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By P. Mogodi

The purpose of the project was to propose a coal clearance system (coal transportation system from the mining face to the plant) that could be used for the planned underground operations at Zondagsfontein Colliery. Components of the current coal clearance system were overlooked during feasibility studies. Subsequent studies of the coal clearance system revealed that the combined capacity of the two trunk belts does not match that of the shaft (main) belt. As a result production downtimes will be encountered due to bottlenecks in the system. Ways of addressing this challenge were analysed by weighing both advantages and disadvantages and ultimately a surge bin option was selected. Belt conveyor simulations were conducted in order to determine the optimum capacity of the surge bin. The configuration of the surge bin in relation to the two trunk belts was chosen by considering development cost, advantages, and disadvantages of each option. It was concluded and recommended that a 500 tonnes capacity surge bin is required to remove the bottleneck from the system.

Jan 1, 2010

By Tad Crowie, Victor Delgado, Nick Katsikaros, Tim Hughes

"A number of silver producers have identified a need for a system to recover silver and gold from base metal flotation concentrates on site rather than sending the concentrate to third party smelters to improve mine economics. Historically intensive cyanidation has only been used for coarse gold gravity concentrates in batch machines but Gekko have applied the InLine Leach Reactor (ILR) to these difficult to leach concentrates.The ILR’s unique ability to operate at various solid to solution ratios, high mass capacity, the ability to handle fines, the use of peroxide to aid silver leach kinetics and simple operation has resulted in significant economic benefits to Hochschild PLC’s Selene and Arcata operations. This paper describes the commissioning phase of the ILR5000BA intensive cyanidation reactors on concentrates from the Selene mine at the Ares Concentrator.INTRODUCTIONIntensive leaching of high grade concentrates in gold ore treatment is now commonplace and is considered an essential feature of most gold circuits (Lane, Fountain and LeBrooy, 2008). The devices commonly used for intensive leaching (InLine Leach Reactor, Acacia Reactor, etc) are specifically designed for the typical coarse nature of the concentrate.In some of these intensive leach applications, significant amounts of silver are co-recovered with the gold. In fact, the intensive leaching conditions of 1 to 2% NaCN in solution and high dissolved oxygen levels, overcome the issue with silver’s slow dissolution rate in traditional CIL/CIP circuits and avoids the formation of insoluble silver sulphide minerals on the surface of the gold (Marsden, 2006).There are a significant number of mine operators producing silver in the form of mixed base metal sulphides flotation concentrates. Typically the mine operators are paid for the silver after processing of the concentrate by the base metal smelter whom recovers the silver during the refining process."

Jan 1, 2010

By Tatiana Ravani von Ow, Leandro Bomvisinho

"The size of mills driven by ring-gear or by a gearless solution has significantly increased in the last years. This has created additional challenges for the driven equipment. The requirements for the mechanical devices and the power grid have become more demanding. Controlled soft starting and operation, especially in dual pinion mills, as well as the protection of the equipment has gained importance. The selection of the drive solution for the mill therefore becomes more critical. Besides the classical criteria such as performance, efficiency and capital costs other factors come in the evaluation of the system such as flexibility and optimization of operation, reliability and the ageing of the grinding equipment.Variable speed solutions offer significant advantages over conventional fixed speed drives due to their application specific features and process optimization capabilities, even for ball mills where these are not seen yet as a must.The initial capital costs are higher than some of the direct on-line solutions however the benefits for the operation during the lifetime of the mill generated by the use of converter solutions justify the additional higher investment.INTRODUCTIONThe method of powering mills such as AG, SAG and Ball has a long and technically interesting history. It can be said; almost every decade in the last half century had its own trend. The trend was dominated by the market demand, by the process development and requirement of the mechanical and the electrical technology but mostly by the price of the applied technology.All has started about 50 years ago with mill diameters less than 20 feet driven by fix speed synchronous or wound rotor motors with the power of about 2 MW. Around 10 years later, the mill sizes increased, but the necessary torque could not be transmitted by one pinion therefore dual pinion solutions were developed to power the mills. However, realization of the dual pinion solution was only possible when load could be evenly shared between the two pinions."

