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Although Mn, Fe, Cu, Ni, and Co have been the main interests since the ferromanganese nodules had been found, the other major components such as Si and Ca might be very important controlling factors in the processing due to the locally variable content. It is because of the fact that SiO2 and CaO are added to decrease the smelting temperature in the reduction-smelting method for manganese nodule processing. We have compiled the 707 chemical data for KODOS (Korea Deep Ocean Survey) ferromanganese nodules, which have been acquired from 1994 to 2001 and have been also standardized from 2001 to 2003 to avoid the discrepancy between the data sets. All 707 chemical data were used for the hierarchical cluster analysis to get the elemental correlations and also classified by the morphological types. The averages from each station were classified by the facies groups (Fig. 1) and the localities. Then all data are plotted on the SiO2-CaO-MnO phase diagram at 1773°K to compare with the best compositional area in the nodule smelting. Variations and distributions of SiO2 and CaO as well as those of Mn, Fe, Cu, Ni and Co in KODOS ferromanganese nodules were also reviewed. The mineral phases assigned by the cluster analysis are CFA (Carbonate Fluorapatite), Fe-oxide, Al-silicate, and Mn-oxide. MnO contents are generally higher than SiO2 contents in most of the morphological types except for the Is- and It-type. The Dt- and Tt-type show wider range and the E-types show high anomaly in their CaO contents. The stations which belong to facies group A and B show generally higher MnO contents than SiO2 contents, however, the stations of facies group C and D show wide range in their MnO and SiO2 contents.

Jan 1, 2004

By A. Lopez-Valdivieso

Particle size enlargement processes play an important role in solid/liquid separation, and in beneficiation unit operations. In the latter, not only the size of the formed aggregates but also their surface properties are very important. Oil agglomeration has a special place among such processes: it is a selective process in which hydrophobic particles are agglomerated into hydrophobic agglomerates which can be recovered by flotation. This explains the broad applications of oil-assisted beneficiation processes not only in the beneficiation of fine coal, but also in agglomerate flotation of many different types of ores, and in coal/gold agglomeration.

Jan 1, 2004

"The development of non-destructive testing (NDT) methods for deep foundations occurred in several parts of the world, gradually coming together into the present state of the art. The compilation of this brief NDT history is the best effort of several knowledgeable members of the Deep Foundations Institute (DFI) Drilled Shaft Committee, coupled with the recollections of several historically important contributors to the science. It is not intended to be exhaustive, but rather concentrates on the origins of the methods in common use and on which this manual focuses.Modern NDT methods, and the spread of knowledge about them, have expanded through application to real foundations projects by the original researchers, sometimes inspired by their own curiosity, sometimes to respond to the cost and time limitations imposed by static testing, and sometimes to address the questions raised on research projects funded by large government agencies such as the Federal Highway Administration (FHWA) in the USA, and various European transportation agencies. Initial attempts were primitive by today’s standards, and equipment limitations often restricted successful application to relatively simple cases. As electronics improved and confidence in them increased, the early researchers began commercial promotion of their methods, published their findings in professional journals, and shared experiences at conferences held by such groups as the DFI, the International Association of Foundation Drilling (ADSC), the International Conferences on the Application of Stress-Wave Theory to Piles and other venues such as ASCE and Transportation Research Board (TRB) conferences.NDT methods were developed to fill a need to assess the quality assurance of deep foundation elements. New pile types and higher design loads prompted engineers to verify the safety of their foundations via additional testing during construction. Static load testing was the traditional method to assess performance, and this method has been used for centuries and perhaps even millennia.Relatively recent alternatives to static load testing for determining the capacity of drilled shafts include the bottom load test method. This method uses a jack embedded in the lower portion of the pile (bottom load test) and was first reported to be used from Canada in the early 1970’s (Gibson& Devenny 1973). The concept immediately caught on in Israel, where it was used as a quality control measure for small-diameter piles drilled in rock (then a new technology). The method was later patented in the US by Jorj Osterberg, and offered as a commercially available service in thelate 1980s (Osterberg, 1989)"

