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By William M. Clark

In 1988, the Chemical Manufacturers Association (CMA) launched Responsible Care®, a program of guiding principles created to address the publics' concern about the manufacture and use of chemicals. The Product Stewardship Management Practice code is a key component of the program. Along with the other five comple­mentary codes - Community Awareness and Emergency Response (CAER), Pollution Prevention, Employee Health and Safety, Process Safety, and Distribution - it has been initiated to protect the health and safety of member companies employees, neighbors, customers, the public and the environment. Possibly no other Management Code requires greater collec­tive effort or comprehensive commitment to implement than Product Stewardship. With its mandated cradle-to-grave control, every employee is required to consider all of the potential cir­cumstances involving product and processes, from raw material supply to customers final use or consumption of product. Degussa Corporation, a long time CMA member, fully endors­es the Responsible Care initiative and is most active in imple­menting the various codes. In fact, the guiding principles of the program are an integral part of the company's business strategy. Degussa recognizes that its long-term success and the health of each of its products, the company and the chemical industry itself, is contingent on the successful implementation of the program. Furthermore, the company believes its role in society and the economy can only be justified and sustained if it improves the overall quality of peoples' lives. Consequently, it is a dictum that Degussa products must provide a net benefit over their entire life cycle - from inception to final disposal - both in terms of their utility and their impact on health, safety and the environment.

Jan 1, 1998

By John C. Schneider

During the past decade, operators and researchers have worked toward a better understanding of the mechanisms operating in flotation. As reported by W. J. Trahar in 1981, this work commenced with the operators determining a relationship between recovery and particle size. They defined three particle size ranges, that being fine, intermediate and coarse. It was noted that the fine and the coarse ranges had slower flotation rates than the intermediate range as demonstrated by their lower recoveries.

Jan 1, 1998

By Paul Chamberlin

Although performing a heap leach test is inherently simple, a lot of information beyond extraction, leach time, and reagent consumption can be obtained from a well designed test program. The following is a list of information to look for and acquire when performing column tests and field heap leach tests.

Jan 1, 1998

By J. M. Girard

Ground control problems at surface mining operations can occur for a variety of reasons. Stress, gravity loading, rock strength, geology, pore pressure, weather effects, underground workings, and many other factors contribute to slope instabilities that range from small rock falls to massive slides of material. While some of these failures can he predicted or controlled by preventive measures, each year many completely unexpected failures occur. Current methods for monitoring generally involve measuring displacements at a few, selected points in and around the suspected area of instability. While most of the displacements along these points will be in a downslope direction, freeze-thaw cycles of water-filled joints, horizontal stresses or pressure, buoyancy in saturated soils, human measurement errors, or other situations can produce deformation in almost any direction, even without any instability in the slope. Determination of which, if any of the observed movements represents a potential hazard is essential.

