Search Documents

By H. Hejny

"The mine of the future will exploit mineral raw materials at greater depths than today, requiring completely different approaches compared to today’s deep mines, in order to get mineral rights. Only these eco-efficient mines will contribute to improved access to domestic mineral resources, secure the sustainable supply of mineral raw materials for Europe and reduce the import dependency. IntelliMine will contribute to realise these concepts of invisible, zero-impact and safe mines. The mine of tomorrow will run an integrated concept in order to guarantee the desired level of sustainability. All operations necessary for the eco-efficient provision of the minerals including waste management will be carried out underground. This will drastically reduce the volumes being transported, minimising above ground installations and thus the environmental impact. IntelliMine will develop necessary innovative methods, technologies, machines and equipment for the safe, eco-innovative, intelligent and economic exploitation of mineral raw materials in the EU, especially at greater depths."

Jan 1, 2011

By J. M. Benson

Titanium is an exciting structural material that can offer significant strength-to-weight advantages over currently used alloys. However, its Achilles? heel is its costly, energy-intensive production process that effectively eliminates it from competing with aluminium and high-strength steels, apart from critical applications where titanium forms only a small component of the total cost. Current attempts are being made to reduce the cost of titanium products and these recognize the importance of minimizing the costs over the total production chain. Powder metallurgy (PM) technologies play a crucial role within this, as the output of the existing and potential primary metal production methods is in the form of sponge or powder. By using PM, costly remelting and forming operations can then be avoided, except in the manufacture of large components. Metal injection moulding (MIM) is an effective process for producing complex net-shape components in large volumes from metal powders. Nevertheless, the commercial use of titanium powders in this process is still in its infancy. The only major supplier of feedstock utilizes a polyacetal-based binder. This gives good green strength but requires a catalytic nitric acid process to remove most of the binder prior to thermal treatment. As this involves additional and expensive equipment and is a potentially hazardous process, there is interest in finding an alternative binder system that can be debound either purely thermally or that involves a less hazardous, more environmentally friendly solvent. This paper describes the use of capillary rheometry to characterize the influence of temperature and shear rates on the flow behaviour of potential binder systems for titanium MIM feedstock. Keywords Titanium, metal injection moulding, capillary rheology, feedstocks, powder loading.

Jan 1, 2011

In this paper, a mixed integer linear programming (MILP) model for the short-term scheduling of open pit mines is formulated. The proposed model aims at sequencing the blocks extraction over multiple short-term periods. The model takes into account multiple processes, waste dumps, and multiple stockpiles. The short-term scheduler makes a decision on the period, destination, and route that ore and waste are supposed to take to minimize costs while meeting all the mining and processing constraints. The destinations of the extracted materials are also controlled by their rock types. A monthly short-term production scheduling case study of an iron ore deposit is carried out over a year to validate the model.

Jan 1, 2011

By D. Norval

Keywords: Pyrometallurgy, slag, metal, entrained, granulation, ferromanganese Water granulation of certain slags with high metal entrainment has customarily not been practised, not only due to the belief that such processes are too dangerous and unproven in the pyrometallurgical industry, but also that it might not be economically viable or environmentally acceptable. General slag granulation, on the other hand, is extensively applied, although in some cases crudely, with disastrous effects, as a result of not recognising the high heat capacities prevalent in slags. Thus, purpose-designed granulation and solidification processes are discussed, taking into account specific applications and the individual signatures of alloys and slags, emphasising that no slag, matte, or alloy responds in similar fashion to a granulation practice. This paper addresses three issues, namely: ? Water-granulation of BOF steel slag, without processing it to render it environmentally safe, physically and chemically acceptable for use by the construction industry, and the process economical ? Processing air-cooled BOF steel slag to change its physical and chemical properties to be acceptable for various uses and extracting metallic and bound iron ? Processing air-cooled or molten manganese slag to lower its manganese content to a level that is acceptable from an environmental and health point of view, and extracting FeMn-alloy of acceptable composition. The latter process culminated in a patented process to extract FeMn from air-cooled and molten manganese slag, and, at the same time, produce a hydraulic (cementitious) slag, thus transforming a possible hazardous by-product into virtually 100% saleable products.

