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By Sano S, Ishikawa T, Nagaoka H, Hayashi Y, Hasegawa M

The stirred mill is regarded as one of the most efficient devices for micronising materials and has come to be actively used for preparation of fine particles. Recently, the demand for ultrafine particles was increased in many kinds of industries. In this paper, autogenous grinding to get submicron particles based on mutual friction feed material has been carried out using a stirred mill. The mill used was made of stainless steel and its volume was about 5.5 litres, and has 12 impeller blades. Sample used was limestone. In the present work, two operating parameters such as stirring speed and feed size of limestone were considered. The ground products were sieved in the size range from feed size to 325 mesh (45 lun), and from 45 to 0.17 pm the size distributions were measured by a laser diffraction and scattering method. The progress of grinding was evaluated by the increasing amount of submicron particles in products. As a result, the rotational speed of impeller with the minimum energy consumption to produce submicron particles was observed. It was found that the autogenous grinding with a stirred mill is an effective method for producing submicronized limestone.

Jan 1, 1993

The Energy Authority of NSW has wide powers and responsibilities conferred by its Act which are pertinent to the State's coal industry and its development into the next century. With respect to coal, the broad objective is to maximise the benefits to NSW and its people derived from the State's coal resources. The initial focus of the Authority's coal-related activities in the late 70's and early 80's was on petroleum substitutes from coal. Research was supported, especially on hydrogenation, and the Authority participated in the Joint Australia/Federal Republic of Germany coal-to-oil feasibility study. It also co-ordinated a State Government initiative to involve the private sector in examining the possible establishment of a synthetic fuels industry based on Hunter Valley coal. With a short-fall in world-wide petroleum supply now seen as less likely for some years, the Authority is looking also at ways of working towards the broad objective in the field of coal utilisation on both domestic and export markets. Areas of interest include possibilities for using washery rejects, means of making NSW coal more competitive as an energy source, use of coal-seam gas and new or special technologies for burning coal. The future is expected to see renewed interest in producing petroleum substitutes, and coal - as the State's major energy resource - is seen as a strong contender as a basis for such an industry. Developments in coal-based power generation are also expected to have an impact, with advanced technologies having a possible place here as well as Overseas.

Jan 1, 1987

By D R. Venkatesulu, N K. Nanda

Due to increased production of steel in India, the thrust is now on iron ore producers not only to enhance productivity from existing mines, but to look also into alternative resources, like lean grade iron ores such as banded haematite quartz (BHQ)/banded haematite jasper (BHJ), which are available in abundance but not yet utilised for want of suitable process technology. In this context, BHJ ore from the Bellary-Hospet sector was collected and subjected to detailed physical, chemical and mineralogical characterisation and beneficiation studies. The as-received sample was found to occur physically as alternating layers of haematite and jasper. The chemical analysis of the sample was 41.20 per cent Fe, 39.10 per cent SiO2 and 0.86 per cent Al2O3. Based on the mineralogical observation, haematite was found to be the lone ore mineral and jasper was the major gangue mineral. The microscopic observations revealed that the ore minerals liberate at a top size of 0.150 mm. Guided by the characterisation results, indicative tests were conducted using gravity and magnetic separation equipment, namely, Floatex«, gravity slime table and wet high intensity magnetic separator (WHIMS). The results indicate that it is possible to upgrade the sample by both gravity and magnetic separation techniques. However, the WHIMS results indicate that jasper grains report to the concentrate at higher gauss intensities. Therefore, based on the encouraging gravity separation results and the availability of new design spirals for treating fine particles, the applicability of gravity spirals for beneficiating BHJ in the liberation size range of -0.150 mm was studied. The sample was ground to a top size of 0.150 mm and was subjected to preconcentration using wash waterless spirals. Tests were conducted at different feed rates, pulp densities and splitter positions. The results indicate that it is possible to upgrade the sample from a feed grade of 41.20 per cent Fe to a preconcentrate ranging from 46 per cent to 62 per cent Fe with a yield ranging from 19 per cent to 55 per cent. The obtained preconcentrate was then subjected to a cleaning stage by using a combination of wash water and wash waterless spirals. The test results indicate that it is possible to obtain a final concentrate assaying 65.75 per cent Fe and 4.75 per cent SiO2 with a yield of 25.9 per cent and an iron recovery of 41.31 per cent. It was concluded that further test work is necessary to increase the recovery and improve the product specification.

