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By Sandra K. Zacharias

Brass, a deliberate alloy of copper and zinc, has been known since before Roman times. There are two main methods of making brass: (1) Cementation or calamine process - crushed zinc ore (calamine, ZnC03 , or calcined calamine, ZnO), is mixed with charcoal and small pieces of metallic copper and heated to about 900°C in a closed crucible, (2) Alloying - metallic copper and zinc are melted together in a reverberatory furnace. According to most modern authorities (e.g. Smith and Forbes 1955), the calamine process was the only one used in western Europe prior to the 18th century. At that time, the alloying technique began to take over, because metallic zinc was successfully produced on a large scale for the first time. Previously, this had been a problem because zinc vapourizes at 906°C or about the same temperature at which it can be reduced from its ore. Thus, some means had to be devised to collect and condense the zinc vapour (Tylecote 1976). Metallic zinc was known, however, earlier than the 18th century A.O. Several early finds have been made, including a rolled sheet of metallic zinc found in excavations at the Athens Agora dating to the 3rd to 2nd century B. C. (Farnsworth et al. 1949). The Chinese were producing zinc by at least the 10th century A. D. and, by the 17th century, Chinese zinc ingots were being imported into Europe by the Dutch East India Company (Needham 1974). Metallic zinc is also mentioned in several European documentary sources from the 16th century (e.g. Paracelsus, Agricola). This study traces the changes in Western brass making methods from Classical to Renaissance times by examining documentary and archaeological evidence.

Jan 1, 1999

By W. M. Williams

"Although manganese is a metal virtually unknown to the layman, it is hardly necessary to point out to the engineer the importance of manganese in modern metallurgy, an importance intimately linked with iron (and steel), the basic materials of engineering construction for hundreds of years and certain to remain so for long into the future. World steel production will approach and perhaps reach 1 billion tons/year in the 1980s; with a manganese content between 0.5% and 1 % in ordinary steels, and more in specialty steels, manganese use worldwide will soon approach 15 million tons annually. Manganese was discovered and isolated in Sweden in 1774 by Karl Wilhelm Scheele (who also discovered molybdenum), but the element was only of scientific interest for several decades. By the early part of the nineteenth century, however, manganese oxide had become commercially available and was in use for colouring glass and for the production of chlorine. Commercial application in metallurgy appears to have been limited to the manufacture of crucible (or ""cast"") steel, a highquality product made by carburizing wrought iron, and melting it in small batches to make ingots which could be rolled and used for special applications, e.g. for the manufacture of fine tools or for ""steeling"" the cutting edges of implements such as wrought iron axes and chisels.* However, it was not until Bessemer's epoch-making invention of cheap steel in 1856, and the dramatic expansion of the steel industry thereafter, that manganese assumed the importance that it holds in modern steelmaking."

Jan 1, 1999

The development of a robust belt sampling strategy and protocol inunderground gold mines is a fundamental requirement for effective grade quality control, ore accounting and mine-mill reconciliations. As part of the ore management system, a belt sampling system has been developed by the author, which is used to predict monthly gold grade and its error for underground/belt/mill reconciliation and grade control. This paper presents the step-by-step development of the belt samplingstrategy and sample preparation protocol at Target, an underground gold mine in South Africa. The belt sampling system at Target consists of an underground belt transporting run-of-mine material into an underground transfer point, a weightometer, a two stage crushing system, a tube splitter and a catchment device. The design allows run-of-mine ore on the belt to be sampled automatically by a go-belt sampler. GyÆs sampling theory of particulate materials forms the basicframework of the belt sampling strategy. The theory is used to quantify the optimum sample mass of broken material to be taken from the belt and to predict its reliability. It is also employed to determine the Fundamental Sampling Error (FSE), time interval between samples and particle size requirements of the final underground belt sample. Further, GyÆs sampling theory provides the means of analysing the crushing processes, splitting, segregation error, analytical variance, and the best sample preparation protocol. Although the belt sampling strategy developed in this study was forWitwaterstrand gold ore, the process is entirely general and may be very successfully used in any underground or surface mine.

