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By Roger M. Nendick

"IntroductionThe stages of development for bringing a mill into production demand that a flowsheet for the process be developed at an early stage. Detailed engineering of the mill may then proceed without duplication of engineering effort on alternative processes. In the case of gold and silver mills, several process alternatives exist which must be evaluated before the flowsheet is finally fixed. The recently developed Carbon-in-Pulp process has added to this choice.Clearly, the major factor in determining the most suitable process is the amenability of the particular ore to a given treatment. Other factors that will also influence the choice are location, climate, power and water supplies, and available capital.Gold and silver milling processes can be divided into three main types:Gravity Concentration;Flotation;Cyanidation.Combinations of the three are frequently used; i.e. flotation followed by cyanidation of the concentrate, or gravity concentration in the grinding circuit with cyanidation of the classifier overflow. The following are the salient advantages and disadvantages of the three main alternatives.Gravity ConcentrationGravity concentration is suitable for free-milling gold ores, i.e. ores in which the gold is relatively coarse and free from sulphides. It should be noted that just because an ore is high grade, it is not necessarily free milling.Gravity concentration methods include jigs, shaking tables, spirals and more recently Reichert cone concentrators. All methods exploit the density difference between gold, which has a specific gravity greater than 15, depending on how it is alloyed, and the gangue, which usually has a specific gravity range of 2.7 to 3.5.A concentrate grade of several hundred ounces per ton might be produced, but recoveries by gravity alone are generally low in comparison to other methods. For this reason, gravity circuits are usually used in combination with flotation or cyanidation circuits."

Jan 1, 1983

By Joseph L. Fournier

Suncor Oil Sands employs delayed coking technology in converting bitumen into synthetic crude oil. Currently up to 10,000 m3 of delayed coke (coke) is produced per day as a byproduct of the upgrading process, of which up to 9,000 m3 per day is placed in dry storage on Lease 86/17. A review was completed to examine the case history of leachate potential experiments from the dry storage of coke and the environmental relevance of coke leachate studies conducted over the past decade. The review included an evaluation of the potential impacts of environmental conditions within the location of coke storage, including precipitation pH, as well as daily and annual ozone trends. Coke leachate potential has historically been characterized using standard leachate testing protocols (i.e., TLCP, SPLP) together with other studies that have employed strong acids and oxidizing agents in the extraction fluids. The present paper highlights prevailing conditions in the Athabasca Valley air-shed with emphasis given to ambient ozone (oxidizers), as well as precipitation pH and acid input deposition rates, and will demonstrate that TCLP / SPLP tests lack the intended environmental relevance relative to the conditions under which coke is stored.

May 1, 2011

By J. A. McCamley

Gypsum scrap generated from wallboard manufacturing, construction and deconstruction activities in North America, Europe and Japan is a recognized environmental problem. Landfill disposal of this gypsum scrap is problematic, with deposits often creating hydrogen sulphide emissions and metallic sulphide groundwater leachates. Of these regions, Europe is the most advanced in dealing with the issue having enacted legislation, which will come into effect in July 2005 that will strongly encourage gypsum recycling throughout the EU. An estimated 10% to 17% of all gypsum used in the wallboard industry becomes recyclable scrap, which represents approximately 1% of the total waste stream in North America. In the United States, 2.5 to 4.5 Mt of gypsum scrap is generated each year; the volume is similar in Europe (the percentage of total tonnage is less because of the higher use of brick and concrete). The Greater Vancouver region of British Columbia has banned gypsum from its landfills, and as a result, all gypsum scrap is now recycled. New West Gypsum Recycling, a Canadian firm, uses its proprietary technology to process large quantities of gypsum scrap that is reincorporated into new wallboard, at percentages ranging up to 25%. The operation of New West Gypsum Recycling Inc. of Langley, Vancouver is examined as a case study and recommendations are provided as to how other urban regions can implement similar gypsum scrap recycling programs.

