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By A T. Job, P R. McAree

There is significant value at stake in the mining industry from the implementation of new technologies that support the enhanced profitability and sustainability of mines. However, in order to realise this value, new technology must be implemented in a way that is both effective and sustainable. The industry has a mixed history for technology implementation that provides fertile ground for understanding what is necessary for innovation to deliver value. This paper describes early stage research investigating why this is so, with the aim of improving how to deliver value. Several case studies are provided covering both successful and unsuccessful technology interventions. The paper identifies the common factors that emerge from the case studies, and offers a path forward for further research in this area.CITATION:Job, A T and McAree, P R, 2017. Three case studies on the implementation of new technology in the mining industry, in Proceedings Iron Ore 2017, pp 407–414 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

Research and Application of Vertical Screw Stirred Mill

Sep 13, 2010

By J. Budac, E. Krause, C. L. Stewart, D. Wrana, S. W. Laundry

"As part of an over-all arsenic management strategy, Inco has developed a novel process that converts a by-product high moisture copper/arsenic sulphide precipitate into a crystalline copper arsenate suitable for the manufacture of wood preservation chemicals.The copper/arsenic sulphide precipitate is atmospherically leached with oxygen and sulphuric acid, producing a crude (blue) copper arsenate precipitate, elemental sulphur, and a copper and nickel containing solution. The blue copper arsenate is dissolved with sulphuric acid, the molar Cu/As ratio is raised to 2, and a crystalline copper arsenate (olivenite) is precipitated by the addition of sodium carbonate. Dissolved copper is recovered using metallic nickel (or matte) and elemental sulphur, to produce a low-moisture (low-arsenic) precipitate suitable for standard nickel-copper processing.The process was successfully piloted at Inco's Manitoba Division between September 1990 and June 1991. The copper arsenate product typically analyzed 43% Cu and 25% As, and the moisture content was about 10%."

Jan 1, 1995

By S. Banisi, J. Marois, A. R. Laplante

"This paper compares the behaviour of gold and ore in the grinding circuit of Hemlo Gold Ltd. Particular attention is given to grinding kinetics, classification behaviour, and liberation. For grinding kinetics, laboratory grinding of gold flakes and silica, 840-1200 um in size (14/20 mesh), was also performed to provide a standard for comparison and to study in a controlled environment the mechanisms of breakage, folding, smearing and impacting.Grinding kinetics were characterized at laboratory scale with breakage and selection functions. The breakage function showed that 75% of gold disappearing from the 840-1200 um class reported to the 600-840 um; this figure is much higher than for silica ( 46%) or most other minerals, and implies that comparatively fewer fine fragments are produced from the breakage of gold flakes, on account of gold's malleability. The selection function of silica was four times that of gold. At plant scale, the ratio of the selection function of ore and gold increased from 6 for at 50-100 um to 20 at 500-1000 um.Observation of original flakes and their fragments with the scanning electron microscope showed that the main mechanism of ""grinding"" from the 840-1200 um to the 600-840 um class was folding rather than actual breakage. This was confirmed by a measure of individual flake weight. The postulated breakage cycle is that relatively globular flakes become increasingly serrated through grinding; they can then regain their original shape through folding and reflattening into cylindrical and spherical shapes, as the majority does; however, some fragments will at this point undergo actual breakage. Photographic evidence is presented to support the proposed mechanisms.Smearing of gold unto silica was observed when silica was ground after a gold, and embedding of silica into gold flakes when gold was ground after a silica. Both mechanisms occur whenever gold and harder minerals are jointly ground, and result in ""unliberation"" of gold. It is postulated that smearing of gold onto other minerals plays an important role in explaining how gravity recovery can increase overall gold metallurgy, especially when used ahead of flotation.Classification of gold in the primary hydrocyclones takes place at a much finer cut-size than ore, 20 vs. 57 um. This and the slower grinding kinetics result in high gold circulating loads in the primary loop, 6700%, and a gold content in the primary cyclone underflow (PCUF) is twenty four times that of the ore. The gold size distribution for primary cyclone overflow is much finer than that of the ore, although they are essentially similar in the PCUF.Liberation, or more accurately ""gravity recoverability"", was assessed with a 7.5 cm (3"") Knelson concentrator. It varied between the thirties for the primary mill discharge and two cyclone overflows, to highs of 89 to 92% for the PCUF and secondary mill discharge, 89 and 92%, respectfully."

