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By D. O. Murchu

Outokumpu Tara Mines located near Dublin, Ireland is Europe's largest producer of lead and zinc concentrates. To reduce dewatering costs and to improve environmental and working conditions, elimination of the lead concentrate thermal dryer was required. This paper describes the development and implementation of the pressure ceramic technology at Tara to replace a conventional vacuum filter/oil-fired dryer system. In 1996 the pressure ceramic filter dewatered 66,600tonnes of lead concentrate, producing a cake at 6 % moisture. Substantial operating cost savings have been realized. Commissioning of a second pressure ceramic filter to handle over 300,000 tonnes/year of zinc concentrates is scheduled for the first quarter of 1997.

Jan 1, 1997

By Aarao de Andrade Lima

Mechanical properties typical of coal are used in the comparisons of pillar strengths based on finite elements and the empirical equations of Holland-Gaddy, Salamon-Munro, Obert¬Duvall, and Bieniawski-PSU. A correlation among the strength parameters which are employed in the empirical equations, in Mohr-Coulomb and Hoek-Brown failure criteria is established. Emphasis is given to the important distinction between the mechanical properties of small rock specimens and those related to the rock mass. An elastoplastic version of Hoek-Brown criteria has been developed and implemented in a finite elements code. The strengths calculated using the empirical equations showed a good agreement when the ratio width by height of the pillars varied from I to 8, except for Holland-Gaddy equation which exhibited lower values. Under the hypothesis of associative perfect elastoplasticity used, pillar strength calculated using Mohr¬Coulomb yield criterion became excessively high for all the models having a pillar width by height ratio above 2. The finite elements solution based on Hoek-Brown criterion predicted strengths around fifty percent larger than Bieniawski-PSU equation when the pillars width by height ration varied from 3 to 8, showing good agreement below that range. It has been concluded that, under the hypothesis of percfect plasticity, stress analysis techniques may overestimate the strength of rock structures subjected to high confining stresses.

Jan 1, 1997

Sphalerite is commonly floated in an alkaline environment and under such conditions the overall activation mechanism is obscured by the hydrolysis of Cu2+ and precipitation of Cu(OH)2. Electrokinetic and kinetic flotation tests show that the activation of sphalerite is a two-stage process; the activation products formed on the surface of sphalerite in near neutral and in alkaline solutions in the first rapid activation stage are "flotation-inactive". These layers, when formed in an alkaline solution, are unstable and are transformed into the "flotation-active" form in the second stage. However, the surface layers formed during activation in alkaline environment by copper in the presence of lead ions are very stable and even after a long conditioning time the flotation rate is not improved. Consequently, while both Cu2+ and Pb2+ activate sphalerite flotation, quite unpredictable effects may result when both are present in the solution.

Jan 1, 1997

By R. Robertson

Dense medium cyclones are the preferred means for cleaning 112 in. x 14 Mesh to 28 Mesh (12.7 mm x 1.0 mm to 0.6 mm) raw coal and are becoming a common choice for cleaning raw coal from a nominal top size of 2-1/2 in. to 3 in. (63.5 mm to 76.2 mm) down to 14 Mesh to 28 Mesh (1.0 mm to 0.6 mm). During the last ten years, dense medium cyclone circuitry design has undergone changes which have combined to improve process efficiency. This paper describes these improvements and compares present day design with the design used prior to the mid 1980's. Improvements in the following areas are described: Raw coal desliming, cyclone configuration, drain and rinse applications, dilute medium circuitry, and instrumentation and control.

Jan 1, 1997

By Roy H. Grau

The trend in underground room-and-pillar cod mining is to employ remote-control continuous mining machines to take extended cuts of 40 A or more. Roof fall safety hazards to the mine worker associated with 4ed cutting are not completely de6ned but are known to include removal of the miner operator from the protective canopy, non-compliance with approved cutting depth and CM operator positioning. This report summarizes ground control research performed by the National Institute for Occupational Safety and Health (?-JIOSH) researchers at the Pittsburgh Research Laboratory concerning extended cuts. A combination of statistical analysis and underground investigations have been conducted. Statistical analysis of extended cut use, along with roof fall accidents and fatalities data delineate the extent of the problem in U.S. coal mines. Additionally, an underground study is described where the long-term roof stability of extended cut areas are compared to standard cuts.

