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By Joseph A. Zupanick

Methane drainage is a mature technology, now commonly practiced in many highly productive underground coal mines throughout the world. Universally, the practice of pre-draining methane will continue to grow as near-surface coal seams become depleted and mining operations are forced to exploit deeper reserves. These deeper coal reserves inherently have higher gas contents. In addition, increases in productivity and extraction rates have caused higher methane liberations per unit of time. As the cost of providing ventilation air increases, the economic justification for implementing a methane drainage program becomes apparent.

Jan 1, 2005

By W. R. Richmond, T. S. Li, D. Ilievski

The reactive precipitation of ferrihydrite was studied in a laboratory semi-batch precipitator, where a highly concentrated sodium hydroxide solution was fed into an iron nitrate solution. Instantaneous hydrolysis of iron[III] takes place when the two reagents are mixed generating supersaturation, and leading to immediate precipitation of ferrihydrite via a primary nucleation mechanism then followed by limited crystallite growth to 3 to 7nm. A mathematical model of the semi-batch laboratory precipitator was used to simulate the pH responses during the precipitation of ferrihydrite at different reagent feed rates. The model comprised of interconnected compartments of averaged hydrodynamic conditions, incorporating physically meaningful turbulent mixing time constants. The precipitation process is described by the solute concentration conservation equation incorporating a postulated ferrihydrite primary nucleation model. It was found that the semi-batch precipitator model predicted the experimental pH response reasonably well. The experimental results demonstrated that the reagent feed rate has a critical effect on the course of the precipitation of ferrihydrite, i.e. it is a rate determining step given the fast hydrolysis and precipitation kinetics.

Jan 1, 2005

By G J. Jameson, A Agarwal

This paper is concerned with the observation and analysis of bubble clusters in a laboratory flotation cell. A device was used in which bubbles were allowed to rise in clean water containing the same frother and collector concentration as in the cell. Bubble clusters were recorded using a high speed camera and analysed using an image analyser. Dodecyl amine was employed as a collector to float silica. The effect of impeller speed on the cluster behaviour was investigated. The results were interpreted in terms of cluster diameter and shape factor. The sizes of the bubbles forming the clusters were also measured and compared to the sizes of the independent bubbles in the cell. It was found that there was an optimum impeller speed in which the cluster diameter was a maximum. Higher agitation and the consequent higher power inputs resulted in cluster break-up while lower shear rates promoted cluster formation.

Jan 1, 2005

By Dennis Ofiara, Michael Lewis

An experimental 1.75 meter Shaft Boring Machine was designed and manufactured by The Robbins Company. The drill was used by contractor Drillcon Raise AB to drill test shafts at an SKB underground test facility. SKB is the Swedish authority responsible for safe management of nuclear waste materials. This “SBM1.8” Shaft Boring Machine was used to drill shallow test shafts ingranitic rock at SKB’s Aspo underground laboratory. The drill used a unique vacuum mucking system. The bored shafts were held to very strict tolerances for bore diameter, straightness, and verticality. This drill was launched and operated from a mobile launcher. Headroom and working space were limited. The SBM1.8 drill produced acceptable test holes. SKB will carry out several studies to determine the suitability of this geology, and of this technique, for safe nuclear disposal. In addition to future use at SKB, many applications are foreseen, particularly in the civil construction industry.

Jan 1, 2005

By Sutham Niyomwas

Keywords: Al2O3-SiCW, Ceramic Matrix Composite, Carbothermal Reduction, Kaolin The formations of Al2O3-SiCw composite have been obtained in situ by carbothermal reduction of a mixture of kaolin and activated carbon. The reaction temperature was controlled at between 1400°C to 1600°C. The synthesized products were mixtures of alumina and silicon carbide in the form of whiskers. The effects of milling time of precursors and reaction temperature are presented. XRD and SEM analyses indicate complete reaction of precursors to yield Al2O3-SiC as product powders, with the SiC having porous and whisker morphology.

