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By James R. Wickens, David La Rosa, Robert E. McIvor, Adrian Dance

"The comminution circuit at Barrick Cortez Gold Mine uses an open circuit primary jaw crusher followed by a standard SABC grinding circuit. The grinding circuit incorporates a 26’Ø x 11’ SAG mill, an Omnicone 1560 pebble crusher and a 16’Ø x 28½’ ball mill. Both mills are driven by 4500 HP motors.In 2007, several comminution circuit studies were performed to assess circuit performance and map a course for improvement. This paper discusses the results of those studies including an analysis of mine-to-mill opportunities, grinding work index efficiency, and ball mill functional performance. Subsequently, improvements to the circuit were made to enhance operating efficiency. Specifically, improvements to the pebble crusher liner configuration, advanced process control system (expert system) and ball mill classification and ball charge are discussed. In addition, other current and future improvement opportunities are discussed.INTRODUCTIONThe Barrick Cortez property is expanding to include the new Cortez Hills open pit and underground mines. Ore from these new mines will be processed in the existing Pipeline mill facility. In conjunction with ore characterization work, performance of the comminution circuit needed to be quantified. Thus, in 2007, the comminution circuit was surveyed and opportunities for improvement identified.Figure 1 below shows the Pipeline mill flowsheet. It is a standard SABC grinding circuit using an open circuit primary jaw crusher followed by a 26’Ø x 11’ (7.92m Ø x 3.35m) SAG mill, in closed circuit with a Omnicone 1,560 pebble crusher, and a 16’Ø x 28½’ (4.88m Ø x 8.69m) ball mill. Both mills are driven by 4,500 HP (3,357 kW) motors. The SAG discharge screen aperture is 5/16” (8 mm) x 1-1/16” (27 mm) slots. Ball mill circuit classification is done with Krebs D20B cyclones."

Jan 1, 2009

By L. L. Chasko

A mine fire is one of the most challenging safety issues facing a mine operator and can occur at any location underground. The National Institute for Occupational Safety and Health (NIOSH) and the Twentymile Coal Mine, Colorado, conducted in-mine experiments to determine the capability of high-expansion foam for addressing underground fires. The tests were conducted in sloping entries with high-capacity diesel-powered foam generators. The following results were observed: a well-designed, maintained, and properly operated high-expansion foam generator can propagate a foam plug hundreds of feet in steep upward sloping (20 pct) multiple entries against a ventilation pressure; stoppings and partitions designed to contain the foam plug in upward sloping entries must be substantially constructed; and the predicted quantity of foam concentrate can be significantly less than the actual amount used due to foam losses, such as bubble breakage on dry surfaces. This paper describes the production of high-expansion firefighting foam and discusses the in-mine experimental tests and results. DISCLAIMER: The findings and conclusions in this report are those of the author(s) and do not necessarily represent the views of the National Institute for Occupational Safety and Health.

Jan 1, 2009

By M. Bilal Khan

Thermal stress relief by means of a typical heat treatment cycle (660oC for one hr) is compared with the one achieved through vibratory stress relief at resonant and multiple resonant frequencies for the D-406 HSLA material. Our analysis of the data is based on the microhardness profiles measured for the entire length of scales, namely, base metal, heat affected zone (HAZ) and the weld bead itself. The profiles obtained using the two techniques mimic each other, for an equivalent 70% stress relief level. The data are further qualified by impact testing wherein the zone of interest is projected in the retention groove to provide impact by the pendulum striker in the Charpy mode. Higher equivalent energy absorption in the treated specimens confirms the efficacy of the vibratory method. The present work rectifies earlier anomaly where heat treatment has been reported at 310oC for the same material.

