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A formalised approach to risk management has been regulated in the United Kingdom (UK) since the Construction (Design and Management) Regulations 1994 (CDM) came into force in 1995. These regulations have recently been revised in 2007. In response to a series of significant claims around the world the UK insurance industry published a code of practice for risk management of tunnels in 2003, and that was followed by an international version in 2006. Probably one of the main contributions of this new approach is the recognition that health and safety risks can best be addressed early in the process, initially by the owner and then by the designers. One of the aims is to achieve elimination of risks by good design. The advantage of a risk-based approach to tunnel design is that all risks are considered explicitly, and any residual risks in the design are communicated clearly to the construction team. This paper looks at the implementation of this formalised approach to risk management with reference to the A3 Hindhead Project. The design has been undertaken in accordance with the requirements of the CDM regulations, and also in compliance with the Joint Code of Practice for Risk Management of Tunnel Works in the UK. An outline of the risk-based design process used is provided, including examples.

Jan 1, 2008

By M. Pérez-Tello

A mathematical model to represent the expansion and fragmentation of copper matte particles oxidized under flash converting conditions is presented. The model assumes that the particles are initially nonporous, have a constant mass prior to fragmentation and travel at a constant velocity throughout the reaction chamber. The model requires the specification of the following five parameters: the particle expansion rate, a fragmentation diameter factor, a fragmentation size distribution parameter and the fractions of the finest and the coarsest particles in the feed that undergo fragmentation. The model predictions show good agreement with the experimental data collected in a laboratory furnace over a wide range of experimental conditions. The evolution of the size distribution of the particles along the reactor length was computed, and the model parameters were correlated with the experimental operating variables. Model predictions indicate that particle residence time is an important factor in the generation of dust. The presence of two maxima in the particle density function may be attributed to turbulent conditions prevailing in the furnace, which cause particles to follow different trajectories within the furnace even if they are injected at the same location.

Jan 1, 2008

By José García-Antón, Valentín Pérez-Herranz, José Luís Guiñón, Henry Reyes

"The majority of chromium electroplating operations employ Cr(VI)-based baths. During these processes, Cr(VI) is reduced to Cr(III). Besides Cr(III) other undesirable impurities are present such as iron, copper and nickel. The build-up of the impurities limits the lifetime of the plating solutions. Since the disposal of spent chromic acid baths is expensive and can cause significant environmental degradation, there is increasing interest in finding ways to regenerate waste chromium liquors.In this work, an electrolytic cell separated by microporous ceramic diaphragms was used to regenerate chromium plating solutions. The effect of the ceramic diaphragm structure parameters, such as porosity and pore size, on the performance indicators of the electrochemical reactor (fractional conversion, current efficiency, product yield, specific energy consumption) was investigated.The fractional conversion, the product yield and the current efficiency increased and the specific energy consumption decreased with the decrease in porosity.IntroductionChromic acid is widely used in industrial applications such as steel manufacture, metal finishing industries, aluminium anodising, pasivation of cadmium, magnesium, and zinc, etching of plastics and another industrial operations related with processing ferrous and no ferrous metals [1]. These processes employ baths with high concentrations in chromic acid, about 180 and 350 g/L, where hexavalent chromium is reduced to Cr(III):"

Jan 1, 2008

By R Simonato

It is now recognised that rotary sample division is by far the best laboratory tool for extracting subsamples from a lot of material. In terms of sampling theory, rotary division, by virtue of the fact that it can extract many increments from the lot during the division process, radically reduces the variance due to distributional heterogeneity in the sample being divided. There are a number of occasions in sample preparation when it is necessary to extract a subsample of a target mass. To do this with rotary dividers taking a fixed fraction of the starting mass is a tedious task. In response to this problem, a variable split sample divider has been designed and built for the mineral industry. This paper discusses the utility of the device and presents test data showing that the machine is capable of making accurate mass split while overcoming segregation in the material being divided.

Jan 1, 2008

Process mineralogy is an inter-discipline in the fields of mineralogy and mineral processing. As a predicting and trouble-shooting tool, process mineralogy helps address all mineralogical issues and problems related to mineral processing. It provides useful information on process design and optimisation, flow sheet development and cost reduction. As more and more complex and refractory ores are being discovered and processed, it is believed that process mineralogy will gain more attention and play a more important role in process design and optimisation. This paper will first discuss the scope of process mineralogy and mineralogical factors that may affect mineral processing of various ores, and then focuses on the application of process mineralogy in process design and optimisation through case studies.

