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By L. J. Olivier

The possible closure and subsequent flooding of South Deep Gold Mine?s (SD) neighbouring Randfontein Estates Limited No. 4 Shaft (REL 4) necessitated the construction of five concrete plugs in the connecting tunnels to prevent the ingress of groundwater into REL4 from flooding SD. This paper describes the proposed controlled flooding of REL 4, the planned in-service monitoring of the five plugs and the water barrier between REL 4 and South Deep Mine, and the long-term maintenance of the plugs and rock mass in the immediate vicinity of the plugs.

Jan 1, 2006

By J. R. L. Read, A. N. Ogden

This paper describes mining industry funded research that is being undertaken to address the critical gaps and uncertainties in our knowledge so that we can develop new approaches and create more effective ways for predicting the reliability of rock slopes in large open pit mines. It is envisaged that this research will not only lead to more effective pit slope design but further reduce the potential for unforseen geotechnical risks by enabling the geotechnician to communicate the risks more effectively with management and to optimise site specific control measures. To achieve this, several research tasks are in hand. The first is to accurately represent the structured rock mass with a 3D computer model (Siromodel) that creates polyhedral blocks from structural distribution data characterised by position, orientation and persistence. Siromodel is being coupled with particle flow and other numerical codes to evaluate how the structured rock mass deforms in the stress environment of an open pit and how a candidate failure surface may propagate through the dilating rock mass along the path of the least shear and/or tension resistance. A beta version of the Siromodel software has been distributed to 20 Sponsor mine sites for technical evaluation. The end state is to develop methods of analysis that characterise the reliability of a described candidate surface, and the probability of the candidate surface propagating to failure, recognising that the rock mass strength may well be defined in a different way than before.

Jan 1, 2006

By Sutham Niyomwas

The Fe-TiC composite powder was synthesized in situ by carbothermal reduction of ilmenite. The standard Gibbs energy minimization method was used to calculate the equilibrium composition of the reacting species. The effects of the reaction temperature (1300 °C - 1500°C) and milling time of precursors on the Fe-TiC conversion and powder morphologies were investigated using XRD and SEM method. The synthesized products showed that composite with iron matrix and titanium carbide as a reinforced phase was formed.

Jan 1, 2006

By Antonio Karzulovic, Sergio Olavarría, Patricio Adriasola

The economical analyses of different Chuquicamata open pit mine planning scenarios, indicate that the pit closure should occur at latest in the year of 2017. However, about 60,000 m of drill holes have demonstrated that below the pit bottom there is a potential of 2.3 billion tons of ore. Hence, Division Codelco Norte developed the scoping engineering for a large underground panel caving operation, similar to El Teniente mine. This project considers the exploitation of a 2500 m 300 m footprint, with three 250 m lifts. The plan considers to initiate the construction in the year 2009, to begin the production in the year 2015 and achieve a production rate of 45 million tons per year in the year 2021. A large-scale transition from open pit to underground mining like this one presents three main challenges: (1) to include the geotechnical aspects relevant for mine design and mine planning, (2) to define the proper surface and underground infrastructure, and (3) to fulfil the project deadlines and to achieve the production targets. This paper summarizes this transition project and discusses these three main challenges.

Jan 1, 2006

By J .. A. Nemes, I. Ragai

This paper discusses one of the common problems associated with sheet metal forming processes, which is spring back. The materials presented here, stainless steel 410 and Inconel 718, are commonly used in aerospace applications for their superior material properties. Standard tensile tests were performed to determine their tensile properties, as well as material anisotropy. In addition, the effect of anisotropy on springback was assessed experimentally through simple multiple-bending experiments in different directions to the rolling direction. Finally, draw-bending experiments were carried out to study the effect of forming conditions, such as blank holding force, on the final springback angles of the formed parts. For both materials, it was found that the R-values measured for different sheets exhibited variation. However, the specimen orientation does not have a large effect on material tensile behavior or springback angle for simple bending. For the Inconel 718 specimens, the springback angle slightly increases with each stage of deformation during multiple bend experiments. The effect of the blank holding force on springback angles was also examined and found to have a significant effect on thin specimens.