Jan 1, 2005

By J. Shen

Direct methanol fuel cells have been the subject of considerable research in the last decade. Performance levels realized in cells, stacks, and systems show that this technology is a promising power source for a wide range of portable applications. A direct methanol fuel cell (DMFC) operates directly on a methanol fuel stream typically supplied as a methanol/water vapour or as an aqueous methanol solution in liquid feed DMFCs. The fuel streams in DMFCs are usually recirculated in order to remove carbon dioxide and to re-use the diluent and any unreacted fuel in the depleted fuel stream exiting the DMFC. The concentration of methanol in the fuel circulation loop is an important operating parameter because it determines the electrical performance and efficiency of the direct methanol fuel cell system. The methanol concentration in the circulating fuel stream is usually measured continuously with a suitable sensor, and fresh methanol is admitted in accordance with the signal from the sensor. There are many factors to consider in developing a methanol sensor suitable for DMFCs. These factors include sensitivity, cost, size, simplicity, reliability, longevity, concentration range, and dynamic response. In particular, reliability and low cost should be addressed. Methanol concentration sensors measure methanol concentration by means of detecting the variations of physical/chemical properties of the solution. In this work, methanol concentration sensors based on electrochemistry, electric-capacitance measurement, infrared sensing, ultrasound sensing, and other techniques are reviewed to discuss their advantages and disadvantages.

Jan 1, 2005

By K. El-Ouassiti, M. Zouadi, C. Bazin, D. Hodouin

Data reconciliation techniques are used to attenuate the effect of measurement errors and estimate unmeasured variables. This paper illustrates the application of data reconciliation to hydrometallurgy processes using measurements from leaching and solvent extraction obtained from laboratory experiments. The application of data reconciliation provides an efficient way to detect gross and systematic errors and produces reliable performance indices for process evaluation.

Jan 1, 2005

By Joel Moskowitz, Jan Cermak

"New York City has unique geologic conditions which must be considered when designing pile foundations. Where shallow foundations are not feasible, the City's subsurface conditions require a variety of deep foundation systems, ranging from high capacity rock socketed piles, to piles end-bearing on bedrock, to friction piles bearing in alluvial or glacial deposits. Pile load testing is essential in confirming pile capacities as pile analyses include assumptions on soil and soil-pile response, and pile driving equipment. Load test results must be interpreted to estimate the long-term pile behavior. Except for lightly loaded driven piles, the New York City Building Code (the Code) requires that pile capacities be confirmed by static load testing. The Code provides the number of static load tests required, test procedures, and acceptance criteria. In the last few decades, methods other than static load testing have been developed including dynamic and rapid (pseudo-static) load tests. Recently, those methods have also been employed on several projects in New York City. The traditional approach to pile load testing in New York City is discussed herein including engineering involved in the analyses of test data with examples. In addition, several projects which included non-static load testing are discussed INTRODUCTIONPile load testing complements the subsurface information and pile design by providing further data on pile-soil interaction for the selected pile type and installation method. Traditional approaches to pile load testing in New York City involve static load tests to verify the design capacity of the piles for a given minimum factor of safety.In the late 1950's, Dr. Phillip C. Rutledge summarized his views on the philosophy of pile foundations in an unpublished, in-house document. He viewed pile foundations as good illustrations of pertinent and impertinent aspects of geotechnical engineering. In the analyses of piles he divided engineering into four general types:(a) Theoretical engineering in which decisions are made based on theoretical analyses. This represents ideal engineering, in which all factors affecting the pile design are well established or, at least, few simplifying assumptions with known effects on the analyses are made."

Jan 1, 2005

By David G. Almond

"Economies of scale and the variable characteristics of many large ore deposits have resulted in grinding installations having large SAG mills fitted with variable speed drives. Problems associated with effective operation of this equipment has created the need for better operator knowledge of mill load behavior and the need for new instrumentation capable of providing accurate information about load movement and composition. This paper discusses two performance enhancing instruments available to address these needs.INTRODUCTIONThe economic demands of new mining projects has resulted in increased equipment sizes and this is particularly evident in milling where there are now many SAG mills operating in the range of 28’ – 40’ diameter with installed powers of 8 – 22 MW. These mills are designed to process very high capacities of ore daily2 and the variable characteristics of many of the deposits mined results in the need to vary the mill speed during processing to cater for the changes in ore hardness. Mill speed changes often result in operational problems associated with high-energy impacts striking the mill liners reducing energy efficiency as well as degrading the grinding media through breakage, accelerating liner wear and in extreme cases even breaking liners. These operational problems have given rise to the need to have instruments aimed at providing operators with accurate information in real time about the load composition and movement within SAG mills.The original concepts for operating SAG mills were derived from past experience of operation of conventional fixed speed ball mills. However, the relatively stable conditions that applies with fixed speed and constant ball charge in ball mills supports theoretical approaches to the grinding process based on energy calculations such as Bond’s Work Index concept. Later a set of parameters Si and Bij were used for describing load kinetics, but all of these methods neglect the details of load movement and how the energy is actually used inside of the mill. It is now commonly accepted as a basic rule that SAG mills grind by impact whilst ball mills grind by attrition and consequently SAG mills are designed and operated to generate a large amount of impacts by the cataracting load without paying sufficient attention to where these impacts are actually occurring. Many mills are operated on the basis that as long as the mill is consuming the expected power there is little attention given to the class of bodies using this energy and this often results in the inefficient use of energy."

