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By T. Ediz

Sarkuysan Electrolytic Copper holds three competitive technologies namely Outokumpu, Southwire (SCR®) and CONTIROD® under the same roof. After more then thirty years experience of Outokumpu Upcast ® in producing oxygen free wire- rod, and twenty years of SCR® experience, in 1999 it was decided to introduce the CONTIROD® process to the customers with a chance and advantage to test capabilities of each process in order to fulfil their requirements, expectations, and turn this know-how to their benefit. After reviewing the milestones of Sarkuysan's evolution in Turkey as global wire-rod producer, this paper will briefly present the modernization and expansion activities in the CONTIROD® plant consisting of the different phases following the first start-up, and the results of these activities. It will highlight the gains and improvements of some operational parameters within this period.

Jan 1, 2007

By Dhananjaya Senapati, E. V. S. Uma Maheswar, C. R. Ray

Carbothermic process of Ferro Silicon production is primarily a slag-less process. However, slag formation is observed in the regular operation as experienced by almost all the Ferro Silicon Producers in different pro-portions. The problem of slagging in the furnaces may be due to: a)Variation in the input burden charge material quality b)Fluctuations in the Carbon balance and/or c)Fluctuations in the Electrode penetrations The problem will be more severe in nature with the increase of the size of the furnace. The operation performance of the furnace gets badly affected if the slag formed in the furnace is not removed from the bath in time and to the maximum extent possible. It is, therefore, very essential to know the characteristics of the slag formed in the Ferro Silicon Furnaces, besides eliminating the very cause of formation itself; and to find the routes of draining of the same from the furnace bath effectively. This paper envisages the effects of using the LIME STONE in the Ferro Silicon Burden in stabilizing the 48MVA Furnace for improved performance and better consistency. Quality fluctuations in the available Raw Materials are compared with that of the requirements for the Ferro Silicon production. The furnace operational data is compared for 12 months period each for the period corresponding to the before and after usage of lime stone in the burden and found encouraging results in the performance. Implications of use of Lime Stone in the burden on the quality of the output alloy are also studied.

Jan 1, 2007

By M. A. Hermanus

This paper examines the occupational health and safety performance (OHS) of the South African mining sector against the backdrop of changes in the composition of the sector, international trends in OHS performance, and the agreement on OHS milestones and targets by mining stakeholders at the Mine Health and Safety Summit of 2003. Although OHS performance has improved, progress is slow and there is need for significant rather than incremental change if the targets are to be realized. Since 2003, fatalities and injuries are 20?25% short of annual milestones and not all commodities show consistent improvement. Statistics on occupational health impacts are unavailable, but noise and respirable dust levels are known to be high in mines, with much work lying ahead to address exposures at source. Trends in regulating and addressing OHS hazards are discussed with reference to the notion of ?systems-thinking? and the targets. Efforts to improve OHS and to respond to changes in the sector are constrained by a lack of training and consistency in risk management, guidance for junior, small and artisanal miners, and holistic approaches to risk. For example, treating risk holistically would involve taking proper account of contractors and women in the workplace, and attending to human factors and ergonomics.

Jan 1, 2007

The coal under the ridgeline is the most valuable part of the known reserve at Solid EnergyÆs Stockton Opencast Mine. Some ridgeline mining had been attempted in the past with mixed results. Solid Energy recognised that significant project planning was required in order to overcome the formidable technical issues associated with mining the area. It also recognised that the local community also had concerns about the potential impacts of this work including the visual impact of changing the topography of the ridgeline and the nearness of the Department of Conservation estate.   This paper outlines some of the risks and challenges that were faced and the management approaches that were adopted to address them.

Jan 1, 2007

By E. Cho

Illinois No. 6 coals of IBC 101 and IBC 112 were treated in solution with sodium hypochlorite to remove their sulfur contents, especially organic sulfur. The lab experiments were conducted in two steps of leaching at room temperature and hydrolysis at 90oC. The removal of organic sulfur from IBC 101 was by 37.8% while that from IBC 112 was only 13.7% under their respective optimum conditions. This large difference in organic sulfur removal is considered to be due to difference in concentration of surface total acid group, 3.14 vs. 0.88 mmol/g of coal.