Jan 1, 2010

By Meghan McGrath

Third generation advance high strength steels with microstructures of acicular ferrite and retained austenite were investigated and meet mechanical property goals. A good combination of strength and ductility were achieved with duplex ferrite and austenite microstructures where cementite formation was suppressed. Transformation induced plasticity (TRIP) behavior produced rapid work hardening. The mechanical properties of two hot-rolled steels with duplex microstructures were compared and had the following compositions: (1) Fe-0.14C-13.87Mn-1.42Si-3.51Al; and (2) Fe-0.06C-14.2Mn-1.85Si-2.38Al. These steels were cast, homogenized, and hot rolled at 900ºC to obtain a refined microstructure with ultimate tensile strengths and elongations to failure of 865 MPa and 39% and 1,217 MPa and 28%, respectively. The amount of metastable austenite in both compositions decreased after tensile testing from 58% and 28% to 6% and 0%, respectively. Microstructures were characterized using optical microscopy, scanning electron microscopy (SEM), and x-ray diffraction.

Jan 1, 2010

By D. S. Dihalu

A generalization of Gy?s model for the fundamental sampling error introduced the new ?parameter for the dependent selection of particles?, denoted as Cij. This allows for modeling deviations from the ideal situation where the selection of a pair of particles is composed of two independent selections. The generalized model potentially leads to more accurate variance estimates in the case of clustering of particles, differences in densities or sizes of the particles or repulsive inter-particle forces. A straightforward and practically applicable method is needed for the determination of this parameter for miscellaneous mixtures in industrial settings. In this contribution, the feasibility of using digital image analysis to determine this parameter Cij, will be demonstrated. Line transect sampling of a digital image was used to construct a transition probability matrix. A new algorithm to derive quantitative estimates for Cij will be presented and discussed. The applicability was verified by a photograph of zirconium silicate particles of sizes typical for industries dealing with pharmaceutical, food/feed, and environmental applications. Conditions affecting the practical applicability are identified and potential pitfalls will be discussed, including e.g. how a potential unrepresentative surface can affect the quality of the estimate of Cij.

Jan 1, 2010

By Steve Wilson, Bern Klein, Jeff Drozdiak, Stefan Nadolski, Andrew Bamber

"In the adaptation of high pressure grinding rolls (HPGRs) to hard-rock mining applications, circuit development has mainly focused on placing HPGRs in the role of tertiary crusher in the preparation of ball mill feed. In order to take advantage of the potential energy benefits associated with HPGR and stirred mill grinding technologies, work was done to investigate the potential of and resultant energy benefits of placing the HPGR in series with a high speed stirred mill in replacement of the conventional cone crusher / ball mill arrangement. The proposed circuit was designed to operate with two stages of HPGR grinding followed by high speed stirred milling.Using a pilot-scale HPGR unit inline with a 20 liter stirred mill, the design criteria, circuit arrangement and consequent comminution energy requirements for a circuit processing copper sulphide ore from Teck Resources’s Mesaba Copper project were determined. These results were then compared to two other circuits, an HPGR / ball mill circuit and a conventional crusher / ball mill circuit processing the same ore.The testwork indicated at a proof-of-concept level that the HPGR / stirred mill circuit could potentially be appropriate for this duty and further work on the concept is merited. While the results indicate that the HPGR component of the circuit was more energy efficient than conventional cone crushing, the energy efficiency of the stirred mill was found to be lower than that of a comparable ball mill undertaking the same duty. However, increased energy efficiency of the stirred mill portion of the circuit is possible with further optimization and further work on the concept is indicated."

Jan 1, 2010

By B. H. Moore

The opportunity to evaluate the pile design procedures used on a major project is an infrequent occurrence. It is even more infrequent that the project involves piles with significant tension and horizontal capacities. This report synopsizes over twenty years of design and construction experience on just such a major pile founded structure. The philosophy governing foundation design procedures is described and discussed. The order and extent of full scale pile testing are evaluated. Principal points in the specifications are established and their effect on construction progress and claims are noted. The report concludes with recommendations for future projects.

