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By W. Morgan, D. Gove

In truck and shovel operations, productivity and cost per ton are influenced by the system matching choice, Optimization involves a balance of the size and number of trucks, the size and type of loading tool and the projected material conditions and haul roads. Caterpillar has updated its Fleet Production and Cost program so miners can more easily look at matching choices and optimize on the variable they choose. This paper introduces the Fleet Production and Cost program. It then demonstrates its capabilities with examples of optimization. Mining operations that use trucks need to properly match the number and size of hauling units (trucks, wagons, scrapers, etc.) to a loading unit (wheel-loader, hydraulic shovel-excavator, cable shovel, push tractor, etc.) to provide the best possible fleet match. Optimizing fleet match minimizes the cost per unit of material moved by that fleet. As haul conditions change (haul length, grade or rolling resistance), there may be need to adjust the number of trucks to maintain the optimum fleet match. Fleet Production and Cost is a tool that can be used to optimize the truck-loader match.

Jan 1, 1995

By Lovitt M

Ora Banda Gold Mine is located in the Eastern Goldfields of Western Australia. Mining is carried out underground by sublevel open sloping resulting in large open stopes. A Mass Blast of approximately 250 000 tonnes was carried out in July 1994 to recover a rib pillar between two stopes, and the crown pillar between the underground mine and the abandoned open pit above. Strategic development within 50 m of the blast consisted of two ventilation shafts and the main decline. This development required careful design and prediction of the blast results. This paper describes the design of the blast, the prediction of the likely effects, the measures taken to reduce the risk to important development, and the results of the blast.

Jan 1, 1995

By Torabi S. R, Daly C. R

Wind blast is the sudden movement of air displaced by the massive collapse of roof rock in underground openings and is experienced as a high velocity flow of air through adjacent workings. The initial flow in the outbye direction is often followed by 'suck back', that is a reverse flow of air towards the newly created void. As part of the Wind Blast Project, undertaken by The University of New South Wales, Department of Mining Engineering, a physical model was constructed. One of the functions of the laboratory wind blast model is to provide insight into the dynamics of the interaction between the falling strata and the air being compressed below. During a collapse, some air is expelled into the surrounding roadways while the remainder penetrates towards the top of the roof elements. In this paper two aspects of the rock mass properties which influence the phenomenon are considered: - Flow paths through the falling roof element, ie the permeability of the roof element; - Bed separation prior to the fall which introduces a void above the roof element. A series of tests was carried out utilising the physical model in order to investigate the relationships between the flow of air through the simulated roadways, the variations in gauge pressure above and below the falling roof element, and the acceleration and terminal velocity of the latter, all as a function of the flow paths through the roof element and of the extent of the void above. The results of comprehensive tests using the wind blast physical model suggested that the time history of outbye air flow in the simulated roadway comprises two distinct phases. a) A primary phase, characterised by a high velocity flow of air which exhibits a peak and corresponds to the period during which the roof element is accelerating. The peak air velocity is related to the acceleration of the roof element. b) A secondary phase, characterised by a residual air flow of a lesser velocity than in the primary phase and corresponding to the period during which the roof element is falling at its terminal velocity. The velocity of the residual air flow is directly proportional to the terminal velocity of the roof element. In a monolithic collapse of a roof element it was shown that the presence of flow paths in the roof element increased the air velocity in the roadway in both the primary and the secondary phases. The presence of an air-filled void above the roof element, on the other hand, influenced the air velocity only in the primary phase by increasing the peak air velocity. The overall duration of the process was however decreased as a result. 'plug type' collapses, where roof failure extends to the ground surface, potentially generate the highest peak air velocities likely to be encountered during wind blasts.

Jan 1, 1995

By Edward DeLilla

Formalized technical audits for mining machinery during manufacturing are a fairly new concept to the North American mining industry. Although used extensively elsewhere, especially in Australia, the concept of independent auditing of machinery design and manufacturing has been slow to gain acceptance in the United States and Canada. Simply stated, a technical audit is an independent, third-party review of all or specific portions of machinery design, manufacturing and assembly to verify compliance with purchase specifications and suitability of the machinery for the specified application. If specified correctly, the useful life of different kinds of structural and mechanical components can be extended beyond normally accepted usage. There is no reason why, if properly designed and built for the application, major structural components on mining machinery cannot be made to last for 20 years before being rebuilt. Also, gearing can be made to routinely last for 15 years.

Jan 1, 1995

By Dale S. Preece

A Discrete element computer program named DMC @istinct Motion Code) has been developed for modeling rock blasting. This program employs explicit time integration and uses spherical or cylindrical elements which are represented as circles in 2-D. DMC calculations have been compared with measurements on bench blasts in the field with relatively good comparison. Structural rock mass characteristics have a significant impact on any blast and DMC has not, until now, included these effects. This paper discusses a recently added DMC capability for treating joints and bedding planes in bench blast simulations.

