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By R. Mensah-Biney

The NC State University Minerals Research Laboratory (MRL) and Waste Reduction Partners (WRP) of the Land of Sky Regional Council joined efforts in 2000 to initiate a technically sound and practical program for the management of high-volume coal combustion by-products (CCBs) in North Carolina. The accumulation of CCBs from coal burning boilers throughout the state of North Carolina posed a substantial storage problem, and the area was overripe for an effective management program, which would be environmentally sustainable. In particular, the public utility generators had filled storage ponds on their properties, and the storage overload had grown to critical proportions. Much the same situation existed for paper mill biosolids, which were stored on site in landfill cells along with daily output of CCBs from the mill boilers. A conversion process via the patented pyro-process12 (US Patent No. 5,342,442) to produce synthetic light weight aggregates (LWA) from CCBs and paper mill sludge was conceived to process large quantities of both these waste materials. MRL and WRP initiated and formed a consortium that brought together academia, private industry and state agencies to evaluate the production of LWA by the pyro-process. The industry partners included representatives from the power companies, industrial ash generators, expediters for coal ash products, as well as concrete block manufacturers. It was important to welcome interested parties from not only the western North Carolina area and other parts of the state but also from neighboring states including Tennessee, South Carolina and Georgia. Membership of this consortium evolved during the intervening years to include the following participants and supporters: Progress Energy Carolinas; Duke Energy; Santee Cooper; Full Circle Solutions; Land-of-Sky Regional Council; NC Department of Pollution Prevention and Environmental Assistance; Ecusta Business Development Center; Blue Ridge Paper Products; Jackson Paper and Manufacturing Company; Miller Perlite; Appalachian Products; General Shale Brick; Metromont Materials; Small Business Technology Development Center of the University of North Carolina system and North Carolina State University The initial development program conducted at the Minerals Research Laboratory (MRL) was to formulate an acceptable LWA product, which fulfilled user specifications for light weight concrete block and structural concrete application. Support work and program coordination efforts were furnished by retired technical volunteers in WRP. The work advanced steadily, using proven technologies well established in the mineral industry, to generate a very satisfactory LWA. The consortium then concluded that a more comprehensive CCB conversion program would have more appeal for full scale manufacture and commercialization, if a variety of products from CCB separation were generated. This product assortment would include bottom ash, low carbon fly ash, recovered carbon of high purity, as well as the synthetic LWA. The bottom ash would serve the concrete block market, the fly ash was in demand for ready-mix concrete, and the high carbon product could be pelletized and used as a fuel for reburn or by the steel industry, and the LWA was a sought-after component for light weight concrete applications. After scouting all these potential markets and finding them to be viable, the consortium then inaugurated an integrated pilot plant program for the CCB separation and conversion. The plan was organized in three (3) parts: (1) Phase I ? bench scale evaluation studies (2) Phase II continuous pilot plant evaluation and (3) Phase III ? conceptual commercial plant design including marketing efforts and attraction of business entrepreneurs to build a full scale manufacturing plant. Phase II would serve to validate the process in a continuous mode and produce substantial quantities of products for preliminary marketing efforts and for demonstration-of-use purposes. The consortium agreed to the name, CAROLINA ASH PRODUCTS, (CAP), for the integrated pilot plant program. The products generated might be designated with the CAP label as: bottom ash would be named CAP Granules, low carbon fly ash would become CAP Ash, recovered high carbon product would be CAP Carbon, and LWA would have the name CAP Stone. Phase II of the program processed 20 tons (18 t) of ponded ash from Progress Energy storage at a rate of 600 lb (271 kg) of raw ash per hour with favorable results. PRELIMINARY STUDIES Prior to committing laboratory research and development effort as well as support and coordination activities to this program, it was necessary to determine (1) the level of need for a freshly launched CCB reutilization program in this state and (2) what degree of versatility was necessary for such a process. State agency records and a survey of recent boiler operations indicated that in the state of North Carolina at least 77 facilities manage CCBs from their boiler operations. Despite continuing development efforts in more eastern parts of the state, the use of CCBs for commercial applications has not increased to a level which alleviates the need to store vast quantities in private monofills on the generator?s property. More than 1.25 million tons (1.13 million t) of CCBs are landfilled in NC annually, with 300,000 tons (271,985 t) per year generated in western NC alone. Many different boiler types, which span both very old units and those that are modern and efficient, were to be found. These included stoker-fired units, pulverized coal boilers, slag-tap furnaces, and fluidized bed combustion boilers covering a range of sizes. Any systems designed to separate CCB components from all these sources and convert them to useful secondary products would need broad processing latitude and flexibility. Up to the present there has been a paucity of research done in the western part of the state to find productive alternatives to storage in landfills. With tipping fees in our largest landfill now approaching $40 per ton ($44 per t) and escalating transportation fees (about $200 per truckload up to 40 tons, traveling a distance of 25 miles), the problem has become urgent both economically and ecologically. A well-designed, integrated wet process for CCB separation into value-added products had much potential to be less expensive than landfilling as well as to provide saleable materials with acceptable profit margins. These preliminary investigations also revealed that other major waste streams, in particular paper mill sludge and municipal and animal waste biosolids were important candidates for priority attention. Since these biosolids could furnish the organic component of a synthetic LWA product, they could be consumed as part of the same program. This added interest value to a growing list of partners to support and participate in the program.