Jan 1, 2005

By Ke Yang

"Drilled shafts are typically used to support structures subjected to large moments at the shaft head. The large moment can produce push and pull forces on the two sides of a drilled shaft. Consequently, the applied moment is partially resisted by the push-pull moment resistance induced from the vertical side shears. This type of push-pull resistance has not been fully recognized in most design and analysis methods. In this paper, a 30 finite element model for a drilled shaft subjected to lateral load and moment is presented and is validated against two field lateral load tests. Based on the 30 finite element model, a parametric study is carried out. It shows that the push-pull moment can resist 18-35% of the applied moment. The parametric study also shows that the push-pull resistance varies linearly with loading eccentricity when the eccentricity is less than the shaft embedment length. A method to estimate the push-pull resistance is proposed based on the results of the parametric study. Then, a new method for lateral capacity prediction is proposed to account for the push-pull resistance. The base shear resistance is significant for short drilled shafts; therefore it is also included in the proposed method. A case study on four lateral load field tests illustrates that the new method could improve the accuracy of lateral capacity prediction when compared with the traditional Broms method.INTRODUCTIONDrilled shafts are typically used to support a variety of structures subjected to large moments. Sound walls, highway signs, traffic signals, high-rise buildings, electrical transmission towers, and bridge piers are examples of cases where lateral loads with large eccentricity would result in high overturning moments on foundations.Current analysis methods for capacity predictions (Broms, 1964a and 1964b; Brinch Hansen, 1961) or deflection predictions (Reese, et al. 197 4) of laterally loaded drilled shafts are based on the lateral resistance of soils and rocks. However, O'Neill pointed out that moments can be partially resisted through the push-pull resistance provided by the vertical side shears due to the rotation of the pile (Reese, 1997)."

Jan 1, 2005

By Chris Chmura, Ketut Karmawan, Ian J. Duckworth

P.T. Freeport Indonesia operates a mining complex located in the highlands of West Papua, Indonesia. Present production from PTFI’s DOZ Underground Block Cave Mine is approximately 40 thousand tonnes per day (ktpd). This paper describes the design process and recommended ventilation infrastructure necessary to expand the DOZ Mine reserves and to increase sustained daily production above 50 ktpd. The enlarged footprint will feature longer production panels of up to 650 m in length, more active draw points, a second large gyratory crusher, and additional men and mobile equipment. The increased ventilation capacity will be achieved through the development of new, dedicated ventilation drifts, and primary Underground exhaust fans.

Jan 1, 2005

By K. Ding

The thermodynamic activity of MnO was measured in MnO-CaO-MgO-SiO2 slags that are typically encountered in the production of manganese-containing stainless steels. A gas equilibration-quenching technique was employed in measuring the activities. Activities of Mn in Pt-Mn alloys were redetermined at 1600ºC, which reconfirmed earlier results of strong negative deviations. MnO activities were then measured by equilibrating slags of various compositions based on a statistical experimental design procedure with Pt-Mn alloys under controlled partial pressure of oxygen in MnO saturated platinum crucibles at 1600ºC. Activities of MnO were found to increase with increasing concentration of MnO, basicity and CaO to MgO ratio. Two multi-coefficient regression models were developed to predict the activities and activity coefficients of MnO in slags at 1600ºC. Keywords: activity, MnO, slag

Jan 1, 2005

By Tugba Kami?oglu

Hydromagnesite (Mg5(CO3).(OH)2.4H20), one of the sedimentary deposits in Salda Lake Basin, is developed under the control of active tectonics regime. Since the occurrence and deposition mechanism of hydromagnesite are unstable under atmospheric conditions, in order to evaluate the precipitation process, systematic host rock, lake water (surface, 20m, 40m, 60m) and hydromagnesite sampling were carried out. Macro, micro, XRD and chemical investigations were done in detail. Not only the results and formation and crystallization mechanism but also hydromagnesite's St values were evaluated. Main resources could be ultramaficmafic surrounding rocks for hydromagnesite formations. However, hydromagnesite development is considered in different phases, because it has showed various characteristics in Kayadibi and Köpekcayin areas. In Kayadibi area Huntide-Dolomite-Aragonite-Hydromagnesite paragenesis has been realized. Hydromagnesite has also formed in Köpekcayiri area, large amount of hyrdomagnesite occurrences and levels various are noticeable. Actual position of hydromagresite levels exhibits tectonic influences in and around the lake. Therefore, the levels seems to exhibit secondary formation properties. In addition, the formations are being still maintained sedimentation as products of a peripheral deposition phases. Resolving and redifferentiation sedimentation processes probably improve in periods of lake water chemistry especially Ca/Mg proportional changes, and also SI variations indicate the mentioned precipitation mechanism. Similarly, side and into the lake hydromagnesite is stored different levels and ultramafics-mafics rocks fallow indicated stages. It is postulated that hydromagnesite formation, which is existed by result of determined developments and multiphase sedimentation, could be originated from probable crack zones on the lake bottom.