Jan 1, 2007

By Doug Harding

The Niagara Tunnel Project (NTP) is a 10.4 km (6.5 mi) long, 14.4 m (47.5 ft)bored tunnel that will run under the City of Niagara Falls from the Upper Niagara River to the Sir Adam Beck Power Station. The completed project will enhance the capacity of the Sir Adam Beck Power Station by adding 500 m3 (17,657 ft3) of water per second through the tunnel. The paper describes the project in which the world’s largest hard rock TBM at14.4 m (47.5 ft) in diameter is being used to excavate the tunnel. Features of the project include the use of a High Performance (HP) Main Beam TBM, state-of-the-art ground support and tunnel logistics systems. A continuous conveyor is used for muck transport from the TBM to the disposal area. The paper will also discuss the optimization of the TBM system as the tunnel advances through the varying geology. In June 2004 the Ontario Government announced that Ontario Power Generation(OPG) had been given approval to proceed with the third tunnel under the city of Niagara Falls—the first two tunnels were constructed in the 1950s using drill and blast techniques. The third tunnel, appropriately named The Niagara Tunnel Project (NTP), consists of a 10.4 km (6.5 mi) long TBM-bored, concrete-lined tunnel with a finished diameter of 12.5 m (41.1 ft). In August 2005, OPG announced the selection of Strabag AG of Austria, one of the largest construction companies in Europe, as the contractor to build the NTP Project at a price of CAN $600 million. In September 2005, Strabag A.G. selected The Robbins Company of Solon, Ohio to design, manufacture and deliver a new 14.4 m (47.5 ft) diameter High Performance state-of-the-art Main Beam Hard Rock TBM to be used in the excavation of the tunnel. In order to meet the aggressive construction schedule as requested by OPG/Strabag, the TBM needed to be supplied as “ready to bore” within a 12 month period after the contract was awarded to Robbins.

Jan 1, 2007

By C. Acuña

The case is presented that the key role of frother is control of bubble size in the pulp zone. Compared to water alone, the addition of frother produces a narrower distribution and finer bubble size. An empirical model is presented for bubble size as a function of frother type using a normalized concentration. The model provides a benchmark for assessing operations. There is no agreed upon mechanism of how frothers act to reduce bubble size. Prevention of coalescence is a common explanation and this action is illustrated. The case against the 'coalescence' model alone is presented and a breakup mechanism is introduced based on pilot cell and single bubble studies. Phenomena associated with bubble shape, velocity and surface flows are used to illustrate the force associated with surface tension gradients. Breakup mechanisms resulting from this force are proposed. The concept can be extended to high salt concentrations which also promote small bubbles.

Jan 1, 2007

By M. Yavuz

Equipment selection in mining operations is an important issue, and also difficult to solve in multiple criteria environments. The paper in question has aimed to develop computer software for solving equipment selection problems in mining. In their paper, Basçetin et al. have analysed two case study problems related to open pit and underground mining method selection. By using Yager?s method1, the authors have selected 18 different criteria in the first case study and 21 criteria in the second case study. However, as emphasized by Ozdemir2, in pair wise comparison matrices the appropriate number of criteria should be seven as the maximum, from the point view of validation, consistency and redundancy. In cases where there are more than seven criteria to be handled, it is suggested that the criteria should be clustered and then the maximum number of clusters and subcriteria of every cluster should be limited to seven4.

Jan 1, 2007

By Chris Tattersall, Tomyuki Kudo, Peter Raleigh, Nestor Garavelli, Steve Redmond, Michael J. Lehnen

Twin bore running tunnels driven approximately 4,500 route feet by a Mitsubishi Heavy Industries (MHI) EPB Tunnel Boring Machine link the West Portal and East Portal on this complex Light Rail Project. One third along the way, the TBM arrives at the Beacon Hill Station which is the deepest underground “binocular” station of its kind in North America and then “walks-across” the station to be re-launched on the other side to complete the drive. This paper discusses briefly the layout and design considerations but then focuses more deeply on the approach by the Contractor to drive and supply the tunnel. The paper addresses the approach used to launch, re-launch and recover the TBM and touches briefly on muck volume control and monitoring plus settlement monitoring and the performance achieved. Also of interest is a unique solution to a difficult launch situation involving a secant pile tieback wall designed with several rows of double I-beam steel walers spanning the eye at the West Portal under the I-5 freeway.