Jan 1, 2009

By Ramona Prillhofer

Salt slag is a waste product produced by the recycling of aluminum. In most European countries (e.g. Austria, Germany) the landfill disposal of this waste is forbidden because the slag contains soluble salts and these represent a potential source of pollution to the surface and groundwater. Additionally, consisting metal and some compounds in the salt slag can react with water and resulting from this, noxious gases are generated. The recovery of useful materials from these wastes is accordingly both environmentally necessary and economically feasible. This study describes a complete recycling-process for the salt slag, which includes a leaching-cristallization-process to obtain the oxidic residue, a pyrometallurgical-step to clear the oxidic residue and finally an extensive characterization of the achieved products. Due to the increasing price of raw materials, the utilization of the oxidic residue into commercial products has been investigated and application possibilities will be discussed.

Jan 1, 2009

By W Stange

Assessing the risks in a mining project is a key aspect of project evaluation. This is an exacting and demanding task because of the complexity due to the need to deal with uncertainty over long time periods. The way risks are assessed and managed is critical to the long-term success of the projects and the business. Discounted cash flow (DCF) analysis is commonly used for project and risk evaluation. A discount rate is selected that accounts for uncertainties in the cash flows. However, it is difficult to determine an appropriate discount rate due to the large number of factors that need to be considered and the complex relationships between risk sources. Using a proven framework, ævalue at riskÆ (VaR), this paper proposes to rigorously model and quantify ærisk at sourceÆ. The approach was first employed to assess financial market risks and is now widely used in the banking sector for risk assessment. In project evaluation, all risk sources are identified and estimated separately to ensure the overall project risk is quantified accurately. A bottom-up approach has been proposed. Estimates are first carried out for risk factors at the bottom of the project structure. The assessment is then applied at increasingly higher levels until the overall project risk is estimated. Value at risk is a versatile methodology and can be used in a local or integrated manner. The final value is objective and the calculation steps can be easily justified and followed. Four case studies have been included to illustrate how the proposed approach can assist management in decision-making.

Jan 1, 2009

By Bill Williamson, Doug Richmond, Kerri Kuntz, Gus Gilman, Larry Heywood

This was a description by the poet of what occurred over two centuries earlier to Hannibal’s troops as he passed through the Alps. Interestingly, the pass that many feel is the route that Hannibal chose, Col de la Traversette, is the sight of possibly the earliest avalanche mitigation known. Monastery records describe a tunnel built in 1470, near the top of the pass designed to protect pilgrims from the upper slopes. For the next several centuries, avoidance and reinforced structures were the primary tactics to defend from avalanches

