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"The first 90 years of the last century generated a considerable volume of technical literature on the subject of grinding mill power and its prediction. It is therefore surprising that during this time there were no published models for predicting grinding mill power draw which were validated using a wide range of comprehensive industrial scale data.Notwithstanding this lack of data, the majority of models placed limited emphasis on the internal dynamics of mills and relied on simple assumptions which considered the charge to take up a fixed position and shape.Laboratory based studies (Liddell, 1986), and industrial data (Morrell, 1993), showed that these assumptions did not hold over a wide range of operating conditions, and brought into doubt the ability of the (then) existing models to accurately predict grinding mill power draw. Furthermore no model treated AG,SAG and ball mills as a single class of devices whose power draw could be predicted with the same equations.Through a detailed investigation of the charge dynamics, coupled with a large data base of industrial mill power draws, this situation was rectified by the end of the century, by which time a model had been developed and validated, which accurately predicted the power draw of all wet tumbling mills. This paper describes this model and reviews some of the earlier attempts at mill power modelling.INTRODUCTIONThe early 1900?s saw the beginnings of published papers which tackled the problem of what influenced the power draw of tumbling mills and what equations (models) were suitable for predicting power draw. This interest continued for the rest of the 20th century and the literature contains many papers that attempted to satisfactorily answer these questions. A common and disappointing theme in the majority of them, however, is the distinct lack of suitable experimentally derived power draw data. This deficiency consequently limited the practical application of many of the attempts at modelling mill power draw. Prior to the early 1990?s some limited data on the power draw of grinding mills in the literature can be found, but as Harris et al (1985) remarked they are ?... too frequently unusable simply because one or more essential variables have been omitted?. The absence of published results, from vigorous experimental testing of the various models, has resulted in a general lack of evaluation of the validity of assumptions and hypotheses that such models contain. Harris et al (1985) however, did make some efforts in attempting to evaluate the performance of various power prediction equations and in so doing further developed a semi-empirical one of their own. However, in using manufacturers? published data, which themselves were undoubtedly generated by proprietary equations of unproven validity, they probably succeeded in generating little more than a consensus of the various errors in these models."

Jan 1, 2003

By J. M. Barker

The concept of global-market access through transportation efficiency is a concept whose time has come. The basis of this approach is customer satisfaction—the higher the better. But beyond what seems almost too logical is the question of how to achieve this market access. All industrial mineral exporters face stiff competition. Factors include proximity of competitive industrial minerals and substitutes, pricing pressure, political and cultural differences, currency fluctuations, communication problems, trade finance restrictions, and transportation imbalances. The following discussion will focus on transportation activities in global competitiveness, but the producer with the larger offering of services will often make the sale, not necessarily the low-cost producer (Cook, 2002). Some key concepts for global-market access are “the market concept,” just-in-time delivery, quality retention, and global customer service.

Jan 1, 2003

By Jonkion M. Font

An expression for the distribution ratio of arsenic between slag and copper matte or liquid copper was developed by both, an extension of the Reddy-Blander model for deriving a priori the arsenic capacity, and by a relationship between the arsenic capacity and the arsenic distribution ratio. In this study, the a priori arsenic capacities in the FeO-SiO2, CaO-SiO2, MgO-SiO2, FeO-CaO-SiO2, FeO-FeO1.5-CuOo.5-MgO-SiO2, FeO-FeO1.5-CuO0.5-CaO-MgO and FeO-FeO1.5-CuO0.5-CaO-MgO-SiO2 slags were calculated at 1573 K. The a priori arsenic distribution ratio between the FeO-FeO1.5-CuO0.5-CaO-MgO-SiO2 slag and copper matte (L s/m as), and between the FeO-FeO1.5-SiO2 or FeO-FeO1.5-CuO0.5-CaO-MgO slag and liquid copper (L s/Cu as) were calculated. The model calculated data are found to be in good agreement with the reported experimental data. The availability of reliable thermodynamic data for slag components and impurities in the slag-matte-metal system is essential for the accurate prediction of impurity capacities and distribution ratio data. The arsenic distribution ratio model developed here, can be extended for prediction in multi-component slags and mattes or liquid metal, and thereby may lead to the development of new slag systems for the efficient removal of arsenic in the copper smelting, converting and refining processes.

