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By T Goswami

The conventional practice in open cut coal strip mining has been to blast the overburden or coal layers in separate blast events. This is done in order to maximise the benefits from throw blasting and also to limit coal losses. Each blast event usually has a particular design of hole diameters, burdens and spacings, explosive charges and blast timing in order to achieve the required blast outcome for either the overburden or coal. This means that each blast has to be separately cleaned on the surface after excavation of the previous blast. Hole locations then have to be individually surveyed and marked, holes drilled, explosives and initiators loaded and the blast fired. Each of these actions takes considerable time and resources and therefore impacts on mine productivity. The mine has to be cleared for each blast event and every blast presents a new potential source for noise, dust or vibration disturbance to the neighbouring population. Exposed highwalls are also subjected to vibration and damage from each subsequent blast event

Jan 1, 2006

By M. Potesser

One of the main targets in the automotive mass industry and supplying industry is the weight reduction of the vehicle for decrease of the fuel consumption. For that reason combinations of different kinds of materials and connections of, for example, steel and aluminium are developed or are already successfully field-tested. A determining factor concerning the quality assessment of the welded joint during hybrid welding is the characterization of the intermetallic Fe-Al layer regarding strength, hardness, morphology and mainly the different phases in which Fe occurs together with the Aluminum (FeAl, Fe2Al5, FeAl3.). A combination of conventional light microscopy, SEM - EDX - analysis, the usage of an atomic force microscope including a Nanoindenter and theoretical thermodynamic calculations turned out to be highly effective. Based on the attained results, the constitution of the intermetallic FeAl layer, influenced by silicon, manganese and zinc, can be predicted.

Jan 1, 2006

By Ali Porbaha

The use of soil nailing technology as a cost effective alternative for excavation support and slope stabilization has substantially increased in the United States during the last decade. For example, in the past thirteen years, more than 185,800 square meters of soil nail walls have been constructed in California alone. The conventional soil nail systems pose difficulties when ground conditions are subject to caving, for instance for silty sand (sugar sand) or cobbles and boulders. The construction industry has developed self drilling hollow bar systems (or pressure injected bored, IBO) that combine both drilling, placing and grouting in a single operation as a solution to speed up construction. While the system is extensively used for temporary applications, nevertheless, some concerns, particularly about corrosion, has limited the use of this technology as a permanent system in North America. This study presents several issues related to self drilling soil nail systems, the results of a field investigation and a summary of the research project.

Jan 1, 2006

By A M. Garforth

Insurers are hesitant to provide coverage for Open cast Pit side wall collapse, and even the consequent damage to plant and equipment in the pit as well as the resulting interference with the mining operations. After a general introduction to relevant principles of insurance, this paper addresses some of the major reasons for that reluctance based upon the authors? extensive claims experience, examines what limited coverage can still be obtained and looks to the future possibilities. Confidentiality of sources and examples referred to in this presentation is a natural imperative so that a bibliography is not provided but reference is made to relevant sample insurance policy wordings.

Jan 1, 2006

By K P. Crameri

The Beta Hunt orebody is situated on the south western limb of the Kambalda dome. It is one of the nickel occurrences in the area which fall into the category of æKambalda Style OrebodiesÆ. These orebodies are renowned as being continuous uniformly mineralised ribbons of nickel sulfide mineralisation. Interestingly, Beta Hunt does not conform to this notion of continuity and uniformity and is in fact highly irregular in its ore distribution due largely to the influence of post depositional structure. In an attempt to understand the ore distribution at delineation stage rather than development stage a detailed footwall topography model is created using all available drilling data. To augment this drilling data, the routine use of downhole EM and borehole radar has been introduced to provide data beyond the confines of the drill core to enhance the geological interpretation of the footwall topography and the distribution of the mineralisation. The implementation of a detailed footwall model and the use of downhole geophysics has proved to be very effective in resolving the orebody complexity issues. Ongoing development of the methods used will continue to refine the interpretation of the geology to enable more efficient extraction of the orebody.

Jan 1, 2006

By Pietro Navarra

A great deal of effort has been expended on how to optimize conventional water cooling circuits in furnace cooling elements, and the results have been largely satisfactory. However, there is a general agreement that the proximity of high-pressure water passages to the flow of molten furnace products is a safety concern. Nonetheless there exists little alternative to the formula: increasing furnace integrity implies the incorporation of more extensive forced-convection water cooling systems. Recent developments in evaporative cooling technology have resulted in the development of a high-capacity heat pipe capable of operating under the thermally intense environments of a metallurgical furnace. The system functions using several kg of a working fluid (water) in total, has no moving parts, and allows for a significant reduction in cooling water requirements. Full-scale pilot tests of a copper tap hole and slag launder were done in 2003 and2005, with detailed results given in this paper.