Jan 1, 2009

By M J. Daniel

Mineral resources all over the world are often heterogeneous and have variable ore properties and ore grade. As a result the ore processed in concentrating plants varies over the life of mines. Consequently the circuits often suffer from bottlenecks typically at the stages of crushing, semi-autogeneous (SAG) and ball milling. Bottlenecks may be remedied with equipment retrofits, however, design engineers should consider a phased approach to the circuit design that delays initial capital expenditure over the life-of-mine. This paper deals with the debottlenecking of existing mineral processing plants by means of high pressure grinding roll (HPGR) applications. It also deals with the use of innovative flow sheet designs using HPGRs for the design of Greenfield plants by engineering or mining companies. In the case of Greenfield plant design an analysis with respect to energy efficiency and operating cost (OPEX) is presented. The analysis compares the performance of SAG based circuits against HPGR circuits that may be influenced by variable ore properties. Globally about 600 HPGRs are installed in various applications in the cement and minerals industries. In excess of 100 of these HPGRs are used since the mid 1980s for crushing and grinding of various ore types including æhard rockÆ applications. HPGR technology is mature enough to be considered as an ideal debottlenecking device. HPGRÆs are versatile, they have a low installation footprint and they are flexible in its machine settings (pressure, roll speed), which can be adjusted to react to ore variations whilst maintaining a high throughput. Examples for the benefits of using HPGR in terms of energy efficiency and operating costs are presented by this paper. æEco-efficientÆ flow sheets and sustainable development initiatives are linked to energy savings as an æenergy costÆ and benefit to the environment. Energy savingsÆ can also be analysed in terms of the ædollar costÆ (OPEX) savings. This paper demonstrates that HPGR is more energy efficient and may reduce the overall grinding energy requirements in the order of 16 per cent depending on the target grind size and ore properties. The HPGR is more cost efficient and may reduce overall grinding costs by as much as 19.3 per cent depending on the cost of energy, grinding media and the rate of grinding media wear in the comminution circuit.

Jan 1, 2009

By B. R. Zernich

Advances in tunneling technology, such as Earth Pressure Balance and Slurry Shield methods, have allowed the tunneling industry to construct tunnels in increasingly difficult ground conditions. In recent years, a number of civil projects including large diameter train tunnels, subway tunnels, water tunnels, sewer tunnels, and combined sewer tunnels have been successfully completed deep beneath the water table in soft ground conditions utilizing modern day Tunnel Boring Machines (TBM). With the increase in difficult ground conditions and higher water pressure comes the inherent need to utilize compressed air to gain access to the TBM?s cutterhead and cutting tools. This paper focuses on one such instance in Los Angeles, CA in which Traylor Brothers Inc. performed a cutterhead intervention by compressing the heading of an 11-foot diameter tunnel to approximately 3 bar gauge pressure. This paper focuses on the environmental controls used to manage ventilation, oxygen levels, temperature, and pressure, as well as discusses the problems associated with toxic gases and the increased risk of fire. The paper will also cover the physical science of the environment and the increased risks of performing basic job functions while in a compressed air heading.