Jan 1, 2009

By I T. Cameron

The commercial production of copper metal involves a sequence of purification stages. One step of this process eliminates bulk quantities of iron and sulphur from matte Cu2S(FeS to produce blister containing 95.5 per cent copper. This task is traditionally performed in the Pierce-Smith converter, a cylindrical vessel in widespread use throughout the copper industry. Typically, multiple Pierce-Smith converters are arranged along an aisle, simplifying material transfer from vessel to vessel. Materials are moved through the aisle in pots and boats, using overhead cranes. In terms of the overall process, the converter aisle represents a critical processing unitùit contributes significantly to the value added nature of the metal. The aisle is subject to significant process disturbances. Thus, improvements in the operationÆs modes and conditions have a direct impact on process profitability. As with any commercial operation, improvements are always sought to increase process performance. The general approach involves process modelling, followed by an application of control and optimisation theory to this model. The results of such a study are then applied to the real process, leading to improved performance.

Jan 1, 1998

By A Tolley

Bauxite residue or ‘red mud’ is a by-product of the Bayer Process, the primary process of alumina refining. Due to its high alkalinity and variable composition, its storage and disposal poses high environmental risks to water sources, surrounding ecosystems and human health. The high alkalinity (pH 12–13) is a significant factor in its classification as hazardous waste; to mitigate this, Australian refineries have integrated neutralisation processes into bauxite refining. Both sea water and carbon dioxide neutralisation processes are applicable. Multiple studies have demonstrated pH reduction from 12–13 to 7–10, depending on the method. The key advantages of CO2 neutralisation are that it allows for carbon sequestration and is more effective when utilised as a pre-treatment for recovery of metals, while sea water neutralisation is more established and has been integrated into two Australian refineries. This paper proposes the application of the bacteria Exiguobacterium oxidotolerans for bioleaching of iron from hematite in bauxite residue. The genus Exiguobacterium is characterised by its high levels of adaptability, halotolerance and alkaliphilic nature. E. oxidotolerans is successful at eluting Fe2+ from hematite via reductive dissolution, which complexes with oxalic acid produced during metabolism. This aquatic bacterium presents a novel process pathway for iron elution due to direct interaction of E. oxidotolerans with hematite via the cell membrane and operates within the pH range of neutralised red mud. The proposed mechanism is extracellular electron transfer, a microbial metabolic process where electron transfer is facilitated between bacterial cells and extracellular material. Currently this is being investigated for promotion of seaweed growth in coastal environments as soluble iron aids and fortifies colonies. This has potential downstream applications for cleaner iron and steel production. While theoretical, this paper explores the neutralisation, bioleaching and application of the Fe(II)- and Fe(III)-oxalate complexes formed.

Sep 18, 2023

By A Jyoti, J R. Black, R R. Haese, E O. Ansah

Copper (Cu) is a critical metal in the transition to a low-carbon power supply. Presently, low-grade copper sulfide ores account for almost 80 per cent of the global reserves. Large amounts of water are required to process these low-grade copper ores. The mining industry utilises lixiviants from recycled water from different sources to conserve water, whilst enhancing Cu recovery. Some utilise intermediate to pregnant leach solutions, sea water, and processed water from electrowinning circuits with highly variable concentrations of ions. Previous studies have highlighted the formation of precipitates that passivate the surfaces of minerals in these low-grade copper ores and/or block flow paths for lixiviant during heap leaching. In this study, we utilised concepts of phase replacement to devise an innovative means of controlling precipitation and increasing copper recovery using industrial brine as opposed to freshwater. We propose the formation of Al-rich phases (such as AlSO4 + or alunite) to replace iron sulfate and iron hydroxysulfates (such as jarosite) during the chalcopyrite dissolution-precipitation mechanism. The rationale is to have available Fe3+ throughout the chalcopyrite leaching process. We tested this method by carrying out various batch experiments using CaCl2, AlCl3, and NaCl industrial brine types compared to freshwater and explored the capacity to leach Cu from chalcopyrite. There is higher Cu recovery during oxidative leaching of chalcopyrite in industrial brine with 91 per cent recovery using AlCl3-rich brine, 84 per cent with NaCl-rich brine, and 56 per cent with CaCl2-rich brine as compared to 35 per cent recovery using freshwater. In the absence of Al3+, various forms of iron sulfates, and jarosite are formed, reducing the availability of Fe3+ for chalcopyrite dissolution. The introduction of Al3+ leads to the formation of AlSO4 + species, thus lowering sulfate activity and the tendency for K-jarosite formation.