Jan 1, 1995

By Mark S. Stagg, Stephen A. Rholl

The U.S. Bureau of Mines has developed computer software which uses fast Fourier transform (FFT) techniques to evaluate blasting data. The software is useful because it allows blasters to evaluate 1) the frequency content of ground vibration time history data; 2) the effects of initiator scatter on the frequency spectra of ground vibrations; and 3) the fragmentation distribution of rock muckpiles from photographs. A one-dimensional version of the software was used in the first two cases. Monte Carlo techniques were used to simulate the scatter of initiators.

Jan 1, 1995

By Jan K. Wolski

This paper presents a simple method for determining air temperature gradients along a tunnel with time-dependent intake air properties. The variable intake air properties may be the flow direction and rate, air temperature and humidity, and the carbon dioxide content. The transient intake air properties are simulated by a series of steady intake air conditions, using a superposition method. The mathematical model was verified by reduced-scale experiments in the Waldo mine. The method may be usefull in conditions where the computation speed is more important than the precision of the results.

Jan 1, 1995

By John A. Franklin, Tom C. Palangio, Norbert H. Maerz

No blast evaluation is complete without fragmentation measurements which until now were inaccurate, costly, time consuming and created delays in production. “WipFrag.s”is a fully automated PC based fragmentation analysis system that uses digital photo analysis techniques to measure broken rock. Fragmentation can be measured in minutes using compact videocameras for image acquisition. Even subtle changes in rack quality can be detected providing the information necessary for pattern optimization, explosives evaluation, timing selection, benchmarking and blast model validation.

Jan 1, 1995

By Nethery JE

At the Red Dome and Mungana deposits in north Queensland, Australia, it is proposed that mineralisation and alteration developed as a "telescoped" overprinting continuum, ranging in style from hypothermal to epithermal, reflecting the major changes that developed in the regional setting over the period circa 325 - 290Ma. Regional assessment suggests that this also applies to many other precious and base metal deposits within a 401an length of the host Siluro-Devonian Chillagoe Formation. A ten stage paragenetic sequence of structural preparation, multi phase intrusion and associated mineralisation, alteration and brecciation is postulated for the Chillagoe district.

Jan 1, 1995

By Streichfuss M, KeBler H-W, Burgwinkel P

This paper describes the design of an expert system used as a part of a diagnostic system for diesel hydraulic drives. A PC-based diagnostic system ruDi (KeBler and Burgwinkel, 1993) was developed to minimise the time for diagnosis and repair work of vehicles with diesel hydraulic drives used in the mining industry. One part of ruDi is an expert system that helps to locate errors in any of a vehicle's subsystems, and supports technicians in removing the cause of a malfunction. Apart from the standard knowledge of diesel engines and hydraulic transmissions, the expert system supports the interpretation of the data obtained during sophisticated engine analysis tests such as high-resolution speed analysis or high-pressure analysis of the diesel injection system. The expert system is designed to diagnose various vehicles of the same type. Data for each vehicle is stored separately allowing checks to be carried out individually for each machine. An additional feature of this system is a database interface to a Maintenance Planning and Control System (MPCS) that allows an automatic generation of work orders for the defects found during the expert system sessions.

Jan 1, 1995

By Szwedzicki T, Jiang J

The acoustic emission (AE) technique has found wide application in rock engineering. Generally, acoustic emission, which is produced by a rapid microcrack growth, is an ubiquitous phenomenon associated with brittle fractures and can provide information on the failure process in rocks. The sudden release of stored energy in the form of an elastic stress wave that travels from the point of origin within the material to a boundary is called an AE signal or a discrete AE event. Based on a number of experiments and analysis, the correlations among the rock type, the complete stress-strain behaviour, mode of failure and AE properties are investigated and the AE pattern has been classified as four types: single-peak AE, double-peak AE, continuous AE and absent AE. Each type of AE pattern corresponds to a certain type of rock and is largely related to the internal structure and imperfection of a rock. Applications of the AE technique in stability monitoring, in situ stress assessment and seismic source location are also discussed.

Jan 1, 1995

By D. W. Horsfall

The washability of South African coals is described and the problems encountered in washing at low densities, to make premium products, are enumerated. The measures taken to overcome those problems, when low density separations became a commercial necessity, are described in detail. The descriptions of processes are with specific reference to the three sizes commonly treated separately in coal preparation namely coarse coal, small coal, and fine coal. Some information is given on the performance characteristics of the plants erected to meet market requirements.