Jan 1, 2009

By D Giurco

As part of global systems of mineral production and consumption, the Australian minerals sector is facing sustainability challenges across technological, social, ecological, economic and governance domains, as well as between local, national and global scales. To ensure that the Australian minerals sector progresses towards sustainability, it is imperative to understand the possible ways in which AustraliaÆs mineral resources could support sustainable futures. A significant research gap exists between the complex nature of questions concerning minerals sustainability and the reductionist methods available to deal with them. This paper argues the need for broader, more integrated approaches to questions concerning minerals sustainability, which can address multiple human perspectives, complex and æmessyÆ patterns and processes across multiple organisational, temporal and geographical scales and whole systems of mineral production and consumption. To inform the development of a new approach to minerals sustainability, this work reviews the contemporary understanding of the Australian minerals sustainability problematic, from the perspective of the Australian minerals sector (Minerals Council of Australia), the Australian research sector (Mudd 2007a, 2007b; Mudd and Ward 2008) and a multi-scale international project (MMSD 2002). This review shows the focus of current responses to the minerals sustainability problematic, identifies the need for an integrated approach to questions of minerals sustainability and addresses how different approaches are informed by underlying and unarticulated assumptions about the tolerability of tradeoffs between different societal goals, the treatment of uncertainty and the application of different conceptual geographical, organisational, temporal and life cycle scales to define the minerals sustainability problematic. The Mineral Resources Landscape proposed, offers an expanded conceptualisation of minerals sustainability, to link minerals production and consumption in an integrated assessment across the entire minerals supply chain, connecting social, ecological, technological, economic and governance domains across local, national and global scales. The key leverage points governing change in the Mineral Resources Landscape are identified as: the material source, extraction and production technologies, level of service and value, and consumption patterns. Mapping the key challenges facing the minerals sector, as identified in the review herein, indicates that the boundaries defining traditional conceptualisations of minerals sustainability focus on the material source and technology and ignore two very key drivers of the Mineral Resources Landscape û the æservicesÆ minerals offer to society and the æconsumption trendsÆ which assimilate these services into society. Understanding these overlooked aspects of the Mineral Resources Landscape, along with the conventional areas of focus, is essential for identifying the Australian minerals sector as a provider of sustainable mineral services. This insight prompts a reconsideration of the role of minerals services and consumption trends, together with the role of the material source and technology in shaping change and the emergence of sustainable systems of Australian minerals production and consumption, across multiple scales and domains.

Jan 1, 2009

By W Dodson

Major ions, d18O and d2H and Carbon-13 concentrations in groundwater from 30 bores near an open pit iron ore mine were used to better understand the chemical evolution of groundwater in the aquifer. The relatively depleted d18O and d2H isotopes of groundwater from various depths suggest that groundwater is recharged from intense rainfall events, with little evaporative effect. The 300 to 500 mg/L increase of major ions relative to that of rainfall is due to evapotranspiration of rainfall during recharge. Geochemical mass balance modelling suggests that the evapotranspiration of rainfall during infiltration through the unsaturated zone varies over six fold from 20 to 130. This coupled with the dissolution of CO2 from the unsaturated zone and partial dissolution of carbonates and gypsum from Tertiary sediments and carbonates from the Wittenoom Formation accounts for the current major ion, d18O and d2H distribution in groundwater. Despite the relatively dissected morphology and steep hydraulic gradient the results of this study highlight the dominance of vertical flow relative to horizontal flow. The study also shows the dominance of rapid recharge by significant rainfall events as an important component of the water budget for east Pilbara aquifers.

Jan 1, 2009

The ventilation conditions at the underground coal mines are influenced; first: by the disturbances of the natural nature (barometric pressure, methane liberation, etc.), and second: by the disturbances caused by the production process. The major goal of this study was to determine the changes of the ventilation parameters, such as the flow, pressure and methane concentration around the longwall panel, particularly, along the longwall face due to the shearer operation (motion). It is well known from the practice, that the movement of the shearer influences the ventilation parameters around the longwall panel, including the gob area. Until now, these data were gathered in a single or multiple locations at the different time. However, only the simultaneous measurements of all of these values allow seeing the time dependent interrelationships between measured parameters. To be able to show these interrelationships, special experiments, described in this paper, were carried out by the author. These experiments were prepared and executed at the BUDRYK Coal Mine in Poland. During each experiment a simultaneous measurements and monitoring of the barometric pressure, air velocity and methane concentration at the different locations along the longwall face, were performed. The investigation was possible by using a special setup of instruments with a short sampling time, i.e., within 2 seconds. The monitoring of the absolute pressure was conducted by using the digital barometer µBar, developed by EMAG, based on the SETRA pressure transducer, model 470. The velocity of air was measured using the electronic vane-anemometers, developed by IMG-PAN. The methane concentrations were measured using methanometers as the part of the EMAG automatic gas monitoring system. The investigation data confirmed that disturbances due to the operation (motion) of the shearer at the longwall face have a local character. It could be also seen that a large diameter shearer (compared to the total cross-section area available for the air flow) is acting as the piston compressing the air (the overpressure) ahead of the shearer. This fact affects the methane mixing process and flow patterns in the vicinity.

