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By B. Genc

After the explosion at Middelbult Colliery, South Africa in May1993, which claimed 53 lives, the South African Coal Mining Industry and the Safety In Mines Research Advisory Committee (SIMRAC) united forces to establish a surface facility to develop and test on-board flame suppression systems for continuous miners and roadheaders. The first test that was conducted in this newly constructed test tunnel at the Kloppersbos Research Facility, CSIR was in July 1995.Since then 70 tests have been conducted using the facility and have focused on on-board active ignition suppression systems for continuous miners (CM) and road heading (RH) machines to enhance the safety of South African mine workers in collieries. These suppression systems are mounted on the CM or RH machine and detect the occurrence of an ignition by means of light-sensitive sensors. The electronic signal from the sensor triggers the suppression system, creating a flame-suppression curtain, containing and extinguishing the flame in the immediate vicinity of the ignition. Forty-three tests have been conducted with an active on-board suppression system present inside the test tunnel. Since flame propagation speed is an extremely important parameter, the CSIR-Miningtek made the results of the test programme available for re-analysis. Flame speed depended on whether a machine was present in the heading or not, the geometry of the heading and the volume and composition of the explosive mixture of gas. Flame speeds of up to 190 m/s were recorded. However, the active suppression systems were almost always successful in containing flame propagation.

Jan 1, 2002

By T. H. Eyde

Worldwide production of natural zeolites during 2001 was estimated to be about 3.5 Mt (3.85million st). Construction and agriculture continued to be the major consumers. Estimated production in North America during 2001, including the United States, Canada and Mexico, was about 40 kt (44,000 st). In the United States and Canada, the zeolitic tuffs are ground, extruded or modified for use as adsorbents, desiccants, ion-exchange media and carriers. In Mexico and the rest of the world, the zeolitic tuffs are cut into dimension stone that is used in construction. Zeolitic tuffs are usually composed of the minerals clinoptilolite, mordenite or both. They occur in a variety of colors and are easy to cut and shape. And they have low thermal conductivity. This construction application is classified with dimension stone rather than with chemical and agricultural uses.

Jan 1, 2002

The Newmont Waihi Operations mill has undergone significant growth over its life. Initially designed as a single SAG mill operation, the circuit has been progressively upgraded since 1988 from a nameplate capacity of 600 000 tonnes per annum to the current rate of 1.3 million tonnes per annum. With future mining potential there is renewed interest to increase the processing rate even further. Over the next twelve months five sustaining capital projects will be undertaken and two major eco-efficiency projects will be completed. With the exception of the large grinding mills, most equipment on a gold treatment plant is replaced after 10-15 years. Waihi Gold mine has been operating for 14 years and has just recently received approval to replace equipment in five main areas; carbon elution, carbon regeneration, scats crushing, intertank screens and variable speed drives. Each project has been justified on improved process efficiencies and operating/maintenance cost savings. The two eco-efficiency projects involve a water balance model and a cyanide optimisation project, both of which are Corporate key performance indicators (KPI).

Jan 1, 2002

By Y. H. Zhan

In beneficiation of phosphate ores it is common to use screening to produce the coarse "pebble" concentrate, and flotation to process the -1+0.1 mm size fraction. The -0.1 mm desliming product is treated as tailings. A new partially hydrophobic flocculant, P(MAAA) latex was developed to enhance flotation recovery of fine apatite particles through selective flocculation.

Jan 1, 2002

By Tim Wolf, Barry Fink

Mine site managers reported occurrences of locking assembly bolt failures on the Enlow Fork Coal Mine's slope belt conveyor. The observations were made after a number of years of operation and raised questions as to the status of the assemblies in operation. These questions prompted a detailed review of the situation by independent consultants. Using operational history of the conveyor and confirmation of belt loads by static and dynamic methods, a locking assembly fatigue curve was created to suggest expected service life. From this work, suggestions were made to modify the pulley assemblies for extended service life.