Jan 1, 1991

By Arcy, D&apos Banister

The productive potential of the Nation's principal active and inactive silver mining districts has been evaluated, using 1964 economic conditions and assumed silver prices ranging up to $3 per ounce. On this basis, the United States has an estimated 5 billion ounces of unmined silver, excluding minor byproduct silver in gold deposits. Approximately 3.5 billion ounces are contained in deposits requiring higher silver prices to be economically minable, and about 1.3 billion ounces are in currently operating mines. An analysis of silver consumption trends since 1954 indicates that the free world industrial market will climb to nearly 800 million ounces annually by 1985. U.S. industrial silver consumption has been projected to increase at an annual rate of 4 percent from 1965 to 1985. Average annual increase for the remainder of the free world has been 8.1 percent since 1953; this is expected to level off with an estimated average increase of 5 percent to 1975 and 4 percent from 1976 to 1985. Foreign silver production has, in the past, exceeded consumption, but in 1960 the supply deficit was over 100 million ounces. U.S. production, also traditionally exceeding demand, was suddenly overtaken at the start of World War II. By 1964 the annual deficit, excluding coinage, was over 84 million ounces. World coinage requirements of silver are fast declining and expected to total only 25 million ounces annually by 1985. In fact, coins are already becoming major short-term source of silver to fill the large deficit between industrial demand and current production. The larger, long-term deficit (to 1985, the limit of this study) must be balanced by silver from the hoards and new production from silver deposits. Eventually all of the deficit must be met by new production or silver prices will rise until consumption is greatly curtailed. To balance free world supply and demand, it is estimated that the free world must produce an additional 85 million ounces by 1975 and 375 million ounces by 1985. The estimated proportion expected from U.S. deposits is 17 million ounces by 1975 and 74 million ounces by 1985.

Jan 1, 1969

The work described herein is the opening phase of an extensive system of underground excavation undertaken under contract with a Malayan authority.The specifications called for the lining of all tunnels in earth or broken rock with circular segmented cast iron lining, similar to that of the London tubes, and it is the installation of these linings which it is proposed to discuss.Owing to the long deferred delivery quoted and the obvious need for speed of access to the internal installation, it was decided to defer driving the completed circular section and substitute two small timbered headings.These could later be opened out in turn to full section and lined without prejudice to traffic, since both of them had access to the internal workings.NATURE OF ROCKThe rock series through which the circular sections were driven consisted of:(a) A wide zone of intrusive porphyritic granite, consisting generally of orthoclase phenocrysts in a ground mass of micro pegmatite. This area showed advanced weathering, varying from a stage showing slightly tinted kaolin containing approximately 20% of small boulders to one of ultimate decomposition to pure kaolin;(b) A narrow zone of weathered augite diorite, consisting of rock masses of a maximum weight of some 100-150 tons, isolated by clay seams up to 1 ft. 6 in. in width.The whole area was in a state of quasi-hydrostatic equilibrium, which resulted in heavy pressure immediately after excavation. Freshly broken faces would appear to be quite solid but, within a few minutes, would commence to sweat and "slab off" under pressure and, unless support was placed promptly, the whole face would burst out and run from above. Mucking was slow, owing to the plastic nature of the clay and the ease with which it puddled into slurry.In zone (b) a good deal of trouble was experienced because of the fact that the somewhat heavy blasting necessary tended to cause movement of the large rock masses. Subsequent scouring out of the supporting clay bands by the waterflow permitted settlement of the ground on to the timbers and many reinforcing sets were therefore required.The timbering of the pilot headings and its relation to the cross-section of the circular tunnels is shown in Fig. 1. Top and side spiling was driven in the ordinary way, but in bad ground intermediate sets and breast boards had to be placed. These sets were usually withdrawn after the...

Jan 1, 1941

The overall objective of this study is to gather operational data from selected surface coal mining systems in the United States, and to assess the potential production and economic capacity of the systems. The study includes: four mines, each using a different mining technique and different equipment. One mine was selected from each of the major coal fields: Midwestern, eastern,, northwestern, and southwestern. The Midwestern Mine is located in the Central Plains and produced 1.45 million tons of raw coal during the study year The Midwestern Mine uses the area mining or box-cut technique. A large in-pit shovel and a bucket wheel excavator are used to remove the overburden. Coal is removed by a loading shovel and transported to the dumping point by large off--highway trucks.