Jan 1, 2009

By Takashi Sasaoka

About 200 M tons of coal were imported into Japan in 2007 and Indonesia was its second largest exporter, accounting for about 30 M tons (12% of the total imported coal). Indonesia produced about 200 M tons of coal, about 75% of which was exported in 2007. As the Indonesian government has decided on an energy policy wherein 33% of the country?s primary energy demand will be met by coal by the year 2025, the domestic demand for coal has increased dramatically in recent years. Over 99% of the coal produced in Indonesia comes from surface mines. However, the conditions of surface mines are worsening each year: the stripping ratio is increasing, approaching the economic ratio, and the infrastructure for coal from inland mining areas is insufficient for such intense mining operations. To meet the demand for coal in Indonesia and the rest of the world, underground mines have to be developed. However, mining engineers and/or miners in Indonesia do not have a lot of experiences, expertise and know-how concerning the plans and operations of an underground coal mine. In addition, the industry faces a lot of problems which include poor conditions such as a steep coal seam, groundwater problem, stability of highwall, etc. Under these situations, a mine targeted in this research attempts to develop a new underground mine from an open-cut highwall because the stripping ratio in the surface mining area has almost reached the limitation of economic value. This paper discusses the possible development of a new underground coal mine from an open-cut highwall by means of field observation and numerical analysis.

Jan 1, 2009

By Matthew E. Meyer

Renovation, rehabilitation, restoration and expansion of existing residential, retail, commercial, hospital facilities and historic structures requires assessment and evaluation of foundation systems of various ages. The concept of demolition and reconstruction in urban areas is often more challenging, costly, and even prohibitive in some cases due to historic regulations. The authors have been involved with numerous projects related to existing foundation assessment and retrofit, including: hotel and hospital expansions, historic Art-Deco hotel renovations and expansions, garage structure expansions, additions to prominent auction houses, casinos, printing facilities; high-rise structure foundation retrofitting; and forensic evaluations of existing building and highway structure foundation systems, and marine bulkhead sheeting systems. The use of non-destructive testing techniques, high-strain dynamic load testing, full scale pile cap load testing and 3-D laser scanning technology has proved to be vital in the assessment and evaluation process, as well as design of foundation retrofit alternatives. This paper presents various methods and techniques to facilitate a phased approach for re-use of foundation systems. These methods and techniques are illustrated through the author?s experience and selected case histories from projects with varied foundation and geologic conditions.

Jan 1, 2009

By Unknown

More than 60 years ago Lakota (Sioux) Chief Henry Standing Bear asked Korczak Ziolkowski to create a monument of Crazy Horse in the sacred Black Hills. Today, you can see Standing Bear’s dream has grown into enormous reality. Crazy Horse Memorial, mankind’s largest mountain carving in progress, is being carved in the round and when completed will be 641 feet long and 563 feet high. Crazy Horse is only 17 miles from Mount Rushmore National Memorial, giving South Dakota unique boasting rights for having two extraordinary mountain carvings in such close proximity

Jan 1, 2009

By C. K. Kocsis

A study was undertaken to evaluate the thermal environment and determine the contributing heat sources within the existing 153 Orebody of Coleman/McCreedy East Mine which would then enable the prediction of the climatic conditions in the mine?s future 170 Orebody. The study entailed continuously monitoring, for a 2-week period, the dry-bulb temperature, humidity and barometric pressure along the existing intake airways from surface down to the 4810 Level and throughout an active mining area on that level. Furthermore, the mining activities and associated equipment that could be responsible for any changes in the temperature and humidity conditions within this mining area were also monitored. These data were then used to develop and validate a climatic simulation of the mine?s mechanized cut and fill mining method. This climatic model was then transposed to the future 5700 Level in the deeper 170 Orebody, to determine the environmental conditions within its production workings and along the main haulage route ascending from that area. Based upon the simulations performed it was shown that the level of ventilation planned for the new orebody should be able to maintain adequate environmental conditions. However, this study did emphasize the importance of the appropriate distribution of airflow in workplaces that used auxiliary ventilation in order to sustain a suitable thermal environment.

Jan 1, 2009

By R. B. Krog

The use of belt air as an intake source at longwall operations has greatly changed over the past decades. The practical considerations for the use of belt air are controlled by a variety of factors including airflow quantity and velocity, coal methane content, methane desorption rates, coal mining rate, belt length, stopping leakage, and the number of gateroad entries. At longwall operations, the advantages and disadvantages of belt air are different for gateroad development and longwall panel extraction. During gateroad development, the use of belt air to ventilate the working section will reduce the leakage from the intake to the belt compared to the belt air being ventilated outby the working sections because of lower pressure differentials. A greater quantity of airflow will reach the last open crosscut with belt on intake than outby, given the same amount of pressure and airflow available at the mouth of the section. This paper will investigate the current ventilation practices regarding the use of belt air during gateroad development and longwall panel extraction. Operating considerations regarding air quantities and pressures to deliver the required airflow will be investigated using ventilation network modeling.

