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By B. Krysa, J. Qiu

The zinc pressure leach plant at HBM&S's operations is now in its fifteenth year of operation. Current pressure leach operation is steady at a concentrate processing rate of around 26.5 tonnes per hour. A new cellhouse with a design capacity of 124,000 tonnes per annum and the capability of expansion of up to 154,000 tonnes per annum was commissioned in July 2001. The potential to expand the capacity of the pressure leach circuit and associated processes, as well as the purification circuit and casting plant, to meet the maximum capacity of the cellhouse has been investigated. This paper reviews current operation of the zinc plant, as well as the possibility of a capacity increase without major process modifications or major capital expenditures.

Jan 1, 2008

By Madan M. Singh

This section is unique to the Handbook in that it is the only section that deals with underground excavations for nonmining purposes. The editors were of the opinion that the section should be incorporated because the subject matter covered by the chapters is closely related to mining, and many mining engineers are currently involved in these activities. As we enter the decade of the 1990s activities in this category will increase, enhancing the relevance and utility of the material discussed. As the population increases, especially in metropolitan areas, the necessity to go underground will be greater. At the present time, not only are subsurface shopping malls and pedways connecting buildings becoming commonplace, but structures as diverse as the Civil and Mining Engineering Building on the University of Minnesota campus, a road-and-fleet maintenance facility in Multnomah County, OR, and even an ice cream parlor (Dairy Queen) in northern Wisconsin have been constructed underground. Placing utilities below the surface has numerous advantages and is now customary. Rapid transit and highways through tunnels in urban areas have been the norm for many years, but subterranean stormwater reservoirs, power plants, industrial warehouses, and food storage silos are relatively new innovations. The philosophy of underground defense installations is ancient, but their requirements and designs have trans-formed radically as technology advances. The use of under-ground space for disposition of wastes is modern, since it is recently that environmental concerns and waste disposal costs have assumed increased significance.

Jan 1, 2008

By G. T. Lineberry

Underground mine development begins with the positive investment decision to mine and ends with the inception of full-scale exploitation. It incorporates all activities, personnel, and equipment required for creation of underground access to a mineral deposit. Because of the depletion of near-surface mineral resources, the reduced mobility of large surface mining equipment, increasingly stringent environmental constraints, and the introduction of promising innovations to rock penetration and rock excavating equipment (e.g., continuous miners, rock borers), under-ground mining is projected to account for an increased share of worldwide mineral production in the foreseeable future. Without proper engineering during the mine development phase, failure of the underground mining project is axiomatic. A frustration attendant to coverage of the complex area of underground mine development lies not only with the need for treatment of the many disparate specialties within the area but even with the lack of systematization of these specialties in what is recognized as a vital precursor to successful mining. Section17 offers insights into (1) the basic principles of the planning and design process, including baseline assessment, reserve determination, premine planning, and subsystem design (Chapter17.1); (2) equipment selection and sizing, with emphasis on exca-

Jan 1, 2008

By P B. Hills, R J. Walton

Geotechnical instrumentation has been implemented as a key step for monitoring and optimising an engineered mine design for managing seismicity at the Beaconsfield Gold Mine. Measurements of displacement, stress change, ground control element load and seismic response of the rock mass allow for back analysis and calibration of critical parameters for feedback into the engineering design loop. Instrument clusters are installed in strategic locations prior to the commencement of stoping in order to determine the nature of the response of the rock mass to stoping. A selection of instruments including instrumented cable bolts and rod extensometers, resistance wire extensometers, hollow inclusion stress cells, vibrating wire stress meters and resistance wire extensometers are used to gather data through a data logging system. The rate at which data is recorded is adjusted to provide more information during periods of anticipated rapid change such as around stope firings or during periods of high seismic activity, and less information during periods of anticipated quiescence. The twofold purpose of the instrumentation is to calibrate the numerical modelling output which forms the basis of the engineered mine design, and to provide an alert mechanism where the behaviour of the rock mass is not what was anticipated, or where the impact of that behaviour may compromise the integrity of the engineered ground control system. The paper describes the location of instrument clusters with respect to stoping, the type of instruments employed and the method of data acquisition. It provides examples of results obtained and illustrates the way in which that information is used to optimise the mine design and manage seismicity.