Jan 1, 1997

By LaBrooy SR

A number of gold processing plants in Western Australia have nickel in their ores, leading to significant levels of nickel on their loaded carbon. The presence of nickel during leaching, adsorption and elution'may have detrimental effects on cyanide consumption, carbon inventory requirements, stripping costs, electrowinning efficiencies and may contaminate the gold bullion.This paper discusses the competitive adsorption of gold and nickel cyanides onto activated carbon and investigates changes in solution parameters that may improve gold adsorption and/or inhibit nickel adsorotion.

Jan 1, 1997

The resources industry is unique in that the finite nature of resource deposits requires a participant to be constantly locating and developing new ones to replace those that are depleted. An effective growth strategy that enables new project developments to be brought on line in time and within budget is therefore of fundamental importance to any mineral resources company. This paper seeks to identify the role of the development project in the company's overall growth strategy and the key performance criteria that a development project must achieve in order to allow a company to meet its growth objectives.

Jan 1, 1997

By Bob J. MacDonald

The Cape Breton Development Corporation is a federally owned Crown corporation in Canada that operates two coal mines the Prince and Phalen Colliery in the Province of Nova Scotia. Retreat longwall mining was first introduced to the shallower workings (I 80m) of Prince Colliery in the early 1980's. Phalen Colliery started longwall retreating in 1987 and since that time has extracted twelve panels. In 1993 there had been a total of eight longwalls varying in widths from 140-230m mined in Phalen Colliery that is on the Phalen Seam. Up to this point there were only minor ground control problems on the faces except for one of the earlier longwalls that was mining a split seam. There is some interaction on Phalen workings from remnant structures in the overlying Lingan and No. 26 Collieries which worked the Harbour Seam. Induced abutments loads along pillar edges have been observed and resulted in poor face conditions when mining the Phalen Seam. The ninth panel, 6 East was the first panel to suffer a major roof fall from the First Major Weighting. This was also the first panel to undermine a paleo sandstone river channel named the Lower Sandstone Unit (LSU). For the first time in Phalen's history subsequent longwalls began to experience periodic weighting events. The 6 East panel suffered a number of periodic weightings and on two occasions had to use foam cement to fill the cavities that resulted. On the next east side panel, 7 East, there were numerous periodic weighting events, but interestingly there was no significant First Major Weighting. 7 East was the first 260m wide panel and all others were 230m or less. This longwall was 3,400m long and began producing in December of 1994 and was still cutting coal in May of 1997. There were five significant roof fall events on this panel, three of which required foam cement to fill the cavities. Of these three the interruption to production varied from four days to seven months. There were definite precursors to each of the weightings including: 1) an increase in audible noise (termed bumping) on the face, 2) supports went rapidly into yield, 3) roof convergence increased, 4) water percolated from the face roof strata, and 5) severe spalling of the coal occurred resulting in increased tip to face distance. Longwall face weightings are a result of geomechanical factors and cannot be avoided However, the loss of roof control is a different matter and highly subjective to operational procedures. The causes of weightings, their magnitude and impact on the mining at Phalen have been investigated. The following factors have been identified as relevant to these occurrences. 1. The influence of pillars in the overlying Harbour Seam workings. 2. Location of the LSU relative to the Phalen Seam. 3. Thickness of the LSU. 4. Pressure arch effect from the adjacent gobs. 5. Poor operational practices on the longwall including: a) slow rate of retreat; b) inadequate supply of pump pressure to the hydraulic supports; c) premature yielding of the yield valves; and d) poor face alignment practices. This paper will review the events that took place on the 7 East longwall and show that the Lower Sandstone Unit is the primary cause of the weightings. However, other factors contributed to the loss of roof control and the formation of the roof cavities.