Jan 1, 2008

By P. Henry

Hydrometal provides an adequate technology to reintroduce lost metal units into the industrial cycle, thereby saving resources and energy, while keeping the environment cleaner. Two case studies of our integrated hydrometallurgical recycling facility (Hydrométal) in Belgium are discussed.(I) Recycling of Cu-Co cement generated at the second purification step of zinc sulfate solution. (II) Recycling of lead complex materials from the lead industry.

Jan 1, 2008

By L. Parthasarathy, S. K. Pan, M. P. Srivastava

"Total iron ore reserves in India, as reported by the Indian Bureau of mines, are 23.6 billion tons. Hematite iron ore reserves constitute about 45 % of the total reserve. If we go by the National Steel Policy-2005 projections, India’s supply of hematite iron ore would not last more than 40 years. Laboratory investigations were carried out for the development of a process flow sheet for treating low grade as well as Banded Hematite Quartzite (BHQ) iron ore. The purpose of these investigations was to aim for better resource utilization.Beneficiation studies were conducted on samples of low grade and siliceous iron ore from the Dalli mines, a captive mine of the Bhilai Steel Plant and BHQ ore from Southern states of India. The process flowsheet, developed for upgrading of low grade iron ore, incorporates wet screening of the ore at 0.5 mm, followed by grinding of the +0.5 mm fraction to below 0.5 mm. The whole –0.5 mm fraction, after grinding, was treated in a conventional hydro-cyclone and stub cyclone followed by treatment in Wet High Intensity Magnetic Separator (WHIMS). This resulted in a concentrate product having >66% Fe content from a feed containing 55.5% Fe with an iron recovery of 48 %. The process flowsheet developed for treating BHQ ore in the laboratory resulted in an increase in iron grade in the concentrate from 43.4 to 61.3 Fe % with a yield of 51.7 % .INTRODUCTIONThe classification of Indian iron ore resources have been made compatible with United Nations Framework Classification (UNFC), which is more scientific and has been adopted in most countries in the world. Iron ore reserves and resources estimated using the UNFC classification system, as of April 01,2000 are about 12,906 million tons of hematite ore and 10,628 million tons of magnetite ore. The Indian Bureau of Mines (IBM) has given a breakdown of these reserves by designation as either lumps or fines of hematite iron ore (Table 1). The percentage of the reserves reported lumps and fines are 42 and 34% of the total reserves respectively. High grade iron ore is less than 10% of the total reserve."

Jan 1, 2008

By A. K. Mukherjee

The roles of pulsating mechanisms such as the amplitude and frequency of the jig cycle are well established in jigging. Also well established are the roles of the size ratio and the volume fraction of the feed. In iron ore beneficiation plants, these process parameters are optimized to achieve the highest efficiency. However, the role of one of the more important feed characteristics, the liberation characteristic of the feed, has not been studied in detail. Evaluation of the liberation characteristics is difficult because the required washability test is not viable for iron ore feed. In this paper, a new method is proposed in which the liberation characteristics are measured through a separation efficiency value. In the new evaluation method, jigging parameters such as amplitude and frequency of the jig cycle are optimized from the fundamental understanding of the process dynamics and feed characteristics such as size distribution. Then, feeds with different liberation characteristics are tested to evaluate the liberation characteristics of feed in jigging.

Jan 1, 2008

Nickel laterite HPAL circuits are known for their complexity and have presented a large number of challenges to process engineers worldwide. An attitude commonly encountered by the author is that the beneficiation of the ore is relatively simple and that the difficult problems are in the realms of hydrometallurgy. On a number of occasions beneficiation has become the 'poor cousin' in the process design phase. Another common theme is that significant difficulties are encountered when beneficiation circuits are started up, invariably slowing the ramp-up of the remainder of the circuit. In some cases the problems impact on throughput for a long period and can require major rectification capital. The HPAL Ni laterite projects encountered each have their own set of beneficiation problems that need to be understood before an appropriate circuit can be designed. This paper will discuss a range of design issues including geometallurgy, ore characterisation through laboratory testing, the application of appropriate sizing and analytical procedures, the selection of appropriate unit operations, materials handling of plant feed and products and setting meaningful plant design requirements.