Jan 1, 2006

By J. V. Simmons

Composite rock mass failures involve intact rock material as well as fracture and shear on existing defects. Experiences from open-cut coalmining in the Bowen Basin of central Queensland are that failures of this nature occur suddenly with little warning, and are much more common than classical structurally controlled failures. Geological conditions and mining practices in the Bowen Basin are described. The circumstances of a sample of composite failures are described in detail in the paper. From this experience it appears that several aspects of conventional geotechnical investigation and design practice have not contributed significantly to either predicting or controlling the risks associated with sudden failures. These practices are described as myths for reasons outlined in the paper. On the other hand, the reality seems to be that high initial stresses and stress changes caused by excavation lead by a process of extensional deformation to a critical stress condition within the rock mass, and that sudden collapse follows when that critical stress condition can no longer be sustained. It is concluded that learnings gained from underground excavations in rock may be more applicable to open pit excavations than previously thought, and that the processes of prefailure deformation require more careful study if we are to develop more reliable risk management controls.

Jan 1, 2006

By X. S. Yuan

With the production increase of Oil Sand in Fort McMurray Alberta, more efficient tailings disposal has become a priority for Syncrude Canada Ltd. A lot of work on tailings research and development has been compiled to determine the most effective deposition to increase reclamation options, water re-use and thermal energy recovery. Efficient flocculation of fine oil sand tailings is the key technology for thickening. It was identified that flocculation of fine transition/marine ore tailings using a single flocculant was not effective. The thickener overflow contains 1-4% solids content compared with the target solids content of <0.5% obtained with Estuarine ore. As a result, novel processes for treatment of fine transition/marine ore tailings have been developed at Syncrude Bitumen Production Development since June 2004. While the conventional processes using a single flocculant, a single coagulation, or a coagulant-flocculant combination was ineffective for transition and marine ore tailings, the new processes including Coagulation-Flocculation-Coagulation (CFC), Flocculation-Coagulation (FC) and Flocculation-Coagulation-Flocculation (FCF) were acceptable options. The key components of these technologies consist of the recipe of chemicals and their adding sequence. With these technologies, almost all sub-micron clay minerals are aggregated together and settle as a whole, resulting in a clear supernatant of less than 0.1% solids.

Jan 1, 2006

By F. Habashi

Magnesium is the eighth most abundant element in the earth&apos;s crust, It occurs in nature in sea water, brines, and a number of minerals, Metallic magnesium was first isolated by Humphry Davy (1778-1829) in England in 1808 via electrolysis of anhydrous magnesium chloride with a mercury cathode, Antoine Bussy (1794-1882) in France extracted the metal in 1828 by reducing fused magnesium chloride with metallic po¬tassium vapour, The first industrial production of magnesium by electrolysis of molten carnallite began in 1886 in Hemelingen in Germany, In 1940 Lloyd M, Pidgeon (1903¬1999) in Canada pioneered the first industrial metallothermic magnesium extraction plant based on the reduction of dolomite with ferrosilicon under vacuum, Since then the magnesium industry developed further and a variety of processes are presently used.

Jan 1, 2006

By Abdul Aziz Hanifah

A novel instrumentation and analysis technique, called GLOSTREXT method has recently been introduced for bored pile load tests in Malaysia. This technique provides an innovative and improved alternative for conventional bored pile instrumentation methods commonly practiced for the past few decades. Results for five case histories involving full scale static load tests for high capacity bored piles with both new and conventional instrumentation details placed in within the same instrumented piles are presented to demonstrate the advantages of this novel technique. Results show good agreement between the new and conventional instrumentation.

Jan 1, 2006

By G. S. Hill, B. J. Huls

This paper on coarse particle recovery (CPR) summarizes a process to capture coarse particles that are not recoverable by regular flotation. Several porphyry copper operations in the world operate analogous circuits that recover non-floated copper from tailings; however, the case presented here is unique in that extensive underlying test work has allowed the authors to elucidate some fundamental principles behind recovery enhancement. This paper discusses an overview of the flowsheet that is proposed to Minera Escondida Ltda., the nature of copper in the feed to the CPR circuit, and the various unit operations within the recovery circuit.

Jan 1, 2006

By Ann Barron

“Hurry up” is the latest battle cry at explosives companies struggling to stay in compliance with the ever-growing onslaught of government regulations. The pressure continues to mount on industry professionals who face stiff penalties if their companies fail to comply with the law. Such penalties can range from monetary fines and revocation of blasting permits and licenses, to increased liability for civil claims or even criminal charges.

