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By Tracy Brettmann

In recent years the Augered Cast-In-Place (ACIP) Pile industry has seen a substantial increase in the quality control options available to Contractors, Engineers, and Owners. Quality control methods range from the simple, manual techniques that have been used for years to new computerized installation monitoring equipment and nondestructive testing methods. Our ability to monitor and test ACIP piles has grown to such a degree that the industry is struggling to determine how much quality control is enough. This paper reviews the many options available and describes the pros and cons of each. The various nondestructive testing methods, in particular, have been difficult to apply reliably due to misapplications of methods and misinterpretation of the results. ACIP piles have unique properties that require the various nondestructive testing methods available be considered very carefully in determining the method most appropriate for a particular use. Some nondestructive testing methods, as well as automated monitoring equipment, potentially can be applied effectively to increase the level of quality control for ACIP piles. The experience gained on real projects using these new methods, in conjunction with the old procedures, provides valuable information for future applications.

Jan 1, 2000

By Lee B. Paterson

Mining Engineers throughout the world have an appreciation for the importance of the role of the Blasthole Drill in one of the primary elements of the mining process. This paper highlights areas that could influence the overall cost effectiveness of that process of breaking rock and the associated downstream mining and ore recovery activities - and how the drill is designed and configured to meet that challenge. Factors influencing drill productivity and overall cost effectiveness are addressed, particularly regarding the benefits which are not necessarily reflected in the drilling process and therefore more difficult to quantify. This paper explores some of the downstream benefits of what we do to the drilling process.

Jan 1, 2000

By S-L. Weeber

Ash fusion temperature is the temperature at which the mineral matter in coal begins to soften, flow and fuse. It is an important parameter relating to coal utilization. Optimum ash fusion temperatures derived from coal in the Witbank Coalfield region are approximately 1400°C, and higher, although temperatures above1300°C may be deemed acceptable. This study attempted to determine which factors, mineralogical or inorganic-chemical, influence variations in the ash fusion temperatures in certain coals. Coal was sampled from the Number 2 coal seam at opencast and underground workings at New Clydesdale Colliery, Witbank Coalfield, South Africa. The samples represented known low and high ash fusion temperature coal. Analyses performed included proximate analyses, calorific value determination, percentage sulphur, ash fusion temperatures, ash analyses (composition of ash), X-ray diffraction, scanning electron microscopy and petrographic studies. Results show that although a complex relationship exists between ash fusion temperature and the various geological and coal parameters, some positive correlative results were obtained. These indicate a possible relationship between low ash fusion temperatures and i) finer size fractions, ii) an increase in iron content present in the form of pyrite and iii) the form in which pyrite is present, namely cleats. High ash fusion temperatures tend to correlate with i) the absence of pyrite or ii) pyrite present as framboids.

Jan 1, 2000

By Frank Barker

Mining operations present a very different environment to the suppliers of explosives, initiating systems and services, both on surface and underground. Typical hazards include underground movement, air quality, ground stability, moving equipment, and the use of explosives. As contractors to the mining industry we do not have management control over the environment in which our people operate. The hazards and consequent level of risk that our people are exposed to in some mining operations are significantly higher by orders of magnitude than in a normal factory environment. Orica Explosives (and other Explosives suppliers) are continually and increasingly identifying opportunities to partner with customers by adding value through the provision of services leading to a reduction in total mining costs. These services include the provision of a bulk underground loading services, delivery of product into underground magazines, magazine management, value added blasting, conversions, rock-on-ground contracts, and blast management programs.

Jan 1, 2000

By Kim A. Lapakko, William W. III White

The ASTM standard method D 5744-96 was developed to provide a well-defined kinetic test protocol, conducted under controlled reaction conditions, with the intent of generating reproducible results. The US Bureau of Land Management, American Assay Laboratories, and the Minnesota Department of Natural Resources cooperated in a intralaboratory and interlaboratory testing of the protocol. Intralaboratory testing was conducted on duplicate samples of gabbro (8) and siltite-argillite (5) rocks for periods of 20 to 125 weeks. The difference between replica& intralaboratory pH readings on drainage from the gabbro for the drip-trickle leach alternative typically did not exceed 0.1 units, although differences as high as 0.4 units were observed. The difference from the mean for rates of sulfate, calcium and magnesium release was typically within 10%. Intralaboratory results for the siltite-argillite samples were generally similar, although a one unit pH difference was observed for one sample. Three different laboratories tested a gabbro sample for 125 weeks, with a maximum difference from the mean pH of 0.5 units. The percent difference from the mean for sulfate and calcium release rates was typically within lo%, although values as high as 30% were observed. Data on intralaboratory and interlaboratory agreement on the flood rinse alternative of the method were limited. Replication on the sample tested was comparable to of better than that observed for the drip-trickle method testing of the same sample.

