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By Tony Rorke, Sydney Thabethe

A large overburden blast was carried out at Douglas Colliery, Middelburg Mine Services, close to a national road in South Africa. The road is a busy route between Witbank and Bethal and damage to the road could not be risked. The section of road next to the blast was particularly prone to damage, because it had been mined out on its eastern flank, and the large blast was to take place on its western flank. There were thus three potential damage risks: 1. Fly rock damage to the road surface 2. Vibration damage to the road substrate 3. Damage caused by bulk displacement of the block supporting the road into the void on the mined out side. This paper presents the design and blasting methods used to control the blast and avoid these three risks. Electronic delay detonators were used in multi-decked holes. Signature data were used to determine the blast timing to make sure that delays were used that would provide destructive interference. The timing direction and sequence was decided using wave interference patterns to direct repeated shocks away from the road. The precise detonators and the odelling capability allowed effective control of the blast vibration result. Each hole was charged with two explosive decks separated by a deck of aggregate to limit the charge mass fired per delay and thus limit the reaction forces acting towards the unsupported road. The vibration and blast results are presented in the paper, together with the design that was applied. Details are provided on how the blast was charged and primed. The detonators that were used are described and the timing design is presented.Copyright © 2004 International Society of Explosives Engineers 2004G Volume 1 - Blasting Next to an Unsupported Road Using Electronic Detonators 1 of 13 It is concluded that damage risk to nearby structures can be effectively controlled using electronic delay detonators, provided the appropriate modelling is applied to obtain the most effective delay periods.

Jan 1, 2004

By B. J. Bluck

Diamond mega-placers, in order to rank amongst the primary diamond deposits, are defined as => 70 m carats at =>95% gem quality. There is only one mega-placer known and that is found along the coast of southwestern Africa fringing the Kaapvaal craton. Placers are classified as residual when they are left on the craton, transient when being eroded into the exit drainage and terminal. Terminal placers, in being the final depositories of diamonds off the craton, have the greatest probability of being a mega-placer and such is the case in the placer deposits near the Orange River mouth, southwestern Africa. There are four main groups of conditions leading to the development of a mega-placer: the craton, the drainage, the nature of the environment at the terminus and the timing. The craton, in its role as the producer of diamonds is significant in respect to its size, diamond-fertility, the degree to which diamonds from successive kimberlite intrusions have been retained there and their availability to the final drainage yielding the mega-placer. Cratons in being buoyant have a tendency to leak diamonds into surrounding basins but in being incompressible often have orogens converge onto them resulting in lost sediment being returned as foreland basin fills. In order to concentrate a bulk of diamonds the drainage basin has to be large with a high proportion of it on the craton. The drainage yielding the mega-placer should ideally not have been preceded by older drainage and other systems that may have robbed the craton of earlier diamonds. The exits of diamonds from the craton need to be few in order to focus on their supply and the drainage network needs to be efficient in order to remove the maximum volume of diamonds off the craton. This efficiency and the focused termination is best achieved by the rejuvenation of a pre-existing drainage network. The drainage should be young enough to yield host sediments friable enough to allow brittle diamonds to be recovered from them.

Jan 1, 2004

By S Thomas, E Grimsey

Mining education in Australia has undergone another cyclical downturn over the past five years and several departments have been discontinued while others are still teetering on the brink of destruction. During this downturn Curtin UniversityÆs WA School of Mines (WASM) has managed to stay alive and well, but this has not been by accident. This paper outlines some of the strategies and experiences that have kept WASM in a strong position and offers hope to other departments and schools elsewhere that are still experiencing difficulty. This paper is also directed at all mining departments and schools that are certainly going to see it all happen again after the next mining boom turns to bust.

Jan 1, 2004

By N. Tsuchida

Sumitomo Metal Mining Co. Ltd. (SMMC) is currently developing the flowsheet to treat stockpiled limonite, a type of laterite ore, at Rio Tuba on southern Palawan Island, Philippines. The new plant will be commissioned at the end of 2004. Rio Tuba Nickel Mining Corporation (RTNMC) has been mining saprolite since 1977, and the limonite ore located above the saprolite ore body has been stockpiled separately according to nickel and magnesium content. Ore from these stockpiles will be blended and used for the operation. The annual production of nickel will be 10,000 metric tons for the next twenty years. The proposed process consists of ore preparation, high pressure acid leach (HPAL), counter- current decantation wash, impurity removal and sulfide precipitation. Precipitated mixed sulfide will be processed to electrolytic nickel by the Matte Chlorine Leach Electrowinning (MCLE) process at Niihama, Japan. SMMC has established new technologies during the process development, such as zinc removal and sulfide precipitation. Applying this technology, preferential removal of zinc can be achieved by hydrogen sulfide gas with negligible loss of nickel. Precipitation of nickel by hydrogen sulfide gas is carried out at low temperature. Slow kinetics is selected for control of the particle size of the precipitated mixed sulfide. Keywords: HPAL, Zinc Removal, MS Production

