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By Stephan K. Schwank

In mid 1993, Bauer Spezialtiefbau GmbH, based in Germany got the order to develop a sampling tool capable of penetrating all different types of seabed sediments including cobbles and boulders and into bedrock. BHP and their partners Benguela Concessions Ltd., had been convinced by the Bauer Trench Cutter Technology and a large scale test in Germany that this system will be the right one to fulfill their expectations for sampling the diamond area off the coast of Namibia. The technique of the tool is based on Bauer's standard cutter technology, which is widely used for the installation of cut-off and diaphragm walls all around the world. The two counterrotating cutter wheels with 12.1 tom torque each cut an area of 3 x 1.2 m (up to 3 x 3 m are possible). The material mixed with seawater was then pumped to the separation plant on board the vessel Geomaster with a capacity of approximately 700 m3/h. Cutter wheels and mud pump were mounted on a special cutter frame and connected by wire ropes and hydraulic hoses to the vessel. An outer frame with four telescopic legs supported the cutter vertically on the uneven seabed and allowed a controlled penetration of the tool up to 6 m into the diamond bearing ground. The tool required a total power installed of approximately 800 kW. All hoses, the 6-inch mud hoses as well as the hydraulic hoses, were stored and compensated on drums on board suitable for a water depth of up to 200 m. Launch and recovery of the tool was effected through the moon pool of the vessel and the 25 m high, special designed drill tower. The 65? to sampling tool had been commissioned in early 1994 in Cape Town. After intensive testing the sampling programme of more than 4000 holes could be successfully completed by January 1995.

Jan 1, 1998

"The last thirty years have seen enormous changes in all aspects of the gold industry, from the technologies of mining and extracting gold to the role it has played in the fiscal policies of nations. In this time, the market price of gold has increased ten fold and mine production has more than doubled. However, the cost of mining and extracting gold has also increased exponentially, and the industry has struggled with declining ore grades and increasingly refractory ore bodies.With the major economic powers of the world shrugging off the uncertainties of the post cold war era and moving into a period of unprecedented political stability, economic growth and low inflation, gold is also losing its lustre as a hedge against inflation and a backing for national currencies. Consequently, countries that had accumulated and hoarded gold for decades are now disposing of these non-performing assets, resulting in major swings in supply of the metal. Fortunately, this has coincided with the end of communism in many parts of the world and a tentative move to free market economies in most of the developing nations. As a result, people are becoming wealthier, and this is creating more demand for gold, principally in the form of jewelry.On balance, the shift in the role of gold, from one in which a significant portion of new gold production lay dormant in bank vaults as insurance against political or fiscal instability, to one in which most new gold is now freely traded as an industrial commodity, responding to normal market forces of supply and demand, has had a negative impact on the price of gold over the last fifteen years. In that time, the gold price has declined from a peak of $850/oz in 1980 to an average price of about $400 through the rest of the l 980's, to a price of -$320/oz today (1997). In large measure, this has been due to the enormous inventory of gold metal that was held by central government banks in vaults around the world, and which has been dumped on the market as soon as the price has started to trend upwards. Even today, after ten years of fairly steady selling by central banks, about 3 0, 000 tons of gold (or -8 years' supply at the present rate of consumption) is still retained in vaults (Murray et al., 1997).The downward pressure on the price of gold has created exciting opportunities for the development and implementation of new technology. Increasing the efficiency of gold recovery from more and more refractory ore bodies, whilst at the same time lowering production costs, have become critical to survival in this industry. These challenges have been met by the development and implementation of new technologies such as heap leaching, carbon in pulp, resin in pulp and the sulphide ore pre-treatment process of pressure leaching, bacterial leaching and fluid bed roasting. For an industry that saw very little technological change in the first seventy years of the twentieth century, the pace of change over the last thirty years must have seemed bewildering at times."

Jan 1, 1998

By M. J. Hrebar

A study was conducted to evaluate the applicability of large wheel loaders (Caterpillar 994 Class) for use as primary loading equipment in open-pit iron-ore operations. Field visits were made to taconite and gold mines that used large wheel loaders. Information was gathered on loader selection rationale; operation and maintenance experience; and production, availability and costs. Brief time studies were conducted to indicate machine performance and utilization. This paper summarizes the field data that was collected, including an economic comparison of wheel loaders and cable shovels in an iron-ore application.

