Rustenburg, South Africa. In 1995 Anglo Platinum embarked on a smelter modernisation project, primarily to reduce site emissions to below the guideline limit of 20 tonnes per day SO2, but also to increase the converting capacity in line with future projected production profiles. To achieve these requirements the existing Pierce Smith converters were replaced with a single large Ausmelt converter and a new acid plant. This was the first time that an Ausmelt furnace had been used for converting, but it had the advantages of being a very robust furnace and was fully enclosed, giving good gas capture. It was thus considered the most appropriate technology from both a process and an environmental perspective. It also enabled the smelting and converting furnaces to be decoupled. The plant was commissioned from late 2001 and the first tap was in June 2002. Despite being a new technology, ramp-up has been similar to other large scale pyrometallurgical operations. Numerous process improvements have been made since start-up, most notably a change from two-stage batch to fully continuous, resulting in the plant now operating above design in terms of throughput. Optimisation of freeboard accretion control was also a major component of the ramp-up activity. This paper discusses the commissioning and ramp-up issues of the new Ausmelt converting furnace, concentrating on the design and process changes, and summarises current operating performance against the original design objectives.

Jan 1, 2005

By M Devia, J Rapkoch

This paper is intended to help design engineers, operating staff and plant managers understand the principles of metallurgical gas handling systems design. It also explains operating, safety and energy savings issues that the designer should take into consideration in the design of process off-gas systems for sulfide smelters. Primary smelting reactors, converters, and other off-gas sources impose challenging duty requirements on the various components of the gas handling systems. This paper reviews the design of common system components including the hood for gas capture at the system inlet, gas conditioning, gas cleaning, ductwork, dampers, hot gas fans, and the appropriate use of instrumentation and controls. The engineer must also be aware of how ductwork system effects and heat losses influence system performance. Also, the analysis of a recently-designed gas handling system will be reviewed, which includes high-strength SO2 gas from a smelting reactor, asymmetrically located Peirce-Smith converters, and a gas mixing chamber to mix the gases before they are sent to two acid plants of different sizes.

Jan 1, 2005

By P Mavros, K A. Matis, N K. Lazaridis

A large number of techniques are in use today to limit membrane fouling, among them certainly is air bubbling (which constitutes the transport medium in flotation) as applied in wastewater treatment; meanwhile, dispersed-air flotation is suitable as a pretreatment stage for microfiltration. The invented and investigated hybrid cell combines the advantages of both flotation and membrane separation, while overcoming their limitations, producing clean water from industrial wastewater. Metals recovery from dilute aqueous solutions is a promising application of this innovative hybrid process of flotation and microfiltration, further to solid/liquid separation. In this study, ceramic flat-sheet membrane modules were inserted inside a typical flotation cell in the laboratory tests, using multichannel geometry, combining flotation with microfiltration by submerged membranes; the latter requiring periodic backflushing. The specific objective was to apply this process for the efficient separation of effluents containing metal cations (here, zinc). The main examined parameters were: the initial metal concentration, flotation surfactant applied and air flowrate. The successful contribution of precipitate flotation was highlighted, while the observed metal removals were of the order of ~100 per cent.

Jan 1, 2005

By M Biesinger, R St C Smart

Diagnosis of the surface chemical factors playing a part in flotation separation of a value sulfide phase requires measurement of the hydrophobic and hydrophilic species that are statistically different between the concentrate and tail streams. Statistical methods, based on the monolayer-sensitive time of flight secondary ion mass spectrometry (ToF-SIMS) technique, have been developed towards this ultimate aim by measuring hydrophobic species (collector ions, dimers and metal complexes, polysulfides) as well as hydrophobic metal ions, precipitates and added depressant species. Reliable identification of specific mineral particles is central to this statistical analysis. A chalcopyrite/pyrite/ sphalerite mineral mixture conditioned at pH 9 for 20 minutes to study transfer of Cu from chalcopyrite via solution to the other two mineral surfaces, since this mechanism can be responsible for their inadvertent flotation in copper recovery, showed no statistical difference in the copper intensities on pyrite and sphalerite (selected from Fe and Zn images) after this conditioning. Principal component analysis (PCA) identifies combinations of factors strongly correlated (positively or negatively) in images or spectra from sets of data. In images, PCA selects these correlations from the mass spectra recorded at each of 256 ¦ 256 pixels in a selected area of particles. In the image mode, PCA has proved to be a much better method of selecting particles by mineral phase with clearer definition of particle boundaries due to multi-variable recognition. It has clearly separated a statistical difference in copper intensities between the sphalerite and pyrite phases. The PCA method has been applied to concentrate and tails samples collected from the Inco Matte Concentrator demonstrating extensive CuOH and NiOH transfer between the chalcocite (Cc) and heazlewoodite (Hz) minerals. Statistical differences illustrate the important discriminating depressant action of NiOH in flotation despite the activation of Hz by Cu transfer. The adsorption of the collector at specifically-identified Cu sites has been elucidated by the study. Importantly, the statistical analysis has been able to confirm some mechanisms and deny others proposed to control recovery and selectivity giving more focus on the control factors.

Jan 1, 2005

Fluorspar was not mined in the United States during 2004, although a small amount of usable synthetic fluorspar (CaF2) was produced from industrial waste streams. The majority of fluorspar consumed in the United States came from imports or stockpiled material purchased from the National Defense Stockpile (NDS). In addition, consumption is supplemented by use of by-product fluorosilicic acid produced at phosphoric acid plants. In 2004, annual production of fluorosilicic acid was 50kt (55,000 st) or about 88 kt (97,000 st) of 92 percent fluorspar equivalent. In 2004, annual production of fluorosilicic acid was 50kt (55,000 st) or about 88 kt (97,000 st) of 92 percent fluorspar equivalent.

Jan 1, 2005

By O N. Savassi

A rigorous methodology for prediction of flotation plant performance is presented, which is based on a standardised batch flotation test called the MFT. The work is part of the FLEET program, developed by MinnovEX with the support of seven large mining firms. The methodology is divided into three key steps: direct measurement of the kinetics of true flotation in the pulp, independent of hydraulic entrainment and other froth effects in the batch cell; benchmarking of the industrial plant over a broad range of ore types and operation conditions; and model calibration to describe froth effects in the plant, with a minimal number of parameters. To date, the methodology has been applied with success at several industrial plants, encompassing copper, gold, nickel, iron, lead, zinc and coal operations. This paper includes a description of the laboratory testwork procedure and scale-up to full industrial circuits. Examples of industrial application are also presented.

Jan 1, 2005