Jan 1, 2011

By Gui DeReamer

Located on the Wabash River in the central portion of the state, the city of Lafayette, IN is relatively small compared to most cit-ies that incorporate tunnels into their combined sewer overflow (CSO) systems. The original CSO plan for the city was to replace two aging lift stations that were built in the 1950s. The original con-cept was to build a new sewer using conventional cut-and-cover construction to eliminate one of the lift stations ? the Parking Lot Lift Station ? and build a new regionalized one at the location of the Pearl River Lift Station. The initial sewer design was sized just to handle the flow that would eliminate the Parking Lot Lift Station. The planning for this project was being developed as part of the city?s CSO long-term control plan (LTCP) that focused on reducing the overflows from the city?s 14 overflow points. However, during the development of the CSO LTCP, a major industrial user indicated it would be increasing its flows to the system, which required additional conveyance capacity to meet the city?s CSO LTCP. After reviewing the design concepts with city representatives during the planning phase of the project, the mayor indicated that he wanted to minimize impacts to downtown businesses; therefore, trenchless alternatives were considered. The last piece of the puzzle that drove the project away from a small diameter pipeline was discovered during a flow monitoring program to collect flow data for the CSO LTCP project. This study revealed a major restriction in the 100-year-old Pearl River Trunk Sewer, located beneath four active railroad tracks. To eliminate this flow restriction, provide more overflow storage and reduce the impact to local businesses, a new 2.7- to 3.6-m- (9- to 12-ft-) diameter tunnel sewer became the most viable solution.

Jan 1, 2011

By Bruno Gemmi

A new warehouse built with prefabricated components over an area underlined by soft marine soil deposits started showing differential settlements well before its completion. Its 103 spread footings carrying up to 4,000kN (450t) axial loads had been cast on jet-grouted columns extending and penetrating a layer of sand at a depth of 10m (33ft). Investigations performed to assess the wholeness and consistency of the jet-grouted columns revealed a state of loose jet-grouted masses and uncontrolled, off target migrations of the jet-grouting. Most of the jet-grouting itself was settling. The following remedial solutions were suggested: 1. Construction of new and better controlled jet-grouted columns. 2. Cement-based soil grouting. 3. Expanding resin injections. 4. Minipiles drilled-through the existing footings and reaching into a denser layer of sand existing at 23m below grade. Remedial solution 1. was immediately discarded due to cost and the possibility of a repeating failure in this non-granular and highly compressible soil. Tests of remedial solutions 2. and 3. were carried out. The outcome of the grouting was monitored by Electro Resistivity Tomography (ERT) (Bares et al., 2003), an innovative 3D electro tomography procedure showing where grout had been actually placed and its migrations off target. A successful 4,000kN (450t) load tests confirmed the validity of the solution. Finally, upon the completion of a successful load test, solution 4. was chosen. It supplied the highest degree of reliability thanks to the ease of controlling the final and actual location of the minipiles and to the higher safety factor provided. All remedial work to install the minipiles was eventually performed inside the building. Additional load tests and settlement measurements confirmed the adequacy and success of the chosen solution.