Aug 24, 2022

By G Brooks

The control of phosphorus in steelmaking is one of the famous challenges of pyrometallurgy. It is well established that highly basic slags, the presence of FeO in the slag and lower temperatures (less than 1650°C) are favourable for phosphorous removal. The thermodynamics of this reaction have been extensively studied under laboratory conditions and the general trends confirmed through industrial trials. However, in general, phosphorus slag/metal distributions measured in industry are far from equilibrium and quite specific to the oxygen steelmaking technology being used. This variability was quantified by Urban, Weinberg and Cappel (2015), who found that the phosphorus partition ratio measured in plants varied with blowing practice, stirring intensity and even converter life. Some recent kinetic studies by Gu, Dogan and Coley (2017) have shown how the kinetics of these reactions vary with FeO content and dissolved sulfur at the droplet scale. A global kinetic model by Rout et al (2018) provides meaningful predictions of where dephosphorisation occurs in an industrial basic oxygen furnace (BOF) and some recent heat transfer modelling by Madhavan et al (2021, 2022) implies that temperature difference between droplets and slag has a role to play in explaining why equilibrium is not achieved. This paper will review the current state of knowledge and provide suggestions on predicting phosphorous removal for industrial operations and how greater removal could be achieved.

Jun 19, 2024

The considerations which led to the decision to_ install discs at the Dampier Pellet Plant of Hamer ley Iron Pty. Ltd. are described. Initial testwork showed that the ore could be ground dry in open circuit to a Blaine index of 2500 cm2/g and that it pelletized readily. The various design criteria including diameter, slope, speed, motor size, depth of sidewall, feed point and water spray location were then determined. Plant performance after commissioning is described including the various problems encountered and the modifications since carried out to overcome them. The main problem was quickly identified as disc feed rate control. Various bin and bin feeder modifications were tried to overcome the effects of the fluidising characteristics of the dry ground ore. Other factors found to affect disc operation are ore size distribution, additives and operator competence.

Jan 1, 1974

By D Bradshaw, E Forbes, M Edraki, M Tayebi-Khorami, E Manlapig

There is an increasing trend in the extraction and development of copper resources from complex deposits. These deposits pose mineral processing challenges, as they often contain low grade disseminated copper ore with high levels of impurities particularly arsenic. Although arsenic is a naturally occurring element, the concentrations of arsenic can be magnified by mining and mineral processing activities. Therefore, while arsenic has no significant market value, its presence in the ore deposit will have production, environmental and human health implications. The mining industry’s approach to life-of-mine planning has improved significantly in recent decades and managing arsenic is not an exception.CITATION:Tayebi-Khorami, M, Edraki, M, Manlapig, E, Forbes, E and Bradshaw, D, 2018. Arsenic pathways in copper mining – sustainability issues and potential solutions, in Proceedings Life-of-Mine 2018, pp 60–63 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

By A Golev, G Corder

The concept of the circular economy has been gaining traction both in Europe and China.In Europe the Ellen Macarthur Foundation see their mission as accelerating the transition from a linear take-make-dispose economic model to a circular model that is restorative and regenerative by design, and aims to keep products, components and materials at their highest utility and value at all times. The Chinese Circular Economy initiative is effectively a sustainable consumption and production program utilising cleaner production, industrial ecology and life cycle management approaches to meet the national challenges of maintaining rapid economic growth while simultaneously enhancing environmental quality and maintaining social progress. A key characteristic of both of these circular economy initiatives is to design out, reuse or minimise the generation of waste.The mining sector, by definition, is represented by linear rather than circular activities, by supplying resources to society. However, being one of the world’s largest waste generators, the sector can adopt similar logic to that of the circular economy to improve its sustainability performance. Waste is a critical issue along the whole metals value chain, from mining waste to eventual end-of-life products, such as scrap steel from construction and demolition waste or the growing problem of electronic waste.CITATION:Corder, G and Golev, A, 2016. Can mining be part of the circular economy or is it squaring the circle?, in Proceedings Life-of-Mine 2016 Conference , pp 121–123 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016