Jan 1, 2008

The emerging discipline of ægeometallurgyÆ is not new but is becoming increasingly recognised as a discrete and high-value activity that reflects an ongoing commercial and cultural trend towards more effective mine site integration and optimisation. The AMIRA International P843 æGeMIIIÆ project (Geometallurgical Mapping and Mine Modelling) is a major new cross discipline research collaboration designed to provide support for this emerging industry trend. The project is currently supported by 18 global mineral companies and involves collaboration between the CODES Centre of Excellence (University of Tasmania), JKMRC and BRC (University of Queensland) and CSIRO Exploration and Mining. These groups represent recognised research excellence in the fields of economic geology, automated core logging, advanced microscopy and process mineralogy, mineral processing, mine planning and resource optimisation. The needs and challenges of geometallurgy as an integrated activity will be outlined together with the ongoing contribution and aims of the AMIRA P843 æGeMIIIÆ project. The main emphasis is on development of predictive geometallurgical indices for key processing performance parameters that reflect inherent geological variability. The ultimate aim is to provide predictive indices of geometallurgical performance that can be confidently embedded into resource models and used for risk-defined mine planning and optimisation.

Jan 1, 2008

By P F. Knights

Mining companies are striving to achieve new levels of operational maturity and drive process improvement across the organisation in the face of unprecedented demand and limited supply of experienced human resources. Advanced analytics techniques can help overcome these fundamental challenges by applying data techniques not previously applied in mining. Today, decisions are usually locally optimised but do not achieve optimum capability for the value chain. Although more information is collected then ever before, it is difficult to link many sources of data together in the same place in real-time, for example plant history, maintenance, mine planning, logistics and engineering data. Consequently complex analysis of data is time consuming and requires specialist skills and knowledge, and is often neglected in the decision-making process. In the future, analytics will close the loop between analysing data and taking action. Analytics will become embedded in the business and routinely applied to improve decision making across the organisation, from senior management to operations and maintenance workers, but will not require specialist skills or be time consuming to analyse data. As analytics becomes embedded in the business process, decisions are supported by data (not on gut feel), and critically, data from many sources are integrated in real-time to improve the quality of decisions. Ultimately, predictive tools will help suggest, or even in some cases automate, courses of action. The main opportunities for analytics exist where the enterprise requires supporting technology to enable it to continue to evolve to higher level of maturity. This will be in the areas of asset management, rapid reconciliation and adaptive planning, and the inbound and outbound supply chains. Advanced analytics are also a key enabler for increasing the effectiveness and realising the true value of Remote Operations Centres to safely and efficiently support operations in remote locations with smaller workforces.

Jan 1, 2008

By N. V. Sujathkumar, I. Vasudhevan, R. Santhakumar

"Freshwater ornamental fish culture is gaining importance in India and cheaper and nutrient rich live foods such as infusorians, daphnids, copepods and tubifecids are needed urgently. In this regard, adequate research has been conducted to produce such live feeds through recycling of agriculture and animal wastes. By this venture, besides generation of additional income, environment is also kept clean. In order to popularise the technologies relating to production of live foods from wastes and generate employment opportunities, training programmes were conducted for 100 Self Help Group women belonging to Thoothukudi district. The topics of the training included, breeding of ornamental fishes by utilizing the building material wastes, production of live foods through recycling of agricultural and animal wastes. A study on feed back was conducted with 100 respondents represented from different villages. The variables such as socio economic status, economic motivation, usefulness of training and constraints were included in this study. The impact assessment of this training of rural women indicated that 79 percent respondents were in favour of using the training for self employment by utilizing different kinds of wastes. Similar training programmes have also been planned in other parts of Tamilnadu. Introduction Ornamental fish culture is one of the most appropriate sectors to provide opportunities of employment to uplift the status of rural women. To ensure women utilize their full potential in useful and profital activities like freshwater ornamental fish culture, it is necessary to provide training and support for rural women which will ultimately lead to empowerment. Self Help Group Women are being trained routinely in India on the production of live foods for ornamental fish culture through recycling of agricultural and animal wastes. In this regard, training programmes were organized for the Self Help Group Women on freshwater ornamental fish culture. Which is gaining much importance in India. Cheaper and nutrient rich live foods such as infusorians, daphnids, copepods and tubifecids are needed urgently. The techniques of live feed production through recycling of agricultural and animal wastes would not only generate additional income by would also keep the environment clean."