Jan 1, 2011

By Michael J. Atwood

Many buildings in Boston are founded on untreated wood piles, which can deteriorate and lose their structural capacity if groundwater levels are lowered below the tops of the piles, exposing the wood to air in the unsaturated soils that surround the piles. The problem of wood pile deterioration due to lowered groundwater levels in Boston first became evident in 1929 following discovery of rotten piles beneath walls of the Boston Public Library building. Repairs to reconstruct the library building?s wood pile foundations were made in 1930 using pit underpinning methods. Today, more than 80 years later, the subsurface conditions beneath several of Boston?s historic neighborhood areas continue to be plagued with low groundwater levels - regrettably resulting in ongoing deterioration to the wood piles that support some of Boston?s oldest and most beautiful buildings. Pit underpinning is still recognized as the preferred approach to repair wood piles and restore uniform foundation support beneath the impacted buildings. This paper provides a brief historical review of the land filling in Boston through the early 1900s that led to the use of wood piles as building foundations. Also discussed is the impact that groundwater level can have on the long term performance of wood pile foundations and the pit underpinning procedures used to reconstruct decayed wood pile foundations in 1930 beneath the Boston Public Library, and today beneath some of Boston?s oldest buildings. Also included are discussions on engineering controls and permitting requirements that help ensure safety and protection to the workers and buildings during underpinning, and some procedures being used to supplement and improve the loading capacity of the reconstructed foundations and facilitate construction of new useable below-grade space.

Jan 1, 2011

By M. Javier

Mining, waste is growing problem both physical accumulation and increasing toxic uncertainties it presents in the long run. Its value ?zero? is strictly calculated by economy. This mining model begs the question: What is the value of waste & what does it represent to the mining industry? Waste is widely accepted as a ?by product? generated as a consequences of the mining process. The abundant waste accumulation affects society, as receptor, in many ways and the waste piles of materials has no use and no destiny. In reality, this waste is monument of imperfection of the extractive industries worldwide. Our planet is finite and has strict limitations, which mining has traditionally ignored. It is time to design a new system, in which clearly, waste design must be integrated in whole mining process; it has no room to postpone. This paper presents a concept in waste design by which toxic mining waste not only can be rendered inert but also act as nutrient to help balance the ecosystems. This concept calls for extractive industries to pursue EQUILIBRIUM with nature (Geomimic). Also, this concept offers countless gains and opportunities fro the industry and by converting liabilities into assets; mining engineers become the managers and stewards of nature. Also, waste design offers new solutions for proper and sustainable waste management of the mining industry.

Jan 1, 2011

By A. Redman

Aquatic organisms are sensitive to free cyanide (HCN) though the presence of certain metals that can form stable complexes and thereby reducing both the amount of bioavailable cyanide. Recent work has suggested that consideration of HCN rather than total cyanide can provide the basis for water quality criteria. Cyanide is often present in complex effluents that affect speciation and bioavailability. We have developed a model to predict the speciation of cyanide in complex effluents and have shown that this model can predict the toxicity of metal-cyanide complexes in terms of HCN. This study evaluated available cyanide toxicity exposures with this model to assess the role of water chemistry (e.g., metal-cyanide interactions) on the observed. Toxicity endpoints based on total cyanide ranged over several orders of magnitude for a variety of metal-cyanide mixtures. However, predicted HCN concentrations among these same tests described the observed toxicity data to within a factor of 2. Aquatic toxicity can be well described using HCN though in certain metal-cyanide mixtures toxicity was jointly described by HCN and elevated levels of bioavailable metals. This work was performed in support of an industry-sponsored reassessment (Gensemer et al 2006) of the U.S. EPA water quality criteria for cyanide (EPA 1985) using free cyanide as the basis for the re-calculation. The work presented in this manuscript presents technical support for using free cyanide as the preferred basis for this recalculation.

Jan 1, 2011

By George Piscsalko

There are numerous methods currently available to assess the integrity of drilled shaft and ACIP piles. Each method has its advantages and limitations. This paper will compare the various available methods as well as introduce a new method for assessing integrity of drilled shafts and ACIP piles. This new method, known as Thermal Integrity Profiling, determines the integrity of the shaft both inside and outside the reinforcing cage by measuring the hydration temperature of the concrete along the length of the shaft. These temperature measurements can be made by either passing a thermal probe through a standard Cross Hole access tube, or from embedding thermal wires within the shaft. This Thermal Integrity Profile method will be described in detail and one case history will be presented. Additional testing methods which will be compared include low strain Pile Integrity Testing and Cross Hole Sonic Logging. Advantages and limitations for each method will be discussed.