Jan 1, 2004

By S. Bastola, Y. P. Chugh

"This research determines shear strength and stiffness properties of bedding planes and joints in the roof strata rocks within 7.5 to 9 m (25-30 ft.) overlying the Illinois #6 coal seam (within the pressure arch zone). A shear test loading device was designed into a 1.334 kN (150 t) Forney Compression Loading Machine to perform direct shear tests in accordance with ASTM D5607-08 “Standard Test Method for Performing Laboratory Direct Shear Strength Tests of Rock Specimens under Constant Normal Force”. The data were used to determine peak and residual friction angles and the dilation angle. A total of 49 bedding plane samples were tested, out of which 46 (36 intact and 10 relatively weak and loose) samples passed QA/QC procedures in accordance to ASTM D5607. Samples from eight (8) different bedding planes- shale/limestone (SL), shale/sandstone (SSs), shale/bone (SB), laminated sandstone (LS), shale/shale (SS), bone/bone (BB), bone/limestone (BL), and limestone/limestone (LL) were tested. The number of samples tested for each bedding plane were: SL- 11, SSs- 8, SB- 5, BB- 4, LS- 6, SS- 9, BL- 1, and LL- 2. Peak and residual shear strength values at 2.75 MPa normal stress range 1.06 – 6.26 MPa and 0.82 MPa to 0.82 – 4.14 MPa, respectively. The average normal and shear stiffness values are about 11.98 GPa/m and 3.11 GPa/m. Dilation angles are low (<10?) and negative in some cases. Angle of sliding friction values range from 9? to 42?. Joint Roughness Coefficient (JRC) values were less than 10.INTRODUCTIONRock mass may be defined as the total in situ rock medium containing bedding planes, faults, joints, folds and other structural features. Therefore, it is discontinuous and may have heterogeneous and anisotropic engineering properties. Upon creation of an excavation in a rock mass, bedding planes and joints are the most likely points of failure initiation. The failure typically occurs either in tensile or shear mode. Upon failure initiation stresses are transferred to the neighboring rock mass and the failure progresses until stability is achieved through equilibrium of stresses and strength. An example of this mechanism is development of the pressure arch. This study determined the shear strength and stiffness properties in shear and compression of bedding planes and joints in the immediate roof strata rocks within 7.5-9 m ( 25-30 ft.) overlying the Illinois No. 6 coal seam (within the pressure arch zone). Since such data are currently not available for Illinois Coal Basin mines, researchers and engineers have been using estimated values for design purposes. The immediate roof lithology in the proposed mining area consists of shale 0.62 m; Bone 0.09 m (0.3 ft.); Limestone, 0.10 m (0.33 ft.); Shale 2.37 m (7.9 ft.); and sandstone 0.55 m (1.83 ft.). The bedding plane samples were provided by a mine in south-eastern Illinois operating at a depth of about 180 m (600 ft.)."

Jan 1, 2015

By M. W. Grabinsky

Better in situ performance data is required in order to advance the rational geomechanical design of cemented paste backfill systems. A few in situ test programs have been conducted, but these have suffered from too few measurement locations within the stope and have not used enough different types of transducers to fully capture the information of significance. In this paper the important geomechanical design aspects are listed, the underlying physical phenomena are described, and some previous in situ measurement efforts are reviewed. A new approach to in situ measurement campaigns is then described including measurement techniques, locations, and the logistical aspects of mobilizing transducers in an active mining environment. A work-in-progress is used to illustrate the principles and concepts involved.

May 1, 2007

By B. Tiryaki, M. Ayhan, O. Z. Hekimoglu

"This paper discusses the aspects of tracking cutters related to the computer-aided design of shearer drums. A comprehensive computer analysis of drum dynamic parameters for multi-tracking tool arrangement is not presently available, as the current computer programs mainly consider the aspects of single tracking. Despite the fact that the single-tracking arrangement is recommended for efficient cutting, some major drum manufacturers have been seen to persistently adhere to multi-tracking, probably due to a lack of information. Further studies in this field are believed to contribute greatly to the current understanding of the computer-aided design of shearer drums.A number of laboratory simulation trials and long-term underground investigations were carried out in detail on tracking cutter arrangement, and an equation required for a computer program was derived. The results obtained from computer assessment of dynamic parameters for drums with multi-tracking arrangement were found to be in accordance with those of the underground trials, indicating the validity of the equations. The procedure adopted for the computer appraisal of the shearer drums designed with a multi-tracking concept, as described in this study, is therefore recommended to be considered in the currently employed computer programs."

