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By J. Samir

The objective of this study is to simulate the isothermal filling up of moulds by a RTM process when adopting CV/FEM and VOF method and when also taking into account the presence of obstacles coupled to the effect of the thickness and reinforcement layers variation. The codes developed intended to ensure an optimal positioning of the injection points and of the vents and also to determine optimal injection pressures, in order to minimize the cycle times. These codes use a mesh generator proper to the team, allowing a discretization of the domain in triangular unstructured elements, with the possibility of a local refinement and inserts inclusion.

Jan 1, 2009

By A. M. Tonnos

Underground mining has yet to see an industry wide solution for control of their ventilation systems due to the complexity and sensitivity of the underground environment. Complexity arises from multi-level, multi-zone operations and sensitivity is associated with the impact that changes in equipment status and output have on air flows and quality throughout the mine. Our approach to solving this challenge incorporates system modeling and industrial control systems in a unified architecture. Although this approach can be applied to other processes and industries, this paper will cover the theoretical and practical aspects of an integrated model-control system (MCS) as it applies to underground mining ventilation.

Jan 1, 2009

By W. Dziurzynski

The present article sets forward the results of field tests that made it possible to validate the mathematical model used in the VENTGRAPH ventilation engineer programmes. The case considered relates to the introduction of a new heading to the ventilation network of the mine. The utilisation of computer programmes in practice is justified by the necessity of ensuring expected performance and secure conditions in the network of mine headings, where - for example - plans are being made to utilise the transport dip-heading, taking into consideration fire and methane hazards. In the article we have presented the methodology of preparation of a database for computer programmes of the VENTGRAPH system, obtained on the basis of ventilation measurements. The next step consists in the execution of a design of the modified network and prediction, this on the basis of heading geometries, of parameters characterising the flow of air for the designed headings. Due to the fact that the heading was in the final stage of driving, following its introduction to normal operation and the stabilisation of flow values it was possible to retake ventilation measurements, which validated the results obtained through computer simulations. In order to execute measurements of the volume flow in the dip-heading, we employed a new wireless multipoint measurement system to determine the velocity field of air in the mine heading; the results are characterised by a high accuracy of measurement. As a part of fire prevention and incident management planning, a series of underground fire case studies for the a validated network flow model has been made. Results of simulations show the capabilities of the FIRE module of the mentioned software, including assessment of stability of flow directions and hints on counter and preventive measures for particular locations of fire.

Jan 1, 2009

The inquiry into the explosion at the Moura No. 2 Mine in August 1994 recommended -?Emergency procedures should be exercised at each mine on a systematic basis, the minimum requirement being on an annual basis for each mine.? (Windridge et al. 1996). In December 1996 the ?Approved Standard for the Conduct of Emergency Procedures Exercises? was published and has been subsequently revised (Queensland Department of Mines and Energy Safety and Health Division 1999). This document provided guidelines for conducting mine site emergency exercises as well as the requirement for a test of state-wide emergency response by holding a Level 1 Mine Emergency Exercise at one mine on an annual basis. From 1998 to date (January 2008) ten Level 1 Mine Emergency Exercises have been held in Queensland, Australia. This paper discusses each of the exercises conducted to date as well as the logistics, scenario preparation, planning and organising required to conduct emergency exercises at this level.