Jan 1, 2000

By Nobuyuki Higashiyama, Ikuo Yonezu

"Hydrogen-absorbing alloys containing rare-earth elements are used in high capacity nickel-metal hydride secondary batteries,' hydrogen storage systems for portable fuel cells, and refrigeration systems. New hydrogen-absorbing alloys containing rare-earth elements have also been developed and introduced into these applications. High performance in nickel-metal hydride secondary batteries is strongly demanded because of the remarkable advancements in portable electric appliances. A large hydrogen absorption capacity, high electrochemical reactivity and superior corrosion resistance in an alkaline solution are required for hydrogen-absorbing alloys used in nickel-metal hydride batteries. The aim of this investigation is to improve the performance of conventional LaNi5 type hydrogen-absorbing alloys. For example, Mm(Ni-Co-Al-Mn)„ type hydrogen-absorbing alloys with various non-stoichiometric compositions were developed. In addition, a new process of rapid quenching process was applied for preparing these hydrogen-absorbing alloys in order to improve their performance.IntroductionRecently, the trend in electronic appliances toward portability has increased the demand for high capacity of secondary batteries as power sources. Since nickel-metal hydride batteries were first commercialized in 1990 in Japan, they have become increasingly popular as power sources for cellular phones, portable computers, electric shavers, and other, products.The performance of a nickel-metal hydride battery, such as its discharge capacity, high rate capability, and charge-discharge cycle life, strongly depends on the characteristics of the hydrogen-absorbing alloy negative electrode. Many types of hydrogen-absorbing alloys have been developed so far. For a hydrogen absorbing alloy to be used as the negative electrode material, (1) it must allow a large amount of hydrogen to be absorbed and desorbed in an alkaline solution, (2) its reaction rate should be high, and. (3) it must have long term durability under repeated charge-discharge cycling. However, LaNi5, a typical rare earth-nickel type alloy, shows significant capacity deterioration during repeated charge-discharge cycling. Therefore the first step in its development was to obtain sufficient corrosion resistance of the LaNi5 alloy for its use as an electrode material. A partial replacement of nickel with cobalt and a substitution of the lanthanum- content with misch metal (Mm), a mixture of rare earth elements such as lanthanum, cerium, praseodymium and neodymium, were very useful in improving the charge-discharge cycle life. However, the discharge capacity of the alloy was still not sufficient for a practical battery. A study of the effect of the partial substitution of aluminum and manganese showed that the best alloy composition was Mm(Ni-Co-Al-Mn)x, as follows.The stoichiometry x of Mm(Ni-Co-Al-Mn)x largely affects the discharge capacity and cycle life. Theose alloys with non-stoichiometric alloys with the compositions of [Mm(Ni-Co-AMn)x: 4.7<x<4.8] have a large capacity and a long cycle life. Nogami' et al. reported that 'a non-stoichiometric alloy with a Mm(Ni-Co-Al-Mn)x (x=4.76) composition showed approximately 10% higher discharge capacity than the stoichiometric alloy (x=5) [1] and greater influence of x on the electrochemical properties of multi-component AB„ type hydrogen-absorbing alloys for batteries."

Jan 1, 2000

By B. M. Nyombolo

Mintek has been involved in the development of bioleach technology for many years, initially for refractory gold extraction, and more recently also for base metals extraction. Mintek, in collaboration with its Australian technology partner (BacTech), is the technology provider for the Beaconsfield refractory gold bioleach plant. At present Mintek, BacTech and Peñoles are constructing a demonstration bioleach plant for copper-zinc concentrate treatment. Bioleach liquors produced in all applications have to be neutralized. In the copper-zinc case, neutralization is required for bleeding iron from the circuit and for adjusting the pH value ahead of solvent extraction. In the refractory gold bioleach circuit, neutralization is required for producing a stable iron-arsenic residue. Some of the challenges encountered in each of these neutralization applications are discussed, and examples of results obtained are presented.