Jan 1, 2011

Keywords: Pyrometallurgy, furnace, Lonmin, platinum, PGM, UG2 Lonmin, earlier than any other primary platinum producer, had to deal with the concentrating and smelting of UG2-rich ores and concentrates respectively. Smelting was performed at a fairly modest scale compared to its industry peers in the Platinum Group Metals (PGMs) industry, and was focused on smelting concentrates obtained through low mass pulls while still maintaining high recoveries at its concentrators. Lonmin gradually smelted larger quantities of UG2 concentrates. Initially two 2.3 MW Infurnco furnaces were commissioned in 1982, followed by three 5 MW circular 3-electrode Pyromet furnaces in 1991. Deep electrode immersions and moderately high hearth power densities were used in all the designs. Lonmin decided to continue with circular furnace technology when it planned its new high-intensity No. 1 Furnace. Neither Lonmin nor the technology supplier and EPCM company foresaw the challenges that scale-up would bring when applied to the smelting of UG2-rich concentrate blends. Superimposed on the high chromite content, was the low base-metal loading, mineralogical difficulties, and fine particle size that came with milling of all concentrates (especially UG2 and recycle materials within the smelter). Through a process of fundamental diagnoses of furnace run-outs and wear patterns observed during repairs, the main challenges operating this high-intensity furnace were identified as sulphur vapour corrosion of the copper coolers, uneven and unpredicted movements of refractory bricks with associated copper cooler lift and matte tap-block movement, the formation of three-phase ?mushy? zones, high refractory and tap-hole wear rates, uncertainty in matte level and associated insufficient matte buffer height, and high furnace operating temperatures. These factors seldom worked in isolation and will be explored in more detail in the paper. The variability in furnace feed characteristics led Lonmin to re-design Furnace No. 1, to invest in back-up furnace capacity, and to invest in improved monitoring and control. These improvements consisted of online and high-frequency off-line feed chemistry and mineralogy monitoring, online pressure monitoring of water-cooled circuits, an alternative matte liquid level measurement in the furnace, and electrode immersion estimation. Improvements were also made at the converters by installing and utilising optical spectral analysis of the converter flame to characterise converter behaviour and achieve the desired iron end-point for white matte. This paper also briefly discusses the current and future expansion plans, as well as ancillary operations at the smelter such as flue-gas handling and materials handling.

Jan 1, 2011

By S. M. Carpenter

In response to the FY2008 Consolidated Appropriations Act (H.R. 2764; Public Law 110?161), the United States Environmental Protection Agency (USEPA) issued the final Mandatory Reporting of Greenhouse Gases Rule (MRR). The rule, signed by the USEPA Administrator, Lisa Jackson, on September 22, 2009, requires reporting of greenhouse gas (GHG) emissions from large sources and suppliers in the United States, and is intended to collect accurate and timely emissions data to inform future policy decisions. The MRR will go into effect on January 1, 2010, and a report of the total emissions for calendar year 2010 will be due to the USEPA by March 31, 2011. Under the final MRR, suppliers of fossil fuels or industrial greenhouse gases, manufacturers of vehicles and engines, and certain facilities that emit 25,000 metric tons or more per year of GHG emissions are required to submit annual reports to the USEPA. The gases covered by the rule are carbon dioxide (CO2), methane (CH4), nitrous oxide (N2O), hydrofluorocarbons (HFC), perfluorocarbons (PFC), sulfur hexafluoride (SF6), and other fluorinated gases as outlined in Table A-1 of Subpart A of the MRR, which is also provided in Appendix A of this report.

