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By C. J. Newman

Prior to 1995, the smelting process at the Kennecott Utah Copper Corporation (KUCC) smelter consisted of Noranda reactors and Pierce-Smith converters. In the consideration of expansion opportunities, the existing process did not lend itself to a program geared towards processing the total output of KUCC mining and milling operations. During 1989 and 1990, a number of smelting options were evaluated. The final selection was the Outokumpu flash smelting process, coupled with the new Kennecott-Outokumpu flash converting technology. Facilities were designed and installed to process 1.0 million tonnes per year of copper concentrate, with the ability to expand to 1.2 million tonnes per year. Following the shutdown of the smelter facility utilizing the Noranda technology in May 1995, the flash smelting furnace commenced operation in June with the flash converting furnace startup following a few weeks later. The smelter has achieved design production targets and environmental goals. Current operating rates are at or above design rates for concentrate and matte processing. Emissions are lower than the permit levels and equate to less than 3.5 kg of S02 per tonne of copper. This paper outlines the design, construction, startup and the first two years of operation of the modernized KUCC smelter.

Jan 1, 1998

By T. A. Doyle

Column and batch test methods are used to simulate and model the leaching of various mining by-products. Batch tests are simpler, while column tests more intuitively represent the field conditions to be simulated. Projects that have included different types of leaching tests illustrate the strengths, limitations, and associated uncertainties of each. Column and batch tests have been used to evaluate arsenic solubility in leachate from treated copper smelter flue dust, to simulate the leaching of pit wall rock from a proposed gold mine, and to simulate the release of uranium from aquifer materials.

Jan 1, 1998

By Thomas P. Mucho

Cable bolts are emerging as the newest ?twist? for roof support in U.S. underground coal mines. For decades cable bolts installed in underground metal mines in the United States and Canada used cement-based grouts for anchoring. The cement anchoring process, because of the time and expense for installation, made cable bolts impractical for use in coal mines. Today, the introduction of resin-anchored cable bolts provides a system more consistent with tradi­tional U.S. coal mine roof bolting practices and requirements. Expecta­tions are that the utilization of cable bolts for a number of U.S. mining applications will expand, particularly in coal mining.

Jan 1, 1998

By C. Flores

The most common experimental approach of studying one variable at a time while holding all others constant is extremely inefficient. Use of statistical methods enables engineers and scientists to obtain meaningful information with the fewest experiments, reducing cost and wasted effort. In particular, the Taguchi method can be more efficient than traditional full factorial experiment designs, as it can study more variables with fewer nuts, and it is more robust against process "noise." Taguchi designs are also simple to formulate and the results can be analyzed by simple PC spreadsheets. The role and benefits of using the Taguchi method in experiments to develop and optimize processes is discussed.

Jan 1, 1998

By D. J. Wood

BHP Copper has grown, in just over six years, from a minor participant to the world's largest privately owned copper producer. BHP Copper's major asset is the world's largest copper mine -Escondida in Northern Chile. Ten years ago investing in Chile was considered high risk. Today, Escondida represents an investment of approximately US$2 billion. Reward is the result of managed risk and Escondida is a clear demonstration of both. The Ok Tedi copper and gold mine in Papua New Guinea represents a Rubicon of risk and a retrospective on reward in a developing country on the doorstep of a developed one. The story of these two mines encapsulates risk in the mining industry.

Jan 1, 1998

By Dai Wang

Stoppings are necessary ventilation control devices for effective air distribution underground. However, one of the major problems underground mining has is that every stopping is a potential leaking source. Since air always flows from a point of high pressure to one of lower pressure, and the total pressure at every point in intake airways is higher than that in the return airways, air will always tend to leak from intake to return (Tien, 1996). In many mines, less than half of the air entering the mine actually gets to the working areas; the rest of it simply short-circuits directly to return airways through leaky stoppings instead (Timko and Thimons, 1983). Leakage through a stopping occurs because of pressure drops across the stopping and available leaky path in stoppings. Empirical equation has been widely used to characterize the relation the amount of leakage and variables that affect leakage. However the use of this equation requires accurate information for constants which are not always readily available. It is the attempt of this paper to derive an equation similar to the Atkinson Equation that can readily be applied to characterize pressure-leakage relationship for any given stopping.

