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In October 2005 Phelps Dodge mining, a US based company, visited several Australian mining companies and mine sites to ascertain the current applications of risk management methods in the organisation. The results of this review, documented by the author, indicated a ælayeredÆ approach from high level site or major hazard analysis through to face level, æstop and lookÆ, methods. The approaches of several companies were summarised in one simple layered model. This model is helpful to other sites and companies to identify potential improvements but also offers an image of best practice that may assist with the governance of OH&S by both company boards and community regulators. The issue is particularly relevant as we discuss national consistency in mining regulation. This paper examines the layered model, the company and site approaches that helped define the model, as well as the suggested implications of the layered model to governance.

Jan 1, 2006

Accidents that resulted in 16 deaths in three West Virginia coal mines, two in Kentucky and one in Utah have government and industry re-evaluating current safety regulations. Even though U.S. mines continue to improve on their safety records, the deaths reminded the industry and state and federal agencies that mining remains a dangerous business. Even so, data from the U.S. Mine Safety and Health Administration (MSHA) show that new technologies and a highly trained workforce has allowed the nation’s coal mines to increase production while providing safer workplaces. Since 1970, coal production at U.S. mines has increased by about 83 percent. During the same period, fatal injuries have fallen by 92 percent. And more than half of the U.S. coal mines operate each year without a lost-time injury. In 2005, there were 22 deaths in U.S. mines, a record low.

Jan 1, 2006

By F. Fournier Dit Chabert, F. Tancret, J. François Castagné, R. Le Gall

During the repair of turbine blades by a laser cladding process, it is observed that interdendritic cracking occurs in the heat affected zone (HAZ). Auger electron spectroscopy, performed on sample broken at high temperature, reveals interfacial sulfur segregation, which is known to be one of the main causes of microcraking in the HAZ during welding processes. Moreover, thermal gradients generated by the process are responsible for important thermomechanical stresses. In the present work, the finite element code Comsol Multiphysics is used to simulate the laser cladding process in order to determine both the thermal field and, using an elastoplastic law, the stress field inside the component. The originality is that the temperature history calculated in the thermomechanical model is extracted then injected in a segregation model in order to calculate the local segregation behavior. This model can be eventually used to predict the risk of cracking as a function of process parameters and alloy chemistry.

Jan 1, 2006

By D. Tao

Froth flotation is widely used in the coal industry to clean -28 mesh or -100 mesh fine coal. A successful recovery of particles by flotation depends on efficient particle-bubble collision and attachment with minimal subsequent particle detachment from bubble. Flotation is effective in a narrow size range outside which the flotation efficiency drops sharply. A fundamental analysis has shown that use of picobubbles can significantly improve the flotation recovery of particles by increasing the probability of collision and attachment and reducing the probability of detachment. A specially designed column with a picobubble generator has been developed for enhanced recovery of fine coal particles. Picobubbles were produced based on the hydrodynamic cavitation principle. Experimental results with one metallurgical coal and one steam coal have shown that the use of picobubbles in a 2" column flotation increased fine coal recovery by 10-30%, depending on the feed rate, collector dosage, and other flotation conditions. Picobubbles also acted as a secondary collector and reduced the collector dosage by one third to one half.

Jan 1, 2006

By F. Castelli

A simplified non-linear method to predict the behaviour of a single pile and/or pile group under horizontal loads is presented in the paper. The evaluation of the non-linear lateral deflection is based on a procedure taking into account the decrease of the model stiffness with the increasing of the applied load. The solution derived firstly for the single pile, was extended to the case of a pile group introducing the p-multiplier (fm) concept proposed by Brown et al. (1988).

Jan 1, 2006

By A Manzoori, M T. Shadloo

This paper describes a CFD modelling study which was carried out to investigate possible improvements in the design of an alumina precipitator tank at the Jajarm plant of Iran Alumina Company. In particular, the tank has an impeller located very close to the tank bottom, such that it quickly becomes covered with settled solids after a shut-down of the agitator, making it difficult to restart. A CFD model was firstly set up in which the existing design was evaluated in terms of flow pattern, off-bottom suspension and distribution of solids, and power consumption. Further simulations were then carried out to test alternative designs, leading to a recommended design, which maintains good mixing, with the same power consumption and without the use of a low-clearance impeller.