By D Reid

The engineering properties of soils and tailings often exhibit significant anisotropy. One area where this has been well documents is undrained shear strength. Materials sheared in directions close to the principal stress direction in situ, i.e. triaxial compression, typically exhibit higher undrained strengths than those sheared in other directions such as simple shear. Importantly, along the most common critical failure surfaces relevant to tailings stability, whether primarily through tailings or a critical foundation layer, saturated materials are generally much closer to the simple shear loading direction than triaxial compression. Therefore, testing undrained shear strength of tailings or foundation soils in triaxial compression is likely to result in overestimation of the relevant strengths for design. Although these issues have repeatedly documented in the geotechnical literature for over three decades, they are not appreciated sufficiently across our industry. In an attempt to address and highlight these issues, a review is carried out of historical reference to the importance of simple shear loading. Attention is then drawn to the techniques applied in three recent post-failure investigations, where simple shear testing was applied. Finally, some relevant laboratory test results from a recent project in which the author was involved are outlined.CITATION:Reid, D, 2018. Importance of the simple shear loading direction to the stability of tailings storage facilities, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 274–284 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By D J. Gray

The 4 km long Huguenot Toll Tunnel in the Western Cape region of South Africa celebrated its tenth anniversary on 18 March 1998. At present a single (South) bore with bi-directional traffic flow is operational. The North bore was originally excavated but not lined and equipped.The tunnel is fitted with a semi-transverse ventilation system comprising 45/350 kW two speed fresh-air and 1 MW exhaust air fans at each of the portals. These provide ventilation through fresh and exhaust air ducts above the ceiling separated by movable partition doors. Secondary air ducts deliver air at low level. The fan control depends on the levels of CO pollution or visibility measured at six positions along the tunnel.The system performed well during initial tests and under conditions of low traffic volumes. As traffic volumes increased, and user complaints of bad air in the tunnel were received on several occasions, we realised that we had a problem. Tests confirmed that natural airflow within the tunnel induced by prevailing meteorological conditions outside the portals affected the performance of the ventilation system causing a plug of bad air to be trapped at varying positions along the operating tunnel.The control systems in the tunnel are presently being upgraded as described by Gray, Rieckert and Bullock (1998). As part of the retrofit we are implementing a new control strategy for the ventilation system which takes into account the external weather conditions. This paper discusses the 24 month long meteorological data gathering exercise, which is on-going, and explores the philosophies planned for controlling the ventilation system. The correlation between winds external to the tunnel and induced airflow inside the tunnel are examined. The effects of the weather induced airflow on the existing ventilation system are considered and proposals given for taking these effects into account in the new control strategy. These include the implementation of an expert system to predict ambient airflow from prevailing weather conditions, and the use of airflow measurements taken in the uncompleted North bore as a cross-check.The paper highlights the need to take cognisance of external weather conditions when designing tunnel ventilation systems.

Jan 1, 1999

By A Nigam, K Biswas, R Sarkar

Because of the problems with 1st and 2nd generations of Advanced High-Strength Steels (AHSS), a 3rd generation of AHSS steels has become prominent and these steels have properties in between the 1st and 2nd generations of AHSS. However, although the 3rd generation of AHSS is a promising candidate as a replacement for its predecessors, there remain some challenges in processing these steels which are essentially medium Mn (Mn content ~ 5–7 wt per cent) and high Al (Al content ~ 1– 3 wt per cent) steels. The use of conventional casting powders based on the CaO-SiO2 system is unsuitable for high and medium Mn/Al steels. This work investigates the development of CaO-Al2O3- based mold fluxes for casting third-generation AHSS steel. Mold fluxes, with otherwise similar compositions but different C/A ratios, are tested and their crystallisation behaviour is examined using differential scanning calorimetry (DSC). A calcium aluminate phase having a composition Ca12Al14O33 was found to be the main crystalline phase in the mold fluxes. A decrease in crystallisation temperature was observed as the CaO/Al2O3 ratio increased from 1.00 to 1.33. The effective crystallisation rate constant exhibited an increase with decreasing crystallisation temperature, indicating a potential influence of nucleation rate on the overall crystallisation rate and suggesting an anti-Arrhenius behaviour in the crystallisation process of these mold fluxes.

Aug 21, 2024

By C A. Cooper, G A. Suter

The sizing of a starter dam for a Tailings Storage Facility (TSF) involves balancing many competing demands. It should cost as little as possible, be high enough to store tailings until the first raise can be constructed, it must be able to contain water safely, and it must be designed in such a way that the long-term integrity of the higher raises are not compromised, among other things. In addition to these demands there is the complication of the behaviour of the process plant, and the tailings during commissioning. Variations in slurry density, excess water in the TSF, initial settled density of the tailings, reliability issues, and beach slopes above and below water can all impact the way the tailings beaches are developed and ultimately impact the ability of the starter dyke to contain the required volume of tailings and water.The conventional approach to the design of a TSF starter dyke is to begin looking at the elevation required for a set of deterministic design parameters, find ways to reduce the size or volume of it as much as possible to reduce cost, and then possibly look at the sensitivity of some of the input parameters. This paper discusses a stochastic modelling approach for starter dykes that allows a wide range of design inputs to be simulated quickly, with an envelope of possible results produced. The sensitivity to different parameters can also be examined to understand which design inputs have the biggest impact on the required dyke sizing. By integrating the 3D TSF modelling tool Muk3D with GoldSim, it will be demonstrated how a wide range of scenarios can be evaluated and how that information can be used to make better decisions about the selection of design options.CITATION:Cooper, C A and Suter, G A, 2018. Starter dyke optimisation with Muk3D and GoldSim, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 466–475 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