Jan 1, 2007

By N. Graham, C. Walker

The SORD Miner is a patented mining principle being developed to exploit mineral and energy resources that current technology can not access. SORD Miner is designed to operate in underground wet, granular, continuously collapsing geological environments such as alluvial and marine deposits. It is somewhat like a cutter suction dredge and should be capable of mining its way through any fine granular material like sand or gravel, pumping the slurry back to the surface. In areas where the target layer is covered, the SORD Miner is inserted below the water table and will tunnel its way to the mineral deposits at depth. This paper describes the development, concept testing and prototype construction of the SORD Miner.

Jan 1, 2007

Ceremonies for the induction of four mining industry pioneers into the National Mining Hall of Fame will be held Saturday, Sept. 22, 2007 at the Charles F. Barber Pavilion (Museum Convention Center) in Leadville, CO. The four inductees are James Harold Courtright (1908-1986), Dr. Howard L. Hartman (1924-2002), Charles Washington Merrill (1869-1956) and Kenyon E. Richard (1915-1993). The inductions will bring to 197 the number of mining “greats” whose engraved photographs and biographical sketches are installed in the National Mining Hall of Fame.

Jan 1, 2007

By E. A. Sarver

The Fe(II) regeneration process is an important aspect of Alternate Anode Reaction Technology (AART) for copper electrowinning (EW). In AART, Fe(II) is oxidized to Fe(III) at the anode during EW, and it must be regenerated to maintain recyclable electrolytes. Regeneration is achieved via Fe(III) reduction by SO2(aq), and the reaction is catalyzed by activated carbon particles. To better understand this process, a kinetic model was developed and experimentally validated for the Fe(II) regeneration in the current work. The investigation focused on the primary reaction mechanism and the reaction rate dependence on four variables: carbon particle size, flow rate, initial Fe(III) concentration and initial SO2 concentration. The Fe(II) regeneration reaction is mass-transfer controlled in the presence of activated carbon. Carbon particle size and initial Fe(III) are the most influential factors under the conditions tested. Initial SO2 concentration is insignificant to the reaction rate.

Jan 1, 2007

By Charlie Watts, Ken Smales, Ron Fleming

The Manapouri Power Station is an underground hydro-electric station located in the South Island of New Zealand, and was constructed in the 1960s. Between 1997and 2002, a second 10m diameter tailrace tunnel was constructed to increase the out-put and to improve the overall hydraulic efficiency and output of the station. A critical economic and project approval consideration for the second tunnel was the outage time required for the breakthrough into the power station. The power station is in part dedicated to providing power to an aluminum smelter with the balance to the National Grid, and apart from the physical problems associated with providing an alter-native power supply to the smelter, the loss of generation revenue and supply risk were significant issues. Innovative planning reduced the planned outage time from several months to21 days, and the breakthrough was eventually achieved in 11 days as a result of additional value engineering measures implemented during construction. This paper describes the engineering optimization that took place during the planning stages of the project and later during construction, as well as describing the construction methodology used.

Jan 1, 2007

By C. Deutsch

Resource estimation for the West Leeville deposit is prepared using a conventional explicit approach. The geologic model is developed using interpretive methods based on visual logging. Grade shells are then prepared at low and high grade cutoffs. The low grade shell includes material of interest (Au > 0.010opt), while the high grade shell is developed slightly below the economic cutoff grade for mining. Grade estimates are made within these boundaries. This paper documents a conditional simulation study to evaluate the uncertainty contributed by both the grade shells and grade estimates. Multiple realizations are generated for the grade shells and the grades. The full combinatorial of realizations are merged to assess the uncertainty and the relative contribution of the grade shell and grades.