Jan 1, 1998

By Pate W. T

This paper describes the development of a dynamic flowsheet simulator for comminution operations. Object oriented software design allows the handling of multiple ore types, blended into multicomponent feed streams. Software objects have been c

Jan 1, 1998

By B. Mather

Discussion by B. Mather I was very glad to see an article on alkali-silica reactivity of concrete aggregate in Mining Engineering. It is a topic that should be reexamined every 45 or 50 years. The last paper (that I am aware of) that examined this topic in Mining Engineering was Rexford (1950), who, at the time, was chief of the Petrography Section, South Pacific Division Laboratory, Corps of Engineers, Los Angeles, CA. The paper was presented at the AIME meeting in Los Angeles in October 1948. Professor Leming's discussion generally reflects the current state-of-the-art; but it provides no references for more detailed information. I wrote a paper titled "How to avoid excessive expansion of concrete due to alkali-aggregate reaction," which was included in the Proceedings of the Second International Conference on Alkali-Aggregate Reactions in Hydroelectric Plants and Dams (Mather, 1995). In it, I emphasized that it was the hydroxide ion (not the alkali ion) that caused the pore fluid in the concrete to dissolve reactive silica, producing alkali-silica gel capable of taking up water, thereby, causing swelling and rupturing of the concrete. Excessive expansion will not occur unless there is a sufficient amount of potentially expansive alkali-silica reaction product and water. However, this will not occur unless there is a sufficient quantity of reactive aggregate and unless there is a mechanism by which the pH of the pore fluid can get well above the normal value of about 12.6. In many cases it is sufficient that the cementitious medium not only contains portland cement but also contains ground granulated blast-furnace slag (GGBFS) or a pozzolan such as fly ash, silica fume, metakaolin, volcanic glass or calcined shale - any of which may have been included for economic reasons. If, however, the person selecting the ingredients for concrete knows that the aggregate is reactive (with no alternate nonreactive aggregate available) and if the person knows that the only available portland cement has a high alkali content (i.e., more than 0.6% Na2Oe; Na2Oe = % Na2O + 0.658 x % K20), then it becomes irresponsible not to establish what reasonable precaution one should take. Professor Leming suggests using one of the following: 30% Class F fly ash, 50% GGBFS or 7% to 10% silica fume. My view is that one should prepare test specimens with the cement and aggregate to be used and then expose these both with and without at least two dosages of each of the various alternative materials (slag, pozzolan and lithium salts), so that the required dosage to control the expansion is established. Then, economic considerations can dictate the final selection. I would point out to the author that GGBFS is not a pozzolan and is not an admixture, but, rather, it is a latent hydraulic cement. An admixture is, by definition, a material other than hydraulic cement. I commend him for suggesting that aggregate producers should become more active in knowing about the reactivity of their products and the precautions needed to permit those products to be safely used in concrete. ? References Mather, B., 1995. "How to avoid excessive expansion of concrete due to alkali-aggregate reaction," Proceedings, Second International Conference on Alkali-Aggregate Reactions in Hydroelectric Plants and Dams, US Committee on Large Dams, Denver, CO, pp. 421-439. Rexford, E.P, 1950, "Some factors in the selection and testing of concrete aggregates for large structures," Mining Engineering, Trans. AIME, Vol. 187, pp. 395-402. Reply by M.L. Lerning Mr. Mather has once again provided a cogent and useful discussion. I am grateful to him for bringing these issues to my attention, as well as to the readers, and I am grateful for his discussion of several important factors in alkali-silica reactivity. Mr. Mather's discussion of the mechanism of alkali-silica reactivity (ASR) notes the critical role of the hydroxide ion. While the alkali hydroxides are highly soluble (reducing the solubility of the other primary hydroxide in pore solution, i.e., calcium hydroxide, and providing hydroxide ions that initiate alkali-silica reactivity), it is, as Mr. Mather quite correctly notes, the hydroxide ion that attacks the silica structure. This point was not clearly stated in my original article. As noted in the text, the requirements for mineral admixtures to mitigate or control ASR vary widely depending on the specific characteristics of the materials