Jan 1, 2009

This geometallurgical study examines the gangue mineral variability at the Bingham Canyon porphyry copper mine in Utah. Understanding an orebody?s mineralogy is important for mine and mill planning because it provides information on the size, texture, and distribution of ore minerals, the relationship between ore and gangue minerals, and the extent and type of alteration. Quantification of the mineralogical variability and properties of an orebody provides valuable input to the ore model and may have a significant effect on recovery optimization. This study was designed to be carried out on an initially detailed scale in order to develop a robust methodology for measuring and quantifying specific parameters, such as the distribution of mineral phases, alteration assemblages and fractures from key ore domains at the Bingham Canyon mine (Figure 1). Details of the methodology are reported below. This technique can be applied to testing the impact of mineralogy on a number of processing parameters. [ ] Figure 1. Ore domain map of Bingham Canyon (Kennecott Utah Copper, 2003) showing the 33 geometallurgical ore domains. The samples for this study were collected from the northwest part of the deposit circled on the map. PROJECT BACKGROUND Geology The Bingham Canyon deposit is a large porphyry Cu-Mo-Au deposit with associated skarn and base-metal replacement deposits mined in an open-pit mine measuring about 2.5 miles across and 4,000 feet deep. The deposit is hosted by the Bingham Stock, a Late Eocene to Mid-Oligocene intrusive complex. The skarn is hosted by the Late Carboniferous-age Bingham Mine Formation, which is comprised of quartzites and basal limestones (Babcock Jr. et al., 1998). The Bingham Stock is a composite intrusive complex that was emplaced over a period of about two million years. The oldest phase is described as a fine-grained equigranular monzonite (MZ), which intruded the country rocks at 39.8 ± 0.4 Ma (U-Pb zircon TIMS age) (Parry et al., 2001). Subsequently, the quartz monzonite porphyry (QMP) was emplaced, followed by intrusion of a latite porphyry (LP). The final intrusive phase, which forms narrow dikes that crosscut the Bingham Stock, is represented by a quartz latite porphyry (QLP), which is dated to 37.5 ± 0.4 Ma by 40Ar/39Ar dating of sanidine (Deino and Keith, 1998). Also present, are a minette dike in contact with a QLP dike (Waite et al., 1998; Deino and Keith, 1998), and a biotite porphyry (BP), a quartz latite porphyry breccia (QLPbx), and a pebble dike (Redmond, 2002). The copper orebody is centered above the Bingham Stock and forms an inverted cup shape with three high-grade copper zones extending to depth. Molybdenite mineralization occurs within and extends below the copper orebody, but is not correlated with copper mineralization. The main sulfide assemblage is chalcopyrite, bornite, molybdenite, and pyrite. Gold is locally intergrown with chalcopyrite and bornite (Babcock Jr. et al., 1998; Phillips et al., 1998). The surrounding country rocks host skarn deposits with three main ore types - garnet skarns, massive sulfides, and iron oxides. The garnet skarns contain chalcopyrite and pyrite with magnetite veins. In the massive sulfides chalcopyrite and pyrite occur either in banded sulfides or in unconsolidated microbreccias. The iron oxides contain disseminated chalcopyrite with minor chalcocite and bornite (Harrison and Reid, 1998). The deposit is overprinted by several stages of alteration. Potassic alteration is concentrated at the center of the deposit. It is surrounded and partially overlapped by a propylitic alteration zone. Both zones are overprinted by sericitic alteration. In the northern part of the deposit evidence for argillic alteration can be found (Bowman et al., 1987). Similarly, the skarn deposit was also overprinted by several stages of alteration: wollastonite, idocrase, and garnet in cherty limestones, and quartz and diopside forming in calcareous quartzites. Distally, diopside was replaced by talc, tremolite, dolomite, secondary calcite, and pyrite, and quartz and sulfide veinlets with biotite and actinolite selvages are present. Andradite garnet, diopside, quartz, magnetite, hematite, and copper sulfides were overprinted by wollastonite (Babcock Jr. et al., 1998). Because the monzonite, quartz monzonite porphyry, latite porphyry, and quartz latite porphyry host the bulk of the mineralization, our research is focused on these lithologic units. Geometallurgy On the basis of geological (lithology, alteration assemblages, fracture density, copper mineralization) and metallurgical properties, the deposit has been divided into 33 ore domains by mine geologists and metallurgists (Figure 1). In map view, these domains cross geologically defined boundaries (MZ, QMP etc.). These domains reflect regions of the deposit that have particular, mapable attributes or properties. They reflect a combination of geological and mineralogical characteristics that combine to impact processing. Alteration, for example, as shown by talc mineralization, is one such key feature. Hardness may reflect the absence of sericitic but presence of potassic alteration. Structural discontinuities such as faulting, fracturing, or development of void

Jan 1, 2009

The risk associated with mining induced seismicity is one of the major threats to the safety and sustainability of deep underground mines. This paper describes techniques that allow site practitioners to efficiently control such risks in mines. The proposed approaches rely on ground support to strategically control seismic risk and re-entry time to tactically control this risk. The strategic approach is based on the detailed understanding of past seismicity to as certain the seismic hazard of individual sources throughout the mine. This approach also relies on assessing the potential damage that these sources can induce on nearby excavations using the excavation vulnerability potential (EVP) and rockburst damage potential (RDP) concepts proposed by Heal et al. (2006). It is then possible to investigate how to reduce the risk of experiencing damaging seismicity in mine drives by locally enhancing the ground support system. The tactical approach relies on a proposed methodology to estimate reliable re-entry times or exclusion periods based on the seismic decay following blasting. Some examples of how these techniques have been applied in Australian mines are given.