Jan 1, 2011

By James Weaver

During the past 16 years, the authors have successfully used high-capacity rock anchors installed inside open-ended pipe piles, driven to bedrock, to provide uplift and overturning resistance for various structures including piers, bridges, power plant components and commercial buildings. These systems were ultimately used on the projects due to a combination of high uplift forces or overturning moments on the structures and the relatively poor subsurface conditions present at the sites. Other, foundation systems such as rock-socketed drilled shafts and spin fin piles were considered but were found to be economically prohibitive or not technically feasible.

Jan 1, 2011

The schlieren technique describes an optical analysis method designed to enhance light distortions caused by air movement. The ability to visualize air flow has significant implications for analyzing underground mine ventilation systems, including the enhancement of surveys and models. Currently, traditional schlieren methods are impractical underground. Background oriented schlieren (BOS) provides a solution to this problem. BOS requires two primary components, a professional quality digital camera and a schlieren background. A schlieren background is composed of a varying contrast repetitive pattern, such as black and white stripes. This background allows the camera?s sensor to capture minor light diffractions, such as those caused by air flow. Although BOS shows great potential for ventilation analysis, sensitivity is an issue. This paper seeks to validate the BOS technique for imaging flow through a regulator by comparing BOS images with traditional schlieren images. This paper also outlines initial experimental efforts used for the validation.

Jan 1, 2011

By Steven R. Lowe

Construction of a pump station, consisting of an inlet chamber, wet well and pump chamber, required excavation to a depth of 9.7 m (32 ft) below ground surface and more than 7.6 m (25 ft) below the ground water table in a rural, but rapidly developing part of southern New Jersey. Private houses are located [ ] within a few hundred feet of the pump station that use shallow wells for water supply. The pump station design anticipated support of the entire pump station on shallow foundations bearing directly on the underlying natural soils. However, during construction, uncontrolled ground water flow caused ground loss and damage to the bearing qualities of foundation soils. As a result, remedial repairs were required including support of the pump station on drilled pile foundations and releveling of the pump chamber that had settled. This case study is an example of where a poor understanding of the significance of upward flowing ground water had a major impact on the cost of construction. Anticipated subsurface conditions The pump station layout is shown in Fig. 1 with the locations of two borings made prior to construction superimposed. One of the borings was located within the footprint of the deep wet well excavation. Generally, this is not advisable where a deep excavation is required below the ground water table. This is because there is a history of projects where ground water seepage, or pressure, has broken out into an excavation through an ungrouted borehole and compromised the integrity of foundation soils. Logs of the borings did not indicate that the borings [ ] were grouted upon completion.

Jan 1, 2011

By I. A. Kunasz

This paper is not intended to review and re-state general information on lithium, but rather to analyze the paradigm that has caused such a rapid rise in lithium production and the development of new lithium producing centers. Details on pegmatites, brines, concentrate and chemicals are amply covered in a number of publications ? SME?s Industrial Minerals and Rocks, Industrial Minerals, Roskill and a host of other publications. There is no question that the latest interest in lithium has been driven by the potential development of the electric car. This stimulus prompts one to recall two symposia: 1. ?Lithium Resources and Requirements be the year 2000?, organized in 1976 by the U.S.G.S. in Denver (1) and the sequel 2. ?Lithium ? Needs and Resources? at Corning, N.Y. (2).

Jan 1, 2011

By D. Kwietnewski

With all of the unknowns associated with tunnel construction, how does a contractor choose a roadheader? This paper presents a review of several models of roadheaders being used in today?s tunnel projects. The features of different models of roadheaders are presented and compared. Roadheader size and cutter power generally determine which roadheader is best for a particular job. We will also present a model for matching features of the roadheader to the anticipated ground conditions such that the most efficient machine is selected for the project.