Jan 1, 1998

By J. H. Tu

The technical paper correctly points out that the kriging variance is not a good measure of the uncertainty of the estimated (i.e., kriged) value of individual blocks. The au thors claim that their proposed jackknife method, which is a rekriging of each block by eliminating, in turn, one sample from the original sample set and then taking the average of the rekriged estimates, not only gives good block estimates, but the resulting jackknife kriging standard deviation is a useful indicator of the "true uncertainty associated with block estimates." However, they immediately abandon the idea of using the block-by-block standard deviations, reasoning that these standard deviations are not independent and that there is no easy way to utilize them. There may be another reason for not using them. The jackknife standard deviations for individual blocks given in their example are mostly in the range of 0.004 to 0.005 oz/st (0.14 to 0.17 g/t) with only one block having a high value of 0.012 oz/st (0.41 g/ t). These individual block standard deviations are as low as the jackknife standard deviation for the mean grade of the entire shape, i.e., 0.0041 oz/st (0.14 g/t). Do they represent the "true uncertainty" of the individual block estimates? Could the authors explain this? In a global shape consisting of a large number of blocks, any given sample will affect the kriged estimate of only those few blocks within its vicinity. This is the rationale for the authors' selective rekriging, making the jackknife algorithm more efficient. On second thought, why not do away with jackknifing altogether? Just cumulate and normalize, if necessary, the kriging weights of each sample used during the ordinary block kriging process, and then compute the global variance from these kriging weights and their respective sample grades? After all, isn't the global mean grade nothing but the weighted average of the samples used in the estimation? Reply by G.S. Adisoma and M.G. Hester The jackknife is one of the many tools in a practitioner's toolbox to solve estimation problems. The strengths of the technique lies in its simplicity, i.e., it uses the concept of mean and standard deviation and the fact that it can be easily combined with other tools, in this case kriging. Because the jackknife kriging (JK) estimate is also the mean of the pseudovalues, the JK standard deviation is attractive just as the standard deviation of the mean explains the variability of the data. The difference is that the pseudovalue calculation in jackknife kriging uses the ordinary kriging (OK) weighting scheme instead of simple arithmetic averaging. The data used to illustrate the jackknife technique in the paper consist of high values that are roughly three times the low values. The resulting JK estimate of the block grades show that the highest estimate is roughly twice the grade of the lowest estimate. The contrast between the low and the high estimate is more evident in the JK estimate than in the OK estimate, even though the mean grades of the blocks for the two estimates are very similar. Nonetheless, in this paper, we are concentrating more on the need for a more realistic measure of uncertainty, or precision, for the estimate. Unlike its OK counterpart, the JK standard deviation of the blocks clearly reflects the original data variation. The highest JK standard deviation of the blocks is three times its lowest value. This follows our intuition that, when the samples used to estimate a block is more variable, the resulting estimation variance (or standard deviation) should be higher than the case where the samples are more uniformly valued. However, block-by-block standard deviation or variance is of little practical value in reserve estimation and classification, as well as in mine planning. One is usually more interested in quantifying not the variance of the individual block estimate, but the uncertainties associated with a much larger dimension, such as the minable reserve. Thus, the thrust of the paper is to find a simple way to obtain a single estimation variance or standard deviation associated with the reserve grade estimate. The discussion by J.H. Tu did not mention how one would obtain the global variance from the OK weights and the sample grades. As a technique that offers a data valuebased measure of uncertainty for its estimate, the "leave-one-out" jackknife fills this need nicely through the block kriging shortcut approach described in the paper. Note: The first column and the last two columns of Table 3 in the paper should have contained a single number each, namely, an OK estimate of 0.0317, a JK estimate of 0.0333 and a JK standard deviation of 0.0041 oz/st, respectively, for the shape, as are obvious from the text. ?

Jan 1, 1998

By Harrison AT, Smart RM

Backfill systems using unconventional cementitious hinders have been successfully used in relatively deep and hard rock tabular mines for longwall, scattered stoping and shaft pillar removals. Two unconventional cementitious systems are discussed: 1. A ground granulated blast furnace slag (GGBS) with an activator containing lime. This has been used with a total tailings 'stable' slurry at a relatively low dosage of less than seven per cent, by mass, based on dry solids. The room and pillar stopes supported with this fill were up to 20 in high and the tailings were relatively high in pyrite. .\ GGBS binder plus a silicate based activator and gelling agent that virtually eliminated all water drainage (and hence post filling shnnkage). The system used a slurry, but the addition of the ;iutivator created a final placed product that had the behaviour of a paste. The system has been successfully used for almost ten years in the following applications: ò sloping widths (mining heights) above 1.6 in; and ò shaft pillar removals in seismically active areas at the end of the life of the shafts. \This paper discusses the technical merits and costs of the systems and compares them to other fill systems (including true paste systems).

Jan 1, 1998

By J Palarski

Over the last 100 years in the Polish mining industry considerable work has been done to assess optimum slurry, develop flexible delivery systems and adjust the fill technology to a wide variety of mining and geological conditions. Sand or industrial mineral waste materials for the backfilling of underground voids are used to control ground movement and surface deformation. This paper discusses various criteria to he considered in the preparation of a fill, including slurry properties, mine infrastructure, mining geometry, placement methods and the purpose of the backfill. This paper presents laboratory and in situ test data on the influence of materials parameters on the slurry flow in a pipeline system, stiffness, permeability, binding time and strength of a backfill, on the distribution of mixture in underground voids or the penetration between roof fall Materials.