Jan 1, 1999

By Milorad Cirkovic

Kinetics of copper concentrate oxidation in roasting processes in a fluidized bed reactor has been studied at temperatures between 600°C and 720°C using particles of 0.038 to 2.5 mm in average size. The analysis of composition of samples has been done by chemical methods. Phase composition has been determined by Siemens X-ray equipment with Cu anticathode and Ni filters at a voltage of 40 kV and a current of 18 mA. The content of sulphur has decreased from 33.23 to 19.02 mass percent with the increase of temperature, but the content of Fe304 has increased from 0.15 to 17.14 mass percent. The new mechanism of copper concentrate oxidation in a fluidized bed reactor is proposed in this study. It has been shown from the mathematical model that the velocity of oxidation of copper concentrate between 600°C and 720°C is virtually controlled by the rate of diffusion of 02 through the layer of reaction product.

Jan 1, 1999

By J. Partinen

Drying is a unit process which has numerous applications in metallurgical process industry. Kumera Technology Center, being a worldwide equipment and process supplier, has developed sophisticated solutions for both direct and indirect drying. In conventional direct drum drying, the energy is taken from combustion of fossil fuels, requiring energy input and emitting considerable amount of off gases. In modem copper smelters, thermal energy from the off gases is recovered in waste heat boilers making the steam available. Using that steam as the energy source for concentrate drying, the total volume of off gases can be considerably reduced and releasing of harmful combustion gases into the atmosphere can be avoided. Kumera Technology Center has recently developed and promotes a new steam drying process for drying of copper concentrates. In the development of the new dryer, Kumera's approach has been to combine the best properties of both the steam dryers and the drum dryers. In the design special attention has been paid to overcome problems of excessive wear and clogging and to reduce the required maintenance operations. In this paper the environmental issues and energy consumption related to both direct and indirect drying processes are discussed. The estimated operation costs and emission levels are compared, based on calculations and the data collected from industry. Finally, the development project of the Kumera Steam Dryer is briefly reviewed

Jan 1, 1999

The Northparkes E26 Mine is AustraliaÆs first block cave mine. This paper presents an outline of the design and construction philosophies that drove the project development and details the excavation, ground support and construction methods used. Features of the block caving method at Northparkes include:high production rates from multiple drawpoints;hard blocky ore fractured along gypsum veins; andloading/unloading of openings due to mining induced stresses.The drawpoints are subjected to high abrasion from the flow of ore, as well as impact from both secondary blasting and from the production LHDs. In order to withstand these harsh conditions and to ensure a low maintenance environment, a conservative approach to ground support was taken. The experiences gained during construction are discussed and whether the design expectations have been achieved. By installing a high level of ground support during excavation of the openings subject to mining stresses, a low maintenance environment has been constructed. Operating costs are therefore minimised and Northparkes E26 Mine continues to produce at the lowest cost per tonne of all Australian underground mines.