Jan 1, 2008

By T. H. Udayashankara

Soil pollution, a very serious environmental problem, has been attracting considerable attention in recent years. It is now generally recognized that land as a component of the environment deserves the same attention and protection as water and air. This recognition has arisen perhaps because of increased incidents of land pollution, the scarcity of land, and increased awareness and concern about long-term effects of land pollution on terrestrial and aquatic eco-systems and on ground water quality. Contamination of land results from a wide range of human activities, including industrial discharge process, disposal of wastewater and agriculture. The environmental impact of exploration, production and refining of crude oil is a major concern in developed and developing countries. Because of the known adverse effects of petroleum hydrocarbons on soil ecology and fertility there has been growing interest in the development of efficient technologies for the remediation of contaminated land, with a view toward making it available for further use. Crude oil is a natural product and as such is susceptible to degradation by naturally occurring micro flora. Bioremediation has become an important method for the restoration of oil-polluted environments. A bench scale study was conducted to evaluate the bioremediation technique in treating soil contaminated with transformer oil. The steps involved in this study are: (1) Preparation of contaminated soil, (2) Extraction of PAHs and PCBs from contaminated soil, (3) Treatment of contaminated soil in slurry batch reactor, and (4) Analysis of PAHs and PCBs by gas chromatography technique. The performance of reactor was assessed by measuring parameters like COD, PAHs and PCBs. The study was con-ducted for six different pulp densities ranging from 20% to 40%. The maximum removal of PAHs and PCBs was observed for 20% pulp density.

Jan 1, 2008

By D A. Shushkov

Analcime-bearing rocks are one of the varieties of raw zeolite material, although the characteristics of analcime are not as good as other kinds of zeolites such as clinoptilolite or mordenite. However, some fields of application of analcime-bearing rock have been found, eg a method of water purification has been developed and patented. Analcime-bearing rocks are rather widespread in the Timan region of the Komi Republic of the Russian Federation. They are represented by Upper Permian siltstones and mudstones. The analcime-bearing rocks have the following mineral composition (per cent): clay minerals (50 - 70 per cent), quartz (ten to 30 per cent), analcime (one to 30 per cent), feldspars (two to ten per cent), carbonates (two to five per cent) and pyroclastic material. Analcime aggregates encrust cavities and infill microfissures in rock. Both microcrystalline (crystals <0.01 mm in size) and medium-crystalline (~0.5 mm) aggregates are observed. The mechanical, gravitational, magnetic, sorption and ion-exchange properties of analcime-bearing rocks have been studied. They are characterised by a high index of grindability and a low index of abradability and crush resistance, low values of the benzol-based pore volume and toluene-based specific surface area, and a medium porosity value. The magnesium based ion-exchange capacity (IEC) ranges from 28.7 to 196 mg+equiv/100 g. Analcime-bearing rocks of the Timan region are characterised by low beneficiation potential. Preliminary ultrasonic treatment of the analcime- bearing rocks is efficient for the destruction of intergrowths along their boundaries and production of free analcime aggregates. The proposed beneficiation procedure yields 95 per cent analcime concentrate. In the Komi Republic, analcime-bearing rocks are utilised in agriculture. They are also used for domestic needs (eg as biotoilets for domestic animals) and the solution of ecological problems (regeneration of soil polluted by oil). We have completed experiments on the purification of potable and industrial water using analcime-bearing rock subjected to thermal treatment. The experiments demonstrated that it was possible to decrease water colouration by 20 per cent, turbidity by 79 per cent, permanganate oxidation by 30 per cent and total iron content by 70 per cent.