Jan 1, 2003

By P. G. West-Sells

Recovery of gold from thiosulfate leachates can be accomplished by adsorption of the gold thiosulfate complex by a strong base resin. Two of the most significant impurities that can decrease this gold adsorption are tetrathionate and trithionate, which are produced as oxidation products of thiosulfate during gold leaching. This paper investigates gold adsorption on a strong base resin (Purolite A500C) as a function of the concentration of these impurities. It is shown that concentrations of tetrathionate and trithionate as low as 150 mg/L can decrease gold loading by an order of magnitude, and that of the two ions, tetrathionate has a stronger detrimental effect. The resin and solution gold concentration profiles were successfully fit using a Freundlich isotherm, which further shows the strong effect of tetrathionate. To counteract the decrease in gold adsorption by tetrathionate, a novel process was proposed. Sulfite was added to the solution to oxidize tetrathionate to trithionate, and a nitrogen blanket was added to ensure that no further oxidation of thiosulfate could take place. It is shown that by incorporating this process, gold adsorption was doubled from both synthetic and real gold thiosulfate leachates.

Jan 1, 2003

By J. Engesser

This paper discusses the effect that water chemistry, and water treatment have on pre-fired pellet quality and bentonite-binding effectiveness. A discussion concerning the effect that water temperature, water chemistry, water treatment, and surface area have on disc filter productivity and filter cake moisture is also included. This report is a summary of the data that were presented in five previous research reports, which are listed as references in this paper.

Jan 1, 2003

Most mining projects will involve some level of financial markets price risk. This is because commodities are generally traded in $US. The project will also incur costs in $A and if based in Australia will seek to generate a return in Australian dollars. Therefore the project faces commodity, foreign exchange and interest rates risk. As a business you may wish to maintain these risks within your business. However if the project requires financing to be provided then the financiers will want to ensure that there is a level of certainty attached to the cash flows to support the debt repayments. This is achieved by hedging the financial market risks. Traditionally the hedging process has been based on underlying assumptions within project models, which incorporate views on the direction of the underlying price risk. These views can be formed in an ad hoc manner. Gathering information from a variety of sources including economic forecasting and modelling, technical analysis, seeking market expert views. However, given the historical accuracy of such forecasts locking into long-term fixed hedging arrangements can create an inflexible environment that can restrict the opportunity to benefit from the underlying volatility of financial markets.

Jan 1, 2003

By A Goldstone, M Fitzpatrick

Contemporary mine wastewater flows are subject to stringent water quality standards before discharge to local waterways. Strict criteria are often applied as a result of fears of extensive acid mine drainage; a feature of the many abandoned mine adits around the Coromandel, Central Otago, and the West Coast. In most cases the USEPA water quality criteria have been used to set treated wastewater discharge water quality standards. In future it is possible that the recently published ANZECC water quality criteria guidelines will be used for this purpose. The ANZECC guidelines also provide for the establishment of discharge criteria at specific sites, rather than accept the trigger values. The use of site-specific criteria for treated wastewater mine discharges was pioneered at the Golden Cross gold mine, near Waihi, in the late 1980s. The procedure used to derive water quality criteria was based on USEPA guidelines. In developing the Golden Cross criteria, only species that occur, or are similar to those that occur in the Waitekauri River were used. The mine commenced discharge of treated wastewater in 1991, and macroinvertebrate communities in the vicinity of the discharge point have been regularly monitored twice a year for the past 12 years. Despite fluctuations in community composition and abundance over that period, no permanent significant changes in the macroinvertebrate communities occurred between sites above and below the treated wastewater discharge. The success of the site-specific criteria at Golden Cross has shown how the application of this methodology can result in the protection of aquatic life while allowing for the discharge of treated mine wastewater.