Jan 1, 2006

By M. Ataee-pour, S. E. Jalali

So far, a large number of algorithms have been developed for the optimization of pit limits, most of which follow deterministic rules. In this paper, a new algorithm is introduced, which follows a probabilistic logic using the Markov chain process. The algorithm is implemented on a transition matrix that corresponds to the 2D conventional economic block model of the mining area. The probability of mining a block is proportional to the desirability it may provide. Applying this algorithm, the probability of mining each block is obtained, and finally, the optimum pit limits are defined as the pit, which provides the highest probability of mining. In order to validate the proposed model, a numerical example is given and the results of the algorithm are compared to those of a dynamic programming algorithm. A 2D analysis of the problem is discussed in this paper. Although dealing with 3D problems requires larger size matrices, the optimization method is the same and the algorithm does not need any smoothing.

Jan 1, 2006

By Shaw-Shong Liew

This paper presents the processes of investigation, analysis, design, construction and monitoring of soil nail stabilisation work to facilitate a 14.5 m deep excavation at an uncontrolled fill ground. An extensive instrumentation programme had been implemented to monitor the performance of the stabilisation solution, to provide validation for the designed nail resistance and groundwater variation. From the monitoring results, it was proved that the soil nail stabilisation technique is effective for loose saturated fill provided that substantial care is taken during implementation. Construction difficulties, solutions to overcome the problems and lessons learned will be discussed in the paper.

Jan 1, 2006

By M. Argiantopoulou

In today?s mining environment, improving production, performance, productivity and profitability is crucial. Production, ancillary, plant and shipping equipment need to be monitored and controlled by online systems delivering production statistics and real-time information to everyone involved, including equipment operators. Traditional systems currently in use today, operate in an iterative mode constantly switching between scheduling and execution. However, the real world tends to change in ways that invalidate such advance schedules. Agent based computing has been hailed as the most significant breakthrough in software development and the new revolution in software. Agent systems are being used in an increasingly wide variety of applications, including complex mission critical systems such as Air Traffic Control. This paper presents the possible ways that multi-agent systems can be applied to mine production and rehabilitation scheduling problems with focus on real time fleet management, plant and equipment performance monitoring, downtime and delay reporting, stockpile management, personnel and equipment tracking and product distribution and transportation.

Jan 1, 2006

By Luis Giraldo

The installation procedure of fully grouted rebar bolts requires that the bolt be pushed through the resin grout until it is fully inserted in the borehole. Resin grout is a highly viscous fluid that is forced to flow through the annulus between the bolt and the borehole as the bolt advances. Variables such as bolt insertion speed, bolt vs. borehole diameter and grout viscosity determine the magnitude of the pressure generated ahead of the bolt tip. Under weak rock conditions, the magnitude of the pressure of bolt insertion is often sufficient to initiate hydraulic fracturing along joints or bedding planes that allow injection of grout into the strata leading to significant loss of bolt encapsulation. The grout pressure front has also been linked to gloving, a bolt installation problem that reduces bolt effectiveness. A series of tests were conducted to characterize the pressure of bolt insertion during bolt installation under various conditions. Analysis of the data shows three distinct stages of pressure build up during bolt installation. Understanding of the mechanisms involved may allow development of strategies for controlling the pressure buildup and its negative impact during roof bolting under weak rock conditions.

Jan 1, 2006

By M Hino, Y Sasaki

Sustainable handling of municipal waste and sewage sludge has an important goal to recycle resources without supply of harmful substances to humans or the environment. The gasification mechanism of phosphorus from municipal waste and sewage sludge during the incineration process has been investigated to develop a phosphorus recovery system. Quadrupole mass spectrometer coupled to an electric furnace is applied to study the vaporisation behaviour of phosphorous gas phases from municipal solid waste (MSW) incinerator ash of sludge during solid-state reduction by carbon. Measurements are carried out in vacuum conditions of 2 x 10-6 Torrs and furnace temperature range 573 - 1773 K, at a heating rate of 7.22 K/minute. It has been found that most of the phosphorus is vaporised as PO2, P2 and P4, in agreement with thermodynamic estimation despite a shift in the temperature regimes.