Jan 1, 2002

By Jennifer P. Harrell, D. Joseph Hagerty

In many areas of the eastern United States, especially in the Midwest, past mining activities have left large and extensive underground openings. Now, renewed mining is occurring in such areas in surface pits. Also, construction blasting often occurs in rock over such old openings. Within the last fifteen years, some attention has been given to the interaction between surface blasting and underground cavities; concern has been expressed about the possible changes in vibrations transmitted through areas underlain by old mine workings (Siskind, Stachura and Nutting 1987). Previous studies also had indicated that underground openings could influence transmission of surface mine blast vibrations (see, for example, Woodward-Clyde Consultants 1977). The principal concern is that underground openings under surface blasting may intensify low-frequency vibrations. If such intensification occurs, use of available equations to predict peak particle velocities and to design blasting patterns and select blasting parameters could lead to possibly damaging ground shaking.

Jan 1, 2002

By P M. Ashley

Antimony (Sb) is an element similar to arsenic that forms anions in surface waters, rather than cations like other metals. Little is known about natural mobility of antimony in the environment. However, recent studies have suggested that antimony has similar toxicity to arsenic. Current New Zealand drinking water guideline values are 3 parts per billion (0.003 mg/l) for antimony and 10 ppb (0.01 mg/l) for arsenic. Antimony occurs principally in stibnite (Sb2S3) in mesothermal vein deposits hosted in low grade metamorphic belts of eastern Australia and southern New Zealand. Many deposits have been mined historically, including one large deposit, at Hillgrove, NSW. Oxidation of stibnite and associated arsenopyrite and pyrite causes local acidification of natural waters but acid is readily neutralised by carbonates in mineralised zones and host rocks, and therefore waters are near-neutral (pH 6-8.5). Antimony dissolves readily in moderately oxidized, near-neutral waters. Experimental stibnite oxidation yielded up to 37 mg/kg (37 000 ppb) dissolved antimony, and mine and tailings dam waters at Hillgrove mine have up to 55 mg/kg (55 000 ppb) dissolved antimony. Natural stibnite can contain >5000 mg/kg arsenic in solid solution and therefore dissolution of stibnite, arsenopyrite and arsenian pyrite also releases arsenic into waters. Resultant dissolved arsenic concentrations are up to 3.6 mg/l (experimental) and up to 7.2 mg/l (mine and tailings dam seepages). Mine and tailings discharge waters have elevated antimony and arsenic where they emerge, but attenuation occurs by deposition of the metals on to amorphous iron oxyhydroxides which can contain >10% each of antimony and arsenic. Historic disposal of mineralised waste rock and tailings into the stream system at Hillgrove has caused contamination of sediments and waters with antimony and arsenic for at least 20 km downstream with effects traceable in sediments for 300 km. Other stibnite-bearing deposits are likely to have analogous environmental effects, particularly from historically-mined sites.

Jan 1, 2002

By R. F. Hüttl

The restoration of surface mining landscapes requires the (re)creation of ecosystems. In Lusatia (eastern Germany), large-scale open-cast lignite mining operations generated spoil dumps widely consisting of acidified, phytotoxic substrates. Amelioration and rehabilitation measures have been developed and applied to these substrates since the 1950s. However, it is still not clear whether these approaches are sustainable. This paper reports on collaborative research work into the ecological potential of forest ecosystem development on typical minesites in the Lusatian lignite district. At first sight, pine stands on minesites along a chronosequence comprising about 35 years did not show differences when compared with stands on non-mined sites of the general region. Furthermore, with some modification, conceptual models for flora and fauna succession in forest stands on non-mined sites seem to be applicable, at least for the early stages of forest ecosystem development. For example, soil organism abundance and activity at minesites had already reached levels typical of non-mined sites after about 20-30 years. In contrast, mine soils are very different from non-mined soils of the test region. Chemically, mine soil development is dominated by processes originating from pyrite oxidation. Geogenic, i.e. lignitic, soil organic carbon was shown to substitute for some functions of pedogenic soil organic matter. Rooting was hampered but not completely impeded in strongly acidified soil compartments. Roots and mycorrhizae are apparently able to make use of the characteristic heterogeneity of young mine soils. Considering these recent results and the knowledge accumulated during more than 30 years of research on minesite rehabilitation internationally, it can be stated that minesite restoration might be used as an ideal case study for forest ecosystem development starting at "point zero" on "terra nova".