Jan 1, 2003

By Ferdi Camisani

The ‘Bible’ 1977 & 1981 ‘South African Mine Valuation’ by C. D. Storrar. Proved reserve (=’measured ore’ USA; ore reserve = the payable portion of the proved reserve) -Fully developed (…immediately available…) -Partly developed (…not immediately available…) -Undeveloped (…unavailable…) Probable reserve (=’indicated ore’ USA) Possible reserve (=’inferred ore’ USA) Life-of-mine reserve (Proved + Probable + Possible)

Jan 1, 2003

By H. H. Murray

Tactical R & D is research and development for a specific application or applications. The mineral scientist has to define and understand the physical and chemical parameters required for a specific or potential application. Then the researcher must know the structure and composition of the mineral and its physical and chemical properties. Can these properties be changed by processing particle size and shape modification, and surface chemical treatment? Examples of tactical R & D in the industrial minerals area will be described.

Jan 1, 2003

By G, F Beach, D Jazzini, R Rounsley

Over the past 20 years within Australia, there have been a number of incidents at mine sites where ammonium nitrate-based explosives have reacted with certain rock types containing sulfide minerals. These rocks have commonly been referred to as æreactive groundÆ. These reactions have frequently led to fires (particularly in ground susceptible to spontaneous combustion) or premature detonation of the ammonium nitrate-based explosives. Clearly, this introduces an element of risk when using ammonium nitrate-based explosives in these areas. Dyno Nobel has been proactive in developing ammonium nitrate-based explosive products that can be used in these types of æreactive groundÆ environments that minimise the risk of premature detonations occurring. A system for assessing æreactivityÆ of sulfide containing rocks has been developed that can be used in the field. Previous literature has been reviewed, identifying Differential Thermal Analysis (DTA) as the most common method for determining the æreactivityÆ of the ground. In the present investigation, DTA has been rejected as a suitable technique for determining ground reactivity, since it measures thermal reactions at higher temperatures over short time periods, conditions that are unlike those in the field. For example, ground at ambient temperature has been found to react with ammonium nitrate-based explosives over long time periods, reactions that are unable to be evaluated using DTA. Other more suitable techniques have been developed to monitor rock conditions that can be measured in the field and give a good indication of potential ground æreactivityÆ with ammonium nitrate-based explosives. Dyno Nobel is currently investigating the reaction mechanisms of spontaneous combustion in reactive ground, the decomposition mechanisms of ammonium nitrate and the role of inhibitors in ammonium nitrate-based explosives. Once complete, this fundamental research will lead to the further development of even lower risk ammonium nitrate-based explosive products for use in æreactive groundsÆ in a variety of mine environments.

Jan 1, 2003

By R Dunne, G Lane, S Ha, D Dreisinger

The paper outlines the 17 Mt/a Telfer Project plant process design from sample selection to feasibility study design. The 366 Mt Telfer mine reserve consists of a diverse range of copper and gold mineralisation, from massive sulfide reef ores to stockwork ore, oxide copper minerals to chalcopyrite, siltstone to competent quartzite, all with relatively high levels of gravity recoverable gold. The complexity of the orebody demanded a flexible plant that could recover copper and gold values by a combination of gravity recovery, flotation and concentrate leaching. The demands of treating ore from a high grade underground mine and a variable grade open pit (that includes underground old mine workings) necessitated a dual train approach from primary crushing to concentrate production in order to minimise the requirement for campaigning of different ore types. An extensive sampling, testwork and technical evaluation program was undertaken to identify processing characteristics and the optimum process route for each ore type. The design experience included: the development of robust primary stockpiling and pebble crushing concepts; detailed review of scale-up of SAG and ball mill pilot plant data to plant scale; the selection of two 15 MW SAG mills and two 13 MW ball mills for the grinding circuit; and detailed modelling of the pyrite concentrate carbon-in-leach (CIL)/sulfidisation acidification recovery thickening (SART)/acidification volatilisation recovery (AVR) process to optimise design for copper and cyanide recovery from leach liquors. The Telfer plant design also measures the development of process design based on experiences at the Cadia Hill Cu/Au concentrator, commissioned in 1998. The differences between the two plants are compared and contrasted.