Jan 1, 1998

By J. S. Lee

Alkyl hydroxamates are well known collectors for oxide copper minerals as evidenced by the large amount of published literature. Our studies on a wide variety of copper ores from around the world have shown that alkyl hydroxamates will recover most of the "floatable" oxide copper minerals from an ore. They are available commercially, and they offer many advantages over alternative technologies for oxide copper recovery. In spite of this, the full potential of hydroxamates has not been exploited in the industry. The objective of this paper is to provide relevant practical aspects and guidelines to facilitate successful application of hydroxamates in operating plants. A critical analysis of the available information and data, based on several case studies, notation testing, and microscopic analysis indicates that alkyl hydroxamates can effectively recover well-defined oxide minerals of copper, but not copper occurrences such as Cu-bearing goethite (often misidentified as cuprite) which report as Acid Soluble copper in chemical assays. Prior to any notation testing with hydroxamates, it is necessary to assess the various modes of occurrence of Acid Soluble copper using microscopic and microprobe analysis.

Jan 1, 1998

By S. Nygren

Nalco Chemical Company and a North Carolina Phosphate operation have formed a successful supplier/customer team effort that has resulted in major improvements in the operation of the clay thickening circuit at the Aurora, North Carolina concentrator. A Nalco OPTICUS® Automated Process Control System for thickener and flocculant control was installed in 1994. The paper will discuss in detail the development and refinement of the OPTICUS system over the past three years. The paper will survey the development and networking of process control for monitoring, controlling and operating four 325-foot Dorr-Oliver thickeners, three 80-foot high-rate Enviro-Clear thickeners and control links to the facility's clay/gypsum blending operation.

Jan 1, 1998

In most States of Australia it is a legislative requirement for underground mines to have a separate means of egress from the normal means of ingress to permit the safe evacuation of workers to the surface in event of an emergency. Such egress may be in the form of a ladderway equipped shaft/underlie or trafficable incline/decline. Additionally, there is a general requirement to have one or more airways, separate to the main shaft or other principal entrance of an underground mine, extending to the lowest level to permit ventilation to all parts of the mine. Fulfilling these requirement is difficult in the development phase of a mine when access underground is achievable by only a shaft or decline in the process by being sunk. What is frequently practiced in Australia is for production to then commence, sometimes in association with continuing development, in the same configuration without the establishment of this separate method of egress to the surface nor additional airway/s with reliance on refuge chambers to cater for back up in any emergency. Not only, could this jeopardise the health and safety of workers in case of an underground emergency it could be construed as a statutory breach of legislation. While recognising that refuge chambers are often used throughout underground operations nowadays their equipping and the criteria for their location needs to be bought into focus. This presentation discusses how such legislative requirement can be met alongside the use and appropriateness of refuge chambers.

Jan 1, 1998

Little knowledge is available that considers the effects of continuous miner position on the possible respirable dust exposure of the remote mining machine operator. Such information could be very useful for increasing the awareness of the remote operator as to those parts of an extended cut that generate higher levels of respirable dust. This data could be used to develop guidelines for positioning the remote operator to reduce his potential exposure. This work details the effects of continuous miner position on dust levels measured on the machine and at the remote continuous miner operator location.

Jan 1, 1998

By Timothy L. Roberts

For many years practicing geotechnical and structural engineers in Texas and Louisiana were reluctant to include augered cast-in-place (ACIP) piles as a viable deep foundation alternate. Three primary concerns were the lack of a final driving resistance to confirm adequate capacity, the inability to inspect ACIP piles prior to installation, and the fact that pile integrity is highly dependent on the skill of the ACIP pile contractor's field personnel. The Deep Foundations Institute (DFI) Committee on Augered Cast-In-Place Piles has responded to these quality control concerns by establishing standards of practice for ACIP pile installation and ACIP pile inspection. Regional areas of the country have different subsurface soil and rock conditions and many times this will influence local installation and inspection requirements. The best way structural and geotechnical engineers can address quality control concerns is to be familiar with the DFI standards of practice, to know the special requirements for a particular project site, and to incorporate them into a well-written ACIP pile specification. The purposes of this paper are to: 1) review the main fundamentals of a successful quality control program, 2) describe how these fundamentals can be applied to the installation of ACIP piles, and 3) add personal experiences from ACIP pile projects in Texas and Louisiana. Nondestructive test methods are frequently used as a quality control tool to evaluate questionable piles. An additional brief discussion of two nondestructive test methods is presented to complete the paper.