Jan 1, 2002

By David Siskind

The authors studied small seismic exploration blasts for vibration characteristics and effects on structures in Mexico. Obtained were 267 three-component recordings of ground vibrations and structure responses from 62 test blasts at six single-story masonry structures. Charges were 4.55 kg (10 lb) of Vibrogel expolsive at depths of 20 and 30 meters. Initial blasts were 240 meters distant and proceeded towards the structures to as close as 5 meters. All blasts were in soil media in two basic types of terrain, low saturated areas and upland dry areas. Structural inspections were before, during, and after the test blasts.

Jan 1, 2002

By Howard Roscoe

Linking Ashford International Station to the new Channel Tunnel Rail Link required over 5000 rotary bored and CFA (continuous flight auger) piles to form tunnel walls and viaduct foundations and to support overbridges and trackside barriers.. Much of the work was carried out close to the existing railway infrastructure. Plunged columns were used to maintain traffic flows over the tunnel site during construction. The results of an extensive programme of vertical and lateral load tests on bored and CFA piles in heavily overconsolidated Weald Clay are compared to illustrate the relative importance of stress relief and of prolonged exposure to bentonite. The completion on schedule of this major piling and ground engineering contract (value £30 million) demonstrates that collaborative working in partnership produced cost effective solutions to a series of challenging technical and logistical problems.

Jan 1, 2002

By A. Mezei

A process has been developed to recover cobalt, gold and bismuth from the NICO deposit in Canada. The process consists of a bulk rougher flotation followed by an optional separation by flotation to produce a bismuth concentrate and a cobalt concentrate, grading on average 12.8 % Bi and 1.8% Co, respectively. Cobalt is leached by pressure oxidation at 97% efficiency, producing a pregnant solution suitable for further processing. Before optimization, about 38% of the bismuth is recovered in the selective concentrate, wherefrom it is recovered by ferric chloride leaching followed by cementation, at overall efficiencies exceeding 98%. The gold is recovered from the cobalt and bismuth leach residues by cyanidation, at 95% efficiency. Previous work described the results of the leaching of the concentrates, recovery of gold (Part I) and the recovery of bismuth (Part 11). This work describes the results of the cobalt recovery testwork and the resulting conceptual flowsheet. The sulfur dioxide-oxygen system was the most efficient for the oxidationlprecipitation of iron and arsenic from cobalt bearing pregnant leach solutions, producing purified solutions assaying <1 mg/L As and <8 mg/L Fe. The efficiency of cobalt solvent extraction (from the resulting purified PLS containing about 1 g/L Co) ranged from 9 1 to 98%; the co-extractions ranged from 88 to 100% for copper, from 28 to 33% for magnesium, from 6 to 7% for calcium and from 96 to 98% for zinc. Sulphide precipitation processes (using either sulfur dioxidelelemental sulfur or sodium sulfide) produced residual copper concentrations in the cobalt strip solution ranging from 0.1 to 2 mg/L Cu. About 90% of the calcium and magnesium were separated by scrubbing the organic with cobalt sulfate, producing residual concentrations of 12 mg/L Ca and from 180 to 330 mg/L Mg in typical feed solutions directed to cobalt carbonate precipitation tests. Cobalt carbonate precipitation efficiencies ranged from 75 to 78% when calcium and magnesium co- precipitations were restricted from 8 to 17% and 0.3 to 0.4%, respectively. The limits required by most stringent specifications on commercial grade cobalt carbonate products were met or exceeded.