Jan 1, 2003

By Sylvie C. Bouffard

The need for a better understanding of the heap biooxidation pretreatment of pyritic refractory gold ores has prompted us to develop a rigorous mathematical model of the process. The hydrological structure of the model takes the form of lateral stagnant pores in contact with a uniformly distributed gas stream and connected to vertical plug flow channels, as suggested by the results of an independent study of column hydrology. A model of pyrite oxidation kinetics was derived based on electrochemical leaching theory and the results of potentiostatic stirred tank and column tests. The growth rates of attached and planktonic iron- and sulfur-oxidizing cells are modeled with separate Monod expressions over three separate temperature ranges corresponding to mesophiles, moderate thermophiles, and extreme thermophiles. Isothermal column tests validate the model simulations. Excellent fits of several leaching indicators (potential, extent of sulfide oxidation, iron concentration, cell numbers) reveal the rate-limiting step to shift from particle kinetics to oxygen gas/liquid mass transfer with increasing temperatures and pyrite head grades. Competition for oxygen between sulfur- and iron-oxidizing microorganisms lowers potentials and slows down pyrite oxidation. This modeling tool may assist engineers in the design and operation of heaps to give more complete gold liberation in a shorter time.

Jan 1, 2003

By Richard K. Komarek, Antonios Zavaliangos, Roman T. Dec

"The work in the paper introduces a 2-dimensional finite element model for analyzing particular material processing in a roller press. Two basic roller geometries are considered: (a) smooth rolls (used for milling and compaction) and (b) rolls with cavities, commonly used for briquetting. A model is presented that is suitable to analyze material behavior through all stages of the rolling process: feeding zone, nip region, neutral plane and release section. It can predict pressure, shear stress, slip of the material over the roller surface, material velocity field, failure of the compact during release and the course of other important process variables.MODEL, RESULTS AND CONCLUSIONSAn associated Gurson model was employed as a constitutive model for the material. The calibration of the model was based on experimental results from an instrumented compaction die. Coulomb friction law was used to describe phenomena on the material/roller surface interface. Powder River Basin sub bituminous coal fines with moisture content 9% was used as a model material.Two finite element models have been set up, one for the briquetting roll and one for the “equivalent” flat roll. Approximately 3200 plain strain continuum elements with reduced integration (CPE4R) were used. Lagrangian-Eulerian (ALE) approach in conjunction with judiciously applied remeshing was employed with the commercially-available, dynamic explicit version of ABAQUS finite element code.Comparison of model predictions with experiment shows that there is an agreement in terms of the general trends of experimental values recorded on laboratory roller presses. Gurson model overpredicts stresses at low densities and, as a consequence, overpredicts roll force and roll torque."