Jan 1, 1997

By Robert A. Field

Static-Load Piledriving utilizes a hydraulic push to facilitate the installation of a pile. The pile is not rotated, impacted or vibrated. A smooth pushing force advances the pile incrementally into the ground. Static-Load devices must have a reaction mass to push against. The most simple form of a Static-Load device is a jack; more advanced equipment, such as the Still Worker, also utilizes this approach. This paper focuses on the use of the Still Worker on three challenging projects. In each case, the existing site conditions made it risky, or unattractive, to utilize conventional impact, vibratory, or drilled-shaft equipment.

Jan 1, 1997

By L. L. Gagné

The Churchill Falls Development will eventually be the largest source of hydroelectric power in North America. Churchill Falls was discovered in 1839, but until recent years it was not practical to begin development of this site to tap the 7 million horsepower available. This $1 billion project is located in Labrador, 700 miles northeast of Montreal and 650 miles northwest of St. Johns, Nfld. The construction will divert the Churchill River 5 miles upstream from the 245 foot Churchill Falls. Rapids above and below the Falls, together with the Falls proper, give a natural head of 1,040 feet. In contrast to the basic simplicity of the surface installations, the powerhouse labyrinth is astounding in size and complexity. The largest in the world, it consists of three major chambers - the powerhouse, 972 feet long by 81 feet wide and 154 feet high; the surge chamber, 763 feet long, 40 feet to 64 feet wide and 148 feet high; and the transformer gallery, 856 feet long by 50 feet wide and 39 feet high. Other major features include eleven inclined penstocks, each 1200 feet long and 20 feet in finished diameter; eleven draft tubes averaging 37 feet in finished diameter and 162 feet long; six vertical cable shafts each an average of 865 feet in length; a series of eleven short bus tunnels linking the powerhouse and the transformer gallery; a vertical power-

Jan 1, 1997

By Jeffrey J. Schwoebel, Jianliang Li, Daniel J. Brunner

A United Nations (UN) administered degasification technology transfer project, funded by the Global Environmental Fund (GEF) is underway at the Shihao Mine of the Songzao Coal Mining Ad- ministration in the province of Sichuan, Peoples Republic of China. This mine exploits multiple seams at depths ranging from 300 to 600 m below surface. In-seam boreholes and frequently spaced in-mine vertical boreholes, developed from underlying galleries constructed specifically for this purpose, currently degasify the seams in advance of mining at the Shihao Mine. Because of ventilation system constraints and the in-situ gas con- tent, longwall mining of the coals at this mine could not proceed without some form of pre-mining degasification. This paper presents a simulation based degasification plan of long, in-seam horizontal boreholes for the Shihao Mine. Simulations with a coalbed reservoir program assessed time dependent degasification characteristics of both vertical and in-seam horizontal boreholes. The simulations used input data from reservoir and desorption tests conducted at the mine site. The results produced system design nomograms to assist mine engineers in defining the appropriate borehole spacing necessary to degasify the seam in the time available for pre-mining drainage. The predicted effectiveness of the current vertical degasification scheme was compared with that for a horizontal borehole program and served as the basis for the recommended in-seam borehole configuration for the project at the Shihao Mine. The horizontal borehole degasification program requires substantially less gallery and borehole development than the present vertical degasification scheme.

Jan 1, 1997

By R. P. Mohring

The South African Coal Industry had its beginnings in the Eastern Cape in 1859 when coal was mined to satisfy the fledgling settlements in the Eastern Cape. The growth in the industry was relatively slow up to the early 1970s when, firstly, the export business was expanded coupled with a major increase in the quantity of coal converted to liquid fuels and utilized for power generation. To meet this increased demand the industry developed many new operations employing the latest mining technology and systems. Coal production in South Africa reached 204 million tons in 1996 and revenue from exports reached R8 billion making it the second-largest foreign exchange earner after gold. In his address Rick P. Mohring describes the role coal plays in the international energy scene and outlines South Africa?s position as a producer and consumer of coal, and the challenges facing the industry. A wide range of steam-coals are produced to satisfy both the local market (power generation, coal conversion and the metallurgical industry) and the export steam-coal market. South Africa is in a unique position regarding the export market as it is still a relatively low-cost producer and is geographically well-placed to play in both the European and Far East markets. There are, however, a number of challenges facing the industry. To retain our competitiveness in the international market, ways of minimizing the cost pressures caused by high-cost inflation, increased environmental protection obligations and a decreasing quality resource base need to be sought. Locally the coal mining industry has a major role to play in Eskom?s goal of reducing the real cost of electricity by 15% in the next three years. Safety and health, productivity and the adaptation of the latest technology are issues being addressed by the industry to maintain its dominant position within the South African economy.