Jan 1, 2009

By V. Bari?ic

The scheduled power cuts of early 2008 were a disturbing reminder that South Africa needs to expand its power-generating capacity. Low-grade and discard coals, of which South Africa has much, are a source of energy and amenable to combustion in circulating fluidized beds (CFBs). Foster Wheeler (FW) has a long record in developing this technology in boilers. The technology is flexible in burning a variety of fuels; low-grade, high-ash coals, good quality bituminous and anthracite coals, and biomass and waste fuels have all been used. CFB boilers are efficient, reliable and can be designed to meet tight emission standards. In recent years once-through supercritical (OTSC) CFB technology has been developed. It enables the next stage in CFB development to proceed to a medium-scale (500 MWe) utility in such projects as Lagisza, which runs at a net efficiency of nearly 44%. Scaling the technology up to 800 MWe with a net efficiency of>45% is planned to be commercial during 2009. CFB technology can reduce CO2 emissions in the repowering of coal-fired and greenfield power plants. It does so through greater efficiencies and by co-combusting coal with biomass. FW has also developed CFB technology for the gasification of biomass, as, for example, in a pressurized gasifier to produce syngas, which can be used for the production of biodiesel, thereby reducing CO2 emissions from vehicles. Carbon capture and storage (CCS) can potentially cut CO2 emissions in the generation of power from fossil fuels in the short term, provided that it gains public acceptance, that the required regulatory framework is created, and that emission-trading mechanisms or other incentives provide a solid return on the major investments required. Oxyfuel combustion is an option in CCS; Foster Wheeler is adapting its CFB combustion technology for oxy-fuel combustion to meet this challenge. It is developing Flexi-burn?, which enables a plant to be operated either with or without carbon capture. This paper describes the status of CFB technology in terms of boiler efficiency and fuel flexibility. It highlights the advantages of CFB technology for oxyfuel combustion, presents a development plan for Flexi-burn?, and discusses a pressurized gasifier for biodiesel applications.

Jan 1, 2009

By Jeane Hull

Jan 1, 2009

The Midvale Slag Site covers 300 acres in Midvale, Salt Lake County, Utah. Midvale (population 10,000) is part of the Salt Lake City metropolitan area (population 936,000). Between 1902 and 1971, United States Smelting, Refining and Mining Co. smelted ores on the site to produce copper, gold, lead, and silver. Figure 1 shows a picture of the historical Midvale smelter operations. [ ] When operations ceased, the site was estimated to contain 2 million tons of slag from these operations. The smelter no longer exists. In 1971, Valley Materials, Inc., acquired the site to process the slag into materials for railroad beds and asphalt highways. During the 1980s, the U.S. Environmental Protection Agency (USEPA) raised concerns regarding environmental impacts associated with the historical site operations. The Midvale Slag Superfund Site was listed on the NPL in 1991. The Site consists of two Operable Units (OUs): OU1 covering the properties north and adjacent to former ore smelting operations; and OU2 covering the smelter site itself. OU1 had historically been affected by wind blown slag dust and stack emissions occurring on OU2 and the Sharon Steel site further to the south. These emissions resulted in elevated levels of arsenic and lead in the native soils. The EPA issued the final Record of Decision (ROD) for the OU1 Site in 1995. The OU1 ROD required the implementation of institutional controls for the undeveloped portions of OU1 in order to restrict future land use to commercial/industrial purposes unless additional remediation was performed. Hence, the land comprising OU1 was originally considered in the ROD to be suitable for commercial or industrial purposes without the need for remedial action. However, development of OU1 for other land uses, including residential or recreational, would require additional assessment and probable remediation. The OU2 parcel was remediated by EPA to allow future land development, and the Sharon Steel site was remediated by EPA and deleted from the NPL. PROPERTY TRANSACTION AND REDEVELOPMENT In February 2006, a private development company, Mercer Bingham Junction, LLC. (MBJ) purchased 130 acres of the OU1 property for the purpose of performing environmental remediation, and developing mixed residential and commercial real estate. Development of the property was conducted in cooperation with USEPA Region 8 (EPA), the Utah Department of Environmental Quality (UDEQ) and Midvale City. The guidelines under which residential development could occur were defined by EPA. The 130 acres was to be developed for open space, residential and commercial use as part the Midvale City Bingham Junction development. Figure 2 shows the general layout of the proposed land uses. [ ] In May 2005, MBJ began pre-acquisition due diligence activities to purchase the 130 acres of OU1 north of 7200 South Street, which now comprises the Bingham Junction Development. This included the completion of Phase I and limited Phase II investigations. The Phase II investigations were performed to evaluate arsenic and lead concentrations in the planned residential areas of the site, and to explore the contents of the historic landfill on the property. The historic landfill area was on the far west side of OU1, adjacent to the Jordan River. Soil samples collected during the Phase II investigation showed that the planned residential parcels did not currently meet the criteria established in the Tech Memo and that additional placement of fill or soil excavation would be required for residential development in this area. An evaluation performed by the previous owner of the property, Littleson, Inc., showed similar results.