Jan 1, 2003

South Africa is a semi arid, water scarce country that has undergone recent major political and social transformation. This transformation has ensured that water management has become a primary environmental concern in the South African mining industry, raising the status of water from an ancillary service to a fundamental factor in mine planning. The coal mining industry has been involved in the development of integrated catchment management plans since the late-1980s when a series of initiatives commenced in catchments where collieries operated. The plans focused attention on water supply and water demand management, the equitable access to water supplies, and intersectoral approaches to decision making, before the promulgation of new legislative and policy frameworks. Development of an integrated watershed management plan for the Olifants River basin, located in the Mpumalanga province, commenced in 1990. The Olifants River is an international river basin of 54 570 square kilometres and shared by South Africa and Mozambique. The upper watershed, locally called the Witbank Dam catchment, will be the focus of this paper. It has an area of 3400 square kilometres and is the major coal mining, power generating, and maize-growing region of the country. The processes embodied in the integrated watershed management plan had no formal guidelines but rather developed in an ongoing fashion over time. The plan commenced with a situation analysis involving the major stakeholders that identified principal technical shortfalls. These shortfalls were investigated under the guidance of multisectoral committees. The Olifants River Forum was started to extend awareness of the initiatives on an informal level throughout the whole watershed. The results of the investigations enabled water quality guidelines to be established for the upper catchment. To achieve the guideline levels additional initiatives were developed including a scheme to manage mine water discharges into the river system, the development of a standard four-step water management process, investigation and development of innovative mine water treatment processes, specifically sulfate reduction technologies, the use of gypsiferous mine water for irrigation, river and dam hydrological models, groundwater models and biomonitoring. Significant outcomes from the process have been achieved including the improvement in water quality in the Witbank Dam catchment. Equally significant have been the development of partnerships between businesses and between businesses and the community specifically in the use of mine water for irrigation. The plan realised a number of requirements for success including, the development of trust, openness and transparency with information, the essential need for consultation and negotiation and the involvement of third parties to validate information. The future still holds the potential for disputes between upstream and downstream water users but understanding, transparency and accountability between all players have, and will in future, enable the matching of the increasing demands on a scarce water resource to the needs of all.

Jan 1, 2003

By Du Gon Lee

This study presents a model to predict fate of resuspended sediment in the development of deep-sea mineral resources including manganese nodules under Clarion-Clipperton area of the Pacific Ocean. The manganese nodules are expected to be developed near future and major research is undergoing in Korea recently concerning many aspects of the mineral resources development. One aspect is about environmental concern related to the deep-sea development, and a major environmental problem is the resuspended deep-sea sediment. In order to quantitatively analyze the resuspended sediment in the water column during the deep-sea development, particle size distribution (PSD) was considered an important factor in this research. The model developed here includes PSD and coagulation process, as well as sedimentation process. The model is one dimensional in the vertical profile, and was designed to describe the change of particle size distribution in the water column in the given vertical point. Based on the mathematical modeling, a numerical model was developed. Using the model, basic simulation was performed under representative environmental setting of the deep-sea environment. The simulation showed the dynamics of change of particle size distribution for 50 m depth of water column from the deep-sea bed, up to 10 days of simulation time. The simulation results indicate that coagulation seemed an important factor in the fate of resuspended deep-sea sediment. As a result, this research shows that the particle size distribution approach, as well as considering the coagulation process, is needed and may be effectively applied to environmental impact analysis of deep-sea resuspended sediment. Key Word: Deep-sea Mineral Resources, Resuspended Sediment, Environmental Impact, Particle Size Distribution, Coagulation, Modeling and Simulation

Jan 1, 2003

By G. A. Brooks

Increasing interfacial area through gas injection is one of the main methods for accelerating reaction between slag, metals, and gases in modern pyrometallurgical reactors. In slag-metal reactors, the generation of a large number of metal droplets into the slag phase through high gas velocity has a much larger effect on the overall kinetics compared to the enhanced mass transfer through mixing. Top blowing technology generates large interfacial areas (>300 m2/tonne) through high impingement gas velocity at short distances between the exit of the injection lance and the metal-slag interface. Phase separation may become a limit at the case of very high interfacial areas, though there is still only limited understanding of the trajectories of metal droplets in slag-metal-gas emulsions.