Jan 1, 2006

By Larry Southwick

In the early 1940's, the Caron ammonia ? ammonia carbonate leach process was used to produce nickel from Mayari ores at the Nicaro plant in Oriente Province, Cuba. While plant operation was generally successful, it was not broadly economical and was shut down. The plant was later restarted in the 1950's and a number of investigations initiated to resolve the more serious operational and performance issues. Processing steps studied included iron reduction (chemistry ? nickel and iron, reductant, equipment), ore variability (homogeneity and consistency of mineral concentrations, serpentine vs. laterite), leach solution strength, nickel recovery (temperature ? reduction and leaching, reoxidation) and a variety of other topics. These studies and their findings will be discussed. Caron himself obtained good results on these ores in the laboratory. They could not be duplicated in the field, the reasons for which will be reviewed. (Note: the ore looked like garden dirt; charcoal made from palm trees was one of the reductants attempted; and ammonia was the leach solution. Mixing the three, so to speak, was to yield nickel.)

Jan 1, 2006

By Zhihong Liu

Monodisperse micron size nickel oxalate particles with rhombohedron morphology were prepared from condensed Ni(OH)2 suspension by a novel gel-sol process proposed by one of the authors. Firstly, condensed nickel hydroxide gel was formed by fast adding 1 mol dm-3 NaOH solution into 0.2 mol dm-3 nickel chloride solution, and then oxalic acid solution with a concentration of 0.25 mol dm-3 was dropped into the gel drop wise through a pump equiped with a pH controller under preset pH value, and in this process, Ni(OH)2 gel was converted gradually into monodisperse nickel oxalate sol. The formation of the nickel oxalate particles was found to proceed through a dissolution-recrystallization mechanism from the nickel hydroxide gel. The product particles exhibited rhombohedron like shape with micron size long axis and sub-micron size short axis. The effects of such factors, as temperature, surfactants, et al, were evaluated experimentally on the particles sizes and morphologies.

Jan 1, 2006

By J. Bleeck, G. Mahrt

INTRODUCTION Many excellent papers have been written and presented regarding agricultural lime and the subject has been covered extensively in books concerning soil science, fertilizing, limestone, etc. We felt challenged to construct a paper that wouldn’t merely be a repetition of past presentations. Therefore, we chose to begin with factors having the most impact on plant growth realizing that the audience is likely to be relatively unfamiliar with this subject. So, we decided to dig deep into the roots of soil and plant growth science in order to better understand the significant role of limestone in this important area. The soil with the higher plants growing upon it forms an open and dynamic ecosystem in which there is flux of energy and material (heat, light, water, nutrients, mineral and organic matter, organisms). Plants root in the soil and then take up oxygen for root respiration, yielding energy for nutrient uptake, water for turgescence and transpiration and use in photosynthesis and the mineral nutrients needed for the synthesis of organic matter. Above the ground the plant takes in light energy and heat using them in photosynthesis to assimilate atmospheric CO2. Photosynthesis is the basic life process of creation. However, we will look at the root room where soil, water, air, and heat economy and the supply of nutrients determine soil fertility and the important role lime plays here. Location is the primary point to be considered when discussing agriculture (climate and soil); secondly, the dynamic and mobility of the minerals (plant nutrients) in the soil; and thirdly the conversion of organic substances into humus. And then there is a great deal of water involved in the growing process. In order to produce 1 kg of dry plant substance, 300 to 800 kg of water must be pumped through the plant and is then lost by transpiration. Cereals, vegetables, and sugar beets consume between 400 to 500 kg of water during the growing process and long-growing crops, such as alfalfa and clover, can consume 600 to 800 kg of water per kg of finished product. Without water, a plant cannot grow. (Reference 1)

Jan 1, 2006

By R Bresca, A McCallum, J Scealy

The Endeavor Mine, located to the north of Cobar, New South Wales, was purchased by CBH Resources Pty Ltd in September 2003. The operation has been producing lead and zinc concentrate continuously for over twenty-three years. In 2004, a water management program was instigated to improve the raw water use efficiency of the mining operation. The water management program involved the establishment of a Water Management Committee, a review and quantification of water use across the site, investigation and implementation of efficient water use practices, and workforce awareness training. The program has seen the amount of water used per tonne of ore milled reduced from an average of 1.08 kL/t in the March 2004 quarter, to 0.68 kL/t in the March 2005 quarter. This paper outlines the Endeavor Mine water management program and may serve as a model for other operations that are planning to improve their water use efficiency.