Jan 1, 2010

By John Sleavin

As part of the Link Light Rail project in Seattle, WA, work was completed at the Pine Street Stub Tunnel (PSST) in early 2007 for the Central Link project. This tunnel was excavated using cut-and-cover construction within the limits of Pine Street. The stub tunnel provides a turn back via double crossover for light rail trains running in the Downtown Transit Tunnel (DTT), as well as a connection point for the next phase of the project, the University Link (Fig. 1). Designing the new University Link tunnel connection to the existing PSST was a tricky task. The on-site geotechnical conditions, buried obstructions, geometry, requirements for construction and balancing operational considerations and neighborhood stakeholder concerns associated with the recently completed PSST combined to create a uniquely challenging assignment.

Jan 1, 2010

By Youliang He

Twin-roll casting is an integrated casting and rolling process that involves the continuous solidification of a melt and the plastic deformation of the solidified metal between two rotating rolls. Computer modeling is a valuable tool to help engineers understand the metallurgical process during twin-roll casting. However, commercially available software can only model either the fluid flow/heat transfer of the melt or the plastic deformation of the solid, but not both. In this study, an object-oriented finite element program was developed to simulate the steady-state fluid flow, solidification and plastic deformation of an A7,31 magnesium alloy in a horizontal twin-roll caster. The melt, the mush zone and the solid were treated as a generalized Newtonian flow in an Eulerian reference frame and different constitutive equations were employed to describe the material behaviours. The effect of operational parameters on the solidification process was discussed based on the simulation results.

Jan 1, 2010

The global tunneling industry has many challenges, both technically and financially, with the latter likely to be a significant feature over the next few years. Many industries have ad-opted standard practices in order to overcome specific technical challenges, from which standard out-comes are anticipated. In tunneling, however, every project is unique so standardized practice is not easy. This requires original thinking and being open to adopting new techniques and technologies as they emerge. Sprayed waterproofing is a hot industry topic and a paper recently presented at the North American Tunneling conference not only discussed this methodology for achieving a dry tunnel but also how it can reduce build costs and construction time. Despite their being relatively few ?universal truths? throughout the tunneling industry, there is one opinion that appears to be shared by most in the sector, ?all tunnels leak.?

Jan 1, 2010

From a distance, the 0.75-km (0.5-mile) rail line that sits in the shadows of Vale-Inco?s Stobie Mine outside of Sudbury, Ontario could be mistaken for a standard conveyor belt hauling ore from the nearby mine. But with its large, yellow-painted loop and interconnected green rail cars that invert themselves on the loop before correcting with a smooth rollover further down the track, one might assume that this is some sort of test track for a new roller coaster. The fact of the matter is that it is the proving ground for Rail-Veyor technology, a technology that the company hopes will one day change the face of ore transportation in surface and underground mines around the world. With a line of linked, low-profile rail cars that are capable of carrying up to 1 t (1.1 st) per car of ore by way of simple, above ground, lightweight rail track, the technology is not groundbreaking. In fact, it was developed in the 1960s for the French State Railroad. A demonstration plant for the Florida Institute of Phosphate Research was installed in 2000 and the first commercial under-ground installation was in 2007 in South Africa at Harmony Gold?s Phakisa Mine. There, a 4.7-km- (2.9-mile-) long tram between two shafts operates three Rail-Veyor trains on a shared track. The difference is that the application that is being tested day-and-night in Sudbury is getting closer to wide production, thanks to the use of computer controlled automation that has helped turn an old idea into a cost-effective modern solution.