Jan 1, 2004

Sasol Roche Blasting Services (SRBS) and its former owners have been in the process of developing and utilising low-density explosives over the last ten years. Many blasts have been fired in varying strata types in a number of mining operations. This has led to a good understanding of the product and the best methods to exploit its characteristics when designing blasts. Unlike some other low-density products, SoftLOAD« is a homogeneous mix that is easily handled and able to be loaded at high load rates. This paper discusses the physics of SoftLOAD« low-density explosives and how through correct utilisation, blasting outcomes can be significantly improved. It also touches on the various side benefits that can provide the blast designer with a more controlled blast.

Jan 1, 2004

By J. Daavittila, P. Jokinen, M. Honkaniemi

In the latter part of the 1980?s Outokumpu Chrome in Tornio, Finland, was in a situation when its twenty-year-old ferrochrome plant was becoming inefficient to sustain economically sound production. The company made extensive studies on the then available processing methods to find out the best possible processing route. As a result the whole plant was practically rebuilt and expanded. When equipment was proven in practical operation an application for FeMn production was developed. Now when Tornio FeCr-plant is considering the expansion the same type of exercise is to be performed with today?s challenges, which will be discussed in the paper. These challenges include increasing costs or decreasing quality of raw materials, increasing energy costs, stricter environmental regulations and demand of better working conditions. The possibilities to respond to these challenges will be discussed in the paper. The future and continuing development with FeCr includes the better utilization of process dusts and a lower consumption of energy. By adapting the latest automation tools to better control of the process even higher efficiencies can be achieved with present technology. New processes are considered for development in the future and some possible technologies will be described.

Jan 1, 2004

By R. A. Hodge

Over the past decade, there has been a significant increase in effort put to tracking progress toward sustainability. Many aspects of society are participating in this “movement” including mining. The drivers are diverse and include evolving ideas in business and public administration as well as concerns for human well-being, community robustness, environmental integrity, and overall social and ethical responsibility. The scale in question varies greatly from local to global. For the most part, there has been a pre-occupation with developing discrete measurable signals. This paper argues that the overwhelming focus on the quantitative is ill-advised and that a more effective approach is to bring together the best of both quantitative and qualitative. The mining industry in particular is well-placed to affect this shift and reap the associated benefits.

Jan 1, 2004

By L. A. Anestiev

A method based on use of calorimetric data for the determination of solidification kinetic parameters is proposed. The method incorporates recent theories of nucleation and growth and allows modeling heat fluxes observed in calorimetric experiment. Statistically optimal estimations of the kinetic parameters, which include the activation's energies of nucleation and growth, are derived from experimental data by means of nonlinear regression analysis. The method is applicable to pure substances and alloys. The evaluation of the kinetic parameters characterizing solidification of pure Al is used for clarifying and exemplifying the method.

Jan 1, 2004

By P. Cheung, J. Gulyas, R. Clary

Over the past 50 years, the use of autoclaves in the metallurgical industry has evolved from final metal recovery (hydrogen reduction) and purification (sulphide precipitate oxidation) to treating whole ores and concentrates. Recent process developments, such as the use of autoclaves for laterite leaching, have necessitated higher temperature and pressure operations, which in turn have seen marked advancements in technology and manufacturing capabilities to keep in step with process demands. This paper will discuss the advances in technology in terms of design, materials and construction of autoclaves and liners, typical dip tube design and geometric layout. This paper will also address specific auxiliary equipment, such as acid and steam injection systems, and components, such as agitator seal systems.