Jan 1, 2005

By S. Mehrdad Heidari

The concentrator plant is located near a very high (105m), large (- 500m) and steep (a, > 45' ) wall. Geologically, the wall was composed of very complicated formations and broad range of soils and rocks type in which a variety of local typical failures models have been occurred on different soil and rocks formations. The construction of concentrator plant structure and other activities have been overshadowed by these local failures. Safety and risk of huge failures were serious concern. For distinguishing the wall conditions a broad campaign of slope stability investigation with detailed geotechnical drilling on berms of wall have been done and the structure of slope was fully identified and further Lab tests and slope simulation models done. Slope stability of the wall was analyzed and the effects of instability factors were described in short term (for construction phase) and long term (for production phase).The results indicated, if a well-appointed drainage system is implemented, the overall stability of the wall in short term will not cause any particular problem but about long term stability, the wall must be supported by rock bolting, consolidation grouting, shotcrete reinforced with fibers. The results have been confirmed by passing one year after this investigation.

Jan 1, 2005

By George Watson, Gu Quanzhong, S. Gerard Sawyer

Bulkheads, also known as hydraulic seals, are used to seal abandoned workings and protect adjacent active mines from explosion and control unwanted inflows of water from poorly sealed shafts, water-bearing strata, and abandoned mine areas or gobs (1). At coal seam outcrops, bulkheads have typically been used to prevent access and to control acid mine drainage. Bulkheads have also been installed at outcrop openings located within the footprint of an embankment dam, or within the reservoir of an impoundment, to prevent stored water or slurry waste from flowing into active or inactive underground mine workings (2). Components of MICON Bulkhead Seal MICON bulkhead seals in mining applications refer to seals designed to impound liquids or slurry. The MICON bulkhead seal is comprised of two concrete block walls set in the front and back and a polyurethane/aggregate core (Figure 1). The two walls are usually dry-stacked, surface-bonded walls constructed with solid load-bearing concrete blocks (ASTM C90) or concrete building brick (ASTM C55). The surface bonding material used in the wall construction must be MSHA-approved. The type of stone, if any, used to fill the space between the walls is not essential. However, MICON generally uses No. 57 limestone in 50 lb. bags, specified to moisture control, shrink-wrapped and palletized. The polyurethane foam used in the construction of the bulkhead seal is engineering specified and formulated by density based on the optimization of cost, seal core thickness, required adhesive strength, the use of stone filler and other required physical properties.

Jan 1, 2005

By O Pasca, B Hogg

Consistent slag blow end point detection remains one of the challenges in the Peirce-Smith converters at Mount Isa MinesÆ Copper Smelter. Under blowing results in foaming on copper blow and carry forward of oxide skims to the anode furnace. Over blowing results in high copper losses to the slag. Both present safety issues and contribute to lower copper production. The end points of the slag making phases are assessed by inspection of a bar sample. A bar sample is a thin accretion layer that adheres to a steel bar when it is inserted into the tuyere while the converter is blowing. This method is biased and subjective, so there is heavy reliance on operator experience. The Semtech Optical Process Control (OPC) system was installed in early 2002 for converter slag blow end point detection. Initial plant trials did not improve all aspects of converter operations, and uptake by operators was poor, so the system was not used. In early 2005, the Semtech OPC system was re-visited and another short trial was conducted to evaluate the permanent use of the system for slag and copper blow end point detection. During this trial, the Semtech OPC method was found to be superior to bar sampling for slag blow end point detection. The implementation and refurbishment of the Semtech OPC system has resulted in plant improvements and given a better insight into converter operation during blowing. Oxide skim generation carried forward to the anode furnace has been shown to decrease with increasing compliance with Semtech OPC. Some of the expected improvements to converter operation were not found to be significant. Semtech OPC is now well received and utilised by converter operators. Individual paper available only. Not included in book or CD ROM Proceedings.