Jan 1, 2000

By G. T. Lineberry, B. R. Yama

Artificial intelligence research has produced several tools for commercial application. Some of the techniques that are widely used today include neural networks, fuzzy logic and expert systems. Artificial neural networks (ANNs) are excellent predictive, pattern recognition and data analysis tools. In the mining industry, ANN techniques are being used commercially for real-time process-control applications. Modeling of spatial data, ore-reserve estimation, tunnel design, long wall-stability prediction and geologic roof classification are additional applications in which neural networks have been applied successfully. In this study, a standard back propagation algorithm was used to train a series of neural networks for a real-world predictive task. After training and optimizing the neural network architecture, the performance of the network is measured on an independent validation set. Results indicate a mean error of less than 1 % between the actual and predicted values. A neural network model was developed for learning the spatial continuity of a mineral field and, consequently, for predicting sulfur values for given coordinates. The neural network not only performed satisfactorily, but in some cases performed even better than the kriging model.

Jan 1, 2000

By T. Hawthorne, H. Barnes

Homestake Mining Company has developed an estimating model, based on other closed projects, to audit and prepare new estimating plans. The results of recent closure audits reveal that the original budgets were often insufficient to cover the present expected expenses. Some of the major areas where technical challenges and costs are increasing include heap leach pile detoxification and rinsing, tailings dam closure, water management and treatment, abatement of contaminated soils, and many others. Risk and sensitivity analysis of each category will develop a level of confidence in the estimate and allow management to focus on the pertinent issues. Periodic audits of closure plans and costs throughout the life of mine serves to focus management attention on the complete costs of production. This will result in improved overall planning and management, and reduce the number of missed opportunities for savings.

Jan 1, 2000

By Joe F. T. Agapito

High stresses and adverse geology in deep coal mines in the state of Utah, USA, have caused numerous bumps. The larger bumps have been associated with seismic events with Richter magnitudes of 3.6 and greater, and in some cases have filled openings for lengths of 150 m. A better understanding of the mechanisms and stress levels involved in bumping is needed to help develop improved stress control design and bump mitigation methods. The geology of the area is notoriously bump-prone. The coal has poorly developed cleating and occurs in multiple seams that are often bounded by very strong roof and floor sandstone/siltstone beds. The overburden is formed by thick, competent strata with numerous sandstone channels This geology and deep cover are the major source of high stresses, causing bumps. This paper evaluates live common stress factors responsible for bump problems: depth, sandstone channels, arching, faults, and coal thickness. It uses ease study data from longwall panels with two-entry/yield pillar systems typical of deeper Utah mines. Results illustrate the importance of analyzing stress factor experience to allow a better understanding of the problem.

Jan 1, 2000

By D. Duvris

Health and safety issues are a very important aspect of mining activities. Although the application of scientific research and current technology shields workers from many dangerous aspects of mining, accidents do happen. Many companies and institutions worldwide have committed to a continuous effort to minimize such occurrences. In this study, the health and safety data pertaining to the Greek mining and quarrying industry for the last 3 decades are presented and critically evaluated with respect to number of workers, annual production, etc. Appropriate indices are also calculated regarding the incidence and frequency of accidents. Health and safety issues specific to mining in Greek are also discussed.

Jan 1, 2000

By Vincent A. Scovazzo

Benchmarking is a business management process that seeks improvement through the study and reapplication of practices conducted by industry leaders. This discussion presents objectives and organization of benchmarking applied to mining geomechanics. Similar procedures have been successfully applied to mining companies, laboratories, and research organizations involved in mining geomechanics throughout the world. Benchmarking is a structured process that allows an organization to learn from the "best" in the field. The objectives of benchmarking vary depending on the company&apos;s targeted areas for improvements. Typical goals include ground control cost reduction, enhanced safety, optimization of geotechnical staffing, development of state-of-the-art design procedures, or the adoption of the "best in the field" geotechnical data management. Once the objective of the study is established and the practices and procedures to be benchmarked are identified, a benchmarking team is formed from internal and outside specialists. Benchmarking in geomechanics is fundamentally different than in most other fields because of the effects of local geologic conditions and regulations, both of which must be understood by all on the benchmarking team, before a comparative analysis can be made.