Jan 1, 1998

By V. B. Achanti

This paper deals with the effect of various bit geometric parameters on failure characteristics of rock material. Improvement of rock cutting efficiency of continuous mining machines has been an interesting research topic for the last few decades. In the current study, an automated rotary rock cutting simulator, duplicating a continuous miner, was utilized to study these parameters in the laboratory. Improvement of bit performance in terms of its life, cutting efficiency, dust production and energy consumption has drawn wide spread attention over the years. Research shows that optimizing bit parameters can result in efficient fragmentation of rock. Indiana limestone rock material was utilized in this study while bit tip angle, bit tip size, bit spacing, depth of cut and cutting velocity of rotary drum were varied to investigate the failure characteristics. The cutting pressure, penetrating pressure and the depth of cut were monitored on the simulator during the cutting process. Air borne dust and settled dust were measured for each experiment. Then, the specific airborne dust and specific energy were determined for the each type of bit. Triaxial tests were carried out to correlate the failure angle of the rock in static case to dynamic cutting process failure. The physical and mechanical properties of the rock were also determined in order to assess their influence on the wear characteristics of each bit.

Jan 1, 1998

By J. G. Groppo

Froth flotation has been shown to be an effective method for reducing Loss-on-Ignition (LOI) of ponded or landfilled fly ash. Reduction of LOI is required for many fly ashes, particularly those produced from low-No, burners, in order to meet ASTM requirements for use as a mineral admixture in Portland cement concrete. An additional ASTM requirement, fineness, is critical in determining end use applicability, and in many cases, classification of fly ash is necessary to produce an acceptable product. Hydraulic classification has been shown to be a simple, cost-effective method for classification of a variety of minerals including silica, phosphate, mica, coal, etc. and has shown to be similarly effective on fly ash. The combination of froth flotation and hydraulic classification facilitate the production of a high quality pozzolan that meets or exceeds ASTM specifications. This combination has been rigorously evaluated and results of pilot-scale testing are presented. Pilot scale testing was conducted on fly ash from two active utility storage ponds and demonstrated that high quality, consistent pozzolan could be produced using APT's Fast Float? Technology. Along with the pozzolan, additional production of aggregate for masonry mortar and a low sulfur, medium Btu fuel were also demonstrated. The Fast Float? process incorporates several simple unit processes to ensure pozzolan consistency; classification controls particle size distribution which is critical to achieving early strength, flotation controls the grade with respect to L.O.I. (Loss on Ignition) while dewatering controls the moisture content.

Jan 1, 1998

By B. W. Cavender

Capital investments are made for a variety of purposes, from providing incremental capacity at existing operations to developing and implementing new technologies intended to radically improve a company's capabilities. These projects generate very different business opportunities and create value in distinctive ways. For incremental improvements, the capital budgeting process assures at least a loose fit between short-term goals and readily available resources. However, the criteria used to evaluate capital projects often prevent a company from committing to more aggressive goals that lie beyond the firm's current abilities or resources. Such projects may not have clearly identifiable future cash flows, and the degree of interaction with other projects and the nature of the risk incurred may be difficult to estimate. Additionally, by focusing only on quantifiable benefits, the budgeting process often fails to recognize "soft" improvements such as increased operating flexibility or new knowledge generated by such projects. By rejecting these projects, the capital budgeting process may actually harm the company's future competitive position.

Jan 1, 1998

In October 1993 it was decided to undertake the fourth phase of mining at Big Bell. This decision followed the exhaustion of open pit reserves in January 1993. Two stages of mining were proposed for the new underground mine. The initial stage would mine the remnant ore, consisting of the rib and crown pillars and lower grade ore on the hangingwall and footwall side of the old open stopes, which were mined from the 1930s to 1950s. Most of the old open stopes were backfilled with either deslimed mill tailings or development mullock, both of which were economic to recover. However, the mineable ore from this resource was difficult to evaluate. The second stage focused on mining ore outside the remnant areas and was initially proposed as a Core and Shell method under a caving hangingwall. This method has since been superseded with sublevel caving, in part due to the very high and deviatoric stress conditions encountered at Big Bell and the relatively long mining cycle required for open stoping. The problems and challenges discussed in this paper will cover the identification of remnant ore reserves, dewatering the old workings, and remnant mining.