Jan 1, 2003

By Ryan W. Ulansky

This paper presents the conceptual design of a magnetically-levitated skip for use in an underground mine. A skip is used to move rock from an underground mine to its surface processing facility. Conventionally the skip is raised and lowered by cables, similar to an elevator. In a magnetically-levitated skip, the cable is replaced with a linear induction or synchronous motor to provide propulsion and levitation. Removal of the cables in a magnetically-levitated skip provides many advantages over a conventional system including the ability: to negotiate corners, to travel vertically in the shaft as well as horizontally to the mining face, and to move a very large volume of material using multiple skips in a small shaft. A magnetically-levitated skip is a safer, more environmentally-friendly, productive alternative to conventional skipping. It has the further advantage to decrease haulage distances for underground vehicles.

May 1, 2002

By Pierre Gratton, Gordon Peeling

The Mining Association of Canada launched the Towards Sustainable Mining initiative in 2004. TSM’s goal is to improve the mining industry’s performance by aligning its actions with the priorities and values of Canadians. The initiative currently includes performance indicators for four areas: tailings management, energy use and greenhouse gas management, external outreach and corporate crisis management planning. Over the past year, the association has been designing a performance assessment and verification system for these performance areas, as its members prepare to move to external verification of their performance in 2006. The presentation will describe the initiative and its evolution, as well as the challenges faced in developing a verification system applicable to an entire sector.

Jan 1, 2006

By B. D. Pandey, M. S. Kim, B. S. Kim

The recovery of Sn from used Pb-free solder (Sn, 3~4 % Ag, < 0.9 % Cu, < 1.2 % Pb) has been investigated by electrorefining in sulfuric acid solutions containing small amount of hydrochloric acid. This involved preparation of the anode material by melting and casting the used solder followed by refining. During electrorefining, dendritic tin was deposited on stainless steel cathode. Increasing the amount of hydrochloric acid up to 0.3 mol /L in the electrolyte enhanced the current efficiency to 92.2 % and the enrichment ratio of silver to 94.3 % in the anode slime which was otherwise 84.7% and 81.6 % in absence of HCl, respectively. The electrolyte containing hydrochloric acid has also prevented the precipitation of tin oxide in the bath. In the scale-up experiment using 1.6 kg anodes, 84.3 % current efficiency and close to 100 % Ag enrichment ratio were obtained, while the purity of electro-refined tin was over 99.9 %. The energy consumption of the winning process was found to be 0.151 kWh /kg-Sn which is competitive as compared to commercial tin electrorefining processes.

Jan 1, 2014

By K. Awuah-Offei

Long-term production scheduling optimization has been a challenging issue for the mining industry because of the size and complexity of the problem. The current planning algorithms have limitations in terms of addressing the stochastic variables underlying the mine planning problem. In this paper, an intelligent agent-based mine planning framework based on reinforcement learning is introduced. The long-term mine planning is modelled as a dynamic decision network. The intelligent agent interacts with the block model by means of a stochastic simulation and employs a Q-learning algorithm to learn the sequence of pushbacks that maximizes the net present value of the mining operation. The intelligent open pit simulator (IOPS) was implemented with an object-oriented design in Java®. A comparative application case study was carried out to verify and validate the models. The proposed method was used in planning an iron ore deposit and the results were compared to the Milawa scheduler used in Whittle® software. The outcome of the study demonstrates that the intelligent agent framework provides a powerful basis for addressing real-size open pit mine planning problems.

Jan 1, 2008

Over the last three decades, the mining industry has been moving towards more underground mechanized mining methods and the number of LHD vehicles utilised has increased. The growth of mechanization and automation has benefited both workers and the mining companies. However, due to the design of the LHD vehicle and the limitations of the operating environment, restrictions to operator visibility are inevitable. The inability of the equipment operator to see clearly (i.e. people, objects or hazards) around the machine has contributed to a number of accidents including fatal injuries. In order to identify vehicle design characteristics resulting in restricted and blocked sightlines, visibility assessments for existing machines are traditionally completed in the field using a light filament technique. Past researchers have used the light filament technique to collect obscuration zones around the equipment and to produce a 2D chart of this information. The 2D shadow diagrams have proved to be useful in highlighting potential equipment problems and have been performed repeatedly to show the potential of redesigning a part of the LHD for improving visibility. The light filament method involves manually collecting data and requires a level of judgment to be used. As a result the method is susceptible to errors and requires around three hours to complete. The objective of the current research is twofold; firstly to develop a rapid method for field visibility data collection using a laser scanner and secondly to compare results of repeat tests for both light filament and laser scanning methods. A MENSI GS100 laser scanner along with Pointscape and 3Dipsos software has been used to collect visibility information and process the data. The research aims to develop the laser scanner as a technique to rapidly evaluate the visibility profile of an LHD vehicle. Machine design changes can then be assessed quickly using these results.