Jan 1, 2004

By Kia Riihioja, Mike Higgins

A major difference between electronic and pyrotechnic detonators is that, in almost all but the simplest of blast layouts, computer software is required to plan a blast using electronic detonators. While it may be possible to program delay times without software, using only the manufacturer’s control hardware, the full potential of electronic detonators can only be realized through software. Until recently, the only software available has been provided by the suppliers of the electronic detonators. These usually have just enough features to create a hole layout and to assign times to the detonators in the holes. The software is also able to communicate only with the manufacturer’s detonators. This means that the client may be compelled to change several parts of the blasting process when a different delay system is adopted, from design through to implementation and reporting, even though these may be sub-optimal at the client’s mine. While many authors have demonstrated improvements in blasting outcomes using electronic detonators, very few have discussed how the delay times were calculated. Where the calculations are discussed, it is also obvious that the delay times must be monitored and re-evaluated as conditions in the mine change. For example, the principles of superposition and scaled distance, burden relief and energy cooperation between holes should be checked constantly for different locations within the mine, changes in rock properties, or even for differences between design and actual hole positions. The most common methods in blast design software to calculate delay times are inter-hole interval, relief contour and direct editing. Although they are simple in concept, they can result in fundamental errors if they are not applied correctly. The software for electronic blast designs should be capable of not just a timing calculation, but also of showing, to some degree, the impact and interaction of the calculated times.

Jan 1, 2004

By Muhammad Tawalbeh

The calculated temperature history of a single particle of MgCl2 hydrates when it came in contact with fused salt electrolyte at 650 °C was determined using the measured heat transfer coefficient for the molten salt bath at 650 °C. The calculations revealed that the entire interior of the particle reached the temperature required for the formation of MgOHCI from hydrated MgCl2 in less than 2 seconds. This was much less than the time required for dissolution of the prills as observed in experiments. It is very likely that the formation of MgOHCI during prill dehydration and dissolution is a result of hydrolysis in the interior of the prills.

Jan 1, 2004

By Vladimiros G. Papangelakis

During the past five years, chemical modelling work at the University of Toronto has elucidated the role of soluble magnesium on the autoclave acidity and has demonstrated why feeds rich in magnesium, and other divalent metals, require more than the stoichiometric requirements in acid to produce a leaching performance comparable to that of low magnesium feeds. This understanding has allowed the calculation of acid additions to the pressure acid leach (PAL) on a less empirical basis. Optimizing acid additions to the PAL confers savings in neutralization costs, ensures high productivity and minimises corrosion problems. Hence, our picture of the solution chemistry inside the autoclave during the PAL process has been substantially improved and is reviewed here. Experimental techniques based on solubility and direct acidity measurements that support the theoretical predictions are presented. Concepts of chemical modelling of electrolyte systems at high temperature and software issues are also discussed. Finally, a better understanding of the solution chemistry at temperature has led to better kinetics models because all metal dissolution and precipitation reactions are acid driven and controlled. . Therefore, reactor modelling efforts by our group are also presented and a reactor model with very good performance, as compared to pilot-plant data, is also made here. Finally, in spite of the above success in PAL solution chemistry and reactor modelling, significant challenges lie ahead in theoretical data gaps and instrumentation; these are also discussed in this paper. Keywords: Laterites, process modelling, pressure acid leach, solution chemistry, chemical modelling, reactor simulation

Jan 1, 2004

By M. Patel, G. Djambazov, J. Shrimpton

"Removing zinc by distillation can leave the lead bullion virtually free of zinc and also produces pure zinc crystals. Batch distillation is considered in a hemispherical kettle with water-cooled lid, under high vacuum (50 Pa or less). Sufficient zinc concentration at the evaporating surface is achieved by means of a mechanical stirrer.The numerical model is based on the multi-physics simulation package PHYSICA. The fluid flow module of the code is used to simulate the action of the stirring impeller and to determine the temperature and concentration fields throughout the liquid volume including the evaporating surface. The rate of zinc evaporation and condensation is then modelled using Langmuir's equations. Diffusion of the zinc vapour through the residual air in the vacuum gap is also taken into account.Computed results show that the mixing is sufficient and the rate-limiting step of the process is the surface evaporation driven by the difference of the equilibrium vapour pressure and the actual partial pressure of zinc vapour. However, at higher zinc concentrations, the heat transfer through the growing zinc crystal crust towards the cold steel lid may become the limiting factor because the crystallization front may reach the melting point.The computational model can be very useful in optimising the process within its safe limits.IntroductionLead bullion is commonly refined by removing various impurities (e.g. copper, silver, bismuth, antimony, etc) sequentially. This in normally achieved by the addition of reagents which selectively react with the impurities and the resulting compounds removed by various means. To aid efficient mixing (ensure uniform reactions), batch mixing of materials via the aid of impellers is common practice in a number of industrial sectors. Excess zinc, added during the desilvering process can be removed by one of three methods: (1) Vacuum dezincing - During vacuum dezincing, a vacuum is drawn on the agitated molten lead within a hemispherical vessel (Figure 1). Vaporized zinc condenses on the inner top surface of the vessel. The temperature at which zinc commences to vaporize lowers owing to heating under a vacuum. This enables vaporized zinc to be recovered in the form of high purity crystals without oxidation. The zinc crystals are recovered once the vessel lid is removed and the vacuum is broken. (2) Chlorine dezincing - In chlorine dezincing, molten desilvered lead is reacted with chlorine gas, forming a surface layer of zinc chloride contaminated with small amounts of lead chloride."