Jan 1, 2009

By Andre C. Zingano

It is a very difficult task to estimate the immediate roof and support behavior in a room-and-pillar mining section in the initial phase of the mining project. There is little information available at this phase, and it is restricted to geomechanic characterization of the rock layers from cores samples, and the in-situ instrumentation of experimental entries and intersections. Even being a pilot excavation for roof support test a good indicator for the behavior of the immediate roof, its behavior for a full excavation mining section is different from a single intersection of two entries, mainly because the stress redistribution caused by the multiple entries excavation and face advance for a full excavation section. The objective of this paper was to calibrate a 3-D numerical model of an experimental intersection, based on the in-situ instrumentation of an experimental intersection excavation, and the geomechanic description of the rock layers. The numerical model was built with the same specifications as the excavation test, including the entry geometry and roof support. The numerical model calibration was based on wire extensometers that were installed at different positions in the roof of the pilot excavation, and on the geomechanic characterization of the rock layers that form the roof, coal seam, and floor. Therefore, it is possible to estimate whether the roof support specification adopted in the test phase will be good enough for the development of the entire mining section.

Jan 1, 2009

By Michael J. Marinigh

"Increased safety requirements, higher operational costs, greater environmental restrictions, and new competitive processing techniques are the challenges smelter operators must confront in order to remain economically viable.In converting furnaces which have tuyères such as the Noranda Reactor and the Teniente, Peirce- Smith and Hoboken converters, efficient tuyère line management is critical to optimizing blowing rates, increasing refractory life, and improving safety.This paper will describe recent improvements made to equipment used for tuyère punching, tuyère silencing, tuyère pyrometry and refractory drilling of tuyères and how the proper application of the equipment can lead to operational and safety improvements."

Jan 1, 2009

By N. T. Beukes

An engineering house?s perspective of required inputs in designing a copper electrowinning tank house and ancillary equipment calls for both understanding of the key fundamental controlling mechanisms and the practical requirements to optimize cost, schedule and product quality. For direct or post solvent extraction copper electrowinning design, key theoretical considerations include current density and efficiency, electrolyte ion concentrations, cell voltages and electrode over potentials, physical cell dimensions, cell flow rates and electrode face velocities, and electrolyte temperature. Practical considerations for optimal project goals are location of plant, layout of tank house and ancillary equipment, elevations, type of cell furniture, required cathode quality, number and type of cells, material of construction of cells, structure and interconnecting equipment, production cycles, anode and cathode material of construction and dimensions, cathode stripping philosophy, plating aids, acid mist management, piping layouts, standard electrical equipment sizes, electrolyte filtration, impurity concentrations, bus bar and rectifier/transformer design, electrical isolation protection, crane management, sampling and quality control management, staffing skills and client expectations. All of the above are required to produce an engineered product that can be designed easily, constructed quickly and operated with flexibility.

Jan 1, 2009

By Walter Kaeck

In a recent upgrade of their system, Amtrak converted a bascule type draw bridge over the Thames River to a vertical lift structure supported by the existing piers. During the bridge replacement, significant settlement occurred on one of the piers and movement continued thereafter. Construction was stopped as Amtrak became concerned as to how much the subsequent construction activities would cause the pier to further settle and tilt, not only impacting the operation of the existing bridge, but also jeopardizing the new lift span. Mueser Rutledge was engaged at this time to help understand and solve the problem. A remedial grouting program was developed to arrest the settlement. As a subcontractor to Cianbro Corporation, Pittsfield, ME, The Judy Company was hired to perform the remedial grouting work. Work platforms were constructed around the pier for support of the drilling equipment. A dual string drilling system was used to install sleeve pipes at depths of up to 185? below the water level. Ultrafine cement grout stabilized with additives was placed at 2.5 foot intervals through the depth of the sand and gravel stratum below the bottom of the pier. Logistics were difficult and the schedule was severely impacted by the remedial work, necessitating working six 12-hour shifts per week and working in the river through the winter months. After four months of drilling and grouting, movement of the pier stopped. At the conclusion of the remedial work, more than a million gallons of ultrafine cement grout were placed. Confirmation borings recovered completely solidified material with compressive strengths ranging from 500 to 1500 psi. The bridge replacement was then completed and is functioning. Continued monitoring through July 2009 shows negligible movement.