Jan 1, 2008

By Tony Amis

There is very limited information relating to the potential impact of temperature cycles, outside the variation that occurs naturally, on the behaviour of foundation piles. Such thermal loading occurs when piles are used as heat exchange elements within a Ground Sourced Heat Pump system, in addition to carrying building loads to competent strata. An investigation has been undertaken where a conventional load test has been extended to include a period in which the load is maintained and temperature cycles applied. Instrumentation was installed in the test pile, an adjacent borehole, two of the anchor piles and the heat sink pile in order to be able to develop an understanding of the temperature variation and associated strain changes within and between the various elements. Conventional electronic strain and temperature gauges have been used in conjunction with optical fibre sensors which also measure strain and temperature changes. The results have confirmed the validity of the assumption made in the thermo-dynamic design of the system, the compatibility of the differing measurement systems and differing installation methods for the optical fibres, and initial assessment suggests that the load-settlement response of the pile is not adversely affected by the temperature cycles applied.

Jan 1, 2008

By Alessandra Bonoli, Garfìm Marianna

"Construction and demolition waste (CDW) is no dangerous material resulting from construction, and demolition of houses, large building structures, roads, bridges, piers, and dams. It is possible to recycle these materials, to reduce environmental impacts, and to reuse them in construction sector. To evaluate in a correct way the possibility to reuse this material it is important to lead laboratory tests to assess the proprieties and quality characteristics. European, Italian and British ad hoc Committees had elaborated specific Standards, to evaluate Geometrical, Physical, and Chemical requirements of recycled materials. A research was carried on to define the guidelines for laboratory tests, their suggested values and quality standards. The Construction and Demolition Waste Construction and demolition waste (CDW) is no dangerous, uncontaminated material resulting from construction, renovation, repair, and demolition of houses, large building structures, roads, bridges, piers, and dams. CDW waste is made up of wood, steel, concrete, gypsum, masonry, railway ties, roofing materials, carpeting, insulation, plaster, metal, and asphalt, and all waste included in CER Code 17. In particular Demolition wastes are defined as materials resulting from the demolition, instead Construction wastes are defined as waste materials resulting during construction process or in pre-manufacturing construction industry. Environmental problems In a lot of cases Construction and Demolition Waste materials were discharged in landfills, these are filling up with CDW and others, and some of them will close in the near future. In addition, illegal dumping of CDW debris can result in future health risks, decreased property values, cleanup costs and enviromental problems. The typical environmental impacts generated by CDW dumps are: 1- Dust problem, which causes air pollution, as will as forming dirty areas. 2- Uncontrolled locations, that will encourage the disposal of other waste types with the usual construction wastes leading to an environmental disaster. 3- The degradation and deterioration of the coastal lands and the natural protectorates. 4- The loss of aesthetic features. 5- Occupation of large areas, causing extra hauling costs. Therefore, it is wise to find other alternatives, like reuse or recycling, other than landfilling CDW debris or illegal dumps, because a proper management and the reduction of CDW amount can save money, conserve resources, and preserve the environment."

Jan 1, 2008

By A. Amiel

Tarkwa Gold Mine is owned by Gold Fields Ghana, IAMGOLD and the Government of the Republic of Ghana in a 71%, 19% and 10% ratio. The mine is operated by Gold Fields Ghana. This large, low-grade, open pit, gold mining operation is located in Tarkwa, in the Western Region of Ghana, approximately 320 kilometres by road, west of Accra, the capital of Ghana, West Africa. In the Financial year ended June 2007, the operation mined a total of 108 million tons of which 22 million tons was ore. The mined ore is processed through three gyratory crushers supplying two heap leach pads (north and south) and a carbon-in-leach (CIL) plant. Before the 6 Sigma project commenced, the current fragmentation was resulting in sub-optimal feed size to these crushers. It was decided to use 6 Sigma methodology to improve the fragmentation. A defect was defined as a fragmentation analysis indicating less than 95% passing 750 mm. The objective was to improve fragmentation in order to achieve a constant throughput to the north heap leach crusher of 1500 t/h, a 5% increase in pit loading efficiency and a 50% decrease in rock breaker hours, equipment damage costs and in-pit sheeting costs respectively. However, this was not to be achieved at the expense of grade control as Tarkwa is exploiting a low grade, high volume deposit and therefore ore dilution must be kept to a minimum. This paper is intended to take the reader through the various 6 Sigma phases of the project (define?measure?analyse ?improve?control), which have resulted in a 10% reduction in loading times, of which half has been attributed to improved fragmentation, as well as a substantial increase in blasted stocks. The focus has been on both drilling and blasting parameters as both processes had to be taken into account. These parameters are technical but personnel factors were also identified and dealt with as they arose. In order to measure the impact of any change in the process parameters on the fragmentation size distribution, cameras have been acquired. One has been installed looking into the bowl of the north crusher and the other one was dedicated to field observation, of individual blasts. Both are used for ongoing fragmentation analysis. At Tarkwa, mining efficiency is strongly dependent on good fragmentation as well as the presence of unblasted ?toes? on the pit floors. Crusher throughput depends on an acceptable ore fragment size. Compliance with plan for actual hole depths was temporarily monitored by manual hole dipping, but this is now being replaced with a fully automated drill data management system developed by Sandvik and Modular Mining. The Six Sigma methodologies, using control charts based on data collected in the field, allowed the mine to improve methods for the control of blasted material. It also enforced the implementation of a quality control programme encompassing the entire drill and blast process.