Jan 1, 2002

By W Herrmann, R R. Large

Volcanic-hosted massive sulfide (VHMS) deposits in ancient, submarine volcanic belts of Australia include mound, lens and sheet-style Zn-rich polymetallic deposits, massive and disseminated pyritic Cu-Au deposits and disseminated, stratabound Au-only deposits. Variation in morphologies, metal ratios, volcanic environments and alteration features indicates there exists a spectrum of deposits from the classic VHMS model, to hybrids between VHMS-porphyry Cu and VHMS-epithermal end members. Zn-rich, polymetallic deposits form eitheron, or just below, the seafloor, whereas the Cu-Au and Au-only deposits form sub-seafloor by replacement of specific volcanic lithologies. Alteration zoned outwards from quartz -> chlorite -> sericite ¦ carbonate is typical of VHMS deposits across the spectrum. Quartz and carbonate alteration is dominant in the Au-only systems,chlorite alteration is commonly developed close to Cu-rich ores, and sericite and carbonate alteration zones are well developed in the stratiform Zn-rich ores. The most useful geochemical vectors for Zn-rich ores are the alteration index [AI=100(MgO + K2O)/(MgO + K2O + CaO + Na2O)], the chlorite-carbonate-pyrite index [CCPI=100(MgO + FeO)/(MgO + FeO + K2O + Na2O)], Mn content of carbonate, Mg/(Mg+Fe) ratio of chlorite,whole-rock Tl, Sb and Ba/Sr ratio, S34S of pyrite, and whole-rock S18O. The most useful vectors for pyritic Cu-Au ores are AI, CCPI, S/Na2O ratio, Na content of white mica, and Fe content of carbonate.

Jan 1, 2002

By M. Karmis

The algorithms for the mathematical modeling to predict productivity of underground room-and-pillar mining systems are well known and documented. These algorithms consider the time-varying relationships between mining equipment for a given geometty of operations as well as other constraints. This paper presents WebConSim, a newly developed, Web-based, user-friendly computer simulation tool for the Windows environment. The simulator is easily customized for use by field engineers, planning engineers and management and will help mine operators plan the optimum mining sequence for different mine geometrie and equipment layouts. Program output includes production data and equipment utilization indices, as well as time driven event chains that can be used for virtual reality presentations.

Jan 1, 2002

By Grant R. J. Bearss

Due to environmental concerns in urban construction, many typically simple projects become very complex or feasibly impossible. The introduction of relatively new concepts has redefined "impossible", again simplifying these projects and making them "possible". Case Study One covers the use of Pressed-in Tubular Piles on portions of the Long Island Expressway in Queens, New York. Innovations in the design, material and installation method solved many typically inherent problems on projects of this type and resulted in cantilevered walls that supported a 35ft (10.668m) excavation. Design predictions and actual measured deflections of this wall were within millimeters. Case Study Two covers the use of Pressed-in Tubular Piles on portions of the Hodogaya Bypass in Yokohama, Japan. Innovations in equipment development allowed for a cantilevered retaining wall to be constructed without affecting the adjacent right-of-way, dramatic reduction of the overall construction duration and installation of tubular piles in soils with SPT N values greater than 160.

Jan 1, 2002

By Q. X. Yun, S. H. Liu

This paper provides a new approach to determine the opening layout in underground mining methods by means of genetic programming. Based on a set of random combination of openings, the layout of openings will gradually improve with the help of genetic operations, including reproduction, crossover, mutation and fitness calculation. The optimal solution will finally emerge according to Darwinian principle: "the survival of the fittest ".

Jan 1, 2002

By Michael Peterson, Robert Davinroy, Robert Rapp, Gregory Hempen, David Herzog, Thomas Keevin

Fish sampling in a deep-water, high velocity, environment is extremely difficult. Conventional techniques such as electro-fishing and netting have been limited to depths generally less than 7 meters (m) and velocities below 1 meter per second (mps). The goal of our study was to sample a bendway weir field on the Mississippi River to assess the effects of the weir field on the fishery. In a bendway weir field, depths can exceed 20 m, and velocities can exceed 3 mps, making conventional sampling techniques inefficient.