Jan 1, 2010

By S. D. Zhang

The first reinforced earth railway bridge abutment in China has been successfully constructed of September, 1985 under the supervision of the Reinforced Earth Researth Group of Shanghai Institute of Railway Technology. In order to verify the reliability of the designed structure and its behaviuors, the 1:10 reduced scale model tests in laboratory and field tests on the actual structure during construction were proceeded. Various loads of different positions were charged, the vertical and lateral earth pressure in the filling soil, the stresses developed in the reinforcements, and the deformations of the models or the actual structure were recorded in those tests. The behaviors recorded are presented and discussed in this paper.

Jan 1, 2010

By Y. X. Tong

The simplicity off Ø=0 analysis has been taken advantage of to evaluate the geotech­nical problems of open caissons, slurry trench walls and piles in Shanghai. Undrained shear strengths obtained by various testing methods are correlated with case record and experimental data. Some problems posed by the construction of tall buildings are briefly discussed. Comments on applications are made to help engineers deal with practical problems.

Jan 1, 2010

By M. Pernot

A 12 m-deep excavation has to be perfomed in the Shanghai soft clay to install an underground electric substation. This article was originally intended to study the behaviour of the wall, the excavation bottom and the surrounding ground during the excavation. Since the works are behind schedule, and the data referring to the excavations are not, therefore, available, the article is limited to a presentation of the analysis methods that we envisaged for the study of the behaviour of the excavation.

Jan 1, 2010

By A. de Meyer

Zincor experienced significant losses of metallic zinc to dross during the melting of zinc cathode plates. In this study five factors affecting the formation of dross are identified from literature. Dross from both the plant and that produced in the laboratory is characterized using XRD. An empirical model, based on laboratory-scale investigations, was developed to quantify the effect these factors on their own or in combination with each other has on the amount of zinc loss to dross. The predictive capability of the model is evaluated based on the laboratory-scale investigations. Predictions are made on the effects that heat treating the cathode plates prior to melting, increasing the cathode plate thickness, washing and drying prior to melting, and loading the furnace in a controlled manner have on the amount of zinc loss to dross. Keywords: Zinc, dross, optimize, smelter, yield, losses, empirical, model, XRD.

Jan 1, 2010

By A. Ochieng

Solids suspension influences the quality of mixing and energy requirement in a solid-liquid system, both of which determine the efficiency of industrial processes such as nickel precipitation. Nickel solids concentration distribution in a stirred tank was investigated using computational fluid dynamics (CFD) and experimental methods. The concentration distribution of the nickel solids was compared with that of sand and glass. The laser Doppler velocimetry (LDV) method was used to measure the velocity field for the liquid-only system and an optical technique was employed to determine the axial solids concentration distribution. Regions of in homogeneity in the tank were identified. It was found that, for a given solids loading, the solids concentration distribution depended on both particle size and particle size distribution. High solids loadings were investigated and a difference in the concentration distribution pattern was obtained with nickel, flint glass and sand particles. The CFD simulation results highlighted problems that could be associated with some conventional experimental methods of determining solids concentration distribution in a stirred tank. Keywords: nickel; CFD; simulation; mixing; solids suspension.

Jan 1, 2010

By Verya Nasri

The use of a single tunnel boring machine (TBM) tunnel of approximately 12 to 13 m (40 ft to 43 ft) diameter for transit systems to house both light rail or subway tracks in a stacked configuration is an advanced concept that allows significant savings in construction cost and time while reducing, to a large extent, the negative effects on the environment. This solution, similar to the recently completed Barcelona Metro Line 9, integrates station platforms, train storages, crossovers, bypass tracks, ancillary areas and utility corridors inside a single tunnel. Each of the underground stations consist of a cut-and-cover entrance structure and ventilation shafts, that also serve as emergency exits. The excavations for the station structures and shafts can be done on one side of the street with nominal impact on traffic and utilities.