Jan 1, 2008

By Erik Westman

Coal bumps remain one of the industry?s most devastating but least understood phenomena. If changes to the internal conditions of the rock mass could be observed there is hope that bumps could be forecasted. Seismic tomography has been used over the past 25 years in an attempt to image these changing conditions in the vicinity of the longwall face. This paper describes the history and practical considerations of using seismic tomography in bump-prone coal mines. The implementation of seismic tomography at six different longwall mines will be described along with lessons learned. Early studies used mining independent sources of seismic energy, including explosives and sledgehammers. Subsequently more operator friendly sources, such as the mining equipment itself and mining-induced seismicity, were used. Seismic energy sensors have been placed in gateroads and on the surface above the mine. Each of these configurations has associated advantages and disadvantages. Although the results obtained have been encouraging, the application of seismic tomography to monitoring a bump-prone longwall face is still immature. The ultimate goal of clearly imaging changing stress conditions in the longwall panel in a manner that does not inhibit mining operation is still distant, yet drawing nearer. When this goal is achieved, the industry will have a capable tool for identifying locations where bumps are imminent.

Jan 1, 2008

By L. A. Cramer

There are a couple of dozen junior platinum mining companies coming into existence in Southern African and most intend to mine, concentrate the PGM?s in a flotation product and sell the concentrate to one of the major producers in South Africa. The price they will receive for their product and hence the return they achieve for their investment will depend upon the large number of factors that influence the market for such a product. Unfortunately the number of buyers is severely limited as it is dominated by the two major local producers, Impala Platinum and Anglo Platinum. Furthermore the current smelting technology has limited capacity for UG2 concentrates and high nickel concentrates will quickly fill any available base metal refining capacity. Few if any overseas buyers can compete for the bulky flotation concentrate produced. This paper will explore those factors such as metal recoveries, metal prices, operating costs, capacity constraints, deleterious elements, transport issues, metal premiums and discounts that are in play, types of flotation concentrates, processing capital costs, PGM grades, etc and their impact up on what smelters and refiners might be prepared to pay for such PGM concentrates. Ultimately simple graphs and equations can be developed for probably payment terms for such concentrates. Those who negotiate well will move to the higher return section of the envelope and those who use the concentrator facilities to produce the most saleable combination of flotation concentrates will enhance their returns. A deep and firm understanding of the issues surrounding this market is necessary in order to negotiate the best possible price for the seller.

Jan 1, 2008

By L. Becze, B. Pierre, S. Di Carlo, G. P. Demopoulos

From January to June 2007, the autoclave production at the Kidd Metallurgical Site was severely affected as a result of plugged discharge lines and extensive precipitation/crystallization of sulphates that caused massive scaling in different autoclave compartments. Work was performed at McGill University to understand the root causes. The crystallization of zinc and ferrous sulphate salts was investigated in terms of solubility measurements. Scale samples were characterized using chemical and mineralogical-spectroscopic analysis. In this paper, following a description of the Kidd zinc pressure leach operation, highlights from this investigation are presented and solutions used to overcome the problem are outlined.