Jan 1, 1998

By Ian Hutchison, Michael C. Salmon

TRC'S INNOVATIVE EXIT STRATEGIES™ FOR MINE CLOSURE , MINE "EXIT STRATEGIES™", WHAT IS AN EXIT STRATEGY™?

Jan 1, 1998

By Kwadwo O. Adutwum, George M. Potter, Todd J. Harvey

Ashanti Goldfields Company (AGC) is the largest gold mining company in Western Africa. Their jewel operation is a highly inte­grated set of mines and plants situated in Obuasi, in the Ashanti region of Ghana. This operation is responsible for mining 5.5 mil­lion tonnes of ore at 4.6 git annually from a series of open pits and underground mines. The sulphide ore is highly refractory with untreated gold recoveries in the range of 30-40%. The milling facilities are quite varied and include an oxide treatment plant (OTP), a heap leach, a sulphide roaster circuit (PTP), a tailings treahnent plant (TIP) and the most recent, a sulphide treatment plant (STP). The sulphide treatment plant, the world's largest stirred tank biooxidation circuit, was commissioned in early 1994. This plant treats approximately 800 tonnes of refractory gold con­centrate per day with overall recoveries of75-85o/o(ll, Biooxidation was selected for its ease of operation and less exotic maintenance requirements as well as its ability to achieve comparable gold recoveries. Unfortunately, despite stirred tank biooxidation being one of the lower cost methods of treating refractory ores, it is still too costly for low grade refractory materials. GeoBiotics, Inc. has developed a proprietary technology that allows the economic treatment of lower grade refractory gold ores through heap biooxidation. AGC has a significant resource of low grade refractory sulphide ore. This ore is too low grade to warrant BIOX™ sulphide treatment and its oxide plant recov­ery is low at 35-45%. GeoBiotics and AGC have completed pre­liminary testing and economic analysis of heap biooxidation for this material. Additionally, the feasibility of producing a gravity concentrate from the tailings of the sulphide treatment plant has been explored. This concentrate would be coated onto the low grade sulphide and biooxidized concurrently. Gold recoveries for the biooxidized low grade sulphide have increased to 75% and the gravity recovery from the STP tailings has achieved 80% uti­lizing a Falcon concentrator. The preliminary economics of the proposed full scale plant are very favourable with a pre-tax IRR of 233% and a payback period of 6 months. This paper details the biooxidation testing, flow sheet devel­opment and preliminary economics of employing heap biooxi­dation for low grade refractory ore treatment at Ashanti Goldfields' Obuasi operation.

Jan 1, 1998

By Roy Norcross, Stephen Gos

For over 100 years Degussa has worked together with the min­ing industry not only providing quality products but also develop­ing technologies to support these products through value added goods and services. For cyanide, these technologies include leach enhancement processes such as PAL™ and Solidox™, and cyanide detoxification with peroxygen based processes such as SILOX™ and Caro's acid using our DegOX™ technology. Degussa has also made important advances in how sodium cyanide is packaged and shipped with our liquid NaCN plant joint venture with MSI, CYANCO in Winnemucca, Nevada, and our Advantage SLS™ solid to liquid cyanide delivery system. All of these innovative technologies developed to support NaCN in mining, provide value to our customers and show Degussa's commitment to Responsible Care·11.1 and dedication to product stewardship. With Responsible Care and the customer in mind, Degussa has developed Advantage CCS™ cyanide control system, which will soon be available for the North American market. Currently there are several CCS units in service installed by Degussa AG (Germany), and we are in the process of designing the next gen­eration of the CCS which should be completed by late '98. Based on our experience working with gold and silver mines all over the world, there appeared to be an opportunity to further assist our customers by providing a better more automated way to control their cyanide additions. By providing the mine with an accurate method for maintaining their desired cyanide levels in their leach circuits, we could help them avoid underdosing and the associated gold and silver losses, and overdosing the cyanide which not only wastes cyanide but may increase treatment costs as well. In the early 1990's, when we began to introduce our CCS units, there were several cyanide controllers and on-line analyzers avail­able. However, they appeared to be too complicated and not made to stand the harsh conditions inside a mill. This resulted in exces­sive downtime and poor analytical results. We also found that many units would be installed but not commissioned by the sup­plier. Based on these observations, along with filtration and con­trol problems on some existing units, Degussa decided to design its own cyanide control system based on our extensive knowledge of cyanide chemistry, using the best components available worldwide.

