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By A. G. Jackson, S. J. P. Laube

"Control of thin films during the growth process is dependent on several parameters that are difficult to monitor, including flux of film material, pressure, substrate temperature, composition, and thickness. One means for easing this difficulty is to take advantage of emission spectra associated with the process and the film. For pulsed laser deposition (PLD), the ion cloud generated by the laser has characteristic emission spectra that can be used to control the flux and, hence, the film. For chemical vapor deposition, the species present can be determined using mass spectroscopy and specific peaks can be used to control the deposition. Raman spectroscopy affords the possibility of real-time control by sensing characteristic peaks associated with film composition and thickness. These spectroscopic methods offer a real-time alternative to process control that is very attractive, because of the ability to accurately control films to achieve the engineered structures and properties sought. Examples are presented to illustrate the capabilities of these methods for thin film preparation.IntroductionThe drive to reduce costs and improve efficiencies of operation sets the tone for much of research, basic or applied. Basic research is limited by the ability of sensors and associated instrumentation to measure parameters accurately and reproducibly. Applied research has the same limitations and also the added constraints of time and costs. Hence, there are strong incentives to explore means for refining existing sensors with respect to performance and cost, as well as finding new sensors and techniques for more accurately and rapidly measuring quantities of interest in experiments and in various processes."

Jan 1, 1997

By John Rushton

Surface mining, from ore extraction to processing, requires many types of equipment to obtain the final product. Mine equipment often includes shovels, drills and haul trucks. Ore processing equipment, including plants, mills and concentrators, are also part of surface mining operations. Surface mining operations emphasize production. Production is where the bills are paid and fortunes are made. However, there must be support to keep the equipment operational. To most production people, equipment maintenance is a necessary evil. Maintenance is not glamorous work. It is often neglected when praise is being passed around. It is easy to recognize higher production, greater capacities, faster cycle times or more loads hauled. But who cares if an engine is replaced in 12 hours instead of 48? The answer is, everyone should - from the hourly miner to the mine manager. Surface mining equipment needs constant maintenance work. It must be lubricated, components replaced, electrical problems repaired and other problems addressed. Repair work for any surface equipment takes time away from production. It costs money. Maintenance costs cannot be avoided. However, they can be minimized. Minewide communication should include operations cooperating with maintenance. Traditionally, operations resist surrendering equipment to maintenance if it can continue to produce. The rationale is, every load that can be hauled today is money in the bank. If the unit is taken down, the money is lost. This thinking is prevalent in many surface mining areas, including the mill. "Not on my shift," the operator thinks. "Let the next crew worry about it. The problem with this thinking is in probability and statistics. The longer equipment goes without maintenance work, the higher the probability of equipment failure. When the failure does occur, it is certain to cause the equipment to remain down longer than if the maintenance department had been allowed to take it down. Many mining operations have closed early in their lives because of poor maintenance practices. This has become the industry standard because substandard levels of performance are acceptable. Management believes it gets five to six hours of work from maintenance people during an eight-hour shift. Actually, the industry average is less than two hours of work per shift. Real productivity levels of less than one hour are not unusual. There are few exceptions. However, a daily work schedule (DWS) will increase productivity at many properties by 50% to 100%. A 200% improvement is not unusual. The DWS will work. Maintenance people are among the most intelligent and motivated people on the property. They deserve the chance to be productive. [ ] In preparing a DWS, management needs to understand two productivity principles - the productivity spread and the real maintenance workday.

Jan 1, 1997

By William J. Miles

For compliance with the Hazard Communication Standard and other federal and state regulations, numerous minerals, chemicals and products need to be evaluated for crystalline silica content at a threshold of 0.1 %. The polymorphs of crystalline silica that can occur in chemical and mineral products are quartz, cristobalite and tridymite. Other natural, industrial and synthetic amorphous silicas and hydrates must be distinguished from these polymorphs to prevent over-regulation in the workplace and environment. A number of industrial silica products are composed of glasses, expanded perlite, diatomite, slags, and precipitated and fumed silica products. Amorphous silica hydrates used for industrial products, include opal (hydrated silica of biogenic or inorganic origin), perlite, pumice and tuffs. In addition, crystalline and amorphous silicate minerals and chemicals, abundant in nature and industrial products, must be distinguished from the polymorphs of crystalline silica.

