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By Robert K. Jonas

Mining companies can improve production and reduce costs by using the best available technology to control their operations. Many mines are challenged to use multivariable predictive control due to limited experience or staffing, as well as being concerned over the robustness and sustainability of predictive controls. As a result many mines are not realizing optimal performance from their assets, and thusly are not realizing the production increases or cost reductions that this technology can deliver. Over the past few years, the application of multivariable model-based predictive control has gained acceptance in many mining processes and has proven to be robust and sustainable for some of the most challenging mining processes. New automated modeling and performance monitoring software have greatly simplified the effort to implement and maintain these solutions. In addition, many progressive companies have chosen to co-source the implementation and service of these solutions to assure project success and continued benefits stream. This technology has been successfully applied to a wide variety of processes; grinding mills, alumina digestion, CCD washer and thickeners, kilns, calciners, roasters, flash smelters, heat exchangers, evaporators, and most recently in the demanding process of flotation. This paper discusses the state-of-the art in advance control technologies in the mining industry, including the impact of these technologies on maximizing benefits, and implementing best practices for long term sustainability. Benefits from recent multivariable predictive control applications in copper mining will be reviewed, and the use of the latest predictive control technologies and practices in mining will be discussed.

Oct 1, 2009

By O. Guyot, A. Broussaud, M. Revalor, G. Legrand, D. Kok, E. Roux

"The paper describes the advanced grinding control system implemented at Newmont Ahafo gold mine, Ghana in 2009 and 2010. It shows how the different components of the Advanced Process Control (APC) system cooperate for increasing plant performance.The SABC circuit processes hard rock from different pits mixed with a variable proportion of oxides. The control strategy is designed to address specific disturbances, including start/stops of pebble crushers, unavailability of oxides, changes in rock size distribution resulting from segregation in the stockpile, and changes in ore type and hardness.The system consists of an expert system per se with extensive use of fuzzy logic, supplemented by an online dynamic model of the process used as a soft sensor, a VisioRock™ rock size measurement system over SAG mill feed before addition of recycled pebbles, and an AudioMill™ system to analyze the SAG mill sound and detect impacts on liners. All these components are embedded in the same OCS© software platform, which, among other benefits, makes it easy to support the entire system remotely. The paper details the physical constraints and the variables that are manipulated. It describes the control strategy and the contribution of each component of the system. It also describes the project implementation and the performance of the system. In addition to a strong involvement and support of management, the very good acceptance of the operators has been facilitated by the remote access system that made it possible to immediately modify the system each time it was needed during the baby sitting phase.The system made it possible to increase gold production significantly through increases in tonnage and recovery thanks to a better control of the grind size through a stabilization of the secondary ball milling circuit and an improvement of the operating conditions of the classifying cyclones."

Jan 1, 2012

By David W. Mogk, Tamara Darsow, Macgregor L. Fogelsong, Robert M. Hunter, Frank M. Stewart, Edwin H. Abbott, Courtney A. Young

Abstract: Development of cost-effective techniques for recovering precious metals from their ores has been the goal of metallurgists for hundreds of years. Today, metallurgists are increasingly called upon to design processes for ores that are refractory to conventional recovery techniques. These challenges and the addition of environmental costs (including site remediation) to the total cost of mining have stimulated a search for alternatives to conventional processes, such as cyanidation. This paper describes the progress made to date in development of an innovative alternative to cyanidation, termed bisulfide leaching, for extracting gold, silver and platinum-group elements from refractory ores and concentrates. While bisulfide leaching can be implemented abiotically, significant benefits accrue from its practice as a bioprocess that integrates the steps of precious-metals liberation and extraction. In many applications, bisulfide leaching appears to offer significant advantages over the traditional cyanidation process. Dissolved bisulfide and hydrogen sulfide are much less toxic than dissolved cyanide and hydrogen cyanide. Recommended workspace exposure limits and harmful concentrations for hydrogen sulfide gas are higher than those for hydrogen cyanide gas. While the facilities required to practice the bioprocess on an industrial scale would be similar to that of cyanidation plants, chemical reagent costs could be 80 percent less. The bioprocess may also offer advantages in the leaching of ores and concentrates that are not amenable to cyanidation. For example, bisulfide leaching of ores containing carbonaceous material may produce higher gold recoveries if the "preg-robbing" characteristic of the material can be controlled biologically or with dissolved sulfide binding. Moreover, in that precious metals are much more soluble than base metals in bisulfide solutions, bisulfide leaching offers distinct advantages over cyanidation for selective dissolution of precious metals from base-metal concentrates. Thus, the bioprocess uses the natural sulfur cycle to mitigate pollutant production and to enhance precious-metals recovery.