May 1, 2004

By N. R. Thote, J. L. Porathur, C. P. Verma

Highwall mining is a highly mechanized coal mining method associated with several advantages, such as a very high production rate (approximately 3,000 t/d) and low production costs. There is no requirement for underground support, ventilation, or blasting. Production leads to added recovery, which is otherwise lost in the ultimate pit. The use of highwall mining can bridge the gap that exists between supply and demand in the energy sector. This paper presents a brief review of highwall mining technology, including current status, analysis tools, and design techniques. In addition, it identifies important parameters from the analysis of failure case studies.

Jan 1, 2014

By Flavio Rojos-Tapia, Oscar Pereira-Cerda, Samuel Sánchez-Pino, Samuel Sánchez-Baquedano

"Pneumatic flotation was introduced to the Chilean Copper Mining Industry in 1993 by Ingeniería de Minerales S.A. (IDM). The technology is based on the designs of Dr. Rainer Imhof from Germany, who is the designer of several different types of pneumatic flotation cells, already sold through his Company Maelgwyn Mineral Service Limited (MMH). The company is represented by Ingenieria de Minerales S.A. (IDM) in South America.Pneumatic flotation, has been used in tough industrial applications .It has been successfully used for metallic ores such as copper sulphide and oxide minerals, copper slag, silica and silicates from iron magnetic preconcentrate (reverse flotation) and gold. It has also provided promising results when applied to molybdenum flotation. The latest applications, with ultrafine molybdenum particles in operating plants, is showing the V and G Cell (end model designed) as a real technological alternative to conventional flotation., The G Cell is an extremely high speed flotation machine with high selectivity which introduces the possibility of producing a final molybdenum concentrate with only one stage of cleaning. This is a completely new development in molybdenum flotation in the industrial circuit which has the potential to dramatically reduce the circulating load in the cleaning circuit. As a consequence the capital costs of future Molybdenum plants may also be reduced. The suitability of the G Cell will have to be determined on a case by case basis but it provides the metallurgist with an alternate flowsheet for consideration.The good performance of the G Cell can be explained by the high gas hold-up and very effective micro-turbulence which helps improve the attachment of solid particles to the bubbles. This technology may change our traditional concept of residence time in flotation. Additionally, the rotation phenomena introduced in the vessel of the G Cell ,creates radial separation forces which are critical to achieving a more rapid separation of the target minerals from the tailing. This results in a much reduced residence time requirement in the flotation machine. Some benefits associated with the use of the new G Cell are: less energy consumption, less maintenance costs, simple and reliable circuit to operate and a small area required for installing the circuits.As a result of the industrial experience in the Chile, the pneumatic flotation type G Cell can be regarded as a technology which must be considered as a replacement technology for the rougher and cleaner stages for fine particle flotation."