Jan 1, 1997

By Y. K. Yen, J. D. Miller, C. L. Lin

Particle size segregation is a common phenomenon in many particulate processes and has many undesirable effects. The size segregation which occurs on a belt conveyor causes a serious problem for on-line particle size measurement using image-based techniques. Whether particle size distributions measured from the top layer of the belt are representative of the total particle population is largely dependent on the degree of size segregation. Therefore, it is important to understand the nature of such size segregation in order to make appropriate corrections for on-line particle size analysis. Monte Carlo simulation has been used to provide segregation information on particles with simple geometry and the results can help to determine important factors in experiments with irregularly shaped particles. It is expected that the relationship between the particle size distribution of the top layer and that of the entire particle population on a belt conveyor can be formulated as a model based function.

Jan 1, 1997

The 1997 Rapid Excavation and Tunneling Conference (RETC) was held at the Mirage Hotel, Las Vegas, NV. The RETC is a biennial event jointly sponsored by SME and the American Society of Civil Engineers (ASCE). Conference attendance was 573 members, nonmembers and students, an increase of seven attendees from the 1995 conference in San Francisco, CA. Exhibitors occupied 51 booths at the Las Vegas RETC. The 1997 conference encompassed 58 presentations in 15 sessions. Participants were given details on achievements and advances that have resulted in new design solutions, alternative work practices and increased productivity within the industry. The page at the end of this article tells how to get your copy of the RETC proceedings, either hardbound or on CD-ROM. Or, if you wish, for the first time a CD-ROM is available with the complete RETC proceedings from 1972 to 1997. This two-disk, archival volume has key-word search capability, is in portable file format and is compatible with PC and Macintosh platforms. RETC program sessions included design and planning, ground support, tunnel boring machine (TBM) case histories, conventional excavation, new technology, difficult ground, geotechnical, shafts and raises, future/special projects, new Austrian tunneling method, international projects, soft ground case histories and water and gas. What follows are highlights of some of the RETC presentations.

Jan 1, 1997

By S. J. Parkin, P. Shead

Extraction of coal at Harworth Colliery is undertaken in the Deep Soft seam at roughly 1000m depth where the strata temperature is 42 "C. Production employs the longwall retreating method using high powered mechanised methods to extract coal at a rate of approximately 40,000 tonnes per week from a single face. This paper describes the climatic conditions encountered on a typical district , 6's district, where the initial ventilation set-up was as a typical U-type district which was antitropally ventilated. Under this initial set-up climatic conditions in the intake typically exceeded 30 "C effective whilst in the face area and in the return airway effective temperatures in excess of 32 "C and 33 "C were common . The paper then proceeds to describe the methods employed to attempt to improve the climatic conditions on the district, especially with regard to the coal face and return airways and describes in detail the effects of reversing the district airflow direction, employing homotropal ventilation, on the climatic conditions. The results of this reversal have been dramatic and have resulted in a substantial improvement in the climatic conditions experienced , however problems have been encountered with the control of methane gas since the changeover. The final part of the paper describes the results of computer simulations to analyse the effect of various ventilation designs on the predicted climate for future production districts in order to de- fine a district layout which will produce acceptable climatic conditions in the working zone without the need to use refrigeration techniques and which will improve methane gas control .