Jan 1, 2010

By Stephen C. Tadolini, John P. McDonnell

"High-strength cable bolts have been used for ground support in underground coal mines for many years. Cable bolts are routinely used as secondary ground support in numerous longwall gateroad support applications, areas that possibly experience the most severe conditions in current underground coal mining. Additionally, when mining ground conditions deteriorate, engineers oftentimes recommend cable supports as a principal solution because of the established credibility for successful ground control. Nevertheless, there is still a reluctance to utilize non-tensioned cable supports as an effective primary roof support alternative.This paper provides historical and recently documented examples of non-tensioned cable supports utilized as an effective primary ground support method in a western U.S. underground coal mine, and it will continue the technical discussion between the differences of various degrees of tension in cable supports with respect to ground behavior and reactions.INTRODUCTIONResin-grouted cable supports are widely used to support difficult ground conditions throughout the world. Through the use of innovative applications and configurations they have proven to be a major paradigm shift in roof support and ground control technology in the U.S. (Tadolini and Koch, 1993; McDonnell et al., 1995; Tadolini and Gallagher, 1994; Tadolini and Trackemas, 1994)Today, the basic cable bolt support consists of a high-strength steel cable installed in bore holes that range in diameter from 25 to 50 mm (1 to 2 in) depending on the strand size and drilling equipment. Cables are offered in both bright and galvanized, for corrosion protection, and range in capacity from about 30 to 60 tons. An example of a resin-grouted cable bolt and the key components is shown in Figure 1. The steel cables are flexible and the support length is not limited by the height of the opening. Lengths of up to 10 m (32 ft) have been supported with high pattern densities when standing supports were not operationally feasible. The most common lengths are 3 to 5 m (10 to 16 ft). An important physical characteristic is that PC-strand has an ASTM minimum elongation requirement of 4%. For comparison purposes, the ASTM 432-08 Standard Specifications for Roof and Rock Bolts and Accessories specifies elongation requirements for traditional roof bolts are a minimum of 12% for grade 40, 9% for grade 60, and 8% for grade 75 materials, respectively. Traditional roof bolts can stretch and elongate twice the length that cable bolts can, which makes design considerations challenging."

Jan 1, 2010

By M. Veiga

"Mining is an energy and water intensive activity. Increasing energy efficiency and reducing water consumption are two of the key requirements in moving toward a more sustainable mining industry. Water reduction, reuse and recycle options are reviewed, identifying cases where these options have been implemented. Then a novel mine water network design method is described, which analyzes a mine/mill water system in order to identify areas where water requirements and water system energy requirements can be reduced. First, a site water balance is determined and major water consumers and sources are specified. Next, multiple possible combinations of supplying water to mine and mill consumers are compared. Finally, low energy and water combinations are identified.INTRODUCTIONMining consumes vast quantities of energy: The whole mining and metals sector consumes over 12% of the world’s energy (DOE, 2009). Mining also requires large quantities of water, although mining water consumption is a relatively small portion of the overall world water use. Even in relatively dry, mining-intensive countries like Australia and South Africa, mine water consumption is only 2-3% of national water demand (Brown, 2003). However, at the local level, when mining takes place in areas where water is scarce, mine water consumption can severely impact local supplies. In addition, acid rock drainage, leaks from waste impoundments, or direct disposal of tailing into waterways can contaminate surface and groundwater (MMSD, 2002). Mine water systems can be large energy consumers, but better mine water systems can reduce both water and energy consumption. Improving water system design and practice are key strategic requirements in moving toward a more sustainable mining industry.This paper addresses conventional base-metal or precious-metal mine sites, which consist of an underground or open pit mine and a mineral processing plant, or mill. Ore is extracted and processed through the plant to produce a saleable product. Tailing, or waste material, is then deposited in a tailing storage facility (TSF). Any rock removed from the mine with no economic value, or waste rock, is stored without being processed."

Jan 1, 2010

Heavy mineral deposits are becoming more complex in terms of their compositional variation, particle mineralogy and size distributions, and present challenges for the operation of separation equipment to achieve the required grades and recoveries. Changes in equipment design and concepts potentially provide new opportunities for the beneficiation of heavy mineral sands deposits. The development of a framework for the fundamental understanding of separator performance issues is a first step to develop new machines. This paper will present a first step analysis of electro-static and magnetic separation machines with their application to real separation scenarios.

Jan 1, 2010