Jan 1, 2008

By Norman O. Lotter

Drill core is preferred as the sample material for metallurgical and mineralogical characterisation and flowsheeting of an orebody. The question arises as to how to do this at the economic optimum, since geologists have several other strategic uses for their drill core. The limiting factors are the cost of extra drilling for the metallurgical testwork and the need to preserve the drill core record. In this study, the representative sampling of drill core at an economic optimum for metallurgical testing is addressed. This phase of the drill core work is preceded by earlier drill core characterisation - for which other appropriate sampling protocols are used - that has provisionally categorised the orebody into geometallurgical units. In stratified sampling of drill core, use is made of a version of the stratified approach to compound distributions proposed by Cochran in 1946. Use is made of Gy’s 50-piece minimum sample mass model to estimate minimum requisite sample mass. In the case where sampling and testwork are required on a Lifeof- Mine blend of a given ore deposit, whereby defined ore types or geometallurgical units are present, the sample mass requirement is significantly reduced by working from drill-core at the geometallurgical unit level. A case study using Raglan drill core is discussed. Using nickel as an indicator paymetal, and sampling at a fundamental variance level of 8%, the minimum sample masses for disseminated sulphides, net-textured sulphides, and massive sulphides are 3.80, 7.37 and 4.39 kg respectively. When the same drill-core is sampled as a Life-of-Mine mixture without knowledge of the geometallurgical units, the minimum sample mass increases to 84.28 kg. It is thus possible to assemble a representative Life-of-Mine sample of drill-core more economically, at the same time validating its representativity. Equivalent calculations for copper, platinum and palladium are discussed, with outcomes consistent with this finding. When all four paymetals are considered, one selects the largest minimum mass out of all four cases. This results in minimum sample masses of 11.67, 74.90 and 175.16 kg for disseminated sulphides, net-textured sulphides and massive sulphides respectively. The simulated Life-of- Mine blend would require a minimum sample mass of 377.33 kg to cover all four paymetals.

Jan 1, 2010

By M. Ounpuu

"Gold, because of low head grade and recovery, is usually of minor importance in the economics of base metal flotation mills. Because of the above little metallurgical attention is usually provided to gold in these mills. But collectively, the gold losses can be significant. For instance, Noranda presently has interest in 13 base metal flotation mills with a collective gold recovery of only 50%. Gold losses are in the order of 150.000 oz per year!The Noranda Technology Centre, in cooperation with Noranda's milling operations, has been investigating the potential of gravity concentration of gold from base metal flotation mills. This paper outlines the pilot and plant testing conducted at three operations with distinctly different ore types; porphyry copper, complex massive sulphide and polymetallic semi-massive sulphide. Testing has been with the Knelson Concentrator which has proven to successfully recover fine gold in a simple, trouble free circuit. Discussion of issues which have risen from the testwork is included. INTRODUCTIONGold, because of low head grade and recovery, is usually of minor importance in the economics of poly-metallic base metal ores. TABLE I presents gold heads and recovery for some of Noranda's base metal mills. It should be noted that the stated recoveries are to payable concentrates, but does not reflect the actual payable gold recovery which in cases is significantly lower. Noranda's average gold recovery into a gold payable concentrates is about 45%. This equates to a collective loss in the order of $57 MM per year of gold"

Jan 1, 1992

By R. Grant, C. Bazin

"Brunswick Mining has investigated grinding media optimization for the purpose of improving the flotation feed and regrind product size distributions to enhance metal recoveries. This paper presents the findings of on-going testing of various sizes and shapes of grinding media. Plant observations combined with estimated breakage rates demonstrate the importance of appropriate selection of media sizes on the milling operation.IntroductionBrunswick Mining and Smelting is located near Bathurst, New Brunswick, and operates one of the world&apos;s largest lead and zinc mines. The ore mineralogy and processing flowsheet have been described elsewhere (Petruk and Schnarr, 1981; Shannon et 01., 1993). Despite the 25 years&apos; milling experience, there has been considerable disagreement as to the required grind size (Grant et 01., 1991). Since 1964, fineness of the flotation feed ranged from 60% to 80% passing 400 mesh (37 um) and averaged slightly above 71% in 1992. Results from mineralogical analysis (Petruk and Schnarr, 1981), laboratory and pilot plant experiments, as well as plant sampling (Grant et al., 1991; Hendriks and Ounpuu, 1985; Shannon et al., 1993) indicate that improved metal recoveries can be achieved by an increase in the fineness of grind, and more specifically by maximizing the amount of material in the 15 urn to 25 um range.This paper shows the results obtained so far from the evaluation of the effect of grinding media size and shape on grinding mill efficiency. The problem of finding optimum grinding media size, shape and composition has been recogrtized since the early 19405. The main criterion for the selection of media size is the size of the material to be ground (Bond, 1958). Although several relationships have been proposed to assist in the selection of grinding media size, none of them are entirely satisfactory (Wills, 1988). Other approaches using the breakage rates and process simulators were developed to help in the selection of grinding media size (Austin et al., 1976; Lo and Herbst, 1986; Concha et 01., 1992; Samskog et al., 1990; Martinovic et al., 1990). Although considerable effort was put into the analysis of grinding media size, very little information is available on the effect of grinding media shape (Norman and Decker, 1985, p. 3C-4). Norris (1952), Kelsall et al. (1973) and Herbst and Lo (1989) have shown that balls are more efficient than other shapes of grinding media including truncated cones and cubes."