Jan 1, 2009

By M. J. Gilbey

Cross passageways between adjacent tunnels in passenger rail or transit systems may be used during train fire emergencies to evacuate passengers to points of safety in the non-incident tunnel. Rescue trains can be brought into the non-incident tunnel to remove passengers to expedite evacuation times as compared to walking along bench walls to the nearest egress stairs. In cases of multiple train emergencies, the required ventilation capacities can result in high pressure differences between the incident and non-incident tunnels. These pressure differences can make it difficult or impossible for a normal person to open doors of a cross passageway between adjacent tunnels. If opened, the velocity of the airflow through an open cross passageway can reach levels high enough to impede passenger evacuation. This paper describes the analysis of this problem for a sample rail tunnel. A ventilation concept that mitigates the problems of high cross passageway door opening forces and high velocities through open cross passageways is presented.

Jan 1, 2009

By Siyabonga Malevu

Chemical Initiatives? Umbogintwini plant is the production facility of Chemical Initiatives? business. Umbogintwini?s J Plant manufactures sulphuric acid. The plant was designed and built by Simon Carves, and was commissioned in 1974. The plant was designed to produce 500 tons/day of Sulphuric acid (H2SO4) at maximum rates. The Sulphuric acid manufacturing is through the famous contact process whereby liquid Sulphur is injected through dried air in a burner operating at 1000 °C to form sulphur dioxide (10.5% SO2). The SO2 gas is then cooled in waste heat boiler no. 1 before being fed to a four pass converter which provides 99.5% SO2 conversion to sulphur trioxide (SO3). The SO3 gas is the absorbed by 98.5% H2SO4 through the inter-pass & final tower to make more concentrated acid and dilute it with water back to 98.5% H2SO4 in acid pump tanks and dispatched to storage tanks. The manufactured Sulphuric acid is supplied to a variety of industrial manufacturing customers includes Pulp & Paper industry, Mining industry, Chemical manufacturing industry etc.

Jan 1, 2009

This paper presents a virtual prototype for the stress analysis of cable shovel components based on combination of flexible and rigid body approach. The general mechanical system of the cable shovel is modeled as a multi-body system with rigid and flexible bodies. The relevant theories applied for the dynamic model are described in terms of Lagrangian multi-body dynamics and finite element method. A virtual prototype of the cable shovel is built in the Automatic Dynamic Analysis Mechanical System (ADAMS) environment, which allows visualizing the motion of general mechanical system and analyzing the dynamic stress of structural components of the cable shovel. An example is given to perform dynamic stress of durability analysis for the boom and handle. Attention of this study is devoted to the mechanisms of damage of the cable shovel and also the critical high stress areas. Keywords: Cable shovel, Von Mises stress, Virtual prototype simulation, Stress virtualization.