Jan 1, 1998

Atlas Copco Construction and Mining Australia identified a number of issues in regard to the skill levels, labour turnover and productivity of our service technicians. In 1994 we were experiencing a labour turnover rate of 42 per cent per annum amongst our technicians. Exit interviews were held with each individual and one of the major areas of dissatisfaction was the degree of product training provided on our equipment, compared to what is required to be competent across the range of our products. These tradespersons were prepared to accept the reduced remuneration that an OEM offers, for the benefit of comprehensive, professional training that, in theory, could be provided. The truth is that we were achieving approximately 40 per cent of our target for training hours because of the demands of field service, pre-deliveries, etc. So, the summary was the same as the industry was experiencing at that time because of skilled labour shortages, production demands, etc people were employed and thrown in at the deep end. A recipe for failure that will be successful every time.

Jan 1, 1998

By S. A. Shuey

The present industrial practice used to separate aqueous cobalt from nickel is multistage solvent extraction processing. This paper describes a different but simpler treatment technology. The proposed technology has been applied to cobalt/nickel hydroxide intermediate solids produced from the treatment of Electrochemical Machining (ECM) waste sludge, The process consists of dissolving the cobalt/nickel hydroxides in basic cyanide solutions. Cobalt and nickel form aqueous .solution metal cyanide complexes. Nickel can be selectively precipitated from the solution as a nickellic hydroxide solid. Cobalt can be recovered from the leach solution by precipitation of a cobaltous/cobaltic cyanide double salt. The double salt product can then be subsequently treated to produce an appropriate cobalt product. The process chemistry, proposed fiowsheet and preliminary reagent costs are presented and discussed.

Jan 1, 1998

By Susumu Okabe

Top blow injection has been applied to continuous copper smelting and converting by Mitsubishi Materials Corporation since 1974. In this process, injected feeds are captured by and dispersed in the molten bath immediately and effectively, and the reaction is enhanced by the agitation of the bath. The continuous motion of the molten bath, however, may cause severe damage of furnace lining materials, if the injection is not controlled and the furnace is not designed properly. In order to suppress refractory wear, especially at the bath line, surface wave of the molten bath should be moderated. A cold model study was carried out with water bath in a cylindrical vessel and the physical model was derived which correlates the oscillation of gas jet impingement on the bath surface and the surface wave. It was found that a half of the proper frequency of the gas jet impingement coincides the proper frequency of the surface wave.

Jan 1, 1998

By David D. Gallagher, Edmond J. O’Donovan

It has been well accepted for many decades that hard starting of conveyors has associated problems. It is particularity damaging to the belt and splices. Recent measurements of hard starts on a long conveyor with a low modulus belt showed very unusual responses. These included violent accelerations and repeated "whip cracking" of the belt. Laboratory investigations of the very high strain rates experienced by the belt during the whip cracking, show mechanisms for belt damage that are not associated with normal usage. This paper outlines the measurement to show that for long, low modulus conveyors, constant torque controls are inappropriate and time ramp controls are really essential.

Jan 1, 1998

By D. D. Lei, H. Sevim, S. M. Gwamaka

Three transportation and handling alternatives for delivering dry coal combustion residues from power plants to underground coal mines were evaluated both technically and economically. The objective was to transport, handle and inject the residues into the old workings of the mine at minimum cost. This was accomplished in the following two steps: simulation models were developed and utilized in identifying technically feasible designs for each alternative and the technically feasible designs were economically evaluated to obtain the cost per ton of material transported. An analysis was conducted for varyous distances and tonnages to reveal favorable operating ranges for each alternative.

Jan 1, 1998

By Knox Van Dyke, Vincent Castranova, Lixin Wu, Mark J. Reasor, James M. Antonini