Jan 1, 2006

By J. P. Weiler

The increasing use of high-pressure die-cast magnesium alloys in the automobile industry requires a better understanding of the mechanical properties, the microstructure, and particularly, the relationship between these two. The goal of this study is to first understand the microstructural features which control the mechanical properties observed from an AM6OB magnesium alloy, and second, to be able to predict the local mechanical properties based on microstructural features encountered in different areas of the die-cast component. The two main tools used in this study are spherical indentation testing, used on local areas of the die-cast magnesium alloy AM6OB to detect changes in microstructure and mechanical properties, and X-ray tomography, used to non-destructively investigate the internal porosity in a sample. The results from these tests are then used to predict the local mechanical properties such as the yield stress, the strain-hardening characteristics, and the fracture properties of the AM6OB component.

Jan 1, 2006

By Z. W. Nkosi, M. Sephton, J. H. Potgieter

The exhaust system is a complex assembly of various components performing important tasks in harsh environments. Carbon steels have been used extensively in exhaust systems, but pressure for lower cost, increased fuel efficiency; lower hazardous emissions, weight savings and increased life expectancy have shifted the emphasis to stainless steels. In response to the growing consumption of stainless steels in automotive exhaust systems, the need to properly evaluate their corrosion resistance properties in order to ensure their appropriate use, has increased substantially. This paper evaluated the most common corrosion and oxidation tests developed that are used and applied it to four common stainless steels often employed in hot end exhaust components. In a summary considering the weight loss of an alloy, it general corrosion rate and pitting resistance under all the test conditions for hot end exhaust components, results indicate that 434 was by far the most corrosion resistant alloy, followed by 1.4509 and 321, and lastly 304 was the least corrosion resistant. In general, the ferritic stainless steels, especially 434, outperformed the austenitic ones under all the test conditions.

Jan 1, 2006

By D. J. Archambeault, A. Saigal

Substantial cost savings have been demonstrated by material design changes after initial product development. As more information about a product's operating environment becomes available to a designer, it is possible to consider a more costeffective material that still meets or exceeds the design intent, such as minimum low cycle fatigue life. This is especially true in the aircraft engine industry, where precise operating cycle data is not available until after the first engine is built and tested. A methodology for predicting estimated low cycle fatigue life has been developed to investigate potential material change candidates for an aft cooling plate. A twodimensional macromechanical finite element model (FEM) has been developed using ANSYS and used to determine the effects of varying material properties. It is shown that slight changes in density, coefficient of thermal expansion and modulus of elasticity have profound effects on component and effective stresses, and therefore, estimated low cycle fatigue (ELCF) life. Aerospace

Jan 1, 2006

By Eric M. Klein

As part of the Woodrow Wilson Replacement Bridge project several damaged wetland and environmental areas were to be mitigated. One of the mitigation projects consisted of constructing a Denil fish ladder around Peirce Mill Dam in Rock Creek National Park, Washington, D.C. The dam is a historic structure operated by the National Park Service. The fish ladder is located between the east abutment of the dam and Beach Drive, a major collector road. Construction of the fish ladder required removal of a portion of the east abutment and an excavation that extended about 22-ft below the pavement of Beach Ave. It was not possible to close Beach Drive except for very brief intervals or at night; therefore, a support of excavation system that would minimize disruption to the public was required. The high groundwater required that the groundwater be cut off prior to excavation; the random rubble and soil fill, and shallow but erratic rock surface precluded driving sheet piling. A jet grout system was selected because the grout probe could penetrate the rubble fill, stabilize a variety of soil conditions, and cut off the ground water prior to excavation. It was not possible to construct a stable wall without tiebacks or soil nails. Given the schedule and tight working conditions it was decided that soil nails through the jet grout wall facing would be the most cost effective method, as it did not reduce the working space as rakers would and would be more cost effective than prestressed tiebacks.