Jan 1, 2000

By A. C. Stevenson

"There are many critical application issues that affect all AC drives, but there are several that are absolutely mandatory for pulse width modulated (PWM) AC drives. If these rules are not followed, the drive system will have insulation, bearing EMI or noise problems. Pulse Width Output VoltageFigure 1 shows the output current of a typical pulse width modulated (PWM) drive. This is, of course, not a clean sine wave thus will have a lot of very significant harmonics. In fact, the harmonic spectrum is directly related to multiples of the carrier switching frequency plus side bands related to the basic output frequency. A typical spectrum for a PWM source bridge switching at 5 kHz is shown in Figure 2. Notice that the spectrum has multiples of the 5 kHz switching frequency and the number of side bands gets larger as the harmonic number increases.IGBT Switching TransientsWhenever we have PWM inverter switching, voltage transients are formed that propagate (usually at about half the speed of light) down the power cables to the motor just like in a radio frequency transmission line. If we do not terminate these transmission lines (motor cables) properly, the voltage pulses will be reflected when they reach the motor end and will be transiently increased up to twice their original amplitude.This transient voltage rise, shown in Figure 3, is important for three reasons:1. Insulation Voltage Stress — Higher voltage stress in the motor connecting cables and motor insulation will lead to a shorter insulation lifetime. If any of the voltage transient peaks exceed the insulation corona discharge level (partial discharge level), the insulation will gradually degrade with each voltage pulse. When it has been sufficiently degraded, it will then fail.Most new “inverter rated” motors have triple layer insulation which has a 1600 to 2000 volt partial discharge level. This will make them suitable to withstand the double voltage peak transient from a 600 volt inverter. It is wise to make sure of this fact, since a “standard” induction motor will only withstand about 1200 volts. Use of a standard motor in this application would shorten its life drastically. This can sometimes be as little as a matter of hours."

Jan 1, 2000

By Jay. M. Khodadadi, Josef Štetina, František Kavicka

"With the aid of the proper original numerical model of solidification the instruction for preparation of input parameters for numerical simulation of technological processes, with change of the phase or structure, will be presented. A method of calculation analysis of influence of therrpophysical properties of materials entering the system of casting-mould-cores environment, and also of boundary conditions on the required simulation accuracy will be suggested. For the cast material, the influence of heat .conductivity, specific heat capacity, density and latent heat of phase transformation also has been analysed. For metallic or non-metallic moulding material"" the influence of the see main parameters has been analysed and, furthermore, their combination, influence of thermal conductivity, and of heat storage. The order of influence of all quoted parameters of a casting and moulding material was established. For example heat conductivity in the liquid state is on the last place. From the boundary conditions the -most important influence on the total solidification time and · on the mechanism of forming of temperature field has the ·boundary condition on the casting mould boundary, then follows the boundary condition on the level of a molten metal. The negligible influence has the boundary condition on the mould frame and on the bottom.IntroductionThe original and universal mathematical model of solidification, cooling and heating has been set up and checked, in order to be capable of analysing a one- to three-dimensional steady or unsteady temperature field of the casting-mould-environment system and, namely, of the system as a whole or its arbitrary parts, during any industrial technological process whose individual processes could be solidification, cooling, heating, refrigeration and others, in any sequence or singly. The model enables the simulation of traditional and also non-traditional technologies of casting in foundries, metallurgical plants, forging operations, heat treatment processes, etc. If solidification is not the matter, the metal part of the system need not be called the casting but a component, a block, a forging and the like."

Jan 1, 2000

By S Jahanshahi, D R. Swinbourne

The classical metal-slag-gas equilibrium technique was used to study the thermodynamic activity of cobalt, iron and their oxides in iron silicate based slags containing under controlled oxygen potential (3.70 x 10-8 to 2.95 x 10-7 atm) at 1573 K. The measured activity of cobalt oxide in FeOx-25 wt per cent SiO2 slags showed positive deviation from ideal behaviour for melts with up to ten wt per cent CoO. At higher silica contents, the behaviour became closer to ideal and in accord with previous studies on silica saturated slags. The activity coefficient of FeO in these slags had virtually no dependence on the CoO content. Partial substitution of silica by lime resulted in an increase of the activities and activity coefficients of CoO, FeO, Fe2O3 and Fe3O4. The results indicate that saturation of the slag with a magnetite phase occurs at CaO contents of five wt per cent and higher. Phase equilibria studies SiO2-FeO-Fe2O3-CaO slags containing cobalt were also carried out using the drop-quench technique. Results from these experiments confirmed the formation of a magnetite solid solution containing about three wt per cent CoO at lime contents of five wt per cent and higher at 1573 K and 2.9 x 10-7 atm of oxygen.

Jan 1, 2000

By W Newton, J Price

This paper outlines the design, justification and performance of a gravity circuit upgrade at the Marvel Loch treatment plant. The design of the upgrade was simple but effective. The key components of the upgrade were the addition of a sluice and a second Knelson Concentrator. The sluice was installed as a pre-concentration step. The upgrade also included the purchase of a Mineral Cone to treat the increased quantity of gravity concentrate. The cost was low because of the use of mostly second-hand equipment. The result was that for a cost of $75 000 the gravity recovery doubled and the overall recovery increased by over one per cent. This paper shows that you do not need to spend millions of dollars to be innovative and successful.

