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Traditionally, production volume has been considered the major determinant of cost. As volume increases, total cost increases but unit cost decreases. This concept has been so widespread in industry that many of the tools used to analyze costs are based on production volume as the sole measure of activity and driver of unit cost-fixed and variable costs, cost-volume-price and breakeven analysis, contribution margin, flexible budgets, and others. Clearly, volume is a driver of cost. It is important in both a tactical sense (to the manager at an operating mine) and a strategic sense (as one determinant to the firm's overall cost position). However, many other factors influence costs as well, even though they have not been studied to the same extent. For example, production managers know that their costs will be reduced if the workforce does not have accidents. Safety costs are to a large extent independent of volume. Other cost components increase as volume increases, such as some environmental charges. Some costs may or may not reflect volume changes. Maintenance, for example, may appear as either a fixed or variable cost, as can operating labor in facilities that are highly automated. In the strategic sense, where the firm is selecting a strategy to pursue competitive advantage and increased profitability, all costs are variable. This reflects both the strategic intent and the long-term time frame associated with strategic positioning. Tactically, on a month-by-month basis, some costs are essentially fixed. Cost driver analysis must therefore consider the relevant time frame.

Jan 1, 1999

By Derek. C. Arnold

In order to meet increasing demands for water supply in the next millennium, the Government of the Hong Kong Special Administrative Region have identified the need for a major new water treatment and transfer scheme. The project now under construction will comprise a 1.2 km long raw water aqueduct, a major new 0.25million cubic metres per day water treatment works (with space for upgrading to 1.2Mm³/d), a 12.1 km long treated water aqueduct and a primary service reservoir. In order to meet increasing demands for water supply in the next millennium, the Government of the Hong Kong Special Administrative Region have identified the need for a major new water treatment and transfer scheme. The project now under construction will comprise a 1.2 km long raw water aqueduct, a major new 0.25million cubic metres per day water treatment works (with space for upgrading to 1.2Mm³/d), a 12.1 km long treated water aqueduct and a primary service reservoir.

Jan 1, 1999

By Curt Swanson, David C. Mathy, Dru R. Nielson, Kent VonAspern

In 1997, Central Contra Costa Sanitary District undertook the design of the Martinez East Side Trunk Sewer Improvements Project. Microtunneling was specified for approximately 1,035 meters (3,400 feet) of 600-mm (24-inch)diameter pipeline to be installed through estuarine soil deposits (San Francisco Bay Mud) and alluvium beneath the congested city streets of downtown Martinez, California. Directional drilling was specified for approximately 275 meters (900feet) of 200-mm (8-inch) diameter pipeline in four separate segments to be drilled through bedrock within narrow utility easements between residential properties. This paper presents a case history for the design and construction of themicrotunneling and directional drilling aspects of the project.

Jan 1, 1999

By M. J. Laurila

Elemental analysis of slurry streams using X-ray fluorescence (XRF) has long been employed. However, detector technology has limited the application of XRF devices. Using detector technology employed on NASA's Mars Pathfinder to analyze soil samples, Process Control, Inc. has developed an on-line analyzer to mount on a sampling system. The prototype XRF elemental analyzer was installed at Detroit Edison's Monroe Power Plant in January, 1998 and has been employed to monitor feedstock quality. A slurry system has been developed for flotation control. This paper describes the testing of the analyzer using the new, draft ISO standard for evaluating the performance of on-line analyzers (ISO/DIS 15239).

Jan 1, 1999

By J. J. Whittaker

Zaldivar is an open pit copper mine operation located in the Atacama Desert, in northern Chile. The plant produces Cu cathodes using 4 solvent extraction trains. The plant was started up May 1995. Since 1996 the plant has been using on-stream analyzers based on X-ray fluorescence and titration for process monitoring and control. Elemental analyzer alone is not able to provide the critical information for plant operation, it has to be complemented by on-stream titrators integrated to one sampling system. The analyzers are located in a prefabricated shelter. The analyzer system project, operation and performance issues are the main topic of this paper.

Jan 1, 1999

By Gao Zhizhong, Zheng Shibo, Gu Zhengxing

Extensive research on the beneficiation of Florida dolomitic phosphate pebble has been carried out by Lianyungang Design and Research Institute of China (CLDRI) in recent years. Test results indicate that the fine-particle flotation process could be used to effectively recover the phosphate values from Florida high-dolomite phosphate resources. With the CLDRI fine-particle flotation technology, a phosphate concentrate with 31% P2O5 and less than 1% MgO could be obtained from a flotation feed containing 25.8% P2O2 and 2.2% MgO at an overall P2O5 recovery of up to 85%.