Jan 1, 2006

By P. A. Olubambi1

Representative samples of the hydrothermal vein deposits of the bulk complex sulphide ore deposit, 10 km south of Ishiagu, in Ebonyin State, South Eastern part of Nigeria were collected from two small scale mining companies. The samples were mixed and successively crushed in a jaw crusher and cone crusher, and ground in a rod mill. Characterization was carried out with SEM, EDX, XRD, XRF and ICP-OES. Mineralogical analysis revealed the presence of sphalerite, galena, siderite, pyrite, quartz and chalcopyrite. X-ray Diffractometry showed that sphalerite mineral in the ore occurs as sphalerite ferrous with varied percentage of Zn and Fe within the various sizes while chalcopyrite occurs as a chalcopyrite group mineral with chemical formula Cu2MnSnS4. Results of the elemental analysis showed variations in elemental composition within the different sizes.

Jan 1, 2006

By Huw Williams

It is becoming increasingly common practice to re-use existing foundations for new projects, especially on urban sites where geotechnical conditions are congested. A knowledge of the foundation dimensions and capacity is essential for this to take place, however, as-built records are often non-existent. Non-Destructive evaluation (NDE) is now becoming an important tool in assessing old foundation properties and their potential for re-use. Pile dimensions are also critical in the power industry, when they are supporting transmission towers which need to be upgraded, and may carry additional wind loading. This paper describes the application of various NDE techniques that are available and how they can be used to determine pile length, shape and capacity in difficult site conditions, including foundations under structures.

Jan 1, 2006

By S. Suda

Hydrogen storage materials have been investigated for more than 30 years, particularly on metal hydrides. These materials are, however, considered today impractical because of their poor hydrogen capacity measured by mass density and their poor surface properties and characteristics against impurities. Recent R&D activities have been located in new categories of materials such as complex hydrides and chemical hydrides. Among these materials, NaAlH4 (one of alanates), Li-based complex hydride, and NaBH4 (SBH: sodium borohydride) are 3 major candidates as hydrogen storage materials. In the presentation, SBH as a non-reversible on-site but recyclable off-site is described in view of its practical availability as the source of H- (protide) applied for a new type of fuel cell named Direct Borohydride Fuel Cell (DBFC) and H2 (hydrogen) for Proton Exchange Membrane Fuel Cell (PEMFC).

Jan 1, 2006

By Paul Downing

While safety and security have always been concerns of the U.S. explosives community, events throughout the world during the past few years have caused us to re-examine our industry’s potential vulnerability and change the way we do business on a day-to-day basis.

Jan 1, 2006

By D. G. Lee

Diesel particulate matter (DPM) often contains small amounts of metal as a minor component but this metal may contribute to adverse health effects. Knowledge of the mechanism for particle formation as well as the size preference of the trace metals is critical to understanding the potential for health concerns. To achieve this, the size and the composition of each particle should be optimally measured at the same time. Single particle mass spectrometer (SPMS) would be the best tool for this objective. In this paper, we therefore will introduce new findings about the mechanism and distribution of the trace metals in DPM, derived from a study where an SPMS was used to analyze freshly emitted DPM. KEY WORDS : Single particle mass spectroscopy, Diesel particulate matter, Characterization, Metal contents

Jan 1, 2006

By K. Adham

Iron chloride pyrohydrolysis (ICP) is used as an efficient way to fix iron as an oxide, for sale as a by-product or for safe disposal. Iron chloride is reacted with water at elevated temperatures to yield iron oxide and hydrogen chloride. Both the steel industry and synthetic rutile producers make extensive use of ICP. Two technologies are available for ICP: fluidized bed (FB) and spray roaster (SR). Both technologies are energy intensive. Here, fluid beds and spray roasters are compared with respect to their fuel and electrical energy consumptions. Roaster size and oxide product characteristics are also considered. Process models are prepared, using the METSIM® software, and specific energy consumptions are compared. The results will help the industry decide which technology best suits its goals and at what energy cost.

Jan 1, 2006