Jan 1, 2009

By T. Payne

Underground heat issues are mainly focused on the detrimental effects to a workers health. However, working in hot, humid conditions has other negative effects. Studies have shown that safety, productivity, workforce morale and operating cost are also worsened in these conditions. The human body has several mechanisms for rejecting heat and remaining cool. However, once the air temperature exceeds about 34°C, the only effective mechanism is by evaporation of sweat from the skin. This is assisted by acclimatisation which is the human body?s enhanced ability to combat extended exposure to heat. The body has to remain well hydrated when working in heat as even small degrees of dehydration cause significant decreases in the ability to work in heat. There are two ways in which heat load can be reduced: Through use of refrigeration/vent/cooling to reduce thermal stress on workers; Reduce the contribution that heat sources have to underground heat load (e.g. reduce idle time, fleet size, etc). Some of the sources of underground heat have the potential to be more manageable than others. Geothermal heat and heat from autocompression will be found in all mining situations in varying degrees depending on geothermal gradient and surface temperature, however, the use of equipment and blasting may be streamlined to reduce the underground heat load. It is through a combination of the available options that most mines will successfully control their heat related problems. Mt Isa, which has been a focus for heat related study in Australia, has successfully implemented protocols for working in heat. Through combining these with the installation of a surface bulk air cooling plant, Mt Isa has consistently reduced the incidence of heat illness. This is likely to be the most cost effective method of reducing heat load for deep mines in Australia. Shallower mines which may only occasionally encounter hot conditions should consider more portable cooling options. This study will review the heat issues in underground Australian metalliferous mines.

Jan 1, 2009

By Anthony S. Spearing

The vast majority of the estimated 100 million rock anchors installed in mines in the USA per year use resin cartridges (Tadolini and Mazzoni, 2006). About 4.5 million per annum of these are bolts with a mechanical shell that if properly installed become effective active supports on installation. In addition, cable anchors (mostly passive) are installed with typically 4 ft of effective resin anchorage length sometimes with mechanical shells, which further makes the installation more difficult. This is because the cable (even with a stiffener tube) is not very rigid. When installing bolts with mechanical shells and cable bolts in the holes, the back-pressure can be so high that the installation is unsuccessful often creating a ?spinner? (an un-tensioned bolt) at best or buckling the bolt thus requiring another bolt/cable to be installed, or leaving a poorly functioning unit. The installation problems can create a significant potential safety hazard and waste time and money. Using a purpose designed test rig that physically inserts different rock anchors into pipes with resin and measure the back-pressure developed with time during the insertion/ installation. The test installation procedure is designed to mirror that used underground by rockbolt operators in coal mines. In addition a computer model has been calibrated that can predict the approximate back pressure of new anchor and resin combinations acting as a screen before physical testing. This research has lead to an understanding and quantification of the insertion back-pressures and this already resulted in improved prototype designs that could lead to more reliable mechanical shell and resin bolt installations.

Jan 1, 2009

By K. N. Karparov

The classical limit equilibrium methods are suspected to be ineffective in predicting the potential for highwall failure in many instances in coal mines around the world. Slope engineers have for many years recognized a block thrust failure mechanism for slope failures, but little work had been done before 2000 to explain the actual mechanisms which must be responsible for the failure. The main reason for this is that limit equilibrium methods implicitly assume rigid blocks, and the resulting force equations must be satisfied everywhere simultaneously for them to have any meaning. This paper will show that the material involved in the slope failure is not rigid; indeed it undergoes considerable permanent deformation during failure. This observation allows the authors to treat the block boundaries independently, because they need not maintain a constant spatial relationship with one another, as is assumed in other methods. To enable analysis of this type the authors assume that the weight of the blocks is evenly distributed. This is reasonable, because the slope material is not strong enough to be self-supporting without some sort of constraint, or strong enough to be able to apply point loads to the surrounding material. The purpose of this paper is to extend the practical application of the analytical method developed from mechanism studies to provide an objective assessment of the risk of slope failure, and therefore guidelines for more stable slope designs. This work is based on studies carried out on two failures in an open pit coal mine in South Africa, and provides a methodology to assess the potential for failure more objectively than is possible with currently accepted methods, while at the same time remaining sufficiently simple to allow a ?back of the cigarette box? assessment by geotechnical engineers on site.