Jan 1, 1997

By Joseph C. Rota

The Carlin Trend is one of the most significant gold mining districts in North America. Located in northeastern Nevada, a total of over 17 million ounces of gold have been produced since 1965 at Newmont Gold Company's open-pit and underground operations. Oxidized portions of the sediment-hosted, disseminated gold deposits at Carlin generally consist of finely disseminated concentrations of sub-micron sized native gold particles hosted in Paleozoic siliciclastic or carbonate rock. Oxide ore is commonly amenable to dump leach or heap leach processing, yielding an average 50 to 70% recovery of total contained gold. Refractory unoxidized ore requires some form of pretreatment oxidation to ensure economic gold recovery. Geologic ore control is typically combined with standard assay and engineering techniques to maintain both grade and metallurgical control ofleach grade ores. Mine geologists provide a vital function through field observation and recording ofmineralogic data during daily, visual blasthole logging. Intricately mixed refractory materials must be separated from oxide ore to ensure highest possible gold recoveries. Geologic information is combined with assay data to create mine polygons in an engineering computer database. Mining selectivity is further enhanced by in-pit ore control geologists who are available to make production decisions based on direct mineralogic observations at active mine faces.

Jan 1, 1997

A mining joint venture presents a real management challenge to achieve harmony with the other participants in the successful development and operation of a mine. This can best be facilitated by a detailed agreement and guided by a set of joint venture principles which recognise the differences of the interests of the parties and seek to establish sound business and personal principles by which differences not anticipated in the agreement might be resolved. The major and minor co-venturers can and do present potential difficulties to one another. This paper, one of the pair in the joint venture panel discussion session, predominately presents the minor's viewpoint. Usually commercial matters such as project finance, areas of interest, divestment, pre-emptive rights and decision-making can be adequately covered in the agreement. However, when the parties disagree and have difficulty in resolving their differences, the joint venture principles should be used to advantage to resolve relationship difficulties.

Jan 1, 1997

By Jim W. Rosteck, Anthony Del Vescovo

In December of 1992, the City of New York, Department of Environmental Protection, solicited bids for Contract 543B. The low bidder was a joint venture of Schiavone Construction Co., Inc. and the J. F. Shea Co., Inc. When completed, the project provides a 4.88 meter diameter water tunnel 8,840 meters long. This paper presents a case history of the equipment and construction methods utilized for this, the first portion of the New York City Water Tunnel constructed by use of a tunnel boring machine.

Jan 1, 1997

By S. K. Kawatra

A high calcium fluid-bed combustor ash has been shown to be an effective binder at dosages of 1 to 2% of the magnetite concentrate weight. Magnetite pellets 1.3 cm (1/2 inch) in diameter were produced with dry crushing strengths greater than 22.3 Newtons/pellet (5.0 pounds force/pellet), which is comparable to the results produced using conventional bentonite binder. The effectiveness of fly-ash-based binders was considerably improved when calcium chloride was added as an accelerator. Addition of calcium chloride at a rate of 0.1 to 0.2% of the total powder weight increased the strength of dried pellets by as much as 22% compared to the strength of pellets made using fly-ash without accelerators.