Jan 1, 2006

By Mike Santaluce

Smelting furnace rebuild projects often require a significant capital expenditure and an extended smelter outage. Smelter operators are increasingly searching for methods and initiatives to shorten furnace rebuild schedules, maintain manageable cost levels, enhance furnace performance and achieve excellent safety results. This paper describes the ?MEPC? Model for furnace rebuilds; a project driven approach which Auburn has developed in response to the need for improving furnace rebuild project outcomes. The ?MEPC? (Management, Engineering, Procurement and Construction) approach better addresses the unique challenges presented by furnace rebuild projects when compared to the traditional EPCM (Engineering, Procurement, Construction Management) model widely in use for these projects today. One key feature of the MEPC model is that a dedicated project management team with representation from all of the major project stakeholder groups is put in place at the onset of the project. The project management team has ownership and accountability for meeting overall project goals over the entire lifecycle of the furnace rebuild project. A second key aspect of the model is emphasis on project management as a completely separate project function with its own specific skill sets, techniques, tools and best practices. These features of the MEPC model offer several advantages in terms of improved planning, coordination, communication and alignment with project goals which contribute to the overall success of furnace rebuild projects. Similar MEPC concepts have been used to deliver excellent project results in other industries and the MEPC approach has been successfully utilized on furnace rebuild projects.

Jan 1, 2006

By D. J. Burger

This paper will highlight the system components of a successful underground mining automation project recently launched at DeBeers Finsch Mine. It will also show that integration of short-term mine planning with other upstream and downstream mining processes in the extraction of kimberlite ore from a block cave is not just critical to the future sustainability of this underground mining operation but also for profitability and cost-effectiveness. This paper will discuss the information data flow required from the mine-planning process through to production for underground block cave mining. The benefits associated with this type of integrated mine planning and automation system will be highlighted.

Jan 1, 2006

By Deepak Vidyarthi

This paper deals with the significance of Explosive Energy in the optimization of blast design parameters, and the benefits emerging out of it. It is based on the original work done by the author in developing and successfully implementing a site-specific software package on ‘Blast Design Optimization’ at Kudremukh Iron Ore Mine in India with a production level of 22.5 million tonnes of crude ore and off-take of Explosives of approximately 5500 tonnes per annum. The software package has yielded tangible results in effecting reduction in Explosive Consumption, substantial savings in the Cost of Explosive, besides Environmental Improvements by way of attenuation of Blast Induced Ground Vibrations as well as Air-Blasts. By carrying out regular ‘Regression Analysis’, and determination of the Rock Constants, it has been possible to further develop software packages as well as prediction curves for prediction of Peak Particle Velocity, Safe Charge of Explosive, Air-Blasts etc. A model has also been developed for the prediction of ‘Fly Rock’ although at KIOCL, fly rock does not pose any problem.

Jan 1, 2006

RME has a vision for a new mill operational paradigm made possible by RMEÆs fast, safe Mill Relining System. This vision can be moved forward into reality at any time with or without guidance from recent development in measurement and predictive modelling tools.Some new liner designs can degrade SAG mill performance because of mill volume loss, ball strike (rotational speed limitations) and other issues often brought about by optimising liners for life and without a backward glance at metallurgical consequences. Freshly relined mills can initially produce as little as 80 per cent of their maximum throughput, that maximum occurring toward the end of the linersÆ wear life. RMEÆs proposition is to design new liners for maximum commercial performance. This may mean more frequent changes of liners but with liners designed to yield optimum grinding, metallurgical and profitability performance. In other words, mill liner profiles and mill relining speed become key operational controls and not simply æmust doÆ maintenance functions. Taken to the extreme, liner profiles may prove capable of ætuningÆ a grinding plant for maximum profitability in any metal price environment. This paper provides an update regarding RMEÆs fast, safe Mill Relining System technologies and outlines RMEÆs vision of a æliner profile versus profitabilityÆ model as a function of metal price, developed intuitively or by using a combination of new measurement and modelling technologies. These new measurement and modelling tools provide the opportunity to predict the optimum commercial outcome, off-line in the virtual world, before committing to an expensive liner experiment.

Jan 1, 2006

By Charles Vaught

This paper discusses the fact that US coal mining organisations are losing the knowledge they need in order to be able to respond to emergencies. The authors note that knowledge management provides a useful perspective from which to view the problem, but that the debate about what constitutes knowledge should be broadened to include a debate about what constitutes management. It is argued here that knowledge is actually shared knowing distributed across group members; that such knowledge can be managed by cultivating it; and that narrative is the medium through which this may be done. The paper then examines NIOSH research that has attempted to use such an alternative knowledge management approach to help potential mine emergency responders better deal with the predicaments they are likely to encounter on-site.