Jan 1, 2004

By R. M. Tyler

The importance of the heavy mineral sands to southern African economic well-being cannot be over emphasized. The value of the worldwide titanium dioxide industry is estimated at $7 billion. Six out of eight of the world?s proposed new project areas are in southern and eastern Africa, and a seventh at Tamil Nadu in India is partly owned by a South African company, Kumba Resources. The HMS industry can be highly lucrative; its return on capital is the best in the mining industry. There are, however, problems, particularly in the smelting technology. The often considerable affect of mining on environmentally sensitive coastal dunes is also becoming increasingly important. The medium-to long-term demand for Ti-dioxide pigment and ceramic grade zircon appears very healthy. If, as predicted, the costs of producing titanium metal can be reduced, then there is huge potential for the metal. In summary, the HMS industry is an attractive one to be in, with good returns and generally manageable risks. New business opportunities and their economic implications for Africa are discussed.

Jan 1, 2004

By George L. Baloo, Dave Kwiatkowski, Jose G. Cañlzales

Capital project funding for a medium to large materials handling project often includes a budget for procurement of supplier-recommended spare parts, and it is the Project Team's responsibility to select these parts. With today's economic climate, limited budget, and other factors, the spare parts selection process is a difficult and arduous effort. This decision carries with it a risk to plant operations and in some cases the commodities producers. Too often the decision-making process is not documented, and the reasons for eliminating and reducing quantities are based on "best guess " Recently on the Solids Handling Phase 2 Project in Jose, Venezuela, the Project Team took a unique approach to this problem. This paper discusses the analytical approach taken by the Project Team, the database system that was developed to manage this problem, lessons learned, and their applicability to pre- project planning and preliminary design.

Jan 1, 2004

By J. Stiksma, K. Buban, J. Oftsie, R. Kalanchey, S. Sadykov, E. McConaghy

The Kazakhmys zinc refinery in Balkhash, Kazakhstan, which employs the Dynatec Zinc Pressure Leach Process, officially launched autoclave operations on December 27, 2003. The Kazakhmys plant is the world's first greenfields zinc refinery based on Dynatec's two-stage pressure leach technology. Production of zinc was realized on February 9, 2004, when the first cathode was stripped. Currently the plant start-up is ongoing, with progression to two-stage zinc pressure leach operation and ramp-up to full design capacity continuing through 2004.

Jan 1, 2004

By N. N. Rulyov

"Starting from fundamental principles of colloid-hydrodynamic theory of disperse systems we have shown that application of strongly non-uniform hydrodynamic fields allows to achieve not only faster rates of flocculation of suspension, but also supports significant improvements in the quality of clarified water and separation characteristics of solid phase. Specifically, it has been experimentally proven that the new treatment method based on these principles (then termed as ""ultra-flocculation"") allows:•,Increase the output of thickeners and pressure filters by 1,5-1,7 times;•,Decrease solids fall through into the filtrate in the process of vacuum filtration by 2¬3,5 times;•,Improve the rate of purification of water phase in the upright thickener by 1,5-1,9 times;•,Decrease flocculant consumption by 1,5-3 times;•,Increase the effective operational life time of cloth filters by 3-4 times;•,Ensure sustainable operation of separation equipment, i.e. decrease the sensitivity of process to variation in suspension concentration, as well as to variations of suspension composition and dispersion characteristics;•,Apply flocculant solutions of concentration 2-3 times higher, thus increasing the capacity of equipment used for solutions preparation."

Jan 1, 2004

By V. P. Mehrotra, D. W. Fuerstenau, A. -Z. M. Abouzeid

The use of pulverized coal for electric power generation results in the production of vast amounts of fly ash. One potential use for waste fly ash is the production of pellets for lightweight aggregates. This paper is concerned with the role of the physical and chemical characteristics of two different fly ashes in governing their agglomeration or pelletization behavior and their strength characteristics. In batch balling experiments, fly ash pellet growth was found to be extremely sensitive to the amount of moisture added. One ash (Mohave) exhibits marked pozzolanic activity whereas the other (Jim Bridger) does not. The pozzolanic activity has a very pronounced effect on pellet growth kinetics, moisture requirements, and the effect of various additives on growth kinetics. Slow drying under ambient conditions produces strong pellets from Mohave ash whereas Jim Bridger ash pellets lacking in pozzolanic activity are weak. Rapid drying at high temperatures results in weak pellets because water necessary for hardening is driven out of the pellet. Steam curing enhances pellet strength. Locked-cycle pelletizing experiments exhibit expected oscillation in pellet production rates and attendant fluctuations in pellet green strength.