Jan 1, 2003

By Adam Graf

Mineral deposits are fundamentally different from most other assets -Every deposit has unique geologic and metallurgical characteristics -Asset (resource) is finite and cannot be truly replaced. -Long timeframe and time-value of reserves -Commodity price volatility (see Torries, 1998)

Jan 1, 2003

By Justin Brown, Michael Kobler, Dave Ragland, Bob Shufflebotham

PROJECT OVERVIEW As the sun-bronzed San Diego students strolled casually to class, mining crews from Atkinson Construction were working only 9 meters below the surface. The330 meter long, 11.3 meter diameter squat ellipse NATM tunnel is part of the9.3 kilometer Mission Valley East Extension Light Rail Transit (MVE-LRT) being constructed for the San Diego Metropolitan Transit Development Board (MTDB). The SDSU segment of the MVE-LRT was awarded to the Clark Construction Group, the parent company of Atkinson Construction for $82.7 million. URS CORP was the prime designer and Hatch Mott MacDonald performed the NATM tunnel design. The construction managers were Washington Infrastructure Services with Underground Construction Managers, EPC Consultants, and ILF Consultants. A NATM tunnel design was chosen as the most cost-effective way to minimize disruption of the university activities. The tunnel passes close to several buildings and directly below access roads, tennis courts and a baseball field. The NATM method of conventional mining uses shotcrete for ground support often reinforced with steel orplastic fibers, welded wire mesh and lattice girders. The tunnel runs from a cut and cover box up a 4.2% grade in a 217 meter radius left-hand curve with several spirals and ends at the underground station 330 meters away. The depth of cover varies from 16 meters near the west portal to nine meters at the station. The design called for a two-pass system with a primary lining of 300 mm shotcrete with lattice girders at 1 m centers and two layers of welded wire mesh. The lattice girders are used primarily for profile control and are not considered a structural element. The top heading was designed to be excavated in one of three excavation sequences depending on ground conditions and depth of cover. In sequence one excavation, the top heading is excavated in two halves with a one-meter separation. In sequence two excavation, a side gallery is advanced 8 or more meters ahead of the

Jan 1, 2003

After a snap-shot survey of water quality of streams draining various coal measures carried out in 2000 - 2001, West Coast Regional Council expanded its monitoring programme to better establish the condition of streams draining coal mining areas and to characterise the variability of water quality with respect to stream flow. Samples were collected for water quality indicators such as pH, sulphate, turbidity, conductivity, temperature and dissolved oxygen as well as macro-invertebrates, fish and assessments of stream habitat. Water quality sampling was carried out at 27 sites on 21 streams located from Page Stream near Seddonville in the north, to Seven Mile Creek near Dunollie in the South, and to Garvey Creek east of Reefton. There was relatively low variability of pH, conductivity and sulphate concentrations at most of the sites sampled. Conductivity and sulphate concentrations reduced with increasing flow and pH generally increased. Significant effects on macro-invertebrate and fish populations were identified at several of the sites where water quality sampling was undertaken. Of the water quality parameters tested, macro-invertebrates were mostly affected by pH. Although not sampled directly (conductivity was used as a surrogate) heavy metal concentration may explain some of the variation in macro-invertebrate communities. Three creeks affected by mine drainage were sampled for fish and no fish were present. Fish appear to be more sensitive to acid rock drainage that invertebrates. Using data from this survey and other studies conducted in the region, the total length of stream that is actually or highly likely to be adversely affected by acid rock drainage was estimated at 125 km. This figure is useful as a gauge as to the magnitude of the issue in this region and for setting of priorities for remediation. However, as it is only an estimate based on limited sampling sites, it should be used with caution.

Jan 1, 2003

By X. H. Zhang, J. G. Cai

This paper discusses the behaviour of large-span tunnels and caverns in hard rock in a major underground storage project. In-situ stresses were measured using hydraulic fracturing during site investigation and 3-D overcoring during construction, with both showing a horizontal stress ratio of 2-3 times the vertical stress. Rock reinforcement design was based on the Q-system combined with numerical modelling for special design cases. Tunnel design and performance were checked and monitored by in-situ instrumentation during rock excavation, including measurements of deformation, convergence, and load on rock bolts. Deformation measurements using borehole extensometers included one borehole drilled into the virgin rock before rock excavation, which provided a direct and very insightful comparison with the various deformation measurements made during rock excavation. These measurements coupled with numerical calculations have proven that the high horizontal stresses to be very favourable to the stability of the large openings.

Jan 1, 2003