"One of the proposed mechanisms involved in the pathogenesis of silicosis is that inhaled silica dust activates a ""respiratory burst"" in pulmonary phagocytes, such as macrophages and neutrophils. This increase in oxidative metabolism results in enhanced generation of reactive oxygen species which if produced in excess, would overwhelm natural defense mechanisms and cause damage to the lung parenchyma. This damage would then result in scarring, fibrosis, and decreased gas exchange.Weiss and LoBuglio' have listed several oxygen species produced by phagocytes which may be involved in cellular injury. These oxidants include superoxide anion, hydrogen, peroxide, hydroxyl radical, and hypochlorous acid. Superoxide anion (0;) is generated from molecular oxygen by the plasma membrane bound enzyme NADPH oxidase according to the following reaction:Once generated, superoxide anion can form hydrogen peroxide:In the presence of myeloperoxidase and halide, hydrogen peroxide can form hypochlorous acid:Superoxide and hydrogen peroxide can also form highly reactive hydroxyl radicals. Hydroxyl radicals can be generated slowly by the Haber-Weiss reaction:In addition. hydroxyl radical production can be catalyzed via the Fenton reaction:Hydroxyl radicals can also be generated from the reaction of superoxide and hypochlorous acid as follows:Recent investigations suggest that, in addition to the reactive oxygen species discussed above, nitric oxide may be a potential mediator of silica-induced toxicity.2-4 Nitric oxide (NO') can be generated by the cytosolic enzyme nitric oxide synthase according to the following reaction:NO synthase exists in two forms. i.e.. a constitutive. Ca2+-calmodulin-dependent form and an inducible. Ca2+-calmodulin-independent form. In pulmonary phagocytes. the activity of the constitutive form of NO synthase is low. However. NO synthase can be induced in macrophages and neutrophils by a variety of stimulants such as lipopolysaccharide. interferon y. chemotactic peptide, platelet activating factor, or leukotriene B4.3.5Once generated. nitric oxide can combine with superoxide anion to form peroxynitrite as follows:Peroxynitrite is a potent oxidizing agent. In addition, peroxynitrite can form peroxynitrous acid. which in turn can produce hydroxyl radical and nitrogen dioxide (all of which exhibit strong oxidizing potential) by the following reactions:Oxygen metabolites have been shown to cause lung damage in vivo.6 Such damage includes edema. leakiness of the alveolar endothelial/epithelial barriers, and airway constriction.7 Superoxide and hydrogen peroxide have been associated with membrane damage and cell lysis.8 These oxidants have also been associated with alteration of cytoskeletal structures at cell-cell junctions and elevation of transepithelial conductance in cultured monolayers.9 Macrophages or neutrophils can be stimulated by bacteria or phorbol myristate acetate to produce sufficient oxidant levels to lyse lymphoma cells.10 This cell killing is inhibited by catalase but is unaffected by superoxide dismutase. hydroxyl radical scavengers. or azide. i.e., an inhibitor of peroxidase. This implicates hydrogen peroxide as the active oxidant. Similarly. Weiss et al.11 have reported that hydrogen peroxide is critical in the death of cultured endothelial cells due to neutrophil activation. In addition. hydroxyl radicals generated by monocytes have been associated with cell injury.12 Lastly. peroxynitrite has been shown to oxidize sulfhydryl groups and to inactivate proteinase inhibitor making the lung more susceptible to damage caused by phagocytotic enzymes.' Therefore. a strong case can be made that activated pulmonary macrophages and neutrophils are capable of causing oxidant injury. This chapter presents in vitro and in vivo data indicating that silica is associated with the production of reactive oxygen species from these pulmonary phagocytes."

Jan 1, 1998

By J. H. Calder, J. C. Hower

Three lithotypes of Phalen coal from Cape Breton County, Nova Scotia, Canada, were subjected to a modified Hardgrove grindability index (HGI) test. The testing scheme differed from conventional (ASTM D-409) Hardgrove testing by, in one case, repeating the test three times prior to removing the -200-mesh fine coal from the Hardgrove mill, and, in a second test, removing fines after each of three successive Hardgrove tests. Only the first stage of the latter testing scheme actually conforms to the standard HGI test. All processed samples were analyzed petrographically by a combined maceral/microlithotype analysis. The increase in the percentage of coal ground to -200 mesh increases through the 60- to 180-mesh fractions for each of the lithotypes for the following two apparent reasons. First, with progressive grinding, more of the oversize material is close to 200 mesh (75 µm), creating a "pool" of particles ready to be ground to -200 mesh, and, second, the removal of fines from the system at each step eases the grinding at the successive step. The fines retained system shows the influence of buffering of further grinding by the particles retained in the grinding mill. The Phalen lithotypes and the series of Central Appalachian coals, evaluated previously by Hower and Wild (1994), differ in that an increase in vitrite and a decrease in trimacerite is observed in successive -200-mesh fractions in two of the Phalen lithotypes. This is the opposite of the trend observed in the slightly lower-rank Central Appalachian coals.