Jan 1, 2009

The Prospero orebody is a part of the Helene mine at Cosmos and was scheduled to begin production in March 2008 after the exhaustion of the Tapinos orebody in the same mine. Treatment of the Tapinos orebody was challenging and it was envisaged that Prospero would have similar properties given that it was also anomalous in deleterious elements and would be of a similar mineral hosting. It was deemed necessary to undertake a metallurgical test work program to identify any potential processing issues, complex mineralogy or significant metallurgical domains. The paper discusses the processes which were employed to undertake the metallurgical test work program and describes the aspects that can be employed by other developers to quickly and effectively assess potential future orebodies. It will demonstrate that the work was successful at determining expected metallurgical behaviour, providing direction for mining operations and highlighting areas for more extensive research.

Jan 1, 2009

A shortage of technical skills in all areas of the mining industry is being experienced worldwide. This has significant consequences for design, operations, productivity and safety and, therefore, needs to be seriously addressed, both in the short and longer term. It is therefore both a strategic and a tactical issue. Importantly, however, since mining is a long-term business, the shortage of skills must be dealt with from a strategic point of view to ensure the supply of the necessary skills for future mining. This paper will deal specifically with the provision of high level technical skills, that is, university graduates in mining engineering, and the outlook for the institutions that are currently producing such graduates.

Jan 1, 2009

By J. P. Brady

A major spontaneous combustion incident occurred in the sealed goaf of the SL3 Panel; Southland Colliery in 2003 resulting in the loss of a longwall and sealing of the mine. The most important issue for the new owners, Yancoal Australia Pty. Ltd, was to effectively manage the atmosphere in the fire affected sealed area. This atmosphere comprised of flammable gases, the products of combustion and excessive levels of oxygen due to pressure differentials across the panel isolation seals with a potential ignition source associated with the residual spontaneous combustion event. The challenges were met in the first instance by the erection of pressure balance chambers with limited success. The problem was not solved until the pressure chambers were pressurized using a Floxal Nitrogen Plant supplied by Air Liquide Australia. Given the success of this approach on a small scale, a higher capacity Air Liquide Floxal Unit was acquired to manage spontaneous combustion at the recommencement of longwall mining operations. This provided the ability to pressurize pressure chambers that were installed in the Maingate Seals behind the face of the adjacent Longwall Block effectively preventing the ingress of oxygen and permitting the goaf to self inert in a reasonable time period. This paper summarizes a new proactive method of mitigating the risks associated with active and sealed goaves. Proactive management of these areas using low flow nitrogen into pressure chambers to maintain a positive pressure has eliminated typical reliance in explosion proof or explosion resistance seals as the primary control.

Jan 1, 2009

By M. N. Chandraprabha

This paper discusses the role of the mineral-adapted acidiphilic microorganism Acidithiobacillus ferrooxidans in the beneficiation of arsenopyrite-containing multisulfides (pyrite and chalcopyrite) and the bioremediation of the resulting arsenical waste water. It was found that adaptation to minerals alters the surface properties of the microorganism. Bacterial adaptation to arsenopyrite and controlled bacterial adhesion to mineral surfaces lead to selectivity in arsenopyrite separation. Bioremoval of arsenic ions (both arsenite and arsenate ions) by Acidithiobacillus ferrooxidans is also discussed. Key words: Acidithiobacillus ferrooxidans, Bioremediation, Arsenopyrite beneficiation