Jan 1, 1998

By Peter K. Liaw, Niann-i Yu, Wei Zhao

"For a plain-weave Nicalon ™ fiber fabric-reinforced silicon carbide (SiC) ceramic composite, little attentation has been paid to the effect of fabric stacking sequence on its mechanical behavior. In this paper, fiber-fabric stacking sequence effects on the elastic stress distributions, ceramic matrix-cracking stress, effective elastic moduli, and flexural strengths of laminated flexural test bars are quantified. A quantification model is established based on the combination of classical laminated plate theories and a fiber undulation model developed by Chou et al. A FORTRAN program is compiled to implement the modeling, which can be run in a SUN work station. The mechanical performance of a continuous fiber-reinforced ceramic-matrix composite (CFCC) with a [0/30/60] lay-up was analyzed and predicted. The variation in the fiber-fabric stacking sequence can vary the elastic stress distributions along the thickness direction of specimens, magnitude of ceramic matrix-cracking stress, effective elastic moduli of the laminate, and crack initiation sites as well as fracture modes. Moreover, all these factors contribute to scatter in flexural strengths of the CFCC.I. IntroductionWith enhanced fracture toughness and the ability of non-catastrophic (graceful) failure behavior, CFCCs are currently under evaluation for high-temperature structural applications in heat exchangers, combustors, hot-gas filters, boilers components, first walls and high-heat flux surfaces gas turbines, space vehicles and nuclear reactors.[1-8] Extensive applications of CFCCs by industry are still hampered by an insufficient understanding of the mechanical behavior, and sometimes, the lack of a well-developed and widely accepted design philosophy, in addition to the high-production costs."

Jan 1, 1998

By P. J. Best

Due to its low mine production costs, competitive rail rates and low sulfur content, the Southern Powder River Basin (SPRB) now commands 30 percent of the U.S. utility coal market. In 1996, production exceeded 260 million tons, a growth of 110 million tons since 1989 and 15 million tons over 1995. Continued growth is expected as the second phase of the Clean Air Act Amendments (CAAA) looms. This growth will be the greatest in the southern part of the basin, where coal quality is higher. This article is an overview of supply and demand issues affecting markets for SPRB coal. It reviews the current markets for SPRB coal and addresses future prospects for market expansion.

Jan 1, 1998

By H. S. Castro

The by-product molybdenite technology in Chile is reviewed. Flowsheets, reagents and some operation features for the actual six Chilean moly plants(Chuquicamata, El Teniente, El Salvador, Andina, Las Tortolas and Pelambres), are presented. The chemical and physicochemical factors involved in the depression of copper and iron sulfides during the selective flotation of molybdenite, with sodium sulfide, sodium sulfhydrate, anamol-D and LR-744, are discussed. Advances in technology to solve problems of excess of lime (precipitation with sulfuric acid); excess of residual flotation reagents (activated carbon and kerosene); and optimization of depressant consumption (Eh control, nitrogen and low-oxygen air), are discussed.

Jan 1, 1998

By M. Kane, O&apos

BHP Iron Ore initiated research programs in January of 1995 to develop long term plans for decommissioning of the waste rock material at their Mt. Whaleback operation. More than 2 billion tonnes of waste rock were deposited during the past 30 years. Ultimately, the operators will deposit a total of approximately 5 billion tonnes in waste rock dumps constructed near the open pit. The Mt. Whaleback operation is located in a semi-arid climate adjacent to Newman, Western Australia, approximately 1200km north-northeast of Perth, Western Australia. The primary research program includes the development of technology for the long term performance of the waste rock dumps with respect to vegetation, slope stability, surface runoff, erosion, and water infiltration. This paper focuses on the design and implementation of a cover system to prevent water infiltration to the underlying waste rock. A laboratory program and the soil-atmosphere modelling completed to design the horizontal field test plots are described. The construction of the horizontal surface field test plots are discussed together with the field instruments installed to monitor performance. The key components of the instrumentation program are the design and installation of large scale field lysimeters to measure the unsaturated flow of moisture into the waste rock from the base of the cover layer. The cover system is designed to maximize infiltration during wet periods for subsequent evapo-transpiration while minimizing surface runoff. The result is a near zero net infiltration to the underlying waste material. A key feature of the design is the use of pit run waste material as the cover material. Monitoring is in progress and will continue for at least two annual wet/dry cycles. The optimum cover system should minimize the net infiltration of water to the underlying waste rock while maintaining physical and ecological integrity for long term performance.