Jan 1, 1997

Considerable attention has been given to the restoration of low-level radioactive (<1000 pCl/g) sites contaminated during the early years of the atomic energy program. Current clean-up activities which involve the relocation of contaminated soils to licensed disposal sites have been shown to be very costly due to the large volumes of soils which must be excavated, transported and stored. Recent characterization studies conducted at Virginia Tech suggest that the volume of soil requiring disposal can be greatly reduced using mineral processing techniques such as classification, density separation and froth flotation. This article discusses the application of these technologies for soil remediation and describes a conceptual flowsheet for treating soil samples from two contaminated sites.

Jan 1, 1997

By Michael J. Mankosa

Carpco has recently evaluated the use of various mineral processing techniques for secondary materials recovery. These applications include recycled foundry sands, plastics and secondary metals. This paper describes different recycling applications and the associated separation solutions. Results from extensive laboratory-and pilot-scale test work in each area are discussed. Industrial installations resulting from this test work will be presented. A detailed description of an industrial installation patented by Carpco for the recovery of plastic and metallics from current waste by-products is presented.

Jan 1, 1997

By A. Feather

The Minataur? Process (Mintek Alternative Technology for Au Refining) is a novel route for the production of high-purity gold using solvent extraction. Following the successful demonstration of the process on a pilot-plant scale, a full-scale 24 t/a production plant has been commissioned at Harmony Gold Mine in Virginia, Free State. The commercial implementation of this process represents not only a significant advance in gold-refining technology, but may be instrumental in initiating important changes in the legislation regulating the marketing of gold in South Africa. Gold of either 99.99% or 99.999% purity can be produced from intermediate process products having a wide range of gold contents. The process comprises oxidative leaching of the solid feed, followed by selective solvent extraction of the gold from the leach liquor to reject impurities, and precipitation of high-purity gold powder. This paper outlines the process, presents selected results of two pilot-plant trials in which 5 kg/d of high-purity gold was produced from silver-refining anode slime and gold-electrowinning cathode sludge, and provides some details of the cost benefits.

Jan 1, 1997

By H. Wu, V. Izaxon

Intensive ventilation is required during the excavation of a mine opening and the subsequent exploitation of the mineral resources. The exchange of heat between the ventilation air and the rock mass has a major influence on the thermal regime of a mine, especially in the initial segment of the airway. In frozen ground, heat flow into the rock mass from the ventilation air can result in the eventual thawing of the permafrost, which can result in roof-rock instability. This paper presents a mathematical analysis of the dispersion process of ventilation-induced heat by thermosyphons placed on the surface of the mine. The principal uses of thermosyphons in the Arctic are to reduce the ground temperature to prevent potentially unstable permafrost from thawing and to increase the bearing strength of the material. The mathematical model of the physical problem, generally known as "the Stephan problem," takes into account the varying thermo-physical properties of air and the frozen and thawed rock mass, the thermal properties of the freeing fluid in the thermosyphons and the phase change of water. Finite-difference techniques were employed to determine the temperature isotherms around the thermosyphons. It was found that two rows of thermosyphons on a 10- x 10-m grid provide an acceptable design spacing for reducing the ground temperature around the mine airway.

Jan 1, 1997

By R. M. Damodaran

The flotation performance of Florida phosphate rock was evaluated in terms of the mixing behavior of reagents and particulates during anionic conditioning of phosphate slurries. The various conditioning variables that influence mixing, namely, solids loading, agitation speed and conditioning time, were investigated to determine their effect on reagent coating of the particles. The phosphate recovery was used to monitor the conditioning efficiency. The mixing characteristics of the phosphate feed were evaluated in terms of the ratio of the mixing power (P) to the minimum power (Pm) required to keep the slurry in suspension. It was found that mixing conditions govern the conditioning time required to obtain a high recovery. Reagentization was slower at lower P/Pm ratios. At higher P/Pm ratios, the flotation recovery was optimized, and the agitation speed was found to have no significant effect. Optimum mixing conditions were obtained for a74 wt% slurry at an agitation speed of 450 rpm (47 radians/sec). Under these optimum mixing conditions, the collector dosage required for an improved recovery was lower and the conditioning time was shorter.

Jan 1, 1997