Jan 1, 1999

By S. Michael Feroz, Paul Gribbon, Jan Rosholt

Approximately six billion gallons of combined sewage are discharged annually into Willamette River and Columbia Slough through Portland’s combined sewer system. The Columbia Slough Consolidation Conduit (CSCC) is an important element of mandated Combined Sewer Overflow (CSO) abatement. It includes2,548m (8,361 ft.) of 3.7 m. (12 ft.) internal diameter tunnel. The CSCC alignment traverses the UP railroad, Columbia Boulevard and parallels an old sewer. Geologic conditions include river alluvium and fine to coarse-grained flood deposits containing cobbles and boulders. This paper describes design and construction of a tunnel in soft-ground, with shallow cover and close to an old concrete sewer.

Jan 1, 1999

By David R. Baughman, John C. Gathje, K. C. Oberg, Gary L. Simmons

Santa Fe Pacific Gold Corp. conducted pressure-oxidation pilot plant studies on refractory carbonaceous gold ores from the Twin Creeks Mine in Nevada. The tests were conducted at Hazen Research Inc., Golden, CO, during 1993 and 1994. Laboratory investigations using CIL cyanidation after batch pressure oxidation demonstrated gold recoveries of 90% to 95%. However, pilot plant testing showed that several of the same ore types responded very poorly, with gold extractions of only 45% to 75%. Plant testing was suspended for approximately four months while extensive research was conducted to determine why these ores responded poorly and to identify potential solutions. This paper describes the batch and pilot plant test results, the extensive research activities that eventually identified the cause of the gold recovery problem and the final semicontinuous and continuous pilot plant operations that confirmed possible solutions. Final pilot plant results showed gold recoveries that were consistently greater than 90%.

Jan 1, 1999

By Charles Schmidt

Phalabonva (Figure 1) is situated in the northern province of South Africa adjacent to Kruger National Park, about 500 km from Johannesburg. The nearest South African port to Phalaborwa is Richards Bay about 700 km distant by rail.

Jan 1, 1999

By Pieter Berendsen

Lamproite occurs in two locations in southeastern Kansas that are in close proximity to each other. In both locations, the lamproite is restricted to north- east-elongated, ellipsoidal depressions measuring about 3 mi by 1.5 mi. At the surface and in the shallow subsurface, lamproite occurs as sills that were intruded into Middle and Upper Pennsylvanian rocks consisting of shale, limestone, and minor sandstone. Isotopic age determinations by Zartman and others (1967) indicate that the lamproite was intruded during the Late Cretaceous (88-91 my). Drillholes for hydrocarbon exploration down to a depth of about 1,400 ft (top of the Mississippian) and numerous shallow drillholes (mostly 200-300 ft) by the Kansas Geological Survey in the northern portion of Silver City dome helped to understand the structural complexity and extent of the near-surface sills. Numerous radial faults showing small apparent vertical offsets limit the lateral continuation of individual sills. Concentric faults are believed to mark the edge of the depression. Wagner (1954) mapped the geology of Silver City dome in considerable detail and recognized a northward dipping, 120-ft-thick, lamproite sill exposed at the surface along the northeastern edge of the dome. The upper 40-50 ft of the sill weathers olive-brown and has a soft, clayey consistency in which only the phlogopite mica is recognizable. The weathered material has been mined by Micro-Lite LLC since 1982 from the exposed sill in an open-pit that measures about half a mile extending in an east- west direction. The bulk of the material, about 98%, is used as an additive in mineral supplements for cattle feed.

Jan 1, 1999

By R. Q. Honaker

Although the fundamental principles of hindered bed classifiers are relatively simple, the complex interactions between the operating parameters provide a degree of difficulty that hinders the ability for on-line plant optimization. Thus, a dynamic population balance model was developed for determining the hindered settling velocity of particles varying in density and size. The steady-state results of the model include partition curves as a function of particle size and density as well as metallurgical data. A statistical comparison of the simulation results with those obtained from industrial units reveal a high level of accuracy with adjusted R2 values greater than 0.95.