Jan 1, 2009

By Sean Harvey

One of the manifestations of the dynamically induced failures in deep coal mines is the violent ejection of coal from the ribs. A possible protection against such failures is the use of a specifically designed dynamic support system with reinforcement units having the sufficient capacity to absorb the kinetic energy of the dynamic failure and a skin support that can adequately contain the disintegrated coal. With this method of mitigation in mind, a recently introduced yielding rock bolt, trade name Roofex, has been identified (Harvey and Ozbay, 2009) as a possible energy absorbing component of a dynamic support system. According to the manufacturer?s specification, the Roofex bolts can yield 300 mm (or more) displacement while holding 80 kN pull load. In order to assess the performance of this support unit in coal ribs, a series of in situ pull tests performed in two coal mines in Colorado. The results show that, under conventional pull test loading conditions, Roofex yielding bolts perform very close to their claimed specifications, thus showing a potential for their use as the main energy absorbing component of a dynamic support system. Further studies are required to confirm the in situ performance of these bolts under dynamic loading conditions and also to develop a containment component for a dynamic support system for the mitigation of dynamic coal rib failures.

Jan 1, 2009

By David Conover

The El Boleo Copper Project is currently in the final design stages for development of a 3-MM-tonne/yr underground copper mine located in Baja California, Mexico. The nearly horizontal mineralized zones are amenable to exploitation by conventional mechanized coal mining technology using continuous miners, shuttle cars, and belt haulage. The mine design resembles a typical full-extraction coal mining operation utilizing a sequence of mains, sub-mains and production panels. Due to numerous faults, mining will be conducted as several small adjacent mines accessed through adits from large arroyos cutting through the mine area. Up to four seams may be mined in some areas with a maximum overburden depth of about 250 m. The ore zone is relatively weak and plastic, subject to extensive creep over time. The mine workings will pass through areas of historical shortwall mining panels where the ground has flowed into old entries and gob areas, and then reconsolidated. A small test mine was developed to evaluate mechanical cutting performance, roof-bolt anchorage capacities, roof and pillar stability and caving behavior. In-mine measurements were combined with two- and three-dimensional FLAC models to evaluate alternative development and production pillar designs. The paper will discuss the various factors influencing ground stability at the El Boleo project and the strategies employed in developing a suitable ground control design.

Jan 1, 2009

This paper describes experimental investigations into the reductive decomposition of arsenopyrite/pyrite (FeAsS/FeS2), a gold and silver bearing iron/arsenic sulphide using metallic iron powder. The main objective was to establish and experimentally confirm the thermodynamic and kinetic feasibility of reductively decomposing the sulphide matrix for precious metals recovery. In this context, cyanidation leach tests were conducted on the reductive leach residues. The arsenopyrite/pyrite flotation concentrate, mainly studied in the hydrochloric acid medium, decomposed through the non?oxidative chemical dissolution reaction and the reductive decomposition reaction for the arsenopyrite and pyrite components, respectively. Desulphurization levels below 65% were achieved at pH values below 0.15 and iron to concentrate ratios above 1, and the system was characterized by overall very slow kinetics. The reaction system had a direct linear relationship with iron to concentrate ratio and an inverse relationship with pH. An analysis of the pyrite/iron galvanic system showed that pyrite forms a partially inert cathodic surface on which the anodic dissolution of iron occurs, supported by the hydrogen evolution reaction. This phenomenon explained the low desulphurization levels and the mineral decomposition seemed to be restricted to the non?oxidative chemical dissolution reaction for the arsenopyrite component. The cyanide leach of the reductive leach residues showed very little improvement in gold recovery. The reductive leach process for arsenopyrite/pyrite has considerable limitations in terms of both desulphurization and precious metals liberation. Keywords: Pyrite, arsenopyrite reductive leaching, hydrogen sulphide, invisible gold

Jan 1, 2009