Jan 1, 2011

By N. Ward

The Gualcamayo Mine is located in the Andes Mountains north of San Juan, Argentina (Figure 1). A property of Yamana Gold Inc, it declared commercial production in July 2009 and has a total mineral reserve and resource base of approximately 88,000 kg of gold. Crushing operations for the open-pit mine are located in a 13,500 m3 underground cavern with a ceiling height of 22 m. More than 3,600 m of tunnels are used to access the cavern and convey the ore. The Project as described in this paper relates to the design and construction of the Main Cavern, Conveyor System Exit Tunnel, the Mechanical System Access Tunnels, and two 4.20 m diameter shafts (Ore Pass #1 and Ore Pass #2) as shown in Figure 2. [ ] Preliminary engineering for the Project was performed by Hatch Chile. Rizzo Associates Argentina, S.A., a division of Paul C. Rizzo Associates, Inc (Rizzo) was contracted to provide geomechanical and geotechnical support for the construction of the access tunnel system and geomechanical design and construction supervision for the cavern and shafts.

Jan 1, 2011

By David Preece

The Thirlmere aqueduct was constructed over 110 years ago to provide water from the Lake District (in the north-west of England) to the city of Manchester some 60 miles (100 km) away. The aqueduct remains, to this day, a key piece of infrastructure in the distribution of raw water in the north-west of England. A short section of the aqueduct was identified as being in poor condition during routine inspections by the owner. Subsequent investigations attributed the conduit damage to the movement of unstable ground over the conduit. Bachy Soletanche Ltd was subsequently appointed to carry out the design and construction of the slope stabilisation works and to undertake repairs inside the damaged conduit. The works were undertaken on an existing slope which, in places stands at a gradient of up to 40º to the horizontal. Strict limitations on plant and equipment were imposed by the client (United Utilities) to ensure that slope and conduit loading and associated vibrations were kept to an absolute minimum during construction. An intensive instrumentation system was installed to monitor surface movements, ground movements at depth, conduit movement and strains across existing planes of weaknesses within the conduit. The solution comprised the installation of spaced piles up-slope and down-slope of the conduit. Restrictions were imposed on the minimum stand-off distance between the outside face of the conduit and the piling works so targeted permeation grouting was undertaken to improve the ?connection? between the conduit and the down-slope piles. The presence of existing sub conduit groundwater flows was suspected and the permeation grouting was focused in areas to minimize disruption to the groundwater regime. The paper presents the basis of the design and highlights the combined construction and instrumentation methods adopted to minimise damage to this valuable asset.

Jan 1, 2011

By F. Ntengwe

The Konkola Mine, a subsidiary of the Konkola Copper Mines Plc (KCM) which is owned by the Vedanta group of companies of India and Zambia Consolidated Copper Mines Holding limited, is located at Chililabombwe in the northern extension of Zambia's Copperbelt province. In its operations, the mine has been experiencing problems in ascertaining the optimum degree of fineness and the operating density of the hydrocyclone overflow in order to achieve high flotation performance. It was believed that recovery of sulphide copper minerals from Konkola ore is a function of the fineness of the grind so that it might be an economical justification to modify the grinding plant in order to run at lower cyclone overflow densities than the case is now. In an effort to improve these operations, it was decided to carry out test work on various hydrocyclones of sizes 0.381 m, 0.4575 m and on 0.508 m. The later was found to give satisfactory results and was installed on the plant. Despite giving satisfactory results there was need to investigate further to establish the working densities and size. Increasing the density of cyclone overflow decreases the per cent passing 75 pm at least in the range 1080-1 150 g/l. Furthermore, hydrocyclones give better separation at low densities of feed and hence the efficiency is high at low feed densities. Circulating load increases with an increase in feed densities and an decrease in the grind. The flotation performance in both sulphide and oxide copper minerals rougher stages is enhanced with an increase in the degree of fineness of the grind, with an optimum being obtained at a density of 1 150 g/l and 81.4% passing 75 µm. Keywords Konkola mine, hydrocylone, optimum degree of fineness, sulphide copper minerals.

Jan 1, 2011