Jan 1, 2006

By M. Sugamata

Creep tests were carried out for friction welded joints of AZ31 magnesium alloy rods under an ambient atmosphere at temperatures between 423 and 573K. Tensile tests were also performed at temperature from room to 573K. The obtained results were compared with those of the base metal. AZ31 extruded rods of 19 mm in diameter were joined by brake type friction welding machine. Creep and tensile specimens were machined out of the welded rods. The tensile strength of the joints was almost the same as that of the base metal at room temperature. However, joint efficiencies of welded joints were about 92% at above 373K. The elongation of welded joints was lower than those of base metal. The welded joints showed appreciably higher minimum creep rate and shorter rupture time than the base metal at all the tested temperatures and initial creep stresses. Creep and tensile rupture of the joints always occurred at near the weld interface. Thus, friction welded joints of AZ31 alloy showed lower creep and tensile strength than the base metal at elevated temperature.

Jan 1, 2006

By J. T. Chen, S. Winkler, M. J. Worswick, O. Orlov

This paper presents a review of research conducted at the University of Waterloo concerned with the application of aluminum alloy sheet and tube in automotive structures and body panels. The research has focussed on formability prediction and results using a range of damage-based formulations. These models include continuum-level damage approaches and, more recently, a so-called percolation damage approach intended to capture microstructural heterogeneity effects on damage development. This paper presents applications of these damage approaches to simulate formability of experiments considering stretch flange panels. The experiments consider drawbead effects associated with the bend/unbend deformation as the material flows through the drawbead. Recent work on simulating in situ X-ray tomography experiments that capture damage evolution during tensile deformation will also be reviewed.

Jan 1, 2006

By W. Carter, P. Chaubal, K. Spaleck, M. Schoeman, J. Bobek, W. Seegers

Keywords: Pyrometallurgy, steel, hearth, blast furnace The Mittal Steel Company operates about 36 blast furnaces on four continents. Furnaces range from 1100 m3 to 4800 m3 inner volume. The focus of the group is to push for increasing productivity and increasing campaign life. This has been especially challenging, as many of these furnaces were not equipped for long campaigns during their prior rebuilds. Monitoring and operating practices have to be modified to match the new philosophy. Mid-campaign hearth repair strategies and hearth design philosophies have had to be reconsidered. The paper describes experiences with the current hearth designs and measures taken for hearth life extension. Additionally, the philosophy of recent hearth re-designs is discussed.

Jan 1, 2006

By Giovanni A. Bonita

The United States Capitol Visitor Center (USCVC) is one of the largest underground structures ever constructed in the Washington, DC, metropolitan area. The 600,000 ft2 (55,750 m2) structure is entirely underground and immediately adjacent to the shallow foundations of the existing U.S. Capitol building. Interior building columns for the USCVC were supported on 186 drilled shafts that varied in diameter from 4 to 9 ft (1.2 to 2.9 m) and in length from 15 to 45 ft (4.6 to 13.7 m). The vast majority of the building utilities were located beneath the basement floor slab. It was decided at the onset of the project to proceed with construction prior to completion of the design drawings, and coordination between the underslab utilities and the drilled shafts had not yet been finalized at the onset of drilled shaft installation. Given depth and location restrictions of the outlets, relocation of the bulk of the utilities was not possible. Almost half of the drilled shafts were affected, leaving redesign as the most feasible remedial solution. The redesign involved adjustments to the shaft length, diameter, and bell. It took place on a case-by-case basis, sometimes only minutes before installation began. Coordination between the field and design team was excellent, and delay associated with the redesign efforts was minimal. In addition, the detailed, high-quality field records kept by both the contractor and field engineers allowed for accurate and fair estimations of the added drilled footage and concrete volumes placed. The additional service fee, which was minimal, was settled quick and fair.

Jan 1, 2006

By James L. Vinson

Wilbur Smith Associates (WSA) has provided planning, engineering and construction oversight assistance to the Tennessee Department of Transportation (TDOT) for three construction projects intended to widen and improve segments of I-40 and associated interchanges in Knoxville, Tennessee. The projects are within the karst terrain of the Valley and Ridge Province. Subsurface conditions are characterized by an irregular rock surface coupled with differential weathering. Because of the projects? impact to local and interstate motorists, consideration was given to innovative planning, materials and construction practices that could accelerate construction. Two innovative deep foundation measures included rock-socketed pipe piles, which act as both foundations and substructure elements for a bridge?s interior bents, and the first widespread use of rock-socketed drilled shafts as bridge foundations on a TDOT project. The pipe piles were used at a site with significant cavities within the limestone bedrock. This resulted in design verification and constructability difficulties that required delays, but measures were ultimately employed to produce a sound foundation system. Over 110 drilled shafts have been constructed at sites with generally low solution activity. Relative to H-pile footings, which were included as an alternate foundation, they have apparently allowed accelerated construction at a competitive cost.