Jan 1, 2004

By J. Best, K. Gallant

This paper explores the age-old concept of mine-mill reconciliation from a new perspective. Advances in reconciliation processes have been slow to materialize because in the quest for “rightness”, engineers, geologists and metallurgists have become entrenched in their viewpoints, dutifully performing to the metrics and expectations imposed upon them by the siloed organization. Moreover, reconciliation has not been viewed as a primary value creator, but an accounting non-value added task. In reality, the knowledge from reconciliation can significantly enhance yields. Critical review of the direct variables (tons, grade, etc.) and other less-obvious variables (incentives, communication, etc.) reveal a complex web of barriers to be cleared by management in order to realize benefits. Also, mineralogical reconciliation methods may offer renewed faith in the process.

Jan 1, 2004

By D. C. Panigrahi

Extensive field studies have been carried out to investigate the pillar fire problems in one coal mine in India. A Thermal IR gun and a Thermovision camera have been employed for thermal scanning to assess the state of heating in selected pillars. Special sampling set-ups have been designed to collect gas samples from the holes drilled into the selected pillars and the multigas detector is used to analyse the composition of samples in situ. In order to predict the spontaneous heating in coal pillars, different gas ratios have been calculated and it has been observed that some of the established gas ratios, viz. Graham?s ratio, Young?s ratio etc. have resulted in negative values in samples containing high amounts of methane. The modified gas ratios have been proposed which will be useful for predicting the pillar fires. These ratios may also be used for assessing the condition of fires in sealed-off areas.

Jan 1, 2004

In a ætypicalÆ gold deposit each tonne of ore will contain tens of millions of very fine gold particles, whereas; at Bendigo the majority of gold in each tonne of ore is present in just five to 15 very coarse gold particles, a distribution more akin to diamond deposits. At Bendigo the minimum sample size required for good assay repeatability is estimated at 4.5 t for each assay. Drill core samples are several orders of magnitude too small to generate representative assays.The drilling data are characterised by a nugget effect approaching 90 per cent, a very skewed distribution and, on average, under-report in situ grade by 50 per cent to 75 per cent. Since 2002 Bendigo Mining NL has completed 47 000 m of diamond drilling, 1200 m of on reef development, collected and processed 100 bulk samples (150 t each), 800 mini bulk samples (50 kg each) and processed in excess of 25 000 t of ore through a pilot plant. The results of this work have provided the information required to develop and verify a robust grade estimation procedure. No standard geostatistical manipulation of the drilling assay data can generate an accurate grade estimate as the samples and associated assays are not representative of the ore being sampled. The recognition of this fact was critical as a radical transformation of the raw drill assay data was required to develop a workable methodology for grade estimation in such a high nugget environment. The aim of the transformation was to reduce the nugget effect and high variance and so approach a lognormal assay distribution. Ideally the average drill grade would approximate actual in situ grade and the assay distribution would reflect actual grade distribution within the reefs. Following the data transformation simple block modeling within the defined resources allows grade estimates to be made that can be used in the estimation of Indicated Resources and hence Probable Reserves. The grade estimates have been checked by extensive bulk sampling and processing of 25 000 t of ore (three per cent of total resource) through a pilot plant with planned full scale mining to provide the ultimate verification.

Jan 1, 2004

By Randy Wheeler

In recent years the issue of seismograph calibration and accuracy has been a major focal point of the ISEE Blast Vibration and Seismograph Section. In fact, questions concerning the consistency and reliability of seismograph measurements essentially led to the development of this ISEE section. One of the early actions of the section involved the development of “Field Practice Guidelines” for the use of seismographs. These guidelines specifically state that “Placement and coupling of the vibration sensor are the two most important factors to ensure accurate ground vibration recordings.” This paper will address the results obtained from using different coupling methods to record vibration and airblast levels generated from production blasting in a limestone quarry. The data obtained clearly indicate that seismometer burial provides the best coupling for recording ground vibrations. Microphone height has also been an issue regarding the accuracy of recorded airblast levels. The data we obtained indicates that microphone height is not a significant factor.