Jan 1, 2007

By A. Luszczkiewicz

This paper presents the beneficial effects of non-oxidative leaching of final and intermediate copper sulfide concentrates with sulfuric acid prior to the final cleaning stage of flotation. This unique process, combining leaching and flotation, appears to be advantageous for difficult-to-treat carbonate-bearing Polish copper ores, such as those processed in copper concentrators at KGHM Polish Copper. It was shown that after the chemical decomposition of about 70 % of the total carbonates naturally present in the flotation feed, a considerable enhancement of subsequent flotation results (both grade and recovery). The resulting products of non-oxidative leaching are solid hydrated calcium sulfate (gypsum), soluble magnesium sulfate and gaseous carbon dioxide. The beneficial effect established by the laboratory leaching tests was subsequently confirmed during a pilot plant operation treating final copper concentrate and a problematic intermediate concentrate at the Lubin concentrator.

Jan 1, 2007

By A. J. Rigby

Computer generated, actual-scale furnace models have been imported into a rendering software application to provide for impressively realistic surface features and lighting. When these models are imported into a 3D engine framework, it is possible to create content-rich virtual environments allowing for complete interactivity and could provide for a powerful tool to conceptualize refractory lining designs. This technology has been applied to illustrate the optimized design concept of an anode-refining vessel, which can be expected to be completely relined in six days and to last for 4-5 years with minimal partial relining. This technology could easily be applied to other smelter furnace, converter and refining vessel designs.

Jan 1, 2007

By E. R. Dixon

Copper SX/EW plants often bleed part of their electrowinning electrolyte to control impurities and maintain consistent cathode quality. Depending on the specific situation at each site, the bleed is either returned to raffinate, to an SX extraction stage, to an SX wash stage, or to the PLS pond, to avoid losing the copper in the bleed. This practice can have undesirable effects on the overall process. An alternative is to electrowin all or most of the copper in the bleed, thus avoiding the recirculation of the copper in the bleed. In this manner, the bleed is converted to metallic copper without interfering with the SX circuit. This in turn reduces the copper concentration in the raffinate, improving global copper recovery because of improved leaching conditions.

Jan 1, 2007

By C. Ringas

Pipelines are used extensively in industry to convey various products. Internal corrosion of pipelines can lead to perforation and leakage of the product. A growing problem, not often accurately recognized, is internal corrosion of pipelines caused by bacteria. Microbiologically-induced corrosion (MIC) refers to corrosion caused by a variety of micro-organisms. This form of corrosion is not widely recognized in many industries, although it is widespread and causes many corrosion problems in pipelines, both internal and external. Sulphate-reducing bacteria (SRB) are responsible for the bulk of the corrosion problems caused by MIC. Corrosion caused by SRB is found extensively in water pipelines conveying raw, potable and waste water, as well as in pipelines conveying slurries. This problem also occurs in pipelines conveying crude oil. This paper describes internal corrosion problems of slurry pipelines caused by bacteria and outlines mitigation methods to improve slurry pipeline integrity, thereby extending the life of such pipeline

Jan 1, 2007

By Robert Hopler

Although electrical instruments were being widely introduced into the study of seismic tremors, attempts to understand and quantify shocks from blasting continued to use rather primitive methods well into the 19th century.

Jan 1, 2007

By Andrew Budek

Reinforced concrete piles are used to carry foundation loads through considerable depths of soil to provide superstructure stability under gravity loads and lateral forces. The creation of cast-in-place (or cast-in-drilled-hole, i.e., CIDH) piles begins with the auger-drilling of a hole of the appropriate depth, into which a cage of reinforcing steel is placed (the cage length is generally equal to the depth of the hole, a construction joint being used to connect the in-ground pile with the superstructure). The pile is then finished by casting with concrete, and the superstructure then appended. The superstructure may either be a column (denoting the structure a pile-column), a column and cap beam, or a footing. Typical pile-column configurations are shown in Fig. 1 (a CIDH pile used in a footing would be similar in overall configuration to Fig. 1(b), with H=0). CIDH piles are well-suited for alluvial soil profiles with a deep water table; such conditions generally allow the auguring of a clean and regular hole.

Jan 1, 2007