Jan 1, 2008

By D Bradshaw, J R. R de Villiers

The non-stoichiometric sulfide mineral pyrrhotite (Fe(1-x)S), common to many nickel and platinum group element (PGE) ore deposits, occurs in varying crystallographic forms with the different types exhibiting subtly different physical and chemical properties. These differing properties are likely to influence the flotation performance of pyrrhotite, which in the case of PGE operations is actively recovered, whereas in nickel operations pyrrhotite is depressed. In this study, examination of natural pyrrhotite samples from Southern African and Canadian nickel and PGE ore deposits revealed a variety of pyrrhotite compositions in terms of iron content (Fe7S8, Fe9S10, Fe11S12) and solid solution nickel concentration. Pyrrhotite composition was correlated with its mineral association depending on whether non-magnetic pyrrhotite occurred in conjunction with troilite, non-magnetic pyrrhotite occurred as single phase pyrrhotite, magnetic pyrrhotite occurred as single phase pyrrhotite or whether the two phases; magnetic and non-magnetic pyrrhotite co-exist. Subsequent microflotation tests of selected single phase pyrrhotite samples revealed that the non-magnetic pyrrhotite is slightly more floatable than magnetic pyrrhotite. Microflotation tests also showed that varying flotation responses occur between differing magnetic pyrrhotite samples. These differences in flotation performance are postulated to be a result of the effects of varying pyrrhotite crystallography, trace metal content and mineral association on pyrrhotite oxidation, formation of surface species and subsequent adsorption with xanthate collector.

Jan 1, 2008

By Jeongbok Seo

This paper describes successful application of driven tapered-steel-pipe piles for two large-scale projects in the New York metropolitan area: Rego Park Mall, Rego Park, N.Y. and 164 Kent Avenue, Brooklyn, N.Y. The combination of side friction and end bearing resistance produced by tapered-steel-pipe piles has been well-recognized as greater than the side friction and end bearing resistance by pipe piles. Forty-four tapered piles were driven and tested at these two sites. Design pile load for the two sites was 260 kips for Rego Park Mall and 400 kips and 300 kips for 164 Kent Avenue. To measure the pile-drive hammer efficiency, the compressive stress in the pile, and to estimate the ultimate bearing capacity of the pile, dynamic load testing using a Pile Driving Analyzer (PDA) was conducted on index piles at the sites. Subsequent to the field testing, data analysis using the Case Pile Wave Analysis Program (CAPWAP) was conducted. Restrike PDA analysis and full-scale static load tests were performed on the selected test piles. Test piles at the project sites exhibited significant time-dependent increases in bearing capacity caused by the effects of "set-up" or "soil freeze." The dissipation of excess pore-water pressure in the soil, which had been disturbed and remolded by driven pile, was generally considered the primary cause of set-up. The increase at the subject sites ranged from 100 to 300 percent of the capacity measured at the initial driving. This paper discusses the results of various types of load testing on tapered piles and the set-up effects by comparing PDA test results acquired during and after pile driving. Finally, an empirical relationship for the New York metropolitan area has been offered for quantifying set-up.

Jan 1, 2008

By Scott M. Mackiewicz

This project includes replacement of the historic vertical-lift span Meridian Bridge (U.S. Highway 81 over the Missouri River) that connects Yankton, South Dakota with rural Cedar County, Nebraska. The new 76-foot wide, 1,590-foot long steel plate girder structure required the use of drilled shaft foundations that extended into the underlying Carlile Shale formation. Designers indicated that an individual drilled shaft capacity of about 2,000 kips will be needed at each of the river piers, and based on the subsurface information, 8 to 10-foot diameter drilled shafts extending to about 115-foot would be required for support of the bridge structure. An Osterberg Load Test was performed on one test shaft to determine the ultimate skin friction and end bearing of the Carlile Shale. This paper describes the design and installation of the load test drilled shaft as well as presents the load test results as compared with predicted design values determined using FHWA methods.

Jan 1, 2008

By M. K. McCarter

Surface mining applies to extraction of mineral resources from water and sediments of rivers, lakes, seas, and oceans; from solutions circulating through broken rock and soil; and from rock and soil excavated from the earth. Surface mining is responsible for the majority of mineral production in the United States and a substantial portion of the world?s total production. This section deals specifically with extraction methods which employ mechanical processes in a relatively dry environment to free minerals from the earth. The following section, Section 15, deals exclusively with aqueous methods. With recognition of the importance of reclamation in all activities which temporarily disturb the earth?s ecosystems, it is appropriate to classify mechanical extraction methods as either deferred reclamation or concurrent reclamation. Deferred reclamation is necessary when the shape and logistics of the excavation require that it remain open throughout the productive life of he project. Upon exhaustion of economic reserves, the opening is then reclaimed in a manner consistent with public safety, environmental acceptability, and land use policy. Methods employing deferred reclamation are commonly referred to as open pit or quarry mining. Metallic ores, industrial minerals, and coal are all extracted using open pit methods. Typical examples are provided in Chapter 14.1.