Jan 1, 1998

By K. J. Boser

"Medium Voltage (MV) metal clad switchgear is referred to as the voltage class from 2.4 kV to 38 kV. Technological advances in circuit breaker designs over the last 20 years have given rise to retrofit options in lieu of complete replacement for older outdated circuit breaker technology. This paper examines the four MV breaking techniques that exist in industry and investigates various retrofit versus refurbish options for switchgear modernization and life extension. IntroductionThe life extension and upgrade of medium voltage circuit breakers is becoming an increasingly important issue in today’s modern industrial facilities from both a reliability and safety standpoint. Unscheduled downtime, loss of production, and plant safety issues are just some of the concerns that need to be addressed with aging switchgear. A thorough examination of the available breaking mediums allows an informed decision to be made when the time comes to assess equipment performance. If you look back over the history of medium voltage breakers, you will find that there have been four breaking techniques developed and widely used:• air magnetic;• minimum oil;• vacuum; and• SF6.Many facilities that were constructed 25 to 30 years ago relied on air magnetic or minimum oil circuit breakers in their distribution systems. At the time, these were the only “tried and tested” options and they afforded good service. Since then, however, newer technology has given us the vacuum and SF6 mediums which have both proven their reliability and monopolized the market. All the methods have their particular place in industry and what follows is a summary of the advantages, disadvantages, and chronological development of each breaking technique."

Jan 1, 1998

By Bruce C. Fielder

"The concentration of uranium in orebodies discovered in the Athabasca Basin of northern Saskatchewan over the last 20 years has increased by a factor of 100. These high grade uranium orebodies are associated with high concentrations of radionuclides, complex mineralogy and an elemental makeup that includes base metals, arsenic, and molybdenum. Exploiting these high grade ores has required metallurgical advances in milling, tailings disposal and effluent treatment as well as changes in the design of uranium mills.This paper describes the most significant advances, including advances in dealing with the environmental issues which have become more prevalent in recent years. The milling processes of the Cluff Lake Mill, Key Lake Mill, Rabbit Lake Mill, and McClean Lake Mill are compared to illustrate both similarities and differences necessary for milling different orebodies.BackgroundUranium mining in Saskatchewan started in 1953 when the Beaverlodge Mine, owned by Eldorado Nuclear Limited (Eldorado), came into operation at Uranium City. Development in the Athabasca basin started in 1975 when the Rabbit Lake mine came into operation. This was followed by the start-up of the Cluff Lake mine in 1980 and the Key Lake mine in 1983. The McClean Lake mine is forecast to start up in the near future. The McArthur River mine recently received construction approval and the Cigar Lake Project and the Midwest Project are currently in the environmental approval process.The Beaverlodge operation ceased production in June 1982 after nearly 30 years of operation. The Rabbit Lake mill processed Rabbit Lake ore from 1975 until 1985, Collins Bay R-Zone ore from 1985 until 1993, and is currently processing ore from the Eagle Point mine (Bharadwaj, Jarvi and Lam, 1996). The Cluff Lake mill processed ore from the D- Orebody from 1980 until 1984. Since then the Claude orebody has been processed and the OP and DS orebodies are presently being milled (SRK. Senes and Melis, 1987; and Cogema Resources Inc. 1994 ). The Key Lake mill processed ore from the Gaertner ore body from 1983 until 1989 and Deilmann ore has been processed since (Cameco Corporation, 1992b and I 994a). Processing of McArthur River ore in the Key Lake mill is scheduled for 1999. The McClean Lake mill will be processing ore from the JLR, Sue and McClcan orebodies associated with the McClean Lake mine. In future ore from the Cigar Lake and Midwest projects will be processed in the McClean Lake mill. (Minatco Limited. 1991a)."