Jan 1, 2009

By Lucian Bogdan

On many occasions during construction and service life of the structure, it is crucial to know the load in post tensioning tendons and anchors. Although there are many methods to measure the tendon force, most of them are cumbersome, expensive and the accuracy differs depending on the method used Dyna Force sensor uses the Elasto-magnetic technology (EM) and non destructive testing (NDT) to direct measure stress level in prestressed strands or bars installed on ground anchors or post tensioning tendons. Dyna Force sensor can be used to rapidly read the change in load during proof and performance tests and compare with the pressure gauge and during the life on the anchor to monitor existing lock-off load. It can be used also to determine the load along the bonded length of the anchor allowing the contractor to increase or decrease this length. The paper presents Dyna Force operating principle and some applications. In conclusion, the Elasto magnetic technology applied through Dyna Force is a new and easy to use approach to monitor anchor load during proof test and service life of the structure.

Jan 1, 2009

By J. A. Finch, R. R. Cunningham

The amount of foam volume generated in relation to the gas flowrate has long been used to define the foaminess of a solution and to characterize surfactants. The vessel geometry and gas flowrate range can affect the foam volume results. A fixed area column was tested alongside a variable area conical vessel with two surfactants. It was found that the fixed area vessel will cause foam volume to expand or contract which masks the effect of the surfactant. The conical vessel showed two regimes of foam volume production dependant on gas flowrate. The low gas flowrate regime revealed the physiochemical nature of the surfactant while a high gas flowrate revealed kinematic properties. Foaming properties of a surfactant is best determined with a variable area vessel at low gas flowrate.

Jan 1, 2009

By J R. Manuel, M J. Peterson

Selected drill core samples from a Ferrobamba-limestone-hosted, magnetite-haematite skarn deposit, located in the Apurimac department of the Andahuaylas-Yauri skarn/porphyry belt of south-eastern Peru, were mineralogically and texturally characterised to gain a preliminary indication of the deposit's potential as an iron ore resource. Optical microscopy, X-ray diffraction (XRD) and scanning electron microscopy/electron probe microanalysis (SEM/EPMA) techniques were utilised to determine the characteristics of magnetite, haematite and/or goethite dominated ore types, including variations in the relative proportions and textural relationships of the ore and gangue minerals. The deportment of elements deleterious to processing performance (eg copper, sulfur and potassium) was determined and the beneficiation potential of the samples was briefly assessed. In drill core sections, the ores are grey to reddish in colour, massive and 'metallic' to dark brown and earthy in character, moderately hard and porous (macro and microporous), with variable gangue infill. Ores often appear weathered, typified by ochreous goethite staining and common minor goethite (except in dense core fragments), occasionally exhibiting a more friable texture with coarse magnetite/martite grains. Silicates and lesser carbonate gangue are visible as blue-green to beige to white scaly and/or shaly surface coatings, and finely particulate infill, often goethite stained. Sulfide-rich ore types also occur in part of the deposit, but are restricted to specific drill holes. Magnetite grain size is relatively coarse, compared with magnetite from typical banded iron formations, whereas discrete silicate gangue is mainly bladed/fibrous and/or layered and micaceous in form. XRD analysis indicates the presence of vermiculite, serpentine, stilpnomelane, chlorite, actinolite and clays. There is a spectrum of ore types representing the gradation from 'fresh' (magnetite-dominated) to oxidised and weathered (martite/goethite-dominated). Martite-dominated samples are generally higher in grade, due to leaching and removal of silicate gangue, resulting in higher macroporosity. Where gangue has been leached out, partial replacement by vitreous goethite and/or hydrohaematite is typical, often preserving the fibrous/layered characteristics of the original silicates.