Jan 1, 1999

By Arafat Ghosheh, Yousuf Abu-Rish, Darwish Amara, Mohammed Baderkhan

The Jordan Phosphate Mines Company is one of the world's major phosphate rock and phosphatic fertilizers producers (the second largest phosphate rock exporter), with ore reserves exceeding 2 billion tonnes, mainly located in the Eshidiya area. The Eshidiya phosphate deposits, 120 km north-east of Aqaba, are of sedimentary origin (as are all phosphate ore in Jordan). Three exploitable beds (Al, A2, and A3) with variable content of P205, CaO, SiO2, etc., are processed in order to produce 68-70,73-75, and 75-77% TCP grades. The A3 bed, which is characterized as the most siliceous containing 40-48% TCP, requires physical beneficiation using wet scrubbing, screening, and desliming by hydrocylone, followed by anionic conventional flotation to achieve 75- 77% TCP grade. For the last 15 years extensive laboratory and pilot tests (including physical, chemical, and mineralogical studies) were carried out. After operating the industrial plant, certain modifications were deemed necessary to adjust the operational parameters and the final flowsheet, which was followed to obtain the targeted quantity and quality of concentrate.

Jan 1, 1999

By Nelson R. Shaffer

Secondary minerals, amorphous materials, and biologic entities that form on building stone can cause aesthetically unflattering changes in color and may even result in stone decay. Techniques to determine causes of such changes generally have entailed destructive sampling and often required chemical, thin section, X-ray, or other relatively slow, expensive measurements. We have found that a rapid leach of in-place stone using small volumes (50-100 ml) of very pure distilled, deionized water provides recovery of sufficient dissolved material to help diagnose stone anomalies. Water is sprayed onto the stone and collected in a nonwetting plastic pan. Ion chromatograph analysis of waters thus collected from more than 160 sites showed wide variations in concentration of anions F, Cl, NO3, and SO4. Anion analyses were made in minutes for less than $20 per sample. Cations Ca, Mg, Fe, and Sr also were detected, and analyses might be used to determine mineral sources using equilibrium computer models. Solid particles filtered from the samples can be examined microscopically to provide further information about atmospheric agents affecting the stone. The collected water can even be evaporated to precipitate dissolved minerals. Chloride values in samples rinsed from stone ran as high as up to 17,000 ppm, nitrate to 100 ppm, and sulfate to 1,000 ppm. Limited data also indicate that measurable amounts of fluoride were found in some of the rinse waters. Chlorides were most abundant in areas where the stone has become dimpled or spalled. Nitrates were generally higher near ground level, and sulfate tended to be more abundant in samples taken from higher sites or from sheltered sites. Dark-stained limestone tended to yield less soluble material than clean-looking stone. Leachable elements were higher in samples from urban areas. Most of our data are from limestone buildings, but the technique works on other types of dimension stone, man-made construction materials, and even natural outcrops of rocks. Longitudinal studies show that soluble materials vary through time and are affected by climate. This rapid, in situ leach technique, although still being perfected, shows great promise in the diagnosis of stone alteration and in the evaluation of stone treatments because it is completely nondestructive.

Jan 1, 1999

By A. T. Iannacchione

Unrecognized roof beam failures resulted in 69% of the falls of ground injuries occurring in underground U.S. stone mines from 1990 to 1996. Field investigations at 45 underground stone mines suggest that excessive beam sag or deflection is the principal unstable roof behavior characteristics associated with miner injuries. Laminated roof structures, common in most underground stone mines, allow the immediate roof to separate into distinct beams. The timely determination of roof beam deflection could provide stone miners with advanced knowledge of potentially hazardous roof. Existing methods to assess roof conditions consist of observational and monitoring techniques. Observational techniques include open drillholes, sounding, wedging, and borescopes. Monitoring techniques include scratch tools, extensometers, telltales, Miners Helpers, and Guardian Angels. 1 Miners have difficulty utilizing these techniques because roof beams are located an average of 8 m (26.5 ft) above the miner's head in environments that are dark, dusty and noisy and these deflections are measured in millimeters of movement. To help mitigate the potential for falls of ground injuries to underground stone miners, the National Institute for Occupational Safety and Health (NIOSH) has developed the Roof Monitoring Safety System (RMSS) to aid in monitoring dangerous levels of roof beam deflection. If enough site-specific information is collected and placed on highly visible maps, individual mining operations could establish general guidelines for responding to specific roof beam deflection occurrences. This would help in implementing a pro-active, comprehensive roof control plan for reducing falls of ground injuries.