Jan 1, 1999

By R. W. Pauls

"Many tens of thousands of hectares of forested land will be disturbed and reclaimed in the surface mineable Athabasca oil sands area during the next few decades. The surface area disturbed by Syncrude’s Mildred Lake development alone exceeds 10 000 ha to date. It is not clear that reforestation of disturbed areas will best accommodate the aspirations of all stakeholders, particularly traditional users of the land. A five-year research program by Syncrude Canada Limited and the Fort McKay First Nations has examined the feasibility of raising bison on land reclaimed after disturbance by oil sands development. Forage productivity and carrying capacity for bison was comparable to that of grasslands elsewhere in Alberta. Concerns regarding compaction of newly rebuilt soil by bison traffic proved unfounded. Bison demonstrated weight gains typical for ranched bison and calving rates averaged 90%, a value typical for ranched bison. The animal husbandry problems encountered were typical of those occurring on bison ranches elsewhere in Alberta. An economic analysis indicates that a 1000 ha bison ranch on reclaimed land has a net present value that compares very favourably with a similar area supporting commercial forest. Subject to approval by Alberta Environmental Protection, the current research project will be expanded as a pilot commercial ranching venture in order to explore its commercial viability as a business venture by the Fort McKay First Nations. At the same time, measures will be implemented to resolve various regulatory issues associated with commercial bison production in the oil sands area.BackgroundSyncrude Canada Ltd. (Syncrude) is proposing, in its land reclamation strategy, a feature that is, depending on one’s background and perspective, regarded as an innovative approach to land reclamation, a threat to the regional forest industry, a creative response to aboriginal stakeholder concerns, a reneging on reclamation commitments, an opportunity to provide an ongoing economic base for postoil sands regional economy, or an environmentally unsound use of the land. These diverse and sometimes strong reactions have been generated by the proposal to introduce bison, either free-ranging or commercial ranched, to the reclaimed landscape."

Jan 1, 1999

Electronic Detonators have made significant strides over the last few years, both in quality of product and performance in different blast applications. The precision and flexibility of the SMARTDET units provides the mines with a powerful means of controlling blast results, giving both cost and productivity improvements. The SMARTDET Electronic Detonator System, robust and easy to use, has been successfully deployed over the last 18 months in improving mine productivity and creating safer working conditions in both quarrying and long-hole stoping. The key to the improvements has been the precision and flexibility of the electronic timing, and the ability of the mine personnel to grasp the concept quickly and use it effectively.

Jan 1, 1999

Hard rock TBMs are very often open machine layouts, with just a part roof shield over the front of the machine. The whole system is designed for fast face advance and the economy of the project often depends entirely on the rate of advance. Typically, hard rock conditions will demonstrate stable and good ground for a major part of the tunnel. However, short sections of crushed shear zones with clay and gouge material may cause serious time delays. Spiling rock bolting has been proven to be very efficient under such circumstances, provided the fully grouted rebar bolts can be placed in a controlled and practical manner.Environmental restrictions are becoming more and more a part of tunnel excavation projects. Even hard rock TBM tunnelling may require a strict ground water control, because of consequences on the ground surface from lowering the ground water level. Such consequences may be surface settlement, negative influence on ground water resources or damage to vegetation.Pressure injection ahead of the advancing tunnel face (in this paper named pre-injection), using microfine cement and chemical grouts, is today a proven technology. As examples can be mentioned (Garshol, 1997) about 100 km of pre-injected tunnels below Oslo City and about the same length of subsea tunnelling elsewhere in Norway. Examples from other parts of the world are also available, like below Stockholm, Sweden, the Inland Feeder project and Hollywood Metro both in Southern California.To take advantage of spiling rockbolts and pre-injection, it is an obvious prerequisite to be able to drill the necessary boreholes in the right positions and at the correct angle. In drill and blast excavation this is simple, but in TBM projects it has repeatedly turned out to be difficult. More than once owners have accepted bids containing reassurance from the contractor that the drilling method will be sorted out later. Experience shows that if ælaterÆ means after start of the TBM operation, it is often too late.