Many types of micro-organisms inhabit iron ore deposits contributing to biogenic formation and conversion of iron oxides and associated minerals. Bacteria such as Paenibacillus polymyxa are capable of significantly altering the surface chemical behaviour of iron ore minerals such as haematite, alumina, calcite and silica. Differing mineral surface affinities of bacterial cells and metabolic products such as proteins and polysaccharides can be utilised to induce their flotation or flocculation. Mineral-specific bioreagents such as proteins are generated when bacteria are grown in the presence of haematite, alumina, calcite and silica. Alumina-grown bacterial cells and proteins separated from such cells were found to be capable of separating alumina from haematite. Biodegradation of iron ore flotation collectors such as amines and oleates can be effectively utilised to achieve environmental control in iron ore processing mills.

Jan 1, 2009

By D W. Nisbet

Today Hudson Bay Mining and SmeltingÆs 777 Project is the largest mining construction project under way in Canada. The project comprises six components: construction of the new 777 zinc-copper mine; construction of the new Chisel North zinc mine that will truck ore out from 600 metres below surface; expansion of the Flin Flon ore concentrator; expansion of the zinc plant to increase throughput by 15 per cent; a spill gas project that will reduce fugitive gas emissions by some 90 per cent; and infrastructure improvements including construction of a new electrical substation. Total investment in The 777 Project is over $US 260 million. Seven years ago, the Flin Flon, Manitoba-based company was fighting for its very existence. How does a company go from down-for-the-count to robust contender in just seven years? Contributing reasons are many, but all have their root in a process HBMS calls æTransformationÆ. It is transformation that has taken HBMS, a very traditional company, through a very non-traditional turnaround (Figure 1).

Jan 1, 2000

By Drury SA, Williams RD, Nind DC

The Airborne Thematic Mapper is an eleven channel digital scanner which acquires image data in the visible, near infra-red, short wave infra-red and thermal infra-red wave- lengths. A description of the system is presented which includes details of the operating wavelengths and performance parameters of the scanner. Consideration is also given to the aircraft installation requirements. During January 1984 the scanner surveyed the mineral rich areas of Leonora, Laverton and Kalgoorlie in Western Australia. This is a region of intense exploration activity for gold and base metals. Some 30,000 square kilometres were systematically surveyed in a period of ten days. This scanner was flown at 7,000 metres altitude giving a ground pixel size of 17.5 by 17.5 metres. The flight line spacing was 8 kilometres. The overall project took some thirty days from conception to completion. The planning and execution of this operation are described in detail. The resulting magnetic tapes provided 11 channels of digital image data over a 30,000 square kilometre area and a variety of image processing techniques were employed in order to capitalise fully on the results. The imagery provides a powerful tool for the geological mapping of the terrain. The data can also be used to monitor the environmental effects of mining operations.

Jan 1, 1986

By N Madani, Y Abildin, E Topal

Mine planning is a crucial part of all mining industry projects, and nowadays, geometallurgical mapping through advanced computer technologies provides an opportunity to involve metallurgical responses of a deposit into 3D block model in order to optimise mine planning activities, especially for production forecasting. Including these metallurgical parameters apart from traditional geology and grade-based attributes into resource modelling leads to an extensive approximation for the economic maximisation of mine production due to better forecasting, planning and increasing certainty and the reliability of the resource model (Macfarlane and Williams, 2014). Commonly, geostatistical techniques and algorithms are used to produce models with the high resolution (Brissette et al. 2014; Deutsch et al. 2014; Tolosana-Delgado et al. 2015). The accuracy of the modelling procedure deeply depends on a reliable block model, produced by spatial analysis of corresponding variables that define the geological, metallurgical, mineralogical and chemical behaviour of the deposit. However, there are special cases, where the application of enhanced geostatistical methods is required, to solve the occurred difficulties between variables with multivariate complexities. For example, in oxide copper deposits, the soluble copper grade is a percentage of total copper grade and recoverable by heap leaching processes (Emery, 2012; Hosseini and Asghari, 2015). Hence, the joint spatial modelling of these variables has two difficulties.CITATION:Abildin, Y, Madani, N and Topal, E, 2018. Forecast the mineral processing destinations based on spatial interpolation of geometallurgical variables, in Proceedings Complex Orebodies Conference 2018, pp 2–5 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