Jan 1, 1975

By H. R. Babitzke

As part of a continuing project to develop refractory metal alloys for high-temperature structural applications, the Bureau of Mines applied solid solution and precipitation strengthening techniques to improve the properties of columbium alloys. The purpose was to investigate the effects of hafnium, tungsten, and boron on the formability, strength, and oxidation resistance of columbium. The experiment was of factorial design with two replications which called for 72 ingots of 36 basic compositions, weighing 150 grams each. Hafnium, tungsten, and boron were evaluated at 3, 3, and 4 levels, respectively. Values of alloy content are all in atomic percent. The highest strength observed was 29,000 psi at 1,200° C for alloys Cb-15Hf (No. 3), Cb-7.5Hf-5W-2B (No. 14), and Cb-15Hf-5W-2B (No. 15). At 1,200° C, the ternary alloy Cb-15Hf-5W (No. 6) which has shown good properties in previous Bureau of Mines investigations was the most resistant to oxidation For boron additions, the alloys oxidized more readily with increasing amounts of this element. The fabricability of the alloys high in boron became increasingly difficult, resulting in an inadequate number of alloys required for a complete statistical analysis for all the tests. As a result of the decrease in ductility, an insufficient quantity of tensile samples were available for a proper analysis for the high-temperature strength data.

Jan 1, 1970

By K. O. Bennington

The thermodynamic properties of hedenbergite, of composition [(Ca0,9516) (Mg0,0583Fe2+0.7134 Fe3+0.0934 Mn0,1366) (Si206)], were experimentally determined at the Bureau of Mines. The standard enthalpy of formation determined by hydrofluoric acid solution calorimetry is AHf298 = -680.96±0.855 kcal/mol. The standard enthalpy of formation from the oxides is AR-96 = -24.55±0.485 kcal/mol. Low-temperature heat capacities were determined by adiabatic calorimetry from 12.3 to 300.1 K. The derived standard entropy is S-98 - 41.218±0.148 cal/mol-K. High-temperature heat capacities were measured with a differential scanning calorim¬eter from 397 to 1,147 K. These experimentally determined data were combined with data from the literature to calculate the Gibbs energies of formation and equilibrium constants of formation over the temperature range of measurements. Standard enthalpies of formation are given as a function of temperature. The standard Gibbs energy of formation at 298.15 K is AGf298 = -641.90±0.86 kcal/mol.

Jan 1, 1984

By Ben Aleck

The objective of this program was to adapt Space Shuttle technology on high-performance spherical pressure vessels to cylindrical pressure vessels. Specifically, a cylindrical aluminum liner overwrapped with fiberglass filaments and prestressed by yielding the liner under a sizing pressure was to be replaced by a higher strength-to-weight ratio steel liner overwrapped with a higher strength-to-weight ratio filament. The steel was cryoworked stainless steel and the new fiber was Kevlar 49. In addition, the heavyweight ends of the aluminum liner were to be replaced by thin-walled domes which required multiple helix angle wraps for their support, in place of the single kite-string wrap from pole to pole of the aluminum overwrapped design. The use of cold swaging of tube-ends to form bosses, demonstrated on subscale development efforts, had not been achieved full-scale when the contract was initiated. Difficulties arose with the full-scale demonstration which were not solvable at the time with the designs and equipment available. hence, an unanticipated development was the finally selected method of making the 4-in.-diameter stainless steel liner with a single boss and no welds in an 0.020-in.-thick wall, from an 0.050-in.-thick, 13-in.-diameter disk. The demonstration vessel failed by leakage during the prestressing step because embedded oxides had formed flaws in the boss region. Such flaws have been avoided by proper temperature control during hot spinning. Hence, a new design was developed which weighs half as much as its recently developed predecessor. Funds ran out before adequate testable hardware was produced.

Jan 1, 1983

Laboratory induced polarization measurements were made on representative samples of concentrated sulphide ores from three environments in New South Wales Comparisons were made with the membrane polarization exhibited by an argillaceous sandstone. The sulphide samples showed a strong polarization effect, the magmtude of whIch depended directly on the conductivity of tlIe pore electrolyte.

Jan 1, 1969

Magnetite cenospheres 40-270 I/m in diameter have been found during the combustion of pyrite concentrate.Micrographs of the surface and internal structures are presented together with comment on the mechanism of forrnation.The similarity to cenospheres found during the combustion of pulverized fuel was noted and speculation raised to their contribution to the dust and fume load in flash smelters.