Jan 1, 1999

Over the last ten years geological and mining software products have evolved greatly. Software companies developing such products have focussed almost exclusively on the development of technical aspects of the applications, addressing geological, ore reserve estimation and mine planning problems. These specialist applications, and the many other new technologies that are being developed by a myriad of niche developers, are an essential part of todayÆs hi-tech mining operations. Technology is also being used in many other areas to improve the mining process and there is no doubt that tremendous advances are being made in all these fields. Yet there is something missing. The manner in which the technologies are used and implemented has led to the creation of many independent and inefficient æislands of technologyÆ where a variety of products from different vendors are used to address different, but related problems. Problems occur with unreliable information, data duplication, data redundancy and transferring data between applications that may be incompatible or even run on different computer platforms. These problems impede the flow and availability of information and hamper day-to-day decision-making by mine management. A solution to this problem is to take a holistic view of all the various technical applications and incorporate them into a single information technology solution. This solution must encompass all of the information requirements of a mining operation and must provide facilities that address much of the modern thinking about mine management, including strategic mine planning, value management, key performance indicators, and maintenance of a mineral balance sheet. Gemcom is developing an Integrated Resource Asset Management System (IRAMS), which is an enterprise-wide integrated computer system that encompasses various applications typically found at a mining operation. The core component of the system is a common, open, industry standard database that can be shared by many users from each of the different departments at a mine. Around that central repository are the primary applications that provide the mine with information it needs to operate. Ensuring that the information is reliable, accurate, shareable, timely and consistent will eliminate many inefficiencies, and provide significant benefits to mining companies. In turn these benefits will lead to significant improvements in decision-making, productivity and profitability for the operation. The initial version of the IRAMS system is currently being implemented at the De Beers Venetia Mine in South Africa. The system is being built around a core repository using the Microsoft æBack OfficeÆ architecture, and incorporates key technical applications from Gemcom, Whittle, De Beers Technical Team, Wenco and JKTech. The benefits of enterprise-wide systems have long been recognised in the commercial arena and enterprise resource planning (ERP) systems such as SAP, JD Edwards and MIMS are becoming commonplace in the mining industry. The more forward looking software developers and mining companies realise the need for efficient management of the information gathered during the mining process and can see that the concepts used in ERP systems apply equally to the technical applications as they did to commercial applications. The use of IT in the mining industry has expanded tremendously over the last five years as enabling technology and management acceptance has become more prevalent, and there is considerable room for dramatic growth over the next five years. The evolution of geological and mining software has now reached the stage where mines will yield the greatest returns by integrating the applications used in each area of their operations.

Jan 1, 1999

By Bernard Scheiner

A number of wells were drilled at two phosphogypsum stacks, one at P-21 owned by IMC and the other at Agrico's South Pierce Stack. Each well was sampled, and composites representing 5-ft increments were leached with synthetic rainwater to determine the extent of metal and nonmetal migration. To simulate what was occurring in the stack, composite samples were placed in a column, so that the column represented the stack in miniature form. Leaching experiments showed that both metals and nonmetals moved down the column when water was added to the top of the column. Data obtained from P-21 showed that with time the concentration of metals and nonmetals reached equilibrium values. The concentration of Ca, SO4, F, Si, and PO4 were -600 ppm,~1,500 ppm, 32 ppm, 14 ppm, and 22 ppm, respectively. Column leaching of South Pierce material, representing 0 to 55 ft of stack, showed that after 355 in. of water, the stack was near equilibrium values down to the 33-ft level. With continued addition of water, the portion of the stack at equilibrium would continue to increase and eventually reach the values observed for P-21. The test showed that the sulfate concentration of the effluent from the stack would never reach the USEPA standard value of 250 ppm. During the leaching test, it was determined that the permeability of the phosphogypsum in the columns was 0.000103 cm/sec. This number was used in the modeling. The data obtained from the leaching experiments cast some doubt on the practice of entombment now being practiced for closure of phosphogypsum stacks. The data clearly shows that with time, the amount of material leaching from the stack is low in concentration, with only the calcium and sulfate at higher levels. When a stack is closed at an existing operating plant, allowing rainwater to fall on the stack and capturing the solution in the existing pond system would eliminate the need for covering the stack, since with time the closed stack would continue to leach and at some point reach the equilibrium values of the P-21 stack. Entombment means that the leachable material in the stack will always be there and will require monitoring forever. Allowing rainwater to decontaminate the stack may be the best environmental solution to the problem.

