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With the continued drop in export coal prices (as measured in US$) delivered to the Pacific Rim market, and a fixed annual 12 per cent increase in overburden, Usibelli Coal Mine Inc was faced with the need to reduce mining costs substantially or else forfeit its foreign coal contractual commitment which amounted to about half of annual mine output. Management made a difficult and fortuitous decision to proceed with an engineered plan to switch from a two seam, extended bench dragline operation to a two seam, cast blast and spoil side operation. While down-sizing and cut-backs became the rule in all departments of the mine, the drilling and blasting budget was more than doubled. Most will agree that this is contrary to what usually happens when a mine is faced with down sizing. The more common scenario would have management target the drilling and blasting budget for decrease as a first priority to cutting cost, and then later witness a decrease in equipment performance leading to an increase in the production cost per tonne. Although Usibelli Coal Mine more than doubled its annual drilling an blasting budget three years ago, the overall stripping cost has be, reduced by more then 37 per cent.

Jan 1, 1995

By François Tremblay

It is well known that removal of organic material such ,as Jacquer, paint, plastic prior to melting improves aluminum recovery. In addition to being an important economically, decoating of aluminum scrap has a positive impact on the environment, through better control of gaseous emissions. Most of the existing thermal decoaters for aluminum have been designed to operate with scrap containing a level of organic material lower than 10%. The main field of their present application is for recycling of used aluminum can, where levels of organic material are lower than 4%. Alcan has recently developed a new thermal decoating system in order to extend applications of this process to a much wider variety of aluminum scrap. The new decoater efficiently processes aluminum scrap with a level of organic material up to 50%. This new technology features the use of fluidized bed technology to thermally control the process. This innovative feature improves both performance and control over conventional delacquering systems based on hot air convection. This paper describes the basic principles of the technology and the design of the? first industrial unit commissioned by the Alcan Recycling plant in Shelbyville (TN) at the beginning of 1994. Typical applications and operating advantages are discussed.

Jan 1, 1995

By R. K. Singhal

A sizable surface mining industry exists in Western Canada. There are the surface coal mines in the provinces of Alberta, British Columbia, and Saskatchewan producing the bulk of Canadian Coal. The two oil sands plants in Fort McMurray, Alberta producing synthetic crude oil are surface mining operations. Much of the metalliferous mining in British Columbia is carried out by open pit methods. This paper discusses the current surface mining methods in both of these industries with particular reference to Alberta. Issues relating to environmental impact assessment, mine reclamation and mine site closure have been dealt with.

Jan 1, 1995

By Paton T. P

In the technical sense, as well as in the professional sense, the word 'model' can have many meanings. More than 23 000 references were uncovered by a simple literature search on keywords ' MO D EL#. and. (META LLURG#. or. M I NERAL#)' . For the purpose of this paper, 'models' will be considered to be mathematical formulations which attempt to represent or approximate a process. The model may be purely, or a combination of: ò fundamental models, based on the laws of physics, chemistry and thermodynamics; ò semi-empirical or phenomenological models, where an intuitive concept of the process is formulated and found by testwork to fit observed behaviour; and ò empirical or 'black-box' models (including neural networks), where a mathematically convenient form is proposed and fitted. Even under this more restricted definition, which eliminates heuristic and statistical 'models', it is clear that the efforts expended in devising and using models have exploded during the years since the first APCOM Conference in 1961, benefiting from the dramatic decrease in the cost of computer power. This paper reviews the areas of usage of computer modelling in the metallurgical and mineral processing industries, from plant design, through off-line support, to on-line modelling and automatic control. In each area, frontiers of new development of the technology are mentioned. It is noted that, while modelling is now standard practice in design, it is not yet the norm in operating and controlling plants. The reasons for this partial acceptance are, it is argued, less related to the limitations of the technology than to the human and organisational factors involved in transferring technology to implementation.

Jan 1, 1995

By Jacqueline A. McClaskey

The U.S. Bureau of Mines (USBM) Information and Analysis Directorate collects worldwide data on virtually every commercially important nonfuel mineral commodity. These data form the base for tracking and assessing the health of the minerals sector of the U.S. economy. The USBM's data collection activity was instituted by the 47th Congress in an appropriations act of August 7, 1882 (22 Stat. 329), which placed the collection of mineral statistics on an annual basis. The most recent authority for the USBM survey activity is the National Materials and Minerals Policy, Research and Development Act of 1980 (Public Law 96-479, 96th Congress). This act strengthens protection for proprietary data provided to the U.S. Department of the Interior by persons or firms engaged in any phase of mineral or mineral-material production or consumption.