Jan 1, 2004

By John C. Wilmot, Robert E. Brewer, Royce J. Smith

In March 2003, Phelps Dodge started up an innovative pressure leach facility for processing copper concentrates at the Bagdad mine in Arizona. This paper describes the development of the concentrate leaching plant at Bagdad and the operational results from start up to present. Optimization efforts and an approach to mineralogical modeling of the concentrate to calculate oxygen utilization are also presented.

Jan 1, 2004

By W. J. Birch

The dedicated documenting of blast design and vibration monitoring results forms part of the best practice methodology for today’s blasting operators. This allows regression curves to be constantly updated and in turn compatible charge weight determinations are based upon the most current data. The point can arise however when so much data becomes agglomerated that variations in blast design, geology or monitoring location response and their effects can pass unobserved and start to have an adverse effect on the forecasting capability of the regression due to a deterioration of the standard error statistic. The simple solution would be to only compile like-for-like blasting returns, but this prospect can quickly become unworkable due to the number of potential variables. In addition it is very difficult to spot subtle variations by simply examining a standard scaled-distance curve mainly due to the intrinsic data scatter that is always present together with the logarithmic nature of the regression curve. If indeed a variation is thought to be apparent, how can the degree and magnitude of its influence to be quantified? The Likelihood Ratio Test when applied to regression data can diagnose subtle variations between data sub-sets and provides a comparative statistic as to the degree of variation. By analysing datasets in such a way, levels of compatibility are obtained, indicating which sets can be combined in order to increase prediction capability.

Jan 1, 2004

By Stephen L. Chryssoulis, Stamen Dimov

"Preg-robbing has been known for many years, where increased losses are suffered because dissolved gold is removed from solution by adsorption onto carbonaceous matter. In direct cyanidation circuits it is reasonable to conclude that the preg-robbed gold is either in a gold cyanide [Au(CN) - 2, AuCN] or metallic [Au°] form. However, in circuits with a pre-oxidation step possibilities increase and multiply even further because of water recycle streams containing apparent and not-so-apparent gold ligands. It is in these circuits where speciation of sorbed gold, i.e. the identification of the gold compound, is useful. The importance arises from the fact that proper identification of the sorbed gold species can be used to determine how, when, where and why gold was removed from solution, thereby identifying the exact cause of the problem and providing clues as to how it may be rectified.INTRODUCTIONTo the best of our knowledge, this is the first attempt ever to speciate gold preg-robbed by carbonaceous matter using a surface sensitive microbeam technique. This approach enables the direct determination of gold species sorbed on carbonaceous particulates, opening an entirely new field in the understanding of the chemistry of gold sorption on carbon. The reasoning behind this effort was to add to the current knowledge of the detrimental effect chloride ions have on gold recovery by the pressure oxidation and in particular why in the ensuing CIL step, gold is not being desorbed from the surface of the carbonaceous particles (Table 1)."

Jan 1, 2004

By Charles R. Barnhart

The Nitrogen Dioxide Cloud: After one year of testing it can be stated that we do know and understand a great deal about why the nitrogen dioxide formation is exacerbated in cast blasting. Picture 1 is an example of how concentrated the NOx can be from a cast blast. It has long been felt that 300 or more milliseconds of timing needs to be put between each row of detonations to allow the rock a maximum time of flight so the cast percentage is high. Our experiments have found that higher cast percentages can make with timing between 150 to 200 milliseconds between rows. Picture 2 show a definite improvement in nitrogen dioxide concentration and most of that was the result of shooting a previously shot end of the cast pattern that had not been dug, thus no confinement of the powder columns.