Jan 1, 2005

By D A. Kepert, D Clark

During early 2004, Fortescue Metals Group (FMG) began an aggressive exploration and drilling program in the Chichester Range, targeting iron enrichment developed in the Nammuldi Member at the base of the Marra Mamba Iron Formation. The timely recognition by FMG of distinct zones of (hypogene) microplaty hematite (mplH) enrichment overprinted by extensive supergene mineralisation led to an early reappraisal of the geological history of the area and characterisation of the possible structural and stratigraphic controls on mineralisation. Regionally, the Chichester Range dips gently at less than 5¦ to the south, however, detailed mapping shows that this regional limb is overprinted by low amplitude, long wavelength, north/south to northeast/southwest trending folds. The locations of major structures in the Marra Mamba Iron Formation, combined with spectral analysis of known mineralisation, allowed extrapolation and prioritisation of exploration target areas. The delineation under cover and understanding of these structures was enhanced by detailed airborne magnetic data. Recognition that supergene mineralisation was associated with a palaeotopography that continued significantly under cover to the south under sediments of the Fortescue River valley led to the discovery of extensive supergene mineralisation together with additional mplH mineralisation. A model for the landscape evolution and preservation of enriched Nammuldi Member was generated in order to help communicate both the complexities involved with targeting drill holes beneath cover and the potential limits to the lateral extents of mineralisation.

Jan 1, 2005

By G. Righettini, G. Desrivières, P. Mousset-Jones, R. Lacroix, M. C. Bétournay, P. Laliberté, S. Hardcastle

"Under the requirement to define the economic advantages of using hydrogen fuel cell vehicles, a broad-scoped project was initiated to quantify the costs associated with operating fuel cell vehicles and diesel vehicles. While ventilation savings are clearly an advantage for the former, a complete and detailed analysis of this and other operational and capital cost elements was undertaken in order to provide the mining industry with factual information in considering the changeover from one technology to another.This paper outlines the results of the investigations to date defining the costs/benefits associated with capital purchases, operations (electrical/diesel, mine air heating fuel, ventilation, openings, surface and underground infrastructure, maintenance, labour, etc.), delivery of energy, regulatory obligations, and mine production. Considerations are given to the type and size of a mining operation, the depth, and location in North America.Significant ventilation power, equipment, and infrastructure savings are possible with the application of fuel cells for shallower mine applications. At depth, where heat is an issue, there is a reduction in benefit. Specific qualifiers such as minimum air velocities, dust dilution, shaft, and heating system velocity limits must be considered on an individual mine basis. While the capital cost for fuel cell mining equipment is currently higher than diesel versions the high cost of fuel cells is anticipated to be reduced significantly in the near future with the intensification of manufacturing. In either case, the operational savings would probably be sufficient to balance the supplementary capitalization costs.Comprehensive reports have been issued."

Jan 1, 2005

By Tim O’Neil

Dressed in black tie and Victorian attire, some 200 people came to Leadville, CO, for a September weekend featuring a National Mining Hall of Fame and Museum (NMHF&M) induction banquet and a scenic mountain train trip to Fremont Pass and the Climax Mine. The 18th annual induction banquet on Sept. 17 began with cocktails and a open house. It was a chance for visitors to tour the National Mining Museum including the new Hennebach Wing, opened in February. The new wing is named in honor of Ralph Hennebach, retired chairman of Asarco. Formerly Leadville Junior High School, the Hennebach Wing encompasses more than1,440 m2 (15,500 sq ft) of floor space in two stories. One prominent feature is a 1923 Wills Sainte Claire touring sedan. Climax Molybdenum donated this first all-molybdenum steel motorcar. Docents were available throughout the museum to give banquet attendees directions and answer questions.

Jan 1, 2005

By R Graber, R Johnson

North American steelmaking practices have evolved based on access to iron ore raw materials containing very low phosphorus contents, typically less than 0.025 per cent P. Cleveland-Cliffs managed Tilden iron ore operation produces iron ore pellets exceeding 0.030 per cent P, which by global standards would be considered low phosphorus, but has limited penetration in the North American iron ore market due to phosphorus content. Recently cathodoluminescence microscopy has augmented more standard ore characterisation techniques enhancing our understanding of the genetic history and process mineralogy of TildenÆs complex martite ore. This paper highlights the unique capabilities that cathodoluminescence microscopy provides for phosphorus mineral identification in fine-grained iron ores.

Jan 1, 2005