Jan 1, 1995

By Szymanski J, Planeta S

For many hard rock mines with near surface deposits, the surface crown pillars form the first line of protection for the immediate underground workings. Underground stopes are typically contained by crown pillar, which protects the level above, rib pillars, and a sill pillar through which the ore collection system is cut. This paper discusses the mining of these pillars, with particular emphasis on the overall stability of the mined out upper part of the mine areas. An area of interest is located in the Canadian Shield, where the mining has progressed below four thousand foot level in the ultramafic high grade sulphide type of orebody.

Jan 1, 1995

By C. L. Schneider, R. P. King

The ability to predict the liberation spectra that will be produced by a closed-continuous grinding circuit is of fundamental importance for the design, optimization and control of most operations in an ore dressing plant. The only known approach through which such a calculation can be performed is the population-balance-model equation. The latest, and certainly most significant, advance made in this area is the solution proposed by King (1990), which requires one textural parameter measured directly from the ore being studied. The main advantage of King's solution is that, unlike the conventional solutions, it does not require the estimation of hundreds of arbitrary parameters that cannot be independently measured. However, King's solution relies heavily on a knowledge of the detailed internal structure of the Andrews-Mika diagram (Andrews and Mika, 1975), which has never been measured for any ore. The characterization of the internal structure if the Andrews-Mika diagram requires the measurement of the liberation spectra at several progeny sizes produced by the breakage of monosize-monograde particles at several different grades. In this paper, a procedure based on magnetic fluid fractionation for generating seven narrow-size, narrow-grade samples is presented. Each of these samples was then broken into six progeny size classes in an ultrasonic mill. The one- dimensional liberation spectra of each of the 42 progeny and seven parent particle samples were then measured by image analysis. The measured linear-grade distributions are presented in this paper. The calculation of the correspondent volumetric-grade distributions is discussed.

Jan 1, 1995

Today's emphasis on the enterprise bargaining process must be seen as an opportunity for organisations to further develop occupational health and safety standards at work. In particular, this shift from a centralised industrial relations system to employer, employee bargaining, presents organisations with an excellent opportunity to develop OH & S at the `shop floor' level. This is despite real difficulties in presenting hard data on the cost benefits. Unfortunately, examination of enterprise agreements ratified by the Australian Industrial Relations Commission (AIRC), show that less than 32 per cent contain provision for occupational health and safety. Those addressing the issues of occupational health and safety have included segments such as: ò rehabilitation activities; ò a new emphasis for workplace occupational health and safety committees; ò formalising procedures related to hazard identification and control; ò the use of personal protective clothing; and ò occupational hygiene and health monitoring issues. For example, an enterprise agreement reached between CIG-Gases and their unions, included clauses which commit employees to attending ten safety meetings and two work place inspections each year, in order for them to receive any further pay rises.

Jan 1, 1995

By Alvin D. Christmas

The missing link is a connector between the congested downtown area of Knoxville, Tennessee adjacent to the former World's Fair site, the I_40 I_75, and Western Avenue traffic arteries. This connecter was designed to accommodate the 37,470 motorists who presently travel through these highly congested narrow paths to be replaced by the 21.8 million dollar Henely Street Connecter. All construction and blasting was to take place while existing traffic was re_routed so as to allow access between the downtown area and the vital interstate corridor. To avoid major traffic problems, the project was to be accomplished in three phases: (1) the Western Avenue viaduct demolition; (2) two new viaducts to be constructed; (3) the open box cut at Henely Street next to the L & N Depot. Due to the past attempts by the Fort Sanders Community Home Owners group and the Historical Society to stop the Henely Street Connector, this project involved a very comprehensive blasting damage control program with special provisions of .5 inches per second measured at the foundation of the closest structure.

Jan 1, 1995

By Kuo En Chang

Many rare earth - transition metal (RE-TM) compounds absorb/desorb hydrogen reversibly at room temperature and atmospheric pressure. For LaNi5 which is used as a battery material, the electrochemical nature of this process is well known. In the case of Nd-Fe-B which has found wide application as a powerful permanent magnet, the absorption of hydrogen has both significant advantages and disadvantages. However, a fundamental understanding of the hydrogenation process at ambient temperatures and its effect on subsequent corrosion behavior is currently lacking. This paper reports the results of the hydrogenation of NdFeB two alloys, (NdDy)15Fe78.3A10.7B6 and (NdDy)15Fe67Co5V4A12B7, which are compared with that of LaNi5. Results show that hydrogenation can be accomplished by either electrochemical methods or immersion in dilute sulfuric acid. For the latter method, the change in lattice parameter indicates that the level of hydrogen absorbed by the NdFeB particles corresponds fairly closely to an overall composition of Nd2Fe14BH2.7. Cyclic electrochemical charge/discharge experiments show that the maximum hydrogen discharge capacities of the NdFeB, NdFeB-Co-V, and LaNi5 are 40, 60, and 210 mA?h?g-1, respectively. Anodic potentiodynamic polarization measurements and calculated values of icon reveal that absorbed hydrogen in NdFeB-Co-V and the NdFeB may lead to significant increases in corrosion rates.