Jan 1, 1997

By G. A. Calboreanu

The deterioration rate of any metal or alloy is increased in a erosion-corrosion application because the passivated surface layer is removed by the solid particles contained in the pumping fluid and the material surface becomes corrosion active again. Numerous attempts were made to engineer a stainless steel with higher hardness and unaffected corrosion performance. Alloys of special interest in such an area are the duplex stainless steels particularly the CD4MCu material which has the capability of being hardened due to its ferrite-austenite microstructure. Unfortunately, the CD4MCu with higher hardness comprises different intermetallic compounds which will increase the corrosion rate. The paper is analyzing the erosion-corrosion performance of a new type CD4MCu with 32% higher hardness and superior wear performance. The corrosion performance of this new alloy is better than the corrosion performance of the common CD4MCu material which the industry could supply. The corrosion effectiveness was evaluated with the Huey test, the potentio-dynamic anodic polarization test and the weight loss test whereas the erosion resistance was established with a low stress ball-on-disk type apparatus. The Wilfley hard CD4MCu material had 39% lower weight loss and 32% smaller volume loss than the common CD4MCu alloy The hardness range of the centrifugal pump parts poured and processed with the Wilfley hard CD4MCu is 320-350 HBN versus 250-255 HBN hardness of the common CD4MCu. After approximately 18 months of experimentation and field testing it was clearly established that the life time of the Wilfley hard CD4MCu is higher than the common CD4MCu and consequently centrifugal pumps were supplied to different customers in North and South America. India and more recently Australia. Sincere thanks to all the A.R. Wlifley & Sons Inc. and Western Foundries Inc. employees who supported and help to implement this work. special thanks to George Wilfley. Dave Cobb. Bill Becker Sr. and Wayne Taylor

Jan 1, 1997

By G. C. Tipper, A. P. Deane, A. G. Myers

SCHEME DESIGN London’s Heathrow Airport, as the world’s busiest international airport, is missing one vital aspect - a dedicated rail link which connects directly to the city. All this is about to change with the construction of Heathrow Express - a fast, high quality rail service between the airport and the centre of London. It was recognised in the mid 1980s that if Heathrow was to accommodate the forecast growth in passenger numbers and the resulting increase in road traffic, a dedicated airport rail service would be vital. The main access into the centre of Heathrow is via a road tunnel with a direct link to the M4 motorway. The airport has introduced a number of traffic management schemes, but these can only achieve so much benefit. Growth in air passenger traffic is predicted to continue at an average of 4% per annum well into the next century and it was clear that significant investment was needed. Heathrow Express at a cost of over £350 million will provide this when it starts its service in June 1998. The business case for the scheme is based on a rider ship of around 15% of air passenger traffic. The initial Heathrow Express service will be based on four trains per hour, up to 8 car train lengths, providing a high speed non-stop service between the airport and central London in just 16 minutes. Initially a joint venture between the British Railways Board and Heathrow Airport, by mutual consent of the two parties, Heathrow Airport recently purchased the British Railways Board share making this one of the largest private sector rail projects currently under construction in the UK. Leaving Paddington, the main rail terminus in West London, Heathrow Express trains will travel 12 miles on the newly electrified line to airport junction, north of the airport. At this point they will leave the mainline to enter a 5 mile tunnel section that runs underneath the heart of the airport. The railway companies are responsible for track work, signalling and electrification of the 12 mile main line section including a grade separated junction over the main tracks for the Great Western Railway which links London and South Wales. Heathrow Airport is re-

Jan 1, 1997

A feasibility study will fail its objective if it does not identify and then correctly assess, all the risks which could have a substantial impact on the financial viability of a project. Before this assessment can be undertaken, one needs to understand the risk profile of the entity which is making the decision about the project. Some of the commonly encountered issues when assessing project risk are related to the problem of not being able to see the wood for the trees. In any risk analysis it is important that conservatism does not strangle a viable project; that the variables are internally consistent with each other, that reality checks are carried out and that appropriate expertise is used. Sensitivity analysis forms a part of the overall project risk assessment; however, it can only test those variables which have already been identified in the financial model. The most useful tool in performing a sensitivity analysis is Monte Carlo simulation. When properly used, it provides a more real world scenario than the simple adjustment of key variables by ¦ 10 per cent one at a time. Monte Carlo can provide valuable information about the robustness of a project. Project risk and sensitivity assessment is prone to the analysis paralysis syndrome. The focus should be on quality rather than quantity.