Jan 1, 2002

By D Syme

In the middle of 2000, BHP Billiton implemented a Six Sigma Plus business improvement program known as Operating Excellence. It was developed based on a business bottom line initiative to deliver 35 - 40c/share and was one of the BHP Billiton strategies to deliver $2 earnings per share and a longer term $40 share price (BHP share price). Cannington is a silver, lead and zinc mine owned and operated by BHP Billiton. Through implementing Six Sigma Plus Cannington wanted to:have in-house capabilities to change and improve; tailor for the needs of each business unit and department; have æSharing of its KnowledgeÆ as a tool for improvement and have a competitive edge across Cannington û to be better than our competitors; learn from and leverage off the successes of improved safety and prior business improvement efforts; and ensure networking and sharing of information have common measurement systems across all assets. As with most business improvement programs û Six Sigma Plus was met with some degree of skepticism, especially given the amount of resources involved. After 18 months, much of this skepticism has been replaced with enthusiasm as peopleÆs understanding and acceptance of its fundamental concepts are being realised. The idea behind Six Sigma Plus is that it combines sound technical solutions with high acceptance by those who need to work with or implement the change. The future vision for Six Sigma Plus is that it become part of what we do at Cannington û just like safety and environment û so that Six Sigma tools and methodologies are used in our every day work.

Jan 1, 2002

By D Whitworth

The Golden Pig mine has embarked on a diamond drill program design philosophy that increases flexibility of the program by greatly increased drill pattern densities. The use of standard broad pattern diamond drilling at the Golden Pig mine has previously lead to operational inefficiencies and impacted significantly on the costs of the mine. The diamond drill program philosophy and its interaction with mine planning is explained. The case study of the E lode mining as used to internally justify the increased drill densities is detailed.

Jan 1, 2002

By K. Mansfield

Spent Pot Lining (SPL) is an unavoidable waste product of the electrolytic process in the smelting of aluminium. SPL is considered to be a hazardous waste in various countries because it contains significant quantities of absorbed fluorides along with traces of cyanide. In 1995, Portland Aluminium undertook the investment of AUD$26,400,000 to construct a Research and Development processing facility at Portland, Victoria, Australia, to treat SPL. Extensive research, development and design were carried out over 5 years prior to the investment decision. This study led Portland Aluminium to install an Ausmelt pyrometallurgical furnace to combust and melt the SPL producing a hydrogen fluoride (HF) laden gas, which was cooled and then converted to aluminium fluoride (AlF3). Both the cooling and AIF3 manufacture were processes developed by Portland Aluminium. Many commissioning, equipment reliability and process problems have been encountered that had not been experienced in the trials at Ausmelt or in the developmental process for the treatment of the furnace offgases to form AlF3. Designs based on anticipated process expectations have had to be re-engineered by the SPL team to ensure plant and operational success. In June 2001, the installation of the final major component - a slag granulation process - was completed. This has produced a vitrified (glassy) slag that is expected to have leachability qualities acceptable to the Victorian Environment Protection Authority (EPA) to allow commercial end uses of the slag material to be developed. Today (September 2001), the smelter has successfully used the fluoride product, namely 65- 70% AIF3, in aluminium production and the SPL plant has significantly increased throughput with expectations to be at annual design rates of 12,000 tonne of SPL in early 2002. "The Alcoa Portland SPL Process" has been technically developed and is a proven process for the treatment and recovery of valuable components from SPL materials.

Jan 1, 2002

By G Varley

This paper describes the mining methods and strategy used to extract the 5 Orebody crown pillar at the Isa Lead Mine over the past five years. The bulk of the crown pillar was extracted by the use of sublevel open stope method. An uphole bench stope was mined to scavenge the remaining ore. Geomechanical issues associated with the crown pillar extraction are described. Stope sizes were gradually increased on a stope by stope basis. This has allowed the maximising of ore recovery while relevant risks were managed. The principles in designing ore rib pillars against various types of fill materials are also described.

Jan 1, 2002