Jan 1, 1980

By Herbert Haas

ChEap power is essential to large-scale mining and metallurgical operations, particularly where fine grinding of large tonnages has to be resorted to, as is the case with an increasing number of mines treating disseminated copper ores, or low-grade gold ores, in the grinding of which considerable power is consumed. A comparison of the cost of generating power with Diesel engines and steam turbines and a brief discussion of the different factors governing the profitable use of either type of prime mover may be timely in view of the importance of a cheap supply of power to the mining industry, and the prominence that has lately been given to Diesel engines in America. As many of our most important mines and largest producers of metals are located in sections where neither cheap coal nor water power is available, and the price of oil fuel is increased by long hauls, the Diesel engine will become a prime mover of increasing importance. This applies particularly to the Southwestern States, where an ample supply of cold water for condensing purposes is unusual and local climatological conditions interfere in securing the high vacua essential to high turbine efficiency. About 12 times as much water will be required for condensing purposes with steam turbines under general conditions as is needed for jacket-cooling of two-stroke cycle Diesel engines; four-stroke cycle Diesel engines require only one-twentieth of the cooling water. Another condition favoring the use of Diesel engines is the high load factor at which most mine power plants operate. The influence of load factor on the cost of generating power is shown in Tables 1. and 2 and in Fig. 1. The higher the cost of fuel and the load factor, the greater will be the proportion of the fuel to the other costs making up the total cost of generating power. Capital charges (interest and redemption), maintenance, operating labor, and lubrication are practically constant amounts regardless of the load-output of the station; the fuel consumption and its cost are practically the only variables with the load. The costs here given are based on conditions as generally found in the Southwestern States, and on Diesel engine operating experience in European countries, where this type of prime mover has reached a high state of perfection, units upward of 4,000 hp. having proved entirely successful in operation.

Jan 1, 1917

By J. F. Lupo

Heap and valley leach operations rely on solution collection piping placed within the heap to enhance both solution recovery and to assist overall solution management. The most common piping used in leaching operations is solid or perforated High Density Polyethylene (HDPE) pipe and Corrugated Polyethylene pipe (CPE). These pipes are widely used because of their low cost, ease of installation, durability, and flexibility. The typical recommended maximum design depth of burial for HDPE and CPE pipes is on the order of 30 meters (100 feet). However, ore heap heights at many facilities exceed 30 meters and some are now approaching 180 meters (600 feet) in height. At very high ore heap heights, the stability and performance of HDPE and CPE pipes becomes a critical issue for leaching facility design and operation. Failure of solution collection piping can lead to poor solution recovery, high hydraulic heads on the liner system, and in some cases, unstable ore slopes due to high solution pressures near slopes. This paper presents a review of methods that have traditionally been used to evaluate pipe stability under high normal loads. A common shortcoming of these methods is the inability to account for beneficial effects of ore arching around pipes and the time-dependent creep (stress relief) behavior of polyethylene (PE) materials. A new analytical approach is developed and presented which includes the effects of ore arching around pipes and creep of PE materials. The results of the new approach show that PE pipes will deform under high heap loads, but can remain stable and functional. Pipe stability is shown to be dependent on the type of pipe backfill and initial backfill compaction. The new approach represents a useful tool for designing applications for PE pipe under high normal loads.

Jan 1, 2001

By P. Mousset-Jones, G. Danko

Variations of the temperature and steam/moisture content of the air with distance and time are modelled for a single airway. The input for the simulation is an air temperature that varies with time, together with the moisture/steam content that results, for example, from a fire with a given distribution of heat and of fume concentrations at the beginning of the airway. The transport of heat and moisture to the surface of the wallrock is assumed to be simultaneous. Such multiphase convection may result in evaporation from the moist wall close to the fire and recondensation downstream. The modelling of this non-linear effect is a unique feature of the new simulation. A new analytical solution is used to calculate the conduction of transient heat within the rock mantle, which, in the event of a fire, is typically a short-term process. This allows for an arbitrary variation of surface temperature with time - unlike that permitted by the age function solution, which is limited to stepped temperature changes. An iterative numerical scheme that has recently been developed to simulate mine climate is used to calculate the coupled transient heat conduction and multiphase surface heat transport in successive length increments along the airway. To demonstrate the simulation procedure a numerical example is presented in which a fire with a given distribution of heat and fume concentrations with time is located at the beginning of an airway

May 1, 1991

By P. J. Routledge

THE purpose of this paper is to discuss the practical aspects of locating gravel deposits and of establishing efficient, portable concrete aggregate beneficiation plants for use on construction projects where limited amounts of high-quality gravel and sand are required. Certain projects are listed, in order to demonstrate the wide variety of problems encountered. Routledge Gravel Contractors Limited, North Vancouver, have supplied concrete aggregate for construction projects in British Colum-bia since 1957. In tl1at year, in sup-plying aggregate for a small project at a site on the northern coast of British Columbia, our quote was as follows: Concrete aggregate to specifications, f.o.b. scow, North Vancouver$ 1.75 per cu. yd. Scowing charges to site. $16.00 per cu. yd. At that time, our company realized that more attractive quotations could be submitted if local gravel was utilized where available. Port-able equipment was then acquired and a simple screening plant (Figures 1 and 1a) was at first used. This was later replaced by heavier, more versatile equipment. The use of suitable equipment, the keeping of cartage to a mini-