Jan 1, 2004

By Bonifacio Degay, Mike Lovitt

PT Freeport Indonesia is a block cave mine that now utilizes an advanced undercut method to set up the min in the Deep Ore Zone (DOZ). In this method a slice of rock (undercut) is broken such that it sits on top of the drawbell level. The drawbells are developed to channel the broken ore into the extraction level and to enable the caving orebody to be drawn out in an even and controlled manner. These drawbells are difficult to form due to the small amount of void that can be developed in the low strength rock before firing. Starting with two rises of 2m square, the void ratio for the entire drawbell around 6%, which would normally result in a frozen and unproductive blast. Orica -Mining Services have worked with PT Freeport in a collaborative effort to find a solution to the mining problem. With excellent control of timing of the blasting it is possible to get fluid flow of blasted rock out of the draw points such that more void can be made available for blasting the remaining parts of the drawbell. The i-konTM electronic blasting system gives the exacting control of timing within the blast to achieve this Dynamic Void Generation (DVG). The solution stops the need to charge close to brows in the drawbells and reduces the cost and time related to developing initial blast voidage. This paper identifies the results of the trials including design, photographic evidence and vibration analysis. The flexibility and accurate timing of this electronic blasting system has enabled single hole initiation rather than 4 or more holes being initiated together, thereby reducing the damaging vibrations to the extraction level.

Jan 1, 2004

By D. Emadi

The ASTM B108 Mould and a Modified Mould were used to cast test bars under a variety of conditions: mould and pouring temperatures, mould coating and tilt. Mechanical properties were determined in the as-cast and heat-treated conditions. The ASTM Mould is less sensitive to casting variables. Enlarging the gating system and adding additional gates to the ASTM mould can improve properties in the tilt position. The reproducibility of properties in as-cast and T6 heat treated bars was investigated.

Jan 1, 2004

A bearing isolator is a noncontact, nonwearing, permanent bearing protection device. It has a rotor and a stator, and the two are unitized, so that they do not separate from one another while in use. The rotor turns with a rotating shaft, while the stator is pressed into a bearing housing. The two components interact to keep contamination out of the bearing enclosure and the lubricant in. Bearing isolators do not require lubrication or any particular shaft finish or condition. The best bearing isolators are made of metal, usually bronze. They use a vapor-blocking feature that inhibits the free transfer of vapor contamination when the rotating equipment is cycled on and off.

Jan 1, 2004

"Full time inspection of drilled shafts by qualified personnel is a necessary part of construction. Detailed inspection procedures for routine inspection are provided in the Drilled Shaft Inspector’s Manual, published jointly by the DFI and ADSC: the International Association of Drilled Shaft Contractors.The use of NDT methods or other observation methods, such as probes, video camera inspection, remote shaft wall inspection devices or various calipers are not suitable substitutes for routine "topside" construction inspection as described in the Drilled Shaft Inspector’s Manual. However, these NDT and other "remote" or indirect observation methods are valuable alternatives to direct entry of personnel into drilled shaft excavations. They should be considered whenever appropriate to reduce the risks of direct entry of personnel into drilled shaft excavations.As described in the Drilled Shaft Inspector’s Manual, observations made during construction are essential for quality construction of drilled shafts. The shaft depth, diameter, plumbness, bottom conditions, reinforcement, concrete continuity, and bearing conditions are most easily checked during construction. Some of these observation methods include excavation around the shaft for relatively shallow inspection, down-hole inspection for end bearing conditions or rock sockets, and video camera devices for remote inspection. In rare circumstances, a drilled shaft can be extracted for inspection. Before concrete placement, the bottom of the shaft can also be probed by drilling or coring to determine if there are voids or soft zones in the material at the base of the shaft.The Drilled Shaft Inspector’s Manual focuses on traditional "topside" inspection for routine drilled shaft construction."