Jan 1, 1997

By Tan Zhenxiang

INTRODUCTION Koolyanobbing is an open cut iron ore mine, which is located in Yilgarn region of Western Australia. To prevent the operators from suffering silicosis diseases and protect the air from being polluted, a series of dust control measures have been taken. These measures include ventilation and dust control system for sample preparation shed, dust collecting system for drill rig, dust suppression system for ore processing plant, dust control for haul road. The details related to individual dust control measure are dealt as follows. SAMPLE PREPARATION SHED DUST CONTROL The sample preparation is one of the major dust sources at Koolyanobbing. The activity is being carried out at the sample preparation shed. It typically needs to go through the following stages, that is, crushing, splitting, drying and pulverising. The amount of dust generated from crushing and splitting is mainly determined by the moisture content contained in the pre- pared sample. A significant amount of dust is generated at the sample pulverising stage due to cleaning sample bowl with com- pressed air. To protect the sample preparing personnel's health and make the dust level in the air meet the requirement from the health and safety authority, a central ventilation and dust control system has been installed at the sample preparation shed. As shown in Fig. l, the system consists of suction heads, suction lines, dust collector and vacuum fan. The fan creates vacuum environment in the system, therefore the dust is drawn into the dust collector through the suction heads and suction lines. The dust collector is of fabric filter. When the dusty air comes to the filter, the dust in the air is collected and retained on the surface of the filter while the clean air passes through and enters the atmosphere. The retained dust is blowed out by the pressured air pulses and deposits into the dust bin underneath the filter. A time relay device is used to control the cleaning time and the cleaning interval. DRILL RIG DUST CONTROL A hydraulic percussion drill is used to drill blast holes. To carry out the drilling operation properly and efficiently, the cut- tings are being flushed out of the hole by the compressed air. In order to prevent from the fine particles in the cuttings escaping to the air, a dust collector is attached to the drill. The collector mainly consists of suction head, cyclone and bag filter. Refer to Fig. 2. The suction head is installed at the lower end of the feed beams and is movable. The moving range is up to 250 mm. It is not only used to restrict the cuttings, but also used to prevent water from entering the filters when drilling wet hole. A 406 mm diameter primary cyclone is used to separate the heaviest particles in the cuttings. It is also used as blast holes sampling equipment. One part of the dust particles are collected by a sample bag through a splitter attached to the end of the cy- clone. The rest of the particles fall down to the ground through the closing rubber. The bag filter is driven by a hydraulic motor (1). It is used to collect the lighter particles in the cuttings. The filtering area is 16 m2 and the dust separation efficiency is up to 99.9%. The working principle of the filter is demonstrated in Fig. 3. When the rock drill (9) flushing is turned on, the pressurised air from the compressor is directed to the rock drill and to the pres- sure switch (10). The pressured air will open the pressure switch to de-energise and close the solenoid valve (4) The pressure affecting the cut-off cylinder (5) keeps the exhaust port flap open. When the flushing valve (8) is closed, the pressure affecting the cut-off cylinder disappears and the internal intake opening flap is closed by a spring. The pressure also ceases to affect the pressure switch and the spring switches the contact to the point 2. The time relay (11) is now activated and gives a 0.5 second current impulse to the solenoid valve and keeps the current cut off for approx 8 seconds. When the solenoid valve is live, it opens and lets an impulse of pressured air to the filters (2). These impulses will clean the filters.