Jan 1, 2009

By B. Cousins

Copper, nickel, zinc and other ?penalty? metals are found with gold together in nature, and have a similar chemical affinity for cyanide used in leaching operations4. As a result, solutions that come from the heap leach pads contain a significant concentration of penalty metals along with the desired gold. In solution, gold and cyanide form the complex Au(CN)2- that is readily adsorbed onto activated carbon. Penalty metals as individual metal ions also load onto activated carbon and, depending on the concentration of cyanide and the pH of the solution, can form various cyanide complexes. Some of these complexes can also load onto carbon while some are significantly inhibited from loading. Copper, for example, can form the dicyanide complex Cu(CN)2-, the tricyanide complex Cu(CN)32-, and the tetracyanide complex Cu(CN)43-. At a low pH and a low concentration of cyanide, the dicyanide complex predominates. At a higher pH and a higher concentration of cyanide, the tetracyanide complex predominates. Without excess cyanide, however, individual copper ions can remain present. Activated carbon is used in gold extraction because it is highly selective for gold and less so for other metals, such as copper3. However, copper has the ability to adsorb (?load?) onto activated carbon and block the adsorption of gold when it is in the dicyanide form and in a high enough concentration. When copper is in the tetracyanide form, copper loading is significantly inhibited, allowing for the maximum gold recovery. In order to ensure the tetracyanide complex is formed, a combination of both available cyanide and elevated pH must be present. In the South Area of Newmont Mining Corporation?s Gold Quarry mine in Carlin, Nevada, copper and nickel loading becomes a problem when certain acid generating zones of the heap are leached. Copper, nickel, zinc and other penalty metals become leachable and the lower pH uses up more of the cyanide and creates carbon loading conditions for the metals. This decreases the carbon?s ability to extract the gold from solution, decreasing the recovery and increasing the concentration of gold in the barren solution that leaves the carbon columns. In this study, operational data from March through to May of 2007 is presented to show how Newmont developed a quick fix to lower pH and elevated metal concentrations that were causing low gold loadings on activated carbon at their South Area Leach (SAL) heap leach operations. Laboratory tested were also conducted to examine the chemical kinetics of metal loading and the individual effects of increased cyanide concentrations. THEORY Copper I ions form four different complexes with cyanide in solution: the monocyanide species CuCN, the dicyanide species Cu(CN)2-, the tricyanide species Cu(CN)32-, and the tetracyanide species Cu(CN)43-. The species are formed from the following reactions: [Cu)(?+-+ K1 (1) Cu ß2 (2) --+?+23)(3CNCuCNCu ß3 (3) --+?+34)(4CNCuCNCu ß4 (4) ] where K1 equals 1019.50, ß2 equals 1024.03, ß3 equals 1028.65, and ß4 equals 1030.35. Along with these complexing reactions, hydrogen cyanide and water also dissociate in solution, as per the following reactions: [H?+-+ KH (5) OHOHH2?+-+ KW (6)] where KH has a value of 109.24 and KW has a 1014 value2. These six chemical equations compete with each other, with domination of one over the others dependent on the CN- and H+ concentrations. Each complex also has different properties when it comes to its loading behavior on activated carbon. The dicyanide copper complex and the monocyanide copper complex have an affinity for adsorption onto activated carbon that is greater than the affinity of gold cyanide for adsorption. They also have a lower solubility in water, which enhances adsorption. The tricyanide copper complex and the tetracyanide copper complex are water soluble and have an affinity for loading adsorption on activated carbon that is less than the affinity of gold cyanide for loading adsorption1. There are three prime reasons for this phenomenon. First, the extra cyanides mask the metal ion more, which blocks the main adsorption characteristic of the complex. Second, the complexes are also larger, making it harder to physically fit into the active sites on the carbon. This helps make the latter two complexes kinetically inhibited from adsorption, freeing carbon active site to load with gold cyanide complexes. Third, it is also important to consider the expressions of the mass and charge balance. These balances describe all the overall concentration of copper and cyanide in solution, as well as marking overall charges of the ions in solution4. This is important because significantly changing the charge from positive/neutral to more negative is another reason for activated carbon to reject adsorbing the higher cyanide complexes. The speciation of copper and other penalty metal cyanide complexes in solution is dependent on the pH. At lower pH values, increased hydrogen ions (H+) can out-compete metals for cyanide ions. Lower free cyanide in the system leads to the lower cyanide species of copper cyanide predominating, with a noticeable concentration of the free metal, monocyanide and dicyanide species of copper cyanide. At higher pH values, hydrogen ions are significantly reduced, reducing the kinetics of HCN formation. More free cyanide remains in the system, allowing for more complexing. With this higher amount of cyanide in the system, the tetracyanide species of copper cyanide predominates, also with a noticeable concentration of the tricyanide species of copper cyanide. Higher copper concentrations, however, require more