Jan 1, 2006

By Jian Yang

The mechanism of resulfurization in the desulfurization process with magnesium vapor produced in situ by aluminothermic reduction of magnesium oxide was clarified in the present work. The influences of various operating parameters on the resulfurization were studied and the methods that could prevent resulfurization were proposed. There are two kinds of mechanisms of resulfurization in the desulfurization process with magnesium. One is decomposition of the desulfurization product of MgS under the inert atmosphere. The other is oxidation of MgS under the oxidative atmosphere. Under the present experimental conditions, lowering operating temperature and oxygen partial pressure in the atmosphere could effectively prevent the resulfurization. Adding CaO onto the melt surface was an effective method for preventing the resulfurization due to transformation of the desulfurization product of MgS into the more stable compound of CaS. Since addition of the activated charcoal powders greatly decreased the transfer rate of oxygen in the atmosphere to the melt surface, it also reduced the resulfurization remarkably.

Jan 1, 2006

By Durell Denysschen, Rafael Abela

The recovery of gold from old mine dumps has been carried out over the last two decades. The gold value and price together with recovery methods, determine whether it is economical to process a dump. Pre-concentration with cyclones and spiral concentrators may offer a method to process dumps considered currently uneconomical to treat.

Jan 1, 2006

By Corby G. Anderson

"Laboratory testing, plant optimization, and the interpretation and application of metallurgical technologies can be tedious, time consuming and costly. This paper outlines the use of proven statistical design of experimentation software for rapid laboratory testing and optimization of operating plants with limited representative sample utilization. This results in less costly required testing, a more thorough understanding of results and the ability to simultaneously optimize several variables and outcomes at once. At the Center for Advanced Mineral and Metallurgical Processing (CAMP), this testing methodology has been used successfully in many metallurgical development and plant optimization projects thereby confirming its real world utility and application. Accordingly, several applied examples in flotation and hydrometallurgy will be outlined in this paper. This will include flotation testing of a copper gold ore, flotation testing of a copper, cobalt and gold ore, optimization of an industrial hydrometallurgical jarosite circuit and optimization of industrial nitrogen species catalyzed pressure leaching of a copper enargite concentrate.INTRODUCTIONWhile flotation technology is now 100 years old, the testing, interpretation and application of lab results can be tedious, costly and time consuming requiring extensive sample collection and preparation. In addition, recent applications like hydrometallurgical pressure leaching and associated unit operations, such as precipitation, still remain more of an art than a quantifiable science. This paper will elucidate the application of STAT-EASE Design-Expert software to minimize required laboratory testing while rapidly optimizing multiple results and outcomes in a statistically valid manner. The STAT-EASE program is based on proven design of experiment fundamentals. In this paper, the real world application of this methodology for lab testing, plant optimization and process development will be elucidated."

Jan 1, 2006

By Sergio N. Monteiro

Natural lignocellulosic fibers are successfully replacing synthetic fibers in many engineering applications. In addition to well-known conventional lignocellulosic fibers, others with promising properties are now being considered. The present work investigated the mechanical and structural characteristics of a relatively high strength fiber, curaua (Ananas erectifolius) from the Amazon region of Brazil. The results obtained from tensile tests confirmed the superior strength while scanning electron microscopy (SEM) analysis displayed features that justify the possibility of using the curaua fiber as an effective reinforcement for polymeric composites.

Jan 1, 2006

We describe a new method of characterising the effect of dissolved materials on the rate of coalescence of bubbles in aqueous media. Single bubbles were allowed to rise to meet the surface of an aqueous solution, and the time of persistence between arrival and bursting of bubble was measured as a function of solute concentration. A laser beam was placed just above the surface of the liquid, with a detector in the light path, so that any disturbance at the surface could be seen as a break in the beam. The arrival of a bubble at the surface could be detected from the behaviour of the trace on an oscilloscope, and when the bubble broke, another significant change in the signal could easily be seen. The time between disruptions was reported as the persistence time. The effect of a homologous series of n-alcohols (C1 to C8) on the persistence time was measured, in aqueous solution. It was found that with increasing concentration of a particular solute, the persistence time increased up to a point, and then declined. However the magnitude of the persistence time was found to increase with increasing numbers of carbon atoms in the molecule. Bubbles of 1, 2 and 3 mm diameter were used. Persistence time increased with increasing bubble diameter, the maximum values observed being of order 100 secs. For a given solute, the persistence (drainage) time increased with increasing bubble diameter. The concentration Cmax at which the maximum persistence time was observed, was found to be independent of the bubble size. It decreased uniformly as the carbon number increased, and was well correlated by the function y1/2 (dy /dc) -2 I dc)-2 . There was no apparent correlation with the surface excess at maximum persistence time.

Jan 1, 2006