Jan 1, 1962

By J. D. Steenkamp

Southern Africa has a history rich in the pyrometallurgical processing of ores. Two of the alloys produced are high-carbon ferromanganese (74?83 per cent Mn) and silicomanganese (59?67 per cent Mn and 14?31 per cent Si). The largest land-based manganese ore deposit in the world is based in the Northern Cape Province of South Africa. In 2010, 6.3 Mt of ore from the deposit was exported, mainly to China, Norway, Japan, and India, and an estimated 1.1 Mt beneficiated locally to produce manganese ferroalloys. In southern Africa the producers of manganese ferroalloys are Metalloys and Assmang, and of silicomanganese Transalloys, Mogale Alloys, and Match Corporation. Submerged arc furnace technology is utilized in the production of high-carbon ferromanganese (HCFeMn) and silicomanganese, applying the discard slag practice in both instances. The carbon content of HCFeMn is reduced using converter technology and that of SiMn using the Perrin process. Ninety per cent of the world?s manganese ferroalloys production is consumed by the steel industry. The consumption (and production) of manganese ferroalloys therefore closely follows worldwide steel production. From 2001 to 2010, the doubling of the worldwide production of manganese ferroalloys can be attributed to an increase in production capacity in Asia and Oceania, with the largest increase in the production of SiMn. Manganese ferroalloys produced in Asia and Oceania are mainly for the local market, with North America, Europe, Russia, and Turkey the major markets for alloys from southern Africa. The major challenges faced by the southern African manganese ferroalloy producers are increasing electricity tariffs and productivity of labour, which require a concerted effort by all parties involved to achieve a satisfactory solution. Keywords manganese ferroalloys, ferromanganese, silicomanganese, southern Africa, South Africa, manganese ore, high-carbon ferromanganese, refined ferromanganese, refined silicomanganese.

Aug 1, 2013

By D. Bernard

Over the last decades, the wrought aluminum casting industry has made significant progress with regards to process consistency by the introduction of new technologies in the field of liquid metal processing and casting. These technologies, combined with the application of best practices, have led to increases in productivity as well as better process performances and product quality. The competition in the addedvalue aluminum products (by opposition to P1020 production) is, however, very strong and involves players that did not hold a major role five years ago but who are now exerting a strong competitive pressure on our industry even sometimes from far abroad. There are still technical and technological challenges remaining in the different areas of aluminum casting production, amongst which metal pre-treatment, furnace operations, in-line treatment and casting hold a predominant influence. The comprehension of the contribution of each individual process step to the entire process chain is a key element and must be considered in future process optimisations. This paper presents the technological position of the casting industry and tries to highlight areas where further progress can be made.

Jan 1, 2006

By Timothy M. Barton

The U.S. Bureau of Mines is conducting research to assess the effectiveness of different chain pillar designs in maintaining gate entry stability. A particular concern is ground control for deep-cover 1ongwalls located at depths in excess of 1,000 ft. The study described in this report was performed in two experimental sections in one longwall headgate section which contained three different pillar designs. Two of the designs used conventional abutment pillars, while the third was a total-yielding pillar system. Both of the test areas were located under 1,800 ft of cover. The purpose of this study was to evaluate the effectiveness of these three pillar designs for gate road stability. As the longwall mined passed the test areas, Bureau engineers monitored entry convergence, roof sag, and changes in roof quality. The study indicated that the all-yield system performed nearly as well as the better of the two abutment pillar systems; but all of the three designs would have failed to provide acceptable stability for second panel mining without considerable artificial support.

Jan 1, 1989

By Merle L. Bowser

An alinement (steering) sensor for continuous mining machines has been developed under a Bureau of Mines contract. A laser source in the entry projects a beam parallel to the centerline of the entry. The beam is optically shaped to a narrow, vertical fan and illuminates an array of optical sensors bunted on the mini machine. These sensors interpret the location of the beam into meter readings of heading (angle) error and lateral displacement errors. The system, which was tested for 5 months in an operating mine, appears to be fundamentally sound, and with some modification, should be applicable to remote or automatic guidance of continuous miners and other machines.

Jan 1, 1976