Jan 1, 2009

By N. Oswald

As coal mines age and become more developed, ventilation modeling becomes more important for the planning and continued operation of the system. Numerous studies have been performed and presented that address the collection of data and measurement of airway friction factor and resistance per unit length values. However, a quantitative analysis of the resistance for stoppings in coal mines for different construction materials and methodologies has not been adequately addressed. In order to develop an accurate/realistic ventilation model both airway resistances and stopping resistance values need to be determined. Over the course of the past two decades Mine Ventilation Services, Inc (MVS) has measured the resistance of stoppings of various construction types in mines throughout the world. An analysis of this data is presented in this paper along with a discussion of measurement methodology.

Jan 1, 2009

By Frank van der Meer, Jorge Portocarrero, Alexandra Gruendken

"The number of High Pressure Grinding Rolls (“HPGRs”, also called Roller Press) installations instead of tertiary crushers is rapidly increasing. The technology has been largely accepted in the minerals industry and benefits, such as superior energy efficiency and a lower overall operating cost compared to alternative technologies, have been demonstrated at a number of operations throughout the world.This paper focuses on coarse hard ore operations and reviews the successful installation of the first Roller Press installed instead of a tertiary crusher at the Los Colorados Plant of CMH (Chile) in 1998. It details the experience obtained over the past ten years of operation from commissioning to the present day. It highlights examples of further developments made in the design to improve machine maintainability and availability as well as wear life of the grinding surfaces.A second focus lies on procedures to derive from small scale testing material properties such as wear life, flake formation and strength and their application to industrial size machines to optimize circuit design, especially when Roller Presses are used in closed circuit with screening.INTRODUCTIONRoller Presses (also known as HPGR, High Pressure Grinding Rolls) are considered today state of the art for the preparation of pellet feed. They are also gaining wide acceptance in coarse ore operations. One of the first successful operations in which a roller press was used to replace a conventional tertiary and quaternary crusher is the Los Colorados plant of CMH in Chile.When the Roller Press at Los Colorados was commissioned in 1988, there were 169 Humboldt Wedag roller presses in operation throughout the world. Of these, 14 were installed in the minerals industry. However, these were installed mainly for grinding pellet feed to increase the Blaine value. Up to that time, only three KHD roller presses had been applied for crushing coarse ore in specialized circuits. Moreover, the installation at Los Colorados was the first Roller Press ever to replace a conventional tertiary and quaternary crusher in a hard ore application."

Jan 1, 2009

By Eugen Gluck, Gus Van Weert, Peter Kondos

"Microwaves have the capability to heat up sulphides, especially clusters of particles of approx. 1 mm. Some sulphides absorb microwaves more readily than others. Molybdenite is especially effective in this regard, possibly due to its flaky nature and/or electrical conductivity. Even where it occurs in low concentrations in a deposit, individual rocks may be ore grade due to the high monetary value of MoS2. Such rocks often result from crushing mined veinlets or stockwork, or are contained in the cutoff grade fraction of ROM. Machine segregation of rocks high in MoS2 by infrared sensors after microwaving could therefore advantageously be used to upgrade lower grade ore between Mine and Mill. This would reduce the size of the latter, and thus its CAPEX and OPEX. Such upgrading could also yield shipping ore for a distant Mill, or extend ore reserves.Barrick Gold Corp. has been supporting the development of MW/IR sulphide sorting for the past three years. The results of MW/IR sorting work on molybdenite and other (pyritic) ore samples from a variety of sources are being presented here.INTRODUCTIONThis paper looks at mechanized, i.e. machine ore sorting technologies currently available and under development, and what conditions would be needed for the potential application of such ore sorting to sulphide mining and milling. Current machine sorting involves no-contact sensing technology for rocks, and signal processing after sensing to activate airblast segregation of certain rocks, normally the smallest mass to keep compressed air costs down.The forerunner of modern sorting is probably magnetic separation, which utilizes an inherent property of certain ores to divert it into mag and non-mags fractions. Radiometric ore sorters, which have been applied successfully for decades in the pre-concentration of uranium ores (Wotruba and Riedel, 2006) initiated modern sorting. In the 90’s, sensor-based machine sorting became a viable means of increasing the overall economic recovery of a resource. This technology became driven by the availability of low cost computing equipment and the concurrent development of algorithms, and by the availability of extremely fast response sensors and air actuators, allowing the sorting equipment to run faster, dropping the cost per tonne. It has been in industrial minerals processing that rock sorting has been most widely adopted, not really surprising. Liberation occurs on a different scale than in the base metal industry. Most industrial minerals are mined from massive deposits, requiring (in the past) no upgrading. Many of these operations now run into product contamination problems, which ore sorting can solve. One illustration: in Finland, a quarry is separating limestone from dolomite at 500 tonnes / hour, with individual rocks weighing up to 15 kg. Many of these industrial minerals operations have stockpiles of earlier discarded below-quality rocks, now being reprocessed with the help of ore sorting. The economics of this are very favourable, going from zero or negative value (stockpiles can not be left when closing the mine) to full product value for at least a portion of the stockpile. This suggests that in the future the economics of overburden sorting could become attractive under the right circumstances and such treatment could well become an integral part of open pit mine development."