Jan 1, 1997

By R. White, C. Doyle, B. Martin, C. Díaz, J. Hrepic, G. Cuthbert

"A program initiated to improve the service life of the magnesite-chrome refractory in the top blown rotary converters at INCO’s Copper Cliff Nickel Refinery identified slag corrosion as a major wear mechanism. Target slag compositions were established to produce a non corrosive slag. A plant program to achieve this target slag by the addition of controlled amounts of do lime and MgO was instituted. Addition to rates of the slag modifiers was optimized based on the slag composition assays achieved and the requirement to address corrosion effects on the high alumina content ladle refractory. A60% gain in TBRC refractory performance was eventually achieved and has been maintained yielding a net annual savings of $700,000. A significant gain in available converter operating time has also been realized.IntroductionINCO’s Copper Cliff Nickel Refinery utilizes two top blown rotary converters (Fig. 1) to smelt a blend of semi-refined nickel concentrates, producing a granulated nickel matte suitable for the adjacent carbonyl based nickel refining operation. The converter, or TBRC, operation is a batch process composed of feed charging and melting, oxidation of the excess sulphur in the matte, and reduction of residual nickel oxide. The final matte, containing about 78% nickel, is tapped at 1600°C from the converter and is granulated in a sluice equipped with high pressure water jets."

Jan 1, 1997

By F. E. Wagner, L. J. Cabri, Y. G. Safonov, N. S. Bortnikov, A. D. Genkin, J. Friedl, G. N. Gamyanin

"A multidisciplinary investigation (including INAA, SIMS, EPMA, and Mossbauer Spectroscopy) was used to characterize gold in four of the largest Siberian mesothermal sulfide gold deposits. These are the Olympiada (""'750 metric tons gold) and Veduga (estimated at 75-100 metric tons gold) deposits in the Enisei Mountain Range and the Nezhdaninskoye (z500 metric tons gold) and Sentachan deposits in the Verchoyansk-Kolyma area. It was found that some of the mineralization is refractory in all four deposits, largely due to the occurrence of ""invisible"" gold in arsenopyrite as well as within pyrite, but with a lesser concentration. The gold concentration and its distribution varies considerably both within and between arsenopyrite grains, with implications for processing options such as heap leaching. The ore most likely to be amenable to heap leaching is the oxidized ore of the #4 orebody of the Olympiada deposit, but further quantitative mineralogical investigations are recommended for this orebody's sulfide ore and for the ores of the Nezhdaninskoye deposit. Following a full mineralogical characterization, it is possible that economic viability will depend on a combination of pre-concentration with or without pre-treatment, followed by heap leaching of some tailings products.Acknowledgements· The Russian authors performed this study under an ""Eco res"" Project which was financially supported by the Ministry of Science and New Technology of the Russian Federation. C.J. Stanley wishes to thank John Spratt and Terry Williams for help with EPMA. F.E. Wagner acknowledges the Deutsche Forschungsgemeinschaft for a grant supporting the Mossbauer studies. L.J. Cabri is grateful to the following: M. Beaulne, D. Carson and J.H.G. Laflamme for technical support, K.E. Haque for technical comments, and D.M. Hausen and W. Petruk for editorial suggestions."

Jan 1, 1997

By Richard D. Begley

This paper will present the results of an analysis of several abandoned coal mine projects and includes field data for over a dozen different reclamation projects recently completed in the state of West . Virginia. The analysis was performed with the objective of summarizing and or classification of the environmental consequences with reference to the characteristics of the mining facilities (surface, underground, etc.). The analysis also addressed the itemized cost of remediation with respect to procedures, environmental concerns and time. The results of the analysis are that each abandoned coal mine site in West Virginia have/had many unique features and in most cases include a combination of environmental concerns that complicate comparisons. The study also revealed that the abandoned mine land program for mines abandoned prior to 1977 that is being financed by a tax on the production of coal, has produced many benefits for the state of West Virginia. This grant program administered by the Office of Surface Mining, has resulted in a high quality methodology of remediation that has been successful for many years in greatly minimizing and/or eliminating environmental concerns from abandoned coal mines.

Jan 1, 1997

By James P. Rider, Charles D. Taylor, Edward D. Thimons

Research was conducted to investigate how ventilation of a mining face is affected when scrubber flow is greater or less than intake flow. Tests were conducted in a full-scale surface test gallery built to simulate a mining entry with a continuous mining ma- chine at the face. Methane gas was released at constant flow at the mining face. Gas measurements taken at six locations near the face were used to evaluate how well the face was being ventilated. Increasing scrubber flow resulted in lower methane levels even when scrubber flow was much greater than intake flow.