Jan 1, 2009

By Simon Lekakh, Von Richards, C. Hank Rawlins, Kent Peaslee

"Batch aqueous leaching and carbonation tests were conducted using industrial steelmaking slags to determine the effect of carbonic anhydrase enzyme as a catalyst. Calcium leaching is a strong function of particle surface area, and the extent can be expressed as a function of time and particle size. Carbonic anhydrase did not affect the calcium-leaching rate, however, it did catalyze calcium carbonate formation to achieve a neutralization time near the theoretical rate. Additionally, carbonic anhydrase modified the precipitate morphology due to accelerated particle nucleation. Time controlled tests in which the pH dropped to ~6 decreased the amount of carbonate produced, and this effect was exaggerated by carbonic anhydrase, while pH controlled tests (>8.5) exhibited the highest rate of carbonation. Because the leaching rate was ~50% faster than the carbonation rate, a further increase in the amount of carbonation may be realized by using carbonic anhydrase however pH must be >10.3.IntroductionSteelmaking slag contains high fractions of alkaline earth oxide based phases (i.e., CaO and MgO) that exothermically form carbonates. Thus, it is being considered as a means of permanent carbon dioxide sequestration. At current U.S. steel production rates, approximately 13-17 million tons/year of slag are generated from basic oxygen furnace (BOF), electric arc furnace (EAF), and ladle metallurgy furnace (LMF) processes [1]. BOF and EAF slag is used as high quality mineral aggregate or cement clinker, while LMF slag, produced at ~15% the rate of BOF and EAF slags, has limited use as blast furnace flux or acid mine neutralization with the majority going to landfill [2]. Based on slag’s chemical nature and immediate availability as a co-product from steel production, the steel industry initiated a project to investigate hydrous carbonate formation in steelmaking slag as a method of sequestering carbon dioxide emitted in steelmaking offgas [3]. The goal of this project is to determine the reactor parameters suitable for the design of an industrial system for treating steelmaking offgas with raw or minimally processed slag."

Jan 1, 2009

By Jeffrey A. Gebhard

As part of the design and construction of the new St. Anthony Falls I-35W Bridge, a full-scale load test was conducted on a 6 1/2-foot diameter drilled shaft in the St. Peter Sandstone. This load test helped identify shaft-rock interaction properties, including end bearing and multiple zones of differing shaft resistance for design of the drilled shafts beneath the three piers adjacent the river. The load test was designed by Load Test, Inc., Braun Intertec and the design team of Figg Bridge Engineers/TKDA and constructed by Design Build Consortium of Flatiron/Manson. Oversight was provided by the Minnesota Department of Transportation. Based on these test results, the drilled shafts supporting the St. Anthony Falls I-35W Bridge were designed to reduce risk and maximize economy for the people of the State of Minnesota.

Jan 1, 2009

By A Valero, G M. Mudd

There is active debate and research around the most suitable indicators to assess the sustainability of mining. The most common approach is to report a range of data for a given mine site (or less preferably, a company total), such as inputs, outputs, benefits and potential costs. The most popular protocol in use (and growing rapidly) is the Global Reporting Initiative (GRI). However, these measures are numerous and still do not allow a single over-arching indicator to be developed. Other measures, such as known mineral resources over time, do not account for critical challenges such as declining ore grades, increasing wastes and poorer quality ores or more difficult mineralogy. By adopting a thermodynamic approach to sustainability, through the concept of æexergyÆ, it is possible to incorporate into a single measure the effective quality of mineral resources. Exergy involves the assessment of the minimum energy costs involved in producing a mineral resource with a specific chemical composition and concentration from common materials in the environment. The exergy of a mineral resource is evaluated from mineralogic composition, concentration (or ore grade) and, of course, quantity, by multiplying the unit exergies with the tonnes of the resource produced (or consumed). Since exergy is a thermodynamic quantity (ie energy or joules), it is additive across different minerals, such as iron ore to gold to copper or even oil and gas or coal û making it an ideal indicator to assess mineral resource sustainability at the industry scale rather than the individual mine scale. This paper briefly outlines the theoretical basis for exergy, and then presents a range of commodity case studies showing the application of exergy to the Australian mining industry. Overall, the usefulness of exergy is clearly demonstrated for use as a broad indicator of the sustainability of mineral resources at the national or even global scale.