Jan 1, 1995

By Ramani R. V

In this paper, a comparative performance evaluation of geostatistical, spectral, and fractal methods is made for short-scale variability prediction. The algorithms compared are: sequential Gaussian simulation method; a random fractal algorithm based on the generalised stochastic subdivision method; and a spectral simulation approach adopted for direct multi-dimensional simulation. The data for this study have been obtained from a mined out coal property. As this property was being mined, a 7315 m by 7315 m (24000 ft by 24000 ft) coal block was extensively sampled at an approximate spacing of 107 m (350 ft) and the 60-ton samples were analysed for sulphur in the 1.50 float gravity fraction. This data set is used here with the three methods to generate the simulated realisations, which are analysed for semivariogram reproduction and for simulation errors. Although all three methods converge to the true semivariogram in an average sense, the coefficient of variation of the average semivariogram for the Fourier integral method is minimum. The realisations generated by the sequential Gaussian method have minimum mean simulation error. The choice of a simulation method based on variability reproduction and simulation errors remains difficult.

Jan 1, 1995

By G. F. Friel, J. C. Edwards, C. C. Hwang

In the implementation of a mine fire alarm and location strategy, the Interpretation of the fire signature Is Important. Smoke and CO are the two dominant fire signatures, and many mine fire detection systems utilize sensors which respond to smoke or CO through a diffusion mode or a mechanical pump mode. The fire signature may be modified during its transport along airways and at crosscuts. The modification occurs through dilution of the contaminants. In this Investigation, computer codes were employed to compute the effects of contaminant dilution on the contaminant signature when a straight flow passage has one dead-end crosscut. The model predicted the airflow within always and the entrainment of contaminants into the crosscut from the airway. One application of the model is to determine the most suitable location for CO detectors for early mine fire detection.

Jan 1, 1995

By Stephen H. Chung

The SABREX computer blast simulation program permits the study of the effective use of explosive energies and predicts the total performance of a blast in terms of:fragment size distribution: muckpile profile; breakage at grade, column and collar with respect to the control case; crack penetration; damage envelope behind and beneath blastholes; a complete cost analysis including explosives, drilling and accessory costs

Jan 1, 1995

By A. C. Nixon, A. D. S. Gillies, Hsin Wei Wu

Ventilation and refrigeration strategies for the 3000/3500 orebodies, Mount Isa Mines, Australia were reviewed. The orebodies lie between 1,200 and 1,800 m below surface and are characterised by steep geothermal gradients, intensively mechanised stoping methods and high ambient air temperatures in summer. Providing acceptable working conditions under these situations is difficult and costly. The ventilation air quantity required in the 3000/3500 orebodies exceeds 550 m3/s when the production rate is greater than 2.5 million tonnes per year. The maximum quantity that can be supplied and exhausted using the existing intake and return ventilation system is estimated at about 630 m3/s. For production rates greater than 3 million tonnes per year, either new intake and return airways will need to be developed or innovative approaches such as controlled partial recirculation used. A description is given of technical and economic investigations conducted at Mount Isa into controlled partial recirculation. During these investigations, a major field trial of a controlled partial recirculation system was undertaken with results indicating that an acceptable working environment can be achieved practically and economically utilising this approach. The cost involved in controlled partial recirculation for supplying the required ventilation quantity when the production of 3000/3500 orebodies exceeds 3 million tonnes per year is examined. A cost comparison between recirculation and other conventional alternatives such as new surface shaft or underground booster fans is included. The results indicate that the option of a new surface shaft will incur a high initial capital cost and moderate annual operating costs. The alternative of underground booster fans will necessitate a moderate capital cost and very high operating costs. Controlled partial recirculation, in this case, offers both the lowest capital and operating costs of the three options evaluated.