Jan 1, 1998

By Chitombo GPF

The dilution of blasted ore with cemented backfill materials has been recognised as a significant factor influencing the economics of some underground metalliferous mining operations. Several mechanisms have heen identified as possible causes of fill failures. The purpose of this study was to determine the possibility of damage as the result of one mechanism, that of production blasting adjacent to bodies of cemented hydraulic fill (CHF). A vibration amplitude transfer function has been developed to model the transmission of blast vibrations from the source, through ore, across the ore to CHF interface and into the CHF mass. The model may be applied in the near field. The model has permitted estimation of vibration amplitude at a point in a CHF mass, to which damage criteria may be applied. A number of assumptions and simplifications have been made to render the problem relatively tractable. Ore and CHF material characteristics recorded by a number of authors were utilised to formulate preliminary damage estimations. A simple application of the amplitude transfer model indicated that a zone of plastically deformed CHF would be produced, and would extend to a distance of approximately 0.5 metres from the interface into the CHF. A sensitivity analysis was also conducted, that indicated that the zone of plastic deformation would be more extensive given appropriate conditions. Recommendations for further model development and future laboratory and field investigations have been made.

Jan 1, 1998

By John A. Lombardi

The solutions used in the heap biooxidative treatment of sulfidic refractory Au ores and concentrates generally load free mineral acid and metals and, in time, become bacteria activity inhibiting due to increased acid and/or metals concentrations. The metals­acid loaded, bacteria action inhibiting, solution must then be: (a) processed, prior to re-use, to reduce its metals and/or free acid mineral acid components to bacteria activity compatible levels; or (b) neutralized prior to discharge. The most common solution processing method to adjust acid-metals contents is liming to effect the precipitation of dissolved metals and neutralization of acid sufficient for solution discharge or re-use. The lime treated solution is high in suspended, colloidal precipitates and requires clarification before reuse. Most often the "bleedstream" of biooxidation solution that is lime treated is discharged and req­uisite volumes of fresh water added to the process inventory. Depending on the level of bacterial action in a heap and the acid consumption characteristics of the ore/concentrate being biooxi­dized, the bleedstream taken from the circulating, irrigation on­off, solution, can be large (e.g., 10%-20% and sometimes as much as 50% of the daily solution flow requires treatment-dis­charge). The lime charge for bleedstream treatment is commen­surately large and represents a major operating cost of the bioox­idation process. The patented HW Process Technologies (HWPT) Engineered Membrane Separation (EMS™) method is an alternative biooxi­dation bleedstream treatment method. EMS™ processing removes the multivalent base metals ions in an acid solution to a small volume EMS™ "concentrate" (typically 25% of the feed­stream volume). The EMS™ method coincidentally makes a "clean acid" EMS™ "permeate" (typically 75% of the feed­stream volume). In general, EMSTM processing enables 75% of the bleedstream volume to be recycled; allows up to 2/3 of the bleedstream acid to be recovered as a 10% solution; and delivers dissolved metals in a highly concentrated stream suited to a. metals recovery or b. reduced cost lime neutralization for a given metals precip­itation relative to full bleedstream neutralization (typically a 30% lime use savings). Implicit in the recovery of process water for re-use and reduced reagent addition requirement for metals precipitation is a significant reduction in wastewater-sludge dis­posal facility size.

Jan 1, 1998

By Robert Dunne

Over the last eighteen months, there has been a dramatic r decrease in the gold price fom US$450/oz to a low of US$275/oz. The prospect of low gold prices, around US$300/oz, appears to be a reality the gold mining industry will have to face over the next couple of years. Already some high cost operations have closed and at others, cost cutting measures and rationalisation have been or are being undertaken. This paper reviews the operating cost of some Australian mines and highlights the potential for cost cutting and demon­strates individual impacts on the dollar's reduction in the cost per ounce of gold.