Jan 1, 1995

By Christopher M. Moore

DK Recycling und Rohelsen GmbH converts 380 000 annual tonnes of iron containing waste materials Into pig Iron. Zinc Is the main reason that these materials are classified as waste. The materials are processed In the conventional way by making sinter which is then smelted in a blast furnace to foundry grade pig iron. The trick lies not in the unit operations which are quite standard but rather In the modifications made to the plant and operating procedures to cope with the much higher levels of tramp elements.

Jan 1, 1995

By R. A. Allwes

In-plane bending and torsion tests were conducted on full-scale masonry walls to evaluate three post-reinforcement designs. The designs were developed to minimize longwall mine subsidence damage to existing residential masonry foundations. The bending tests show that vertical and horizontal post tensioned tendons significantly increase the resistance of a masonry wall' to in-plane bending. The torsion tests reveal that post tensioned tendons increase a masonry wall's limit of deformation but do not increase its torsional stiffness. The torsion tests also show that the masonry units minimally contribute to the torsional stiffness of a masonry wall.

Jan 1, 1995

By M. Balakrishnan, K. A. Natarajan, J. M. Modak, J. S. Gururaj Naik

The ability of various fungal species isolated from gold mines to uptake gold and base metals such as zinc, copper, iron and lead from gold-process cyanide effluents was investigated. Under identical treatment conditions, different strains showed wide variations in their ability to take up gold and other base metals. Aspergillus terreus exhibited as high as a 60% gold uptake. Almost complete removal of zinc was possible with various fungi and with the yeast Saccharomyces cerevisiae. Studies at various metal concentrations showed a higher gold uptake from dilute solutions, and studies with Aspergillus niger showed that gold uptake by living cells increased gradually as the contact time increased. Metal uptake capacities between living and nonliving cells were also compared. A waste biomass (ABM- I), obtained from a fermentation industry, wasalso identified as having a high gold uptake capacity. At 5% (W/v) solids, ABM-I could efficiently remove up to 83% of the gold contained in an effluent solution within 24 hrs.

Jan 1, 1995

By D O. Hayba

Metal-rich slurries discharged from excess-enthalpy geothermal wells at Kawerau (NZ) indicate that an efficient ore precipitation mechanism operates in some feedzones. In our conceptual model, which takes into account the relative permeabilities of liquid and gas phases in boiling fluids, a metal-precipitating liquid phase is effectively immobilised along boiling fronts, leading to the formation of highly concentrated ore. Chemical equilibrium and heat/mass transport modelling demonstrate the general applicability of this conceptual model to hydrothermal eruption environments.

Jan 1, 1995

It is no longer adequate in running mines and quarries to simply select the best equipment. Today's competitive international commodity markets demand superior efficiency. This requires efficient production and commercial processes together with systematic involvement of people in continuous improvement of processes. True Total Quality of Management (True TQM) principles provide an operating philosophy for maximising productivity and minimising unit costs of output. Unfortunately, even though these principles are proven in all industry sectors worldwide, they have not always been used correctly. This paper describes basic methodology for correct use of these principles to successfully improve the productivity of rock breakage production processes.

Jan 1, 1995

The rising tide of environmentalism has adversely affected many mineral producers, but it has also provided them with a number of opportunities for mineral applications. These markets are as diverse as water treatment, waste disposal, and flue-gas desulphurization. Whilst legislation is forcing up the industry's environmental standards, the advent of environmental management provides an opportunity for producers to display its 'green' credentials. The picture painted of the extractive industry by environmentalists is undeservedly black, because the more efficient a producer is, the more effectively that producer conserves the very resources he exploits. The 1993 IM Forum examined these issues and how they affect the mineral producer, and this publication comprises the papers presented at that meeting.

Jan 1, 1995

By J W. Simmons, T H. Antoun

"Rock fragmentation is an important component of explosive mining and excavation techniques andis the culmination of a damage accumulation process dominated by crack propagation. During the past 20 years, improved computer modeling of this process has resulted in new and promising computational tools for improving explosive mining and excavation procedures. This paper discusses one of these new computational tools, a computer model called BFRACT."

Jan 1, 1995

By M. K. Larson, J. K. Whyatt, F. M. Jenkins

The U.S. Bureau of Mines conducted an overcore stress measurement on the 5300 level of the Lucky Friday Mine, Mullan, ID, to investigate the stress regime around an experimental stope in a rock-burst-prone mine. The result indicated a stress field with unexpected magnitude and orientation [F . 135 MPa (19,600 psi) oriented S 80E1W]. An unusual amount of rock-burst activity was encountered during subsequent excavation. A careful review of the overcore data suggested the overcore strain measurements were valid. Moreover, concentrated rock-burst activity suggested that the measured stress field did exist, but was localized and therefore did not represent the far-field in situ stress field.

Jan 1, 1995