Jan 1, 1997

By R. J. Sawyer

The Greens Creek underground polymetallic mine restarted production in 1996 from a newly discovered high grade ore zone. Efforts to improve payable gold recovery have focused on gravity separation. The paper compares testwork and plant results for a newly installed gravity circuit.

Jan 1, 1997

By P. T. Velu, R. G. Reddy

"The use of emf measurements to derive classical thermochemical data has been in use for many years. The reaction associated with electrochemical process is harnessed in a galvanic cell and energy involved measured in terms of electromotive force. The property requirements of sensor electrodes used differ for various aqueous, molten salt and solid electrolyte systems. The electrodes for molten salt electrolytes need special care for construction. This paper describes the studies carried out using an Ag/ AgCI reference electrode. This electrode was used to measure the solubility of compounds in molten salt electrolytes. The results obtained using this electrode are in excellent agreement with the values from chemical analysis method.I. IntroductionThe technique of obtaining a metal from its oxides by electrolysis is more than a century old process now. In these processes, it has been well established that for halide electrolytes, only the dissolved oxides are available for the dissociation at the electrode to release the metal during electrolysis. Therefore, the solubility of metallic oxides in the molten salt electrolytes is an important parameter which determines the economical and technical viability of these processes. The widely used molten salts systems in halides are fluorides and chlorides. The fluoride electrolyte system is used in our present study.The viability of obtaining aluminum alloys by in-situ electrochemical processing has been outlined in our earlier publications[1-8]. Studies on the solubility of various alloying element compounds is a part of our ongoing research efforts for the direct production of Al-Li alloys. As mentioned above, the solubility of lithium oxide and lithium carbonate compounds in molten fluoride electrolyte system have studied using EMF technique. The change in potential of the molten electrolyte was measured by a working electrode against the reference electrode with the addition of lithium compound."

Jan 1, 1997

By Michael J. Brnich

Since 1991, Pittsburgh Research Center (PRC-formerly part of the Bureau of Mines) researchers have recorded extensive interviews with 30 individuals who are experts in the area of mine emergency response. These individuals, who have an average of 35 years of mining experience and 29 years of mine emergency response experience, related stories and observations from events that they experienced during their combined 850 plus years in mine emergency response. The purpose of this effort was to gather information that could be passed on to both today?s and tomorrow?s mine emergency responders to train and guide them in handling future events. This is the first of two articles which report the responses that these experts gave when asked how they think people who may have to respond to a future mine emergency should be trained. During the interviews they discussed how training should be conducted, who should be trained, and what topics should be included. This article will cover the first two areas: what training methodologies would be most effective and who needs to participate.

Jan 1, 1997

By B. Moudgil, M. Bogan

A bench-top centrifuge was used to study the consolidation behavior of phosphatic clays. A mathematical model (based on, first-order kinetics) was developed to describe the relationship between the void ratio (at any time) and the effective stress. The permeability of the sediment as a function of the void ratio is also described. The results of this analysis are then compared to data obtained by other consolidation testing methods. The centrifuge results indicate that consolidation data may be developed in a short period of time (hours) as compared to days or weeks when other techniques are used.

Jan 1, 1997

By F. S. Knoll

Magnetic separation employing superconducting technology is now accepted within the Kaolin processing industry, proving the value of this technology and its ability to operate reliably even at the most remote site. Developments in superconducting magnet engineering, including cryogen free operation, combined with experience in mineral processing enables new forms of Wet and Dry superconducting magnetic separation to be developed. Applying the high magnetic force advantages at 5 T else available from such magnets to other materials is now a reality. High magnetic force mineral separating system developments are reviewed allowing the mineral processor to take advantage of a technology that is no longer confined to the laboratory.

Jan 1, 1997