Jan 1, 2004

By David R. Macedon

"Through the years, a wide variety of dust control methods have been utilized at mineral processing operations. While some have been successful, many have been highly ineffective. Dust Control systems currently in use include baghouse systems, fog systems, surfactant spray systems, and foam dust suppression. While baghouse systems can be effective, they are capitalintensive and costly to operate and maintain. Chemical dust control programs can be very effective. However, if applied incorrectly, they can have detrimental effect on mineral recovery. Thus, many operations utilize a combination of baghouses and water, often with limited success.Recent advancements in surfactant and polymer chemistry have resulted in substantially improved chemical dust suppression programs. These products range from non-corrosive surfactant/humectant combinations for road dust control to foam-based systems for crushers and transfer points, to advanced polymers for pile binding and soil stabilization. These advances are discussed in detail, citing results from fieldwork in the precious and base metals industries.INTRODUCTIONThe global nature of the mineral processing industry presents a unique set of challenges. Traditional thinking would tell us what works in one place should work in another. This could not be further from the truth in the area of dust control. We learn very quickly that there are a number of factors that can affect the efficiency and success of a dust control program and that these factors are not all chemical or equipment related. Some of these factors include facility maintenance, product selection, water quality and characteristics, and economic considerations.What has been learned from past experience is that each mineral processing plant presents a unique set of factors that will affect the ability to create an optimal dust control program. This paper presents a myriad of treatment options that will highlight the advancements in chemical dust suppression products and equipment."

Jan 1, 2004

By A. Abdollahi

Modification of the silicon in Al-Si alloys can be performed by adding a very small amount of some elements like Na, Sr and Ca to alter the form of silicon from an acicular shape to a fine fibrous one. This modification results in a considerable improvement in mechanical properties especially elongation, Metallographic observations in A356 alloy indicated the degree of the modification with Na, Sr and Ca, They showed that the effect of Ca as a modifier is not as strong as is Na or Sr while Na is the most effective modifier, Although modifiers improve mechanical properties, they also increase porosity in castings, The reduced pressure test (RPT) and Tatur test showed that the increasing porosity with Na is the most and with Sr is the least.

Jan 1, 2004

By J. Walker, G. E. Kim

Since May of 2000, Mogas Industries, in partnership with F.W. Gartner Thermal Spraying Co. and using the services of Perpetual Technologies, has invested time, energy, and resources towards developing novel ball valves for high-pressure acid-leach (HPAL) service. In addition to developing new valve designs, an aggressive coatings development effort has been undertaken to improve the protective quality of the coatings so as to enhance the performance and extend the life of valves in severe HPAL conditions. In 2001, Mogas Industries qualified and applied a nanostructured titanium oxide (n-TiO2) coating for gold and nickel/cobalt HPAL services. The n-TiO2 coating provided dramatically superior protection against abrasive and erosive wear, fared very well against high-pressure autoclave corrosion testing, and has performed well in HPAL service.

Jan 1, 2004

By O C. Aitken

Mining project developers are committed to taking on all the challenges and obligations of financial risk management. It is interesting that our current models of project finance have not changed markedly in principle for some 700 years, yet the rules which prepare the way for effective project assessment and subsequent loan management still do not seem to be well understood by project or corporate developers. Probability and gravity fill the opposing trays of the golden balance of financial risk. Understanding the relationship between these opposing, but intimately related elements is critically important for successful risk management. It is important to move beyond the qualitative approach and use quantitative methodologies to measure the financial impact of the occurrence of each major risk. We live in a world where the only constant is change and thus it is not surprising that a bankerÆs life is still governed by assessing, measuring and pricing risk. Banks are attracted to funding well managed companies with strong cash flow projects. But we are more risk averse compared with the credit appetites of late last century. This attitudinal shift has resulted in tougher term sheets for the early 21st century, encompassing more conditions, warranties, undertakings and stronger cash sweep provisions. Banks require well balanced portfolios to achieve an acceptable spread of risk, thus there is a more restricted market for small company lending than that available to large multi-project corporate entities with less concentrated risk profiles. Because of this focus, junior company debt finance remains comparatively expensive and especially so for more challenging geographical and political environments.

Jan 1, 2004