Jan 1, 1995

By Bernardo Portillo, Alejandro Perez, Daniel Norrgran, Joseph Wernham

High gradient permanent magnetic separators (termed "Ferrous Wheel") are described as used to recover the iron bearing minerals from mill tailings at the Grupo Acerero del Norte's Hercules iron mines in Coahuila, Mexico. The pilot scale test work as well as the "in-plant" test work provided the basis for a 385 MTPH plant expansion to be commissioned late in 1995. Approximately 6 million metric tons of flotation tailings averaging 50 percent iron, mostly as hematite, are contained in two separate ponds. The tailings are relatively fine at 93 percent -200 mesh and 72 percent -500 mesh. After testing various recovery methods, a high gradient permanent magnetic separator was selected to produce a preconcentrate prior to flotation. The separator uses a flux converging matrix to generate high gradient magnetic fields and capture the hematite. The advantage of the Ferrous Wheel high gradient permanent magnetic separator is the use of permanent magnets as opposed to electro-magnets. Further the vertical rotating ring is much more conducive to matrix cleaning as opposed to the conventional horizontal ring separators. This feature also allows the use of a wide range of matrix materials to achieve the optimum metallurgical response

Jan 1, 1995

By C. J. Beyke

In recent years recycling of household batteries has received increasing attention, primarily for environmental reasons. This article reviews the major battery types and some of the technologies available to recycle them. It also discusses issues such as collection and sorting which are related to battery recycling in the United States. Finally, results from research being conducted by the U.S. Bureau of Mines on the reclamation of nickel-metal hydride, alkaline, and zinc-carbon batteries are presented.

Jan 1, 1995

By Lloyd M. English

During the past 30 years, the research arena has changed significantly in all fields, mining included. The relative representation of the topics of research, how the research is performed and who has performed the research have all changed. Although there are a lot of subjective ideas and anecdotal "analyses" concerning these changes, there has been no actual study of these trends to verify the facts. This study was divided into six five-¬year periods for the purposes of comparison. Some of the trends analyzed are co-authorship, research areas, research sponsors and cooperative efforts. In today's research arena, 30 years is a long time. Technology has advanced more rapidly than in any time previously and that pace continues to increase. There are more researchers, more tools for research and an increasing number of companies, agencies and institutions engaged in research. The pace of change and its impact is often discussed and debated at professional meetings and in institutions that engage in research. These conversations will often influence the research decisions of the participants in directions to take or subjects to pursue.

Jan 1, 1995

By Robert W. Bartlett

Biooxidation of an ore heap containing only a few percent of sulfide minerals requires insertion of a very large amount of oxygen either by natural air convection, forced air ventilation or gaseous diffusion. While shallow heaps, those with lateral distances much greater than their height, are of great interest for many heaped ore processing operations, natural convection is often ineffective for oxidizing them because of inadequate lateral flow into the heap's interior. Oxygen can diffuse into a shallow heap from its upper, horizontal surface in contact with air. Oxygen diffuses through the air-filled void space within the heap, driven by the oxygen concentration gradient resulting from internal oxygen depletion caused by mineral oxidation. Oxygen diffusion, coupled with the chemical reaction kinetics oxidizing the sulfide minerals, is analyzed for conditions of rapid mineral oxidation kinetics, requiring small mineral grain sizes, and for typical ore heap biooxidation parameters. Practical limits on heap heights are presented for effective biooxidation of the sulfide minerals within times of interest for heap biooxidation of refractory sulfide gold ores, one to three years.

Jan 1, 1995

By Claude Cunningham

The primary reason for blasting is to fragment rock. In production blasting, the fragment sizes produced are known to exercise an overwhelming influence over working costs: handling costs and tonnage throughput are directly affected by secondary breaking, loading and crushing, all functions of fragmentation. In addition, particular size fractions are frequently of intense interest in terms of market or process requirements.

Jan 1, 1995

Caving is the lowest cost underground mining method, provided that drawpoint spacing, drawpoint size and ore handling facilities are designed to suit the caved material and that the drawpoint horizon can be maintained for the draw life. In the near future several open pit mines that produce in excess of 50 000 tons per day will have to examine the feasibility of converting to low cost, large scale underground operations. Several other large scale, low grade underground operations will experience major changes in their mining environments as large dropdowns are implemented. These changes demand a more realistic approach to mine planning than has occurred in the past, where existing operations have been projected to increased depths with little consideration of the change in mining environment that will occur. As economics force the consideration of underground mining of large, competent orebodies by low cost methods, the role of cave mining will have to be defined. In the past caving has generally been considered for rock masses that cave and fragment readily. The ability to define cavability and fragmentation, the availability of large, robust LHDs, a better understanding of draw control requirements, improved drilling equipment for secondary blasting and reliable cost data have shown that competent orebodies with coarse fragmentation can be exploited by cave mining at a much lower cost than with drill and blast Methods.

Jan 1, 1995