Jan 1, 1998

By Mitchell Gordon

"In almost all thickener applications the highest possible solid/liquid separation efficiency is what is desired by the user. There is a trend in the industry due to monetary restraints and environmental pressures to look at ways to extract this maximum performance by either retrofitting existing thickeners or installing the most cost effective new thickener. This paper looks at some of the common problem areas and presents a range of solutions developed by Outokumpu Mintec in North America and outokumpu's subsidiary Supaflo Technologies Pty. Ltd.The Emerging PictureAfter many hours of discussions with a large number of plant personnel over the last two years a picture began to emerge regarding current thickening operations in the industry. Initially, it seemed that everybody had their own unique process problems and therefore needed a correspondingly unique solution. Looking more closely at all the cases and the ideas that we had either implemented or suggested, it gradually became apparent that the majority of operators all had one and the same process need ....""Better Separation Efficiency""The range of operational problems that were uncovered in the survey were much more varied than expected and often were not even considered initially to be thickener problems. Often, it was only after the rejection of many solutions to the problem, generally due to capital cost, that the actual cause of the problem was looked at and found to be a thick-ener.A summary of the problems that have so far been identified is presented in Table 1. They are subdivided under three major categories of environmental, process and paste fill to highlight the wide range of mining activities that can be affected by poor thickener performance. These seem to be the major areas where the need for better separation efficiency is rooted."

Jan 1, 1995

By Pierre Montrueil, Marcel St-Amant

Within the next few years, underground mobile equipment will be partially automated. Mining methods will integrate more and more automation. Such an evolution will be possible only if adequate underground communication systems are developed. This is expected due to the available competence in Canadian telecommunication, to the economic pressure on the Canadian mining industries for international competitiveness and to the social changes where a better working environment (i.e. less accidents) becomes a major concern. CCARM propose the concept of a Production Area Network for Automated Mobile Units called PANAMU as an intermediate size communication system. It can be implemented using mature present-day technology and it can be integrated in some mine wide communication systems. It can evolve so as to incorporate new technologies because of its modular concepts. In this paper, the communication requirements are estimated, the amtmptions are defined, the concepts of the PANAMU are presented and an over- view of its implementation is described. CCARM presents this article to the mining industry as a document for discussion.

Jan 1, 1994

By W. Beres, R. E. Miller, B. Shiari, L. R. Zhao

A dynamic multiscale (MD/FE) method has been used to study dislocation generation and plastic deformation during a nanoindentation process which is physically associated with the generation of heat within the specimen and as a consequence with a temperature rise. Two different techniques are applied to study the temperature effect on the nanoindention process. In the first technique, a global Nose-Hoover thermostat is applied to the entire atomistic region to keep temperature constant during simulation (finite temperature approach). In the second method, the thermostat is applied only on a damping region along the MD/FE interface. Both techniques are able to effectively and efficiently absorb high frequency reflected waves from atomistic/continuum interface. The temperature profile of the atomistic region beneath the indenter is reported and discussed at four different initial substrate temperatures for both techniques. The loaddisplacement (load/unload) curves for different temperature-controlling techniques are compared and discussed. The nucleation and propagation of dislocations in the atomistic region are investigated for both techniques. Correlations between the observed features in the load-displacement curves with the motion and pile-up of dislocations are reported as a function of temperature.