Jan 1, 1999

By D. Brunner

System simulation is an increasingly popular technique for analyzing and improving existing as well as newly designed underground mining operations. An engineering firm that specializes in simulation helped a major metals producer build a long-range planning model of an existing underground mine. Subsequently the team adapted this model to assess technology alternatives in the design of a new mine. The two models differ in the level of detail used for modeling the development process. This paper discusses the differences in approach between the models along with the experiences gained and challenges faced during the construction and use of the models.

Jan 1, 1999

By Clayr Alexander

Stillwater Mining Co. (SMC) is engaged in developing, extracting, processing and refining palladium, platinum and associated metals (PGM)from the J-M Reef. This geological formation is located in Stillwater, Sweet Grass and Park counties in southern Montana. Associated byproduct metals include rhodium, gold, silver, nickel and copper. SMC’s current mining operations are near Nye, MT. The company is currently developing a second underground palladium and platinum mine, the East Boulder project, about 21 km (13 miles) west of the Nye operations. A 5,650-m (18,550-ft) tunnel is required to gain access to the ore-bearing horizon (J-M Reef).

Jan 1, 1999

By Jean P. Murray

The extractive metallurgical industry is a major consumer of high-temperature process heat. It is, consequently, a major contributor of C02 emissions and other greenhouse gases derived from the combustion of fossil fuels for heat and electricity generation, or from the process itself. These emissions can be substantially reduced by replacing fossil fuels with solar energy as the source of process heat. Concentrated solar radiation can supply a large amount of thermal energy to endothermic reactions at temperatures exceeding 2000 K. Another potential for C02 emission reduction exists as well. Thermodynamically, the total amount of energy required for metal production at any given temperature is the enthalpy change of the reaction, AH. Of this total, an amount equal to the Gibbs free energy AG must be supplied as high quality energy in the form of electrical work or by using a reducing agent. Many conventional metallurgical electrolytic processes and reducing furnaces are unable to add only the thermodynamically required electricaVchemical energy due to process inefficiencies. Electrical work in excess of AG for the reaction may be used to supply process heat, or excess chemical reducing agent burned to supply process heat. Besides the thermodynamic and economic drawback, this inefficiency results in excess C02 emissions derived from the combustion of fossil fuels. With these practices, energy becomes an important cost element of the metal produced. Highly-concentrated solar energy has the demonstrated potential to separate these two forms of process energies, allowing the addition of only the thermodynamically required high-quality energy while high-temperature solar process heat is provided to the reactor. Examples of metal oxide reduction processes that have been studied experimentally in solar furnaces include the production of Fe, Al, AI/Si alloy, Mg, Zn, Tic, Sic, CaC2, TIN, Si3N4, and AIN by carbothermic reduction of their oxides, and the high-temperature solar- electrothermal reduction of ZnO.

Jan 1, 1999

By M Lentz

This paper will discuss the issues associated with blasting in an urban mining environment that have been addressed by Winstone Aggregates at the Mt Wellington Quarry. These issues include - control of vibration and air overpressure, repeatability of shot performance, fragmentation on an extremely low maximum instantaneous charge, compliance with Territorial Authority regulations and perception. Over the last two years, in order to address these issues, Winstone Aggregates have undertaken a programme of continuous improvement, which has included; ò implementation of new technology; ò revising site procedures; ò conducting an investigation into the structural response of local buildings; ò investigating safe extrapolation; ò extensive public consultation; ò establishing credibility during the consent process; ò identification of perception issues; and ò building relationships and trust with neighbours. The issues addressed at the Mt Wellington Quarry have increasing significance for traditionally rural mining operations, as the input of the local community being urban or rural, increases. New and existing operations have the potential to adopt best practice now, building trust with the community and raising the profile of the industry.  

Jan 1, 1999

By W. J. Schlittler

Auxiliary Equipment pumping systems to support primary, secondary and regrind grinding circuits will be the primary focus of this paper. Every grinding system is unique and requires special design considerations for proper application of pumps to transport mill discharge. To satisfy the majority of applications, a new series of pumps has been developed by Svedala, known as World Class Pumps. Selection of these newly developed pumps for each type of grinding circuit will be presented. Specific components of selection are materials of construction, piping system, classification method, material characteristics and slurry characteristics. Both horizontal and vertical pump applications will be reviewed with emphasis on rules of pump piping and sump design.