Jan 1, 1999

By Allan J. Breitenbach

Heap leach operations provide a low-cost method for recovering gold, silver, and copper metals from low grade ore materials. The processed ore materials are stacked in controlled lifts on a lined pad facility for heap leaching. A controlled barren solution is applied to the heap ore surface by sprinkler or drip emitter irrigation, and ore metals are leached into the solution for collection and extraction in plant process facilities. The leach pad and solution collection facilities are lined with impervious materials for containment of all process solutions. The liner system typically includes a composite geomembrane and clayey soil liner with a protective drain cover fill to maximize solution recovery and protect the underlying groundwater conditions. This paper discusses the types of pad liner systems currently used by the mining industry and the "good, bad, and ugly" lessons learned in engineering practice over the last 10 years in the design and construction of heap leach pads.

Jan 1, 1999

By J. Michael Howard

Holes cored through the Prairie Creek lamproite volcanic complex at the Crater of Diamonds State Park by companies interested in the site's commercial diamond potential give an opportunity to redefine the size and shape of the Prairie Creek pipe. Relationships of cored rock sequences and the discovery of a previously unrecognized major rock type allow a reinterpretation of the sequence and type of intrusive activity. Trench sampling of diamondiferous rock units yielded a diamond content far below what was anticipated based on an estimate from historical records. Inadequacies of shallow bulk-testing methods for a diamondiferous pipe are examined.

Jan 1, 1999

By 1980, the U.S. mining community had reached a broad consensus regarding coal pillar design. The pillar load could be estimated from tributary area theory, and the pillar strength from empirical formulas and laboratory coal strength testing. Then the growth of longwall mining required new thinking. Recently, powerful design methods have emerged from analysis of large data bases of real-world pillar successes and failures. These include the Analysis of Retreat Mining Pillar Stability (ARMPS), the Analysis of Longwall Pillar Stability (ALPS), the Mark-Bieniawski rectangular pillar strength formula, and guidelines for preventing massive pillar collapses. Sophisticated numerical models have also helped transform the pillar design landscape. In the process, our understanding of pillar mechanics has been greatly enriched.

Jan 1, 1999

By B. Schimm

Mining of material without blasting and / or selectively becomes more and more important for high quality ROM-products. Surface Miners have been developed especially for this purpose. The cutting technology of these machines has been improved, so that harder material as well as wet and sticky materials can be cut with better results now. Especially the cutting drum design and more precise drum manufacturing process now allow production and equal tool wear over a long period. The better knowledge of rock parameters influencing the cuttability and cutting results allow higher production, less cutting tool wear and therefore reduced production costs.

Jan 1, 1999

By Kadri Dagdelen

The classification of selective mining units (SMU) and the assignment of grades to those classified SMU are very important in open pit mining, especially for precious metal mining. When the classification is done, the true values of the SMU grades are unknown. These unknown SMU grades are mostly estimated analyzing the geologic data and blast hole assays. To classify the SMU's based on the estimate of SMU grade, without considering uncertainty associated with unknown SMU grade, yields incorrect decision in sending material to appropriate destination. In this paper, a method is developed to classify SMU's considering the uncertainty associated with unknown SMU grades. By using this method, traditional estimate of SMU grade is replaced with conditional probability distribution of SMU grade. The decisions about the destination of a given SMU are performed by minimizing the loss due to misclassification. Also, the asymmetric loss function by penalizing the overestimation and the underestimation unequally is used in assigning grades to classified SMU's. A case study is carried out to apply the traditional ore control techniques and proposed method in classification of SMU's and the assignment of the grades in a hypothetical gold mine.

Jan 1, 1999

By D J. Bradshaw

It is well known that the chemical environment determines the success of the flotation process, however its characterization and control is difficult to achieve. This work evaluates the use of various measurements, including mineral potential measurements, in gaining an understanding of the influence of varying parameters such as the milling media and the reagent suite composition on the flotation performance of a platinum group metal (PGM) bearing ore. The results showed differences in the response of the various mineral electrodes to the different conditions, however the changes in flotation performance of the different minerals in the ore could not be wholly described by the electrochemical changes, demonstrating the limitations of these measurements.

Jan 1, 1999