Jan 1, 2009

By T. Könighofer

Processing of copper-cobalt orebodies in Africa?s Copper Belt has received much recent attention with various flowsheet options being developed specifically for the refining of cobalt. The upfront leach and copper refining routes are well understood whereas the refining of cobalt is more complex, requiring numerous impurity removal steps to produce high purity metal. This paper describes an investigation into one of the possible processing steps in the refining of cobalt, namely, cobalt solvent extraction. The paper emphasizes the importance of upstream impurity removal to achieve the required cobalt solvent extraction feed composition. 18% (v/v) Cyanex 272 in an aliphatic diluent is used as the organic phase. The pH profiles in the various stages are evaluated in order to obtain a raffinate containing <10 mg/[l] cobalt and with a low magnesium content reporting to the stripping section. The pH profile is also used to minimize the impurity deportment to the cobalt electrolyte. The effect of adding a preneutralization stage before feeding the organic phase to the extraction circuit is investigated. Zinc build-up in the stripping stages is also looked at. It is recommended for the purpose of this study that four extraction stages at an O:A ratio of 1 with a pH profile from 4.9 to 5.7 be employed. The pH is controlled with 40 g/[l] NaOH. A preneutralization stage is required, where the organic phase is contacted with 10 M NaOH. Two scrubbing stages are recommended at an O:A ratio of 40, using the cobalt electrowinning advance electrolyte as the scrub liquor. Three strip stages are to be employed at an O:A ratio of 0.67.

Jan 1, 2009

This paper describes DRA?s involvement with the expansions at Tati Nickel, Phoenix Mine, that have taken an initial plant design of 3.6 Mtpa (originally built by Murray & Roberts), up to 5 Mtpa, and eventually 12 Mtpa capacity. Initially, the plant could not achieve the design name plate capacity for the first few years of operation, as a consequence of the notoriously hard and abrasive nickel ore affecting primarily the operation of the crusher circuit. In order to extend the life of mine, Tati? assessed and then redefined the mining plan, choosing to increase the Phoenix mine reserves to a lower cut-off grade. In order to increase nickel units produced, the concentrator had to therefore treat additional tonnage at lower head grades. Site investigations and field tests around the comminution circuits are outlined, indicated that the milling circuit could be increased to 650 tph, from the initial design of 470 tph, for a similar feed grade and recovery. A project was initiated to debottleneck the crusher circuit and achieve the new target throughput. (Project 5M). This was followed by a feasibility study of the impact of pre-concentration by DMS, which after promising laboratory tests, was followed up with the installation of a 200 tph ?demonstration? plant. The success of this demonstration plant provided the impetus to expand the supply to the 5 Mtpa mill from a large preconcentration stage. A gyratory crusher (one of the largest and most powerful) will receive ore directly from the open pit operation, feeding into a secondary-tertiary crushing plant followed by a modular DMS preparation circuit. Four large DMS processing modules have been installed to treat the tonnage, with high expected rejection levels. Finally a review of the DMS process capability on an ostensibly disseminated micro-gabbro nickel ore is given, which shows the remarkable impact that preconcentration can have on an operation, both in terms of profitability and a successful process ?expansion?. The performance of the DMS plant has significantly extended the life of mine, allowing the mine to significantly reduce mine cut-off grades and curb its previously selective mining practice.

Jan 1, 2009

By Yi Luo

Subsidence events occurred over inactive room and pillar (R&P) mines, including abandoned mines or sealed portions of active mines, are classified as unplanned subsidence because of their timing and distribution are unpredictable. When investigating such subsidence cases, many uncertainties exist and disputes often focused on whether the observed structural damages are caused by mine subsidence or other natural or artificial causes. However, solid evidences to identify the causes are often lacking. In order to conduct a thorough and impartial investigation, good knowledge in subsidence theories a

Jan 1, 2009

By D. H. Ryan, J. T. Graham, A. Navarra, J. A. Finch, S. Somot

Pyrrhotite (Po) is widely considered to be the most significant mineral in the self-heating of sulphides. It is therefore desirable to determine the amount of Po in mineral samples. This is commonly accomplished through x-ray diffraction (XRD) or quantitative evaluation of materials by scanning electron microscopy (QEM-SEM). This paper introduces another quantitative method based on Mossbauer analysis that requires limited sample preparation and has the additional potential to detect the sulphur/iron ratio within Po. The technique is explored using pentlandite/pyrrhotite mixtures.

Jan 1, 2009