Jan 1, 2009

By Andre Pienaar, Larry Wilson, Clive Dawkins

The development of implementation of cost effective emulsion explosive and portable pumping system for the replacement of package explosives in the deep level gold mining environment. A number of versions of portable pumps will be presented, demonstrating continuous improvement on these systems. Data on reliability of units in the field will be presented.

Jan 1, 2009

Federal regulations require the use of methane monitors on all mining machines. All machine-mounted methane monitors currently used in underground coal mines rely on catalytic heat of combustion sensors. As a comparison, although not currently approved for use on underground mining equipment, instruments with infrared sensors are evaluated in this study. Potential advantages of using infrared sensors include faster response time, long-term stability, and reduced maintenance needs. Tests conducted in the laboratory and at a full-scale model mine compare the performance of catalytic heat of combustion and infrared sensors operating under test conditions designed to simulate airflow conditions underground.

Jan 1, 2009

By A. E. Ketler

Conventional Atmospheric Monitoring System (AMS) installations for monitoring CO, CH4, O2 and air-velocity throughout underground mines are usually relegated to a modest 3-5 mile extent and with data communication speeds confined to a ponderous 1-5K baud range. New US-MSHA and state regulations require fast reporting of unsafe conditions, and the old 20-30 minute updates are no longer acceptable. To communicate farther and faster has always been a problem, because data reliability degenerates with excessive distances and high speeds. Because of this, very large mines often resort to costly optical-fiber media, using expensive OF cables and repeaters to obtain the necessary coverage. This entails high initial cost, as well as high maintenance and downtime costs to repair or replace broken optical fibers. Rel-Tek has pioneered with its DX-Bus communication data highway, which uses inexpensive twisted-pair telemetry cables, which can now communicate well into the 20-mile extent of the largest mines -- normally a brick wall for low-tech AMS systems. This extended range, enables the use of twisted-pair cables and provides a low cost alternative to OF systems. This paper discusses the DX-Bus, and its latest accomplishment, the ?B-LINK,? a unique high-speed communication repeater that maintains the 19.2K-Baud data rate. On-going innovations to our workhorse Millennia-DX computer software have kept pace with this extra speed/distance phenomenon, resulting in a dually-optimized AMS package: both hardware and software. Cost savings are substantial, and at no sacrifice of reliability ? nearly always at 100%. Sensor updates are measured in seconds, not minutes and hours. Twisted pair copper cable is cheap to purchase and install and a breeze to maintain. Rel-Tek uses the B-LINK's wide branching capabilities to enable the AMS to extend 20-miles both far and wide. Actual experience in large US coal mines -- both longwall and continuous mining operations -- confirms the large mine performance. The ventilation and safety benefits to the mining industry are immeasurable.

Jan 1, 2009