Jan 1, 1998

By T. Dunn

FMC Corporation has achieved a significant cost reduction through a new proprietary solution mining and processing technology at its Green River, Wyoming Soda Ash Facility. In the first phase, completed in October 1995, trona ore is dissolved, recovered and processed with the new technology, and then fed into an existing refining plant, replacing dry mined and calcined trona ore. The second phase, completed in April 1996, produced a fmal high purity product and increased capacity by 635,000 t/a (700,000 tpy). Both phases were completed under budget and well ahead of schedule.

Jan 1, 1998

By B. T. Field

Pyroprocessing systems range from low temperature dryers to high temperature reactors. The materials and process requirements cover a broad spectrum. It is not the intent of this paper to do a detailed examination of individual processes and equipment, since that can be found in a multitude of other sources; rather it is the intent of this paper to examine the key process variables and offer empirical guidelines to assist in a user?s overall evaluation.

Jan 1, 1998

The sixth international symposium on mining with fill nearly coincides with the 25th anniversary of the Jubilee Symposium on Mine Filling. That symposium, held in August 1973 in Mount Isa, in part to commemorate the 80th anniversary of The Australasian Institute of Mining and Metallurgy, was the first in what has turned out to be a very successful series of symposia. Subsequent symposia were held in Sudbury, Canada (1978), Lulea, Sweden (1983), Montreal, Canada (1989) and Johannesburg, South Africa (1993). The series of symposia has now become an established part of the mining industry calendar, and it will be interesting to see which country is given the honour, and accepts the challenge, to organise the next symposium.One way of predicting the future, or some small part of it, is to revisit where we have already been with a view to determining the existence of any trends that may impact on the future. An historical review of filling practice and research, with special emphasis on Australian experience in particular and worldwide in general over the previous 25 years, will enable me to address the historical and predictive objectives. Controversy can always be achieved by producing a best of list; it can be guaranteed that everyone will disagree with at least one of the nominations. On this occasion, the best contributions by individuals or groups in a number of areas of mine fill technology, over the last 25 years, will be the basis for the nominal awards. The controversy can be increased by posing a number of questions that, hopefully, some of the authors will address during their presentations. I imagine the social functions will be busy enough, but the questions may just add to the cut and thrust of the debate.

Jan 1, 1998

By L. A. Henry

The island of Jamaica consists predominantly of Carbonate rocks which vary in chemical & physical characteristics. Currently these rocks are used for construction and road aggregate, landfill and as a raw material in the manufacture of cement. Over the past fifteen years the Geological Survey of Jamaica with assistance from a number of international aid agencies and the private sector have identified deposits of high calcium/high brightness limestones which have the potential to be utilized as a high quality filler and a number of other commercial applications. Geologically, these limestones are formed within the Eocene Swanswick Formation, the Oligocene Walderston-Browns Town Formation and to a lesser extent the Miocene Montpelier and Newport Formations.

Jan 1, 1998

The Boliden Aitik concentrator in Sweden processes 2,000 tph of low grade copper ore. The plant consists of five grinding lines feeding four bulk flotation banks with a scavenger concentrate regrind mill, and a column cleaner circuit with a regrind mill. The authors installed a model-based expert, optimizing control system to maximize copper recovery in the bulk flotation circuit while maintaining an appropriate copper grade in the cleaner feed. The optimizing control system uses on-line assays and calculates and implements set points for cell pulp levels, air rates and reagent addition rates. It combines the power of a dynamic population balance model which estimates mineral liberation in each stream, an optimizer which computes appropriate set points and a rule-based module which implements the strategy. The benefits have been evaluated over three months. The model-based expert, optimizing control system generates a measurable increase in copper recovery, around 0.5 per cent and an optimized bulk concentrate grade. The need to maintain the optimizing control system and other practical aspects are discussed.

Jan 1, 1998