Jan 1, 2006

By L. J. Surges, C. Bazin, D. Hodouin

"A kinetic model was developed for the conditioning and flotation processes of an industrial lead concentrate dezincing circuit. The models were incorporated into a flowsheet simulator. Simulation results demonstrate the advantages of split conditioning of coarse and fine particles and the potential of this approach for the production of the heuristics required for the development of intelligent control strategies.The conditioning model relates the proportions of activated and hydrophobic surfaces and residual reagent concentrations to activator and collector reagent flowrates. The model accounts for the solids and water flowrates, and for the solids grade and size distribution. The flotation model uses the predicted proportion of hydrophobic mineral surface, the aeration rate and the froth depth to estimate cell, bank and circuit performances. IntroductionFlotation has been the object of modelling and simulation studies for more than two decades. The process is usually modelled as a kinetic one in which the particle flotation rate constants are key parameters. Rate constants are related to the operating variables (pH, reagent flowrates, aeration rate, etc), however these relationships are seldom established in the literature.In spite of the large amount of literature on flotation modelling and simulation, few papers deal with the interaction between flotation rate constants and operating variables. This important gap, which was identified in the early seventies by Woodburn (l970), still exists. One of the first attempts to include operating conditions in a flotation simulator was made by King (l973), who explicitly introduced the aeration rate into an air bubble loading model. Lynch et al. (1981) used an empirical model to relate the proportion of slow floating particles to the ratio of collector per ton of ore. Such empirical relationships are difficult to calibrate and cumbersome to use when an activator and a collector are added to slurries in which particle size distribution and surface characteristics are changing. Eascur and Herbst (l982) relate in a fundamental way the mineral flotation rate constants to the aeration rate, froth depth, agitation and frother concentration, however the model does not account for reagent flowrates. Niemi et al. (1982) have proposed a model for the conditioning of minerals and included it into a conventional flotation simulator."

Jan 1, 1988

By J. Severin

Surface mining operations are increasingly involving the design and development of deeper and larger open pits, often with plans to transition into underground mass mining operations. Experiences at the Palabora Mine in South Africa demonstrate the complex interactions between underground workings and the steep slopes above that may lead to slope movements that potentially pose safety and economic concerns. To properly assess the rock mass response to these interactions for planning of future developments, understanding the controlling influence of geological and geomechanical structures is crucial. Preliminary results are presented from a detailed review of historical slope monitoring data from the Palabora Mine, before and after the initiation of block caving 400-m beneath a 800-m deep pit. This paper demonstrates that a detailed analysis of geology and monitoring data can be used to better understand the kinematic controls of complex rock slope displacements and interactions between open pits and underground mines. This investigative treatment of the monitoring data is important in understanding the failure mechanisms prior to undertaking sophisticated 3-D numerical models.

May 1, 2009

By Robert D. Irvine

"Enhanced concern for protection of the environment and attendant actions by environ-mental regulatory authorities in support of this concern are influencing, to varying degrees, the demand and supply of a range of industrial minerals in a number of jurisdictions. These influences take a variety of forms.In this paper, the author seeks to delineate certain broad trends which are occurring relative to industrial minerals and the environment and then, through a series of examples, to outline opportunities, developments, and impacts respecting a number of industrial minerals produced and consumed in Canada and the United States."

Jan 1, 1996

By Patrick R. Taylor, T. A. R. Putra

A review of various methods to treat high arsenic copper concentrates through pyrometallurgical processing is presented. Examples are drawn from various past and current operations and research. Various aspects of the engineering alternatives for treatment methods are discussed. Some of the methods discussed include: controlled oxidation roasting, adaptation of some smelter technology to accept higher amounts of arsenic, complete oxidation with arsenic fixation; sulfation roasting; acid baking, soda ash roasting, and others methods. Other topics include: a short discussion of other problematic impurities; the effects of arsenic on copper electro-refining and product purity; and methods for the ultimate disposal, or marketing, of the arsenic. The latest work being done at the Colorado School of Mines on soda ash roasting is also presented.

Jan 1, 2014

By W. G. Hatch

Introduction Classified equipment originally installed in 1923 in the Britannia mill consisted of eighteen Model C Dorr Simplex classifiers, each in closed circuit with a pebble-mill. These machines were only three feet wide and of light construction, so that their raking capacities were necessarily limited, the maximum being about 20 tons per hour for each classifier. On conversion from pebble-mills to ball-mills, in 1924, attempts to increase circulating loads with higher rake speeds resulted only in overflowing a coarser product to the flotation cells. The elevator type of classifier was developed locally in 1935 and during that year two units, each having a sand carrying capacity of from 30 to 40 tons per hour, were installed. With such loads, a material increase in the grinding capacities of the ball-mills was noticed, and, after further development work on the elevator classifier, fifteen of the small Dorr classifiers were replaced by units of this type, capable of handling approximately 75 tons of sand per hour, with later alterations increasing this capacity to well over 100 tons per hour. In the meantime, the three remaining ball-mills had been placed in circuit with Dorr FX classifiers, one of which was six feet wide and the others five feet wide. Impartial and exhaustive tests conducted on the Dorr FX versus the elevator classifier showed the average results on these machines at Britannia to be substantially the same. A large amount of testing was carried on to determine the effect of circulating load on the output of the grinding units. This work indicated a rapid increase in the grinding rate as the ball-mill feed increased up to about 60 tons per hour, after which a relatively slow increase took place up to 100 tons per hour. No benefits were derived from higher circulating loads. A 300 to 500 per cent circulating load, depending on the nature of the ore treated, is considered to be within the economical range for the grinding of Britannia ores.