Jan 1, 2008

By Dietrich Gross

This paper describes an advanced oxy-fuel combustion technology for re-melting aluminum that significantly reduces energy consumption and emissions. This oxy-fuel combustion technology developed by Jupiter Oxygen is a patented process for combustion of fossil fuels with pure oxygen while excluding air, thereby creating an undiluted high flame temperature and increased efficiency for process heating in industrial furnaces. This unique process has led to improved heat transfer and longer residence time while maintaining the same process temperatures as with air combustion. The energy efficient combustion process allows aluminum companies to operate at a substantially lower cost due to a dramatic fuel savings of up to 70% for natural gas and waste oil (1). The results of more than 10 years of day-to-day experience utilizing the Jupiter Oxygen Corporation oxy-fuel combustion technology licensed to Jupiter Aluminum Corporation in the aluminum re-melting business are discussed.

Jan 1, 2008

By Todd Nottingham

Channel deepening of major ports is challenging designers to explore innovative solutions to ensure stability of bulkheads, such as for the Oakland Inner Harbor. This particular challenge was met with the use of the SPIN FIN® Tension Pile for restraint of an HZ combination wall along the Oakland Inner Harbor Shoreline in Oakland, California. A SPIN FIN pile is a pipe pile with welded plates at the pile tip that increase pile capacity. A brief history of the project will be provided as well as results of pile load tension tests, pile strain gauge, and wall deflection under construction loads. Tension pile load deflection results will be discussed with recommendations toward establishing deflection-based ultimate load criteria. A discussion of predicted wall loads and field observed wall loads will be provided.

Jan 1, 2008

By Donald W. Gentry

This section deals with one of the most fascinating aspects of mining the evaluation of mine investment opportunities. Be-fore proceeding further, it is important to clarify the meaning of some fundamental terms used frequently in the text. 6.0.1.1 Mine Valuation vs. Evaluation The words "valuation" and "evaluation" in a mining context are often used interchangeably. However, for the purposes of this section, a distinction is made between the two terms in accordance with commonly accepted practice. The word valuation in a mining project context has the rather narrow meaning of placing a dollar or other currency value on the worth of the project as a whole. In other words, the value of a mining project refers to a measure of the desirability of ownership of that property. As such, the major item of interest is, "what is the mine worth?," or `what is the value of the mine?" The value of a mining project may actually be determined in the marketplace at any specific point in time, or it may be estimated by one of several methods. The topic of mine valuation is discussed in more detail in Chapter 6.1. The word evaluation in a mining project context connotes the broader meaning of determining the numerical values of all