Jan 1, 1994

By Jiwen Zhang

Abstract Due to the blocking nature at the crusher station, straightforward application of queuing theory cannot give realistic results on the performance of a shovel-truck-crusher system. A new queuing network-based model has been developed in which, the crusher station is formulated into an open queuing network and the whole shovel-truck-crusher system into a closed queuing network with the crusher station as a special server. To fully account for the influence of blocking, Monte Carlo simulation is first used to obtain the performance parameters of the open queuing network for the crusher station. The closed queuing network for the entire system is solved by applying the Extended Summation Method (ESUM), in which the crusher server is described by the simulation results. The model has been applied to the Yuanbaoshan open-pit coal mine to analyze its shovel-truck-crusher system and to improve its efficiency. Results indicate that the blocking at the crusher is an important factor affecting the crusher output and in turn the efficiency of the whole system, and prove that the model can realistically describe the behavior of such systems.

Oct 1, 2009

By Jiwen Zhang

Due to the blocking nature at the crusher station, straightforward application of queuing theory cannot give realistic results on the performance of a shovel-truck-crusher system. A new queuing network-based model has been developed in which, the crusher station is formulated into an open queuing network and the whole shovel-truck-crusher system into a closed queuing network with the crusher station as a special server. To fully account for the influence of blocking, Monte Carlo simulation is first used to obtain the performance parameters of the open queuing network for the crusher station. The closed queuing network for the entire system is solved by applying the Extended Summation Method (ESUM), in which the crusher server is described by the simulation results. The model has been applied to the Yuanbaoshan open-pit coal mine to analyze its shovel-truck-crusher system and to improve its efficiency. Results indicate that the blocking at the crusher is an important factor affecting the crusher output and in turn the efficiency of the whole system, and prove that the model can realistically describe the behavior of such systems.

Oct 1, 2009

By T. G. Joseph, K. Barron

A strain-softening constitutive relationship is introduced that describes the post-failure stress-strain curve for rock regardless of whether the rock is intact or broken. The core of this relationship is an “apparent friction” concept that relates the post-failure apparent cohesive and frictional characteristics of the rock to the strain. The relationship can be determined for a given rock via a series of triaxial strength tests establishing the peak strength and corresponding strain for a range of confining pressures, together with the determination of the base angle of friction via a simple tilt test. The postulates and assumptions used in deriving this relationship are verified from results of tri-axial tests on both intact and broken rock. This strain-softening relationship is then applied to coal. Having determined the post-failure stress-strain curve for coal specimens, this information can then be used in a finite element program, such as Phase 2, to examine the post-failure characteristics of coal pillars. Using example data, the strength of coal pillars of different width/height ratios are estimated and compared with well-known empirical pillar size-strength relationships. In addition, the post-failure stress-strain behaviour of a coal pillar is compared with an empirical relationship reported in the literature.

Jan 1, 2003

By Ludwig M. Strah

"Wear is a universal problem and is present in all cases wherein one weighted surface moves with or relative to another surface. A practical description of wear as applied to mineral processing plants is outlined.With the advent of higher material and maintenance costs, more attention is being focused on the field of wear resistant linings. The aforementioned is magnified today as the production facilities continue to be designed to handle larger daily capacities. These changes, higher costs and larger plant handling facilities have necessitated the introduction of different materials and designs to combat the never ending battle against wear.In order that wear be understood, it can be relegated to two specific types:1 - Mechanical Wear - due to movement of one loaded surface relative to another.2 - Chemical Wear - more easily defined as corrosionMechanical wearMechanical wear can be subdivided into two basic forms:A.,Material movementB.,Material impactMaterial movement Abrasion is the result of, as earlier stated, the straight move¬ment of one loaded material relative to another.Material impact Is the striking effect when a mass strikes another from various angles and at various speeds. Impact can be severe enough to permanently damage and distort the basic component installed to overcome impact."

Jan 1, 1983