Jan 1, 2008

By S. Y. Fantaye

This paper discusses the design, construction and performance of a 30 inch thick diaphragm wall recently constructed in Baltimore, Maryland at Inner Harbor East. The project site is an established marina and waterfront property. The geologic profile consists of fill, alluvial silt and clay, Potomac sand and clay, decomposed rock, and weathered rock on top of gneiss bedrock. The approximately 1,300 ft long perimeter diaphragm wall serves as a water cut-off, perimeter basement wall and support of excavation for the high rise project?s five levels of below-ground parking. Due to the fast track construction and the tight schedule, the initial design of the diaphragm wall was based on a limited amount of geotechnical information. Supplemental borings were then performed along the alignment of the wall to verify the design assumptions and wall depths. Additionally, the design criteria required that the wall be keyed into a competent stratum with low permeability. The Engineer of Record for the diaphragm wall, Mueser Rutledge Consulting Engineers (MRCE) completed the design and produced accelerated construction documents allowing the developer to release the drawings early for bid. This paper describes the theoretical soil parameters used to develop the loads, moments, and shears for the design of the diaphragm wall and the temporary tieback anchors. It also discusses the refinement of these soil parameters using the observed wall displacements and tieback pre-stressing forces as a baseline. This paper compares the calibrated parameters to the values used in the design of the wall. It explains how the soil structure interaction model was developed and the soil parameters calibrated using PLAXIS 2D non-linear finite element software. The paper also discusses the use of the proprietary CWS joint by Soletanche/Inquip JV as end stop between consecutive wall panels and the unique top-down construction utilized to support the diaphragm wall at the Southeast double re-entrant corner.

Jan 1, 2008

By A Castleden, G Cavanough, M Kochanek, J Cunningham

ROES« is a proposed new mining system for underground hard rock mines. Ore is accessed from within a shaft, which is located close to or within the stope, and pitched either vertical or within approximately 20 degrees of vertical. The shaft is designed to exclude personnel entry so production drilling and explosive placement is done using remotely controlled or automated machines. Routine remotely controlled survey of the shaft, stope back and broken rock within the stope is typically done following each blast. The survey may include excavation geometry, rock fragmentation and geotechnical characteristics. Blastholes are surveyed before placement of explosives. This provides mine operators and engineers with real-time data, allowing them to monitor production performance and risk factors so that they can make rapid changes as required. ROES« is designed to apply to open stoping or sublevel caving situations either in disseminated, geologically defined, thick tabular or narrow vein orebodies. The technologies developed for ROES« will also have potential applications to block caving operations to reduce the risk of frozen ore and poor fragmentation. In a typical sublevel open stope application, ROES« will reduce the amount of stope-associated development by about half and therefore will allow ore to be brought on-stream sooner and at significantly reduced cost. Other savings are expected to flow from the centralisation of mining activities and operational data, reduction in mining fleet, reduction in ventilation requirements, improved occupational safety and reduced mine complexity. CSIRO and Orica Mining Services are developing the required technology and AMIRA is seeking sponsorship for a project to trial the mining method. This paper details the ROES« method, expected benefits and applications and includes typical stope and mining block designs and design requirements.