By E A. Agorhom, M Beyuo, C Owusu, I Quaicoe

Understanding the mineralogy and liberation of gold particles in an ore is key to the development and optimisation of gold processing operations, being cyanidation or gravity separation. This can be achieved through basic historic geological information, gold deportment studies, chemical speciation and metallurgical test works. The present study assessed the nature of the occurrence of gold particles (mineralogical composition, liberation, associations and surface chemistry) and its effect on the process route (cyanidation and gravity separation) of a typical paleo placer gold ore deposit within the Tarkwaian Rock system. The investigative approach used involved chemical assay, quantitative X-ray diffraction (QXRD) and quantitative evaluation of minerals using scanning electron microscopy (QEMSCAN). The ore samples (A, B, C, D, E, F) used were obtained from six active pits of a gold mine working on this orebody. The results of the mineralogical analysis revealed that the ore is highly oxidised and comprised quartz (>80 per cent) and Muscovite mica (>6 per cent) as the major mineral phases in all the samples. Trace amounts of hematite, kaolinite and todorokite were also identified in all the samples. The chemical analysis showed presence of gold (Au) in all the samples with samples B (3.62 g/t) and C (3.96 g/t) containing the highest concentrations. Trace amounts of copper (Cu), iron (Fe), sulfur (S), aluminium (Al), arsenic (As) were also detected in all the ores. The QEMSCAN mineralogical liberation and gold association results revealed that the gold grains were relatively coarser in all samples (P80 > 80 µm Au in size) except F (P80 < 32 µm Au in size). Gold grains were highly liberated especially in sample B with the majority of the locked gold grains forming complex associations. All the samples responded well to cyanidation and gravity separation except samples C and F, respectively.

Aug 24, 2022

By R Justa Cámara, J María Bertrán Llop

"The need for suitable geotechnical characterisation of the rock mass for underground construction is evident. The enlargement project of Railways of the Generalitat of Catalunya (FGC) in Sabadell is a patent example.In general, it is uncommon to encounter problems in the identification and characterisation of certain relevant weak rock formations, which affect project designs. However, all materials should be properly studied, as mischaracterisation can lead to a suboptimal design, resulting in construction problems during the course of the work.Good quality rock is generally not difficult to characterise, but this is not the case for Quaternary or Tertiary cemented soils. Geotechnical investigations based on boreholes do not provide enough information because samples are often badly damaged during the drilling process, if appropriate techniques are not taken. The samples can be altered and may not be representative of the in situ?material.The design and construction of the extension to the FGC line in Sabadell highlighted the importance of the characterisation of Quaternary and Tertiary cemented soils, in particular their rigidity and its underestimation. The twin tunnel project had a total length of 5.1 km, including five stations with 3.5 km excavated by tunnel boring machine (TBM). The remaining 1.6 km was constructed using cut and cover methods. The TBM portion of the tunnel had a bored diameter of 6.83 m with an internal radius of 3 m and 0.25 m thick precast concrete segments. Much of the tunnel alignment passed through and was affected by the presence of certain stiff layers of Quaternary cohesive materials.In this paper the TBM challenges faced will be discussed in detail. In particular:&nbsp; TBM excavation rate reductions and overheating problems due to the required excessive thrust and torque floating problems in the lining due to nil earth pressure over the rings and the development of an improved, controlled setting time mortar to address this issue block-in and block-out methodology for each station, in some cases with internal blocks to prevent earth pressure drops and soil scouring the relevance of performing simpler solutions, for example, hyperbaric interventions to examine the cutter wheel tools when it has been shown that interventions under atmospheric conditions were equally feasible the implementation of conventional bivalve machines as standard procedure for excavation of diaphragm walls in stations, where in fact, hydrocutter machines or pile boring machines may have been required, given the mechanical characteristics of the materials to be dug out.CITATION:Justa Cámara, R and María Bertrán Llop, J, 2014. Underground extension of the FGC line in Sabadell through cemented soils, in Proceedings 15th Australasian Tunnelling Conference 2014, pp 161–170 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Sep 17, 2014