Jan 1, 1998

By Ann Hubbs, Vincent Castranova, Jane Y. C. Ma, De-Hwa Chao, Joseph K. H. Ma

AN OVERVIEW OF THE ACTION OF TETRANDRINE ON SILICOSISBecause of the persistent presence of silica dust in the lungs silicosis is a progressive and irreversible disease. At present, there is no proven effective therapy for silicosis. Limited choices of therapeutic intervention with corticosteroids and other immunosuppressive regimens 1,2 have been accepted for some forms of pulmonary fibrosis. These treatments are only minimally effective, and the results provide little understanding of the disease state due to the lack of correlation between drug activity and the mechanism of fibrosis. Thus, continuing effort must be made in the search for effective antifibrotic agents, which may be used to provide a sequential analysis of the fibrotic process and to open the door for further research and clinical development. Tetrandrine is one of hundreds of drugs screened for antifibrotic activity by Chinese scientists. It has been used in China as a treatment for silicosis in open clinical trials3 and in laboratory animals. The action of tetrandrine on pulmonary fibrosis has been attributed to its ability to inhibit particle stimulation of alveolar macrophages, a key cell type central to the fibrotic process, to release oxygen radicals and inflammatory cytokines. Alveolar macrophages (AM) residing on the alveolar wall, are the predominant phagocytic cells of the lungs responsible for pulmonary defense against inhaled microorganisms and other particles and thus play an important role in maintaining the homeostasis of the lungs. 7 Ample evidence suggests that cells of the monocyte-macrophage series play an important role in the immunopathogenesis of pulmonary fibrosis. When upregulated by silica, alveolar macrophages generate reactive oxygen metabolites8·9 which can damage lung parenchyma and release fibrogenic growth factors and cytokines, 10,11 such as interleukin 1 (IL-1), which can induce fibroblast proliferation and collagen synthesis. The cytokine-mediated fibroblast proliferation and collagen synthesis are key steps in the development and progression of pulmonary fibrosis .11 Previous studies by our group have shown that tetrandrine exhibits strong binding affinity to AM and inhibits particle-stimulated respiratory burst activity (oxygen consumption, superoxide anion release, and hydrogen peroxide secretion) in these cells. 13 In addition, studies by Kang et al. 14 have reported that tetrandrine inhibits silica-induced release of fibrogenic factors such as IL-1 which are capable of inducing fibroblast proliferation and collagen synthesis. Reist et al. 15 further suggested that the antifibrotic action of tetrandrine may be mediated in part by the direct effect of this drug on the ability of fibroblasts to respond to proliferative agents. These results indicate that the mechanism of silicosis involves activation of AM and fibroblasts by silica, resulting in abnormal collagen production due to miscommunications between the cell types. Tetrandrine may interrupt this process by direct interaction with the lung cells.

Jan 1, 1998

By John R. Goode

Barrick Gold Corporation operates gold mines in the United States, Chile, 'Peru, Canada, and in the near future, in l1anzania. Barrick meets environmental requirements and limits the potentially adverse effect of cyanide discharge to the environment using various cyanide destruction techniques. Barrick operations use, or have used, natural degradation, ferrous sulphate, hydrogen peroxide, Caro's acid, alkaline chlorination, and the SO/Air process for cyanide destruction. This paper presents a general discussion of the options for controlling cyanide in plant effluent and provides details of Barrick's operating experience including general notes on costs.

Jan 1, 1998

By D. Scott Barr

The Zarafshan/Newmont Joint Venture operates the Muruntau heap leach project, located in the Kyzylkum desert of central Uzbekistan. The mine produces more than 12.4 t/a (400,000 oz/year) of gold from low-grade oxide ore stockpiles adjacent to the Muruntau open pit. It is op¬erated by the Navoi Mining and Metallurgical Combine and is one of the largest gold resources known (Fig. 1). Since commissioning in 1995, total heap leach production has exceeded 21 t (675,000 oz). The joint venture uses four-stage crushing and screening to produce a final product for heap leaching, Merrill-Crowe processing and local refining.

Jan 1, 1998