Jan 1, 2006

By A. Andrews

Paper written on project work carried out in partial fulfilment of MSc (Eng) degree Solid state sintered silicon carbide ceramics are used in aggressive environments as sealings. There exist data concerning corrosion, but there are only few data concerning their electrocorrosion behaviour. Therefore the electrochemical corrosion of solid state sintered silicon carbide (SSiC) ceramics has been studied at room temperature in acidic and alkaline environments by using potentiodynamic polarization measurements. The investigation showed a pronounced electrochemical corrosion in bases and acids. In HCl andHNO3pseudo-passivity features due to the formation of a thin layer of SiO2on the surface were observed, whereas in NaOH soluble silicate ions were observed, resulting in more pronounced corrosion. The microstructural observations of initial and corroded samples reveal that the residual carbon found in the microstructure do not dissolve preferentially. Keywords: Corrosion; SEM; SSiC; polarization test.

Jan 1, 2006

By M. Kumral

The efficiency of an ore-processing unit depends on the consistency of the characteristics of raw material entering the plant. When the mined ore is highly variable in quality, the only way to ensure consistency is to homogenize the ore prior to feeding to the processing plant. The homogenization can generally be achieved by the bed blending operation. Given that the stockpiling and reclamation processes are very expensive, it is necessary to design the process in such a way as to minimize variabilities of specified properties of raw material. In this paper, for alternative stacking types, optimal stockpile geometry is found in three stages: First, stockpile input is simulated by sequential Gaussian simulation, and then the variance reduction ratios (VRR) as a criterion of stockpile efficiency are calculated for various stockpile geometry scenarios by a stockpile simulator written in FORTRAN. Second, multiple regression analysis is performed to model the VRR by the use of stockpile length, the number of layers and stacker speed as the independent variables. Finally, the model is an optimization problem. Decision variables are the stockpile length, the number of layers, stacker speed and stacking type. The genetic algorithms (GA) are used to minimize the VRR. The approach was demonstrated on data from an iron orebody. The problem was to reduce fluctuations of iron, silica, alumina and lime contents in the stockpile output. The results showed that the approach could be used for the bed blending design efficiently. Keywords: bed blending design, multiple regression analysis, genetic algorithms, iron ore, content fluctuation

Jan 1, 2006

By M. Natarajan, C. J. Cutler, E. Mponda

Keywords: Pyrometallurgy, furnace, KCM Nkana, Zambia The Nkana smelter was initially commissioned in 1931, with two reverberatory furnaces, two Peirce-Smith converters, and blister copper casting facilities. Reverberatory furnaces were the mainstay of production up until 1994, when an El Teniente Converter (CT) was installed to upgrade reverberatory furnace matte to white metal, prior to converting in conventional Peirce-Smith (PS) converters. In 2000, a decision was taken to increase the proportion of concentrate smelted in the CT by introduction of bone-dry concentrate injection through the tuyeres. A flash dryer with a nominal capacity of 1 200 metric tons per day of dry product, and associated tuyere injection system was commissioned in March 2004. Based on the projected concentrate arisings from the KCM mines into the future, as seen in 2004, it was decided to develop the CT to be the primary smelting vessel at Nkana, to handle a minimum of 1 250 tons per day of concentrate, and to operate only one reverberatory furnace in slag-cleaning mode pending a full evaluation of alternative slag-cleaning technologies. The anticipated cathode production from Nkana was to be in the range 140 to 150 000 tons per annum. This paper details the outcomes from trials that were carried out in August and September 2004, using two reverberatory furnaces for slag cleaning. The results of these trials, plus further work in October and November, provided confidence to move to one reverberatory furnace for slag cleaning in December 2004. With the advent of Vedanta as the majority shareholder in KCM at the end of 2004, the approach has been to maximize the available smelting capacity. Currently, two reverberatory furnaces and the CT are on-line, with the higher silica concentrates going to the reverberatory furnaces with an appropriate amount of pyrite, and the cleaner concentrates going to the CT. Expansion of the smelter is currently under investigation.

Jan 1, 2006