Jan 1, 2000

By G. A. Irons, D. Colbert

Several electric arc furnace (EAF) shops have increased the zinc and lead grades of EAF dust by reinjecting it into their furnaces; however, the kinetics of this operation are poorly understood. To understand the kinetics, EAF dust was injected into 70 kg heats of iron or steel in an induction furnace. Supplemental additions of carbon and oxygen to overcome the heat load on the system were also investigated. In all cases, the dust was chemically transformed, and the zinc content increased from 16% Zn to 60 - 80% Zn. About 50% of the zinc in the EAF dust dissolved in the iron or steel. The zinc oxide in the dust is thought to be reduced by carbon and the zinc vapour subsequently dissolved in the iron. A kinetic model for the dissolution process is proposed, and the implications for EAF dust recycling are discussed.

Jan 1, 2000

By Masanori Abe, Yoshitaka Kitamoto, Kazuhiro Nishimura

"Ferrite plating is a chemical processing which utilizes Fe2+ - Fe3+ oxidation to synthesizing polycrystalline films of ferromagnetic spinels (MFe20 4, M = Fe, Co, Ni, Zn, Al, Cr, TI, etc:) directly from an aqueous solution at 24 - 100°C. This low temperature process allows us to fabricate new ferrite film devices on · substrates of such non-heat-resistant materials as plastics, GaAs integrated circuits, and biomaterials. Synthesized from an aqueous solution the ferrite plated ·films are highly biocompatible. Thus various magnetic device and biomedical applications have been proposed and realized using ferrite-plated films. Ferrite-encapsulated polymer microspheres are applied to antibody carries for enzyme immunoassay, and also to toners/carriers for photocopying. Perpendicular magnetic recording media utilizing plated CoNi ferrite films are proposed. The low-temperature synthesized films of NiZn and Co ferrites are potentially used as soft-magnetic and/or insulating layers, respectively at high/microwave frequencies.IntroductionFerrite plating is a processing which facilitates the formation of crystalline spinel ferrite films with various compositions, (Fe, M)30 4 (M = Fe, Co, Ni, Zn, Al, Cr, TI, etc.), directly from an aqueous solution at 60 - 100°C [1]. This opened the door to fabricating novel ferrite-film devices using substrates of such non-heat-resistant materials as plastics and GaAs integrated circuits [2-4]; conventional ferrite film preparation techniques such as sputtering, vacuum evaporation, MBE, LPE, etc., require high temperatures(> -600°C) for crystallization of ferrites, which deteriorates the non-heat-resistant substrates. Recently we extended ferrite plating to be preformed at room temperature [5, 6]. This enables us to use as substrates such organic materials as biomaterials (e.g. enzymes) having very low heat-resistance."

Jan 1, 2000

By J. Pesl, U. Kemey, F. Sauert

"The CONTOP® smelting cyclone is a water-cooled, upright, high-intensity smelting reactor. The technology for the reactor was initially developed and brought into industrial-scale operation in the area of non-ferrous metallurgy. The two largest smelting cyclones were built with a capacity of 32 tons per hour of copper concentrate mix.The newest industrial CONTOP® plant treats up to five tons per hour of zinc-bearing residues including EAF dust. The highly concentrated zinc-lead oxide produced is sold to the zinc industry. The slag fulfills the leaching criteria and is used in waterway construction. The heat transferred to the cyclone cooling system and the off-gas boiler produces steam from which power is generated in a turbine.V AI has erected a new CONTOP® demonstration plant at MEFOS, Lulea, Sweden. A zinc volatilization rate of 90% was achieved during hot commissioning with Swedish EAF dust.Treatment costs in the range of 85 to 100 EUR per ton were estimated in a feasibility study on the treatment of 73,000 and 57 ,000 tons EAF dust for a group of steelmaking mills in Southern Europe."

Jan 1, 2000

By J. W. Merks

Spreadsheet software is an effective tool for simulating dynamic stochastic systems such as mineral processing plants. The two-product formula is used to show how to set up a Monte Carlo simulation in a spreadsheet template and how to calculate variances of dependent variables. The key to a reliable and realistic simulation model is to obtain unbiased estimates for all independent variables and variances in the set that defines the stochastic system. Monte Carlo simulation is also a powerful tool for optimizing sampling procedures, for applying sensitivity analysis and for designing and evaluating experiments.

Jan 1, 2000