Jan 1, 2008

By Thomas Barczak

Roof support systems are designed for roof control to prevent unplanned falls. It sounds logical and has been the conventional thinking in support design since supports were first installed. In order to determine which support system should be used or which would be the most effective, the degree of control provided by the support system must be known. This question embodies the concept of a ground response curve, which is a measure of support control by assessment of the convergence in the mine entry as a function of the support capacity. In this National Institute for Occupational Safety and Health (NIOSH) study to optimize standing roof support design, ground response curves were developed for longwall tailgate conditions from numerical models of Pittsburgh Coal Seam geology. The models were calibrated against tailgate convergence measurements that were made in two Pittsburgh Coal Seam mines as the depth of cover varied during the panel extraction. Ground response curves were developed for four loading conditions: (1) development, (2) side abutment, (3) front abutment near the longwall face, and (4) full extraction inby the face. In general, the tailgate convergence and required support capacity increase through each of these loading stages. It was concluded that prior to failure of the rock mass, the support system regardless of its capacity has relatively little impact on tailgate convergence. Recognizing that the support cannot prevent much of the (pre-failure) convergence that is occurring is an important part of support design. Supports that exhibit high loading stiffness but cannot sustain that loading through a displacement compatible with the ground response curve will not provide adequate roof control because they can fail prematurely. The required capacity depends on the loading plus yielding characteristics of the support and the amount of rock failure that has occurred. The loading plus yielding character establishes where the support loading intersects the ground response curve. Design criterion for support capacity based on the identifying the onset of strain-soften rock response leading to ?damaged roof? is proposed as a foundation for assessing support design requirements. The capacity without accounting for the loading and yielding character of one support should not be used to assess the capacity requirement of an alternative support design, particularly when the loading and yielding characteristics are significantly different. A sensitivity study was made to evaluate the impact of mining height and overburden depth. As expected, the results show that convergence increases with increase in mining height and increase in overburden depth. Some specific support examples are also analyzed. Although this is a first step and the two-dimensional numerical models have limitations, these initial studies provide valuable insight into the control provided by the roof support system and will ultimately lead to optimizing support design based on specific mine site conditions.

Jan 1, 2008

By Craig H. Olson

"A new ship dock at a Philadelphia area refinery will be capable of docking the largest tanker to travel the Delaware River, the Stena V-MAX, which will induce significant lateral loads. The loads at the dock, a system of mooring dolphins and platforms, will be resisted by over 150 pipe piles, including some 20- and 30-in diameter, reinforced, concrete-filled pipe piles and H-piles. Construction included driving the pipe piles to the required ultimate capacity, flushing the pipe pile casing clean of overburden materials, followed by drilling rock sockets into the underlying Wissahickon Formation. The Wissahickon Formation is a complex subsurface that includes variations in depth to bedrock, rock quality, degree of weathering and the presence of very hard quartzite lenses or inclusions. Because of the problematic subsurface, the designers and client requested extensive pile dynamic analysis (PDA) testing by TRC Engineers (TRC).Before beginning, the contractor requested that TRC perform the WEAP (wave equation analysis program) to evaluate the proposed hammer (APE D30-32 open-end diesel) to drive the piles into the proposed bearing strata while maintaining allowable compression stress levels. The WEAP provided a prediction of blow counts and stresses for various ultimate capacities, and showed that for the HP14x89 piles with a required ultimate capacity of 480 kips, a blow count of at least four blows per in at a stroke of 8.0 ft was necessary.New Approachway RampThe PDA testing began at the new dock approachway ramp, parallel to the existing one. The new structure is a 300-ft-long by 21- ft-wide concrete deck supported on seven bents; each has two 24- ft-diameter steel open-ended pipe piles. Every pipe received an HP 14 x 89 x 80-ft pile that was later driven beyond the pipe pile tip to create a composite pile. The pipe piles were later cleaned of overburden materials and finally filled with concrete and rebar. At each bent, a cap was installed on top of each pair of pipe piles, and then a prefabricated concrete deck was added."

Jan 1, 2008

By M. I. Brittan

Cyanide leaching of two West African gold ores was studied in multiple laboratories to provide process-engineering data for plant design purposes. Unusually slow leach extraction kinetics were observed using routine cyanide leach test procedures with pregnant solution monitoring. Carbon-in-leach testing, however, showed normal rapid kinetic behavior, with the same ultimate gold extractions being reached in much shorter elapsed times. Kinetic curves based on washed solids assays also exhibited more typical leaching characteristics. The results bore all the hallmarks of some equilibrium inhibition of the leaching. It was surmised that ore gangue components were responsible for weakly adsorbing gold-cyanide complex reaction product, thereby holding up soluble gold in the solid phase. The term ?preg-borrowing? was coined to describe the reversible phenomenon and distinguish it from irreversible preg-robbing. The two ores investigated may represent an extreme form of a more general effect that in most instances might pass unnoticed. The effect can lead to misinterpretation of kinetic leach curve data and underestimation of calculated ore head grades.

Jan 1, 2008