Jan 1, 2008

By C Dell

Hillgrove, situated on the New England plateau of New South Wales, is an area rich in history and resources. Key resources are predominantly antimony, gold and scheelite and the area surrounding the historical field is environmentally sensitive and topographically challenging. Since acquiring the Hillgrove leases, Straits Hillgrove Gold has undertaken a significant exploration program on these historical mining areas with the goal to return the field to production. This exploration program has enabled Straits to significantly increase the resource base and has subsequently enabled the planned redevelopment of Hillgrove to be realised. In October 2006, installation of mining infrastructure and the initial stripping of existing development had commenced. To successfully redevelop Hillgrove, Straits has had to adopt a highly mechanised, trackless, diesel mining operation which will see the production rate commence at an initial rate of 250 kt/a of ore from a narrow vein environment. This ore will be processed on site to produce antimony metal, gold bullion and a scheelite concentrate.

Jan 1, 2008

By Daniel Haines, Benjamin Konshak, Michelle Crull

American Technologies Incorporated Group (ATI) is the prime contractor with U.S. Army Corps of Engineers, Huntsville Center (CEHNC) in the Honolulu District for the removal of munitions and explosives of concern (MEC) at the Former Waikoloa Maneuver Area. The site is approximately 123,000 acres on the Big Island of Hawaii, which was used as an artillery firing range with live ammunition and other explosives deployed. ATI utilizes state of the art metal detection equipment to find and excavate metallic anomalies that have hazard potential. Both the investigation and disposal procedures present challenges due to residential communities and archeological sites that are located in and around the site. In order to excavate metallic anomalies safely and without adverse impact, ATI utilizes CEHNC-designed, open front barricades constructed of sandwiched sheets of aluminum with a support structure. When munitions or explosives are located, ATI is responsible for safe disposal using shape charge perforators to detonate the item where found. Sandbags are used for mitigating the effects of all detonations.

Jan 1, 2008

By R Badreddine, J Rose, L De Windt, P Chaurand, L Raimbault

Municipal solid waste of incineration (MSWI) bottom ashes are recycled as aggregates in civil engineering. These heterogeneous materials are composed of crystalline and glassy solid phases which contain trace metals, presenting a potential risk to the environment. Secondary ion mass spectrometry (SIMS) can provide quantitative chemical information, in particular the localisation of metals at trace level. Unstable glassy phases formed during incineration are present in relatively high proportions. Their analyses suggest a continuum between melilite-bearing glasses and dark glasses enriched in iron with abundant spinel aggregates. These primary glasses are enriched in zinc (~4500 ppm) but depleted in lead (~800 ppm) by comparison with the bulk chemical composition and reference materials. Heterogeneous cementing and encrusting admixtures on coarse grains are studied in a second step. SIMS imaging suggests a superposition of band zones including an intermediate layer enriched in iron oxyhydroxides and a superficial layer with calcium accumulation. A strong spatial association between lead and iron is systematically observed. Extended X-ray absorption fine structure (EXAFS) supports these observations by demonstrating that lead co-precipitation within iron oxyhydroxides, or sorption on their surfaces, may be a main containment process in the cementing and encrusting admixtures, whereas lead speciation is globally more complex in MSWI bottom ash.

Jan 1, 2008

By A. V. Z. Brink

This paper describes the development of a monitoring architecture that allows for continuous monitoring of the process of mining, the underground environment, the state of the rockmass and its response to mining. The system is based on an open standard and is non-propriety. It allows for dense sensor arrays in the workplace, wire less communication to the closest power line, and TCP/IP communication to a central server. Continuous monitoring and quantification of the appropriate parameters allows a mine to optimise its mine process; to dynamically access the safety and health risk to people and equipment; and to quantify exposure to potential heath hazards such as dust, gas or noise. Current application examples of continuous monitoring include an application to optimise drilling and blasting thought fragmentation monitoring; an application of wireless sensor network-based monitoring in to provide early detection of potential rockfalls; and a trail to continuously assess the gold grade at the shaft through correlation with radioactivity. It is unlikely that a single monitored parameter will provide adequate knowledge of the assessed risk or even an optimisation approach. Multiple parameters are being combined using cognitive science tools such as Bayesian theory and other statistical methods to improve the accuracy and relevance of, for example, risk quantification. The decision maker is not confronted with massive amounts of raw data but rather with a single knowledge statement such a probability of failure, a human physiological strain index or an optimisation index.

Jan 1, 2008