Jan 1, 2004

By M. Hosseinzadeh

By changing the quality of consumed refractory bricks in burner zone of sarcheshmeh copper complex anod kiln removing of carbon precipitation phenomenon was studied. For blister deoxygenation LPG is blowing in anod kiln and cause destoring microsturcture and bonding of refractory bricks. Studies are shown that in a part of the bricks which have a temperature of 800 - 1000 °C , iron content phases in magesia - chromite bricks are like catalist and cause increasing the rate of carbon precipitation reactions . In a way that in comparsion of two bricks with best and medium quality with different analysis, this problem is more critical in best quality bricks containing high iron oxide. Therefore special magesia spinel bricks suggested and installed in burning zone.

Jan 1, 2004

By R. A. L. Drew, G. Mendoza-Suarez, J. Filipi, R. Vintila, J. A. Kozinski

Economics and environmental considerations along with the increasing demand of hydrogen encourage development of novel technologies such as plasma processing of hydrocarbons and thermal cracking of natural gas. Plasma discharges, either in thermal or non-thermal regimes are expected to allow low temperature and fuel flexible on-site hydrogen generation. The main drawback of thermal plasma reformers is the high-energy consumption resulting from high-temperature operation. On the other hand, non-thermal plasma, generated by dielectric barrier discharge (DBD), is able to simulate the chemical reactions employing much lower energies than those required by thermal treatment processes. The non-thermal plasma process allows for instance, a direct conversion of methane into hydrogen and carbon black with no CO2 release. The focus of this research was on the GHG-free method of H2 generation in compact non-thermal plasma reactors using low, medium and high permittivity dielectric ceramics. A stable, non-thermal plasma was generated by placing a dielectric ceramic between two electrodes with a 25 thou gap and applying an alternating current of 1-5kHz and voltages of 4-8kV. In order to ensure energetic efficient plasmas, experiments were conducted to analyze the behaviour of different permittivity ceramics. It was found that the dielectric properties of a ceramic, when used in a DBD reactor, have a strong influence on the discharge characteristics, which in turn influence the power consumption. Higher dielectric constant resulted in higher conversion rates of methane (higher yield of hydrogen and carbon). At the same time, the mechanical properties of the dielectric material, which are closely associated with its processability, influenced its resistance to electron bombardment, as well as thermal and mechanical damage. Therefore a reliable ceramic should have good dielectric properties, in addition to good thermo-mechanical stability.

Jan 1, 2004

By E. Bane Kroeger

Rib failure is a hazard that has resulted in many injuries and fatalities in underground coal mines, especially in soft coal seams. Conventional rib control methods including rib boarding, shotcreting. steel meshing and geogridding, are fairly expensive and time consuming to install. Some methods, such as rib boarding, have met with marginal success at controlling rib failure. Under this research, the Rib Strap System (RSS) introduced by Dr. Chugh in 1999, was modified and new components were added. Both bench scale and full size prototypes were tested in the labs at SIUC to determine the best materials for fabrication and easier methods for assembly and installation. This laboratory research has developed new methods of securing the strap ends to smaller rib hoards, a new device to post-tension two straps together, and a technique for replacing straps without having to drill new rib bolts or for retrofitting straps to rib hoards that are already in place. The method used to secure the strap end to rib boards developed during bench-scale testing was dubbed the wrapped staple technique. It is very simple, requiring only 10-15 staples, with the end of a strap secured to a rib board in about 45 seconds. Several different prototype designs for a new device to join the strap ends together and tension the strap were fabricated and tested in the labs at SIUC. The device, dubbed the rib strap buckle, was very easy to install and held the straps firmly. One specific buckle design worked extremely well during testing and exceeded all expectations. The laboratory research also developed a method of replacing a damaged rib strap that can also be used to add rib straps to existing rib boards. The technique uses nails, spacer blocks, and band clamps to secure the new board and strap. This technique was developed to allow one person to replace a strap using only a hammer and screwdriver, negating the need to drill and install a new rib bolt using mine equipment such as a roof bolter or scoop. In addition to the technical feasibility, the cost of materials for the rib strap system was compared to the rib boarding method currently being used at a mine in the Illinois Basin. The mine is using 20 rib boards on each pillar at cost of about $223.60. The costs for the rib strap system depend on the materials chosen for fabrication but for the base case, were about $97 per pillar.

Jan 1, 2004