Jan 1, 1998

By J. S. Anderson

Size reduction models of cone and impact crushers have been developed using Whiten's generic computational structure for the description of crushers. They incorporate a laboratory single particle breakage test and the t-family of curves to describe the breakage behaviour of the feed ore. A quantitative model of 7-foot cone crushers has been developed, based on surveys of Svedala (Kobe) and Nordberg machines. Survey data on a Canica vertical shaft impact machine have been used to validate the impact crusher model. Given the crusher operating conditions, such as tonnage, feed size, set and liner condition, or rotor speed and radius, plus breakage information on the feed, the models provide good predictions of product size distribution, and appear to be robust over a wide range of conditions. They are incorporated in commercially available computer simulation packages.

Jan 1, 1998

By Rob McIvor, Joe Keating, Gary Simmons

As more complex ores are processed, finer grinding becomes more necessary. A cross section of several industries will be presented with discussions not only of find grinding issues but also the classification of fine particles. JOHN MANSANTI: Our next topic will be fine grinding. Again, the intent is to present a topic that is generic enough to apply to multiple industries. Our first speaker is Gary Simmons. Gary is filling in for Phil Walker from Twin Creeks. Phil was not able to join us this week, because of some issues they're having with the autoclave. Gary, being involved in the development phase, is very familiar with the topic. Gary spent about three years with American Cyanamid and another four years with Noranda. He also spent some time with Meridian Gold, then became the director of metallurgy with Santa Fe Pacific Gold. He spent seven years there and is presently the director of process technology with Newmont Gold.

Jan 1, 1998

By Yoshiaki Suzuki

Since 1973, Saganoseki Smelter & Refinery had operated two flash smelting furnaces together to produce 330,000 mtpy of copper. However, in 1990's, economical situation required the smelter more increased productivity to remain competitive. The program, to integrate two flash furnaces into one was carried out maintaining the same production. Modifications were done on the pneumatic concentrate drying system, concentrate feeding system, concentrate burner and furnace cooling system, etc. to double the, furnace throughput. A new large cryogenic oxygen plant was constructed replacing two old plants. Single flash smelting furnace operation has started in March 1996. This paper describes about details of modifications and operational results.

Jan 1, 1998

By R Brake

The Enterprise Mine Project (EMP) is being developed by Mount IsaMines Limited as the future source of copper ore at the Mt Isa miningand processing complex. Environmental engineering is one of the majortechnical challenges facing the project because of the depth of theorebodies, high virgin rock temperatures and hot ambient surfacetemperatures in summer. This paper discusses the engineering principles adopted by EMP to manage the risks associated with working in these adverse thermal conditions.

Jan 1, 1998

By Luc Rombouts

The resources and reserves calculation of marine diamond deposits should be based on a systematic sampling grid. The distribution of the sample grade results tends to be very skew and has a large variance. A bias is easily introduced due to the fact that the grade distribution of the samples is very different from the grades of the area of influence. The temptation is always there to extrapolate the highest grade samples simply to their area of influence. If this is done, the higher grade areas will be systematically overestimated, while the lower grade areas will be underestimated. Such a bias should surely be avoided by weighing the sample grades in such a way with their neighbours, so that the estimated grades have a similar distribution as the grades of the blocks. The grade distribution of small mining blocks tend to be lognormal-like. If the coefficient of variation is known, i.e. the standard deviation divided by the mean, then the grade distribution of the small mining blocks is relatively well-defined. The distribution of the diamonds within the deposits can be simulated, based on the histogram of the sample results and on the semivariogram. The diamonds tend to cluster in trapsites. From the semivariogram and the histogram, the average size and spacing between trapsites, and the grade distribution within the trapsites, can be calculated using the model of the General Family of Discrete Distributions. Using such a simulated deposit, the grade distribution for different block sizes can be obtained. The grade distributions become more lognormal-like with increasing block sizes, as the trapsite effect is reduced.

Jan 1, 1998

By K. G. Sutterer, P. T. Wang, R. Sweigard

One possible alternative for the disposal of flue gas desulfurization (FGD) by-products is to use it as backfilling support material in highwall mine adits. The finite element method was used to analyze the variation in stresses and displacements within and around a highwall adit backfilled with FGD materials. The engineering properties of the rock material and the optimum mix of the FGD materials were obtained from laboratory tests. Finite element analyses show that, for the case in question, the roof displacement would decrease about 48% and the peak stress could be decreased by about 58%. The study indicates that fairly weak FGD materials can eventually lead to the stability of backfilled highwall adits.

Jan 1, 1998