Jan 1, 1999

By John L. Watson

Many metals-based industrial processes experience limitations in their operations due to an inability to effectively separate solids and liquids where partidesizes are less than 25 microns. Steel plant sludges ,generated, from the cleaning of furnace off-gases represent a typical example of processing difficulties attributable to material characteristics, and recycling or even efficient disposal of these materials is often a major problem. The use of a magnetic field to augment the traditional mechanisms of vacuum dewatering has, been demonstrated in previous work to have significant value in separating solids and 'liquids, where the solids exhibit some magnetic character. Magnetic vacuum dewatering has been used with magnetite ores and with blast furnace sludges and magnetic fields have been incorporated successfully in drum and disk vacuum filters. The research described in this paper investigates the use of magnetic seed material and flocculants to extend the application of magnetic, vacuum filtration to non-magnetic pulps. It is shown that the addition of a flocculant can enhance the capacity of drum and disk magnetic fIlters when treating materials, such as steelmaking sludges, which are only partially magnetic. In addition, the use of seed magnetite with a flocculant is shown to improve the dewatering of fine hematite pulps in a drum magnetic filter. However the use of a flocculant and seed magnetite had only limited success in improving filtration in a disk magnetic filter with a fine quartz pulp. A disadvantage of magnetic vacuum filtration with seeding appears to bean increase in cake moisture due to water entrapment in the floes resulting from agglomeration and magnetic attraction.

Jan 1, 1999

By M. W. Smith

Pennsylvania has 2500 miles of streams that do not meet water quality standards due to acid mine discharge (AMD), making AMD the greatest cause of water pollution in the state. The problem is mainly caused by abandoned coal mines. Pennsylvania is using a watershed-based approach to abating AMD which includes remining as a key component of a comprehensive restoration strategy. The Tangascootack Creek Watershed was targeted for AMD restoration through remining. Geologic mapping and overburden data were analyzed using Earth Vision software to identify areas of coal reserves which could be remined to improve water quality. Incentives are offered to encourage mining in these designated areas.

Jan 1, 1999

Mechanical and electrical (M&E) systems in road tunnels are constrained by the traffic envelope and the construction profile. Whilst these spatial constraints are often ælocked inÆ early in the design process, the detailed M&E design continues for some considerable time after key civil engineering issues have been resolved. Ventilation design criteria for both normal and emergency operation often involves considerable negotiation with a wide range of stakeholders. Final system performance and spatial requirements are only finally resolved when suppliers are selected following the tender process. Lighting design is dependent upon a wide range of factors including tunnel lining materials and associated colours as well as agreed maintenance regimes. Cabling systems can only be developed when the general arrangement for power distribution is agreed and a system of substation, switchrooms and equipment rooms is in place. Many other systems such as fire protection and communications facilities fill the available space beyond the traffic envelope, where physical, structural and æsight lineÆ requirements must all be accommodated. The more co-ordinated civil engineering and M&E design is and the earlier the process starts the better the outcomes for all parties.

Jan 1, 1999

By Lamar S. Todd

The direct production of metal from a sphalerite concentrate is an attractive route for primary zinc. A series of operations and conditions have been selected to efficiently cause the following overall exothermic reaction. The process uses a continuous circulation of molten copper for material and energy transfer between the unit operations. Sulfide concentrate is reduced with an excess of superheated copper to make a copper alloy and white metal. The alloy is stripped of volatile metals under vacuum and some metals can be separately condensed. The residual copper and the white metal are fed into a copper converter to be blown with oxygen for desulfurizing and the superheated copper is recycled. The paper will include a detailed material flow sheet for the process, discussion of the operating conditions of the individual units, behavior of minor elements, and zinc quality.

Jan 1, 1999