Jan 1, 1946

By A. E. M. Warner, A. Vahed, P. J. Mackey

In the decade 2002 to 2012 some 6.7 million tonnes of new copper concentrate production capacity was brought on line, corresponding to 2 million tonnes of contained copper. This increase in concentrate supply necessitated the commissioning of a number of new copper smelters as well as the modernization and/or expansion of existing plants to meet the demand. This paper gives an overview of the copper extractive industry, reviews recent copper production trends and changes in the copper industry, including an examination of pyrometallurgical and hydrometallurgical technology developments. WorleyParsons has supported a number of the projects involved in these developments and this role is briefly discussed. The paper introduces a number of ideas related to possible future directions of the copper industry.

Jan 1, 2014

By P. Woo, N. Brodusch, R. Gauvin, H. Demers

The scanning electron microscope (SEM) was primary developed for imaging applications. With the introduction of the Si(Li) energy dispersive spectrometer (EDS), simultaneous imaging and x-ray microanalysis became possible. However, long working distance and high current were needed because the position and small solid angle of the EDS detector. The high spatial resolution is generally obtained at short working distance with a SEM. Unfortunately x-ray microanalysis is never performed in the best imaging conditions. The annular silicon drift detector system is inserted below the objective lens which gives a higher solid angle (up to 1.3 sr). In consequence, a lower working distance and probe current can be used. An improved spatial resolution becomes possible during x-ray microanalysis. With this x-ray detector installed on a cold-field emission scanning electron microscope, quantitative x-ray microanalysis with high spatial resolution at low beam energy and low current becomes possible with the possibility of using the various different type of imaging at the same time. Also, since the count rate can be as high as 1,500 kcps, which lowers significantly the detection limit of elements as well as the minimum feature sizes of different phases that can be distinguished.

Jan 1, 2014

By H De Beer

The 14MW SAG mill at Tarkwa, Ghana, experienced a frozen drop charge incident on 10 February 2010. This caused downtime of 112 hours, a repair cost of $200k and production loss of 162,000 tons, corresponding to a loss of $8.9M. A new locked charge protection system was installed on the two Tarkwa mills on 30 July 2010, mitigating this risk. This system calculates the ore angle in real time while the mill is starting up and trips the mill if the ore angle exceeds a trip angle setting. The calculation of the ore angle is derived from the mill motor rotor currents only - no mechanical transducers are required. The head of Gold Fields West Africa, Peter Turner, says of the new system: "This is excellent work and the type of technology that has had and will continue to have, major opportunity cost impacts on our business."

Nov 1, 2011

By EJ. Reichhardf

The Molopo Farms Complex is a major, layered ultramafic/mafic, early Proterowic intrusion which is totally covered by sediments of the Karoo and Kalahari Fonnations and situated in southern Botswana and northeastern South Africa. The approximately 3000 m thick, generally fine- to medium-grained ultramafic and mafic cumulates are intrusive into equivalents of Thmsvaal Supergroup sediments and lavas. Multiphase defonnation resulted in tilting and segmentation of the Complex into individual tectonic blocks. Sr isotopes document at least two chemically distinct parental liquids which interacted in a complex manner to form an approximately 1000 m thick rhythmically layered succession which straddles the ultramafic/mafic boundary. Repeated mixing resulted in a complex cryptic layering pattern and numerous sulfide-enriched layers which contain significant PGE+Au concentrations.

Jan 1, 1994

By Engin Burak Anil

Objective, accurate, and fast assessment of damage to buildings after an earthquake is crucial for timely remediation of material losses and safety of occupants of buildings. Laser scanners are promising sensors for collecting geometrical data regarding the damaged states of buildings, as they are able to provide high coverage and accuracy at long ranges. Yet, we have limited knowledge on the performance of laser scanners for detecting earthquake damage, and requirements of such data collection. This paper focuses on characterizing the performance of laser scanners for detecting thin cracks for damage assessment of reinforced concrete frames. We identified a series of crack parameters based on the state-of-the-art damage assessment codes and standards. Similarly, we identified parameters, which affect the performance of laser scanners for detecting cracks, based on prior research in this area. We studied the width, depth, and orientation of cracks; sampling interval of the scanner, and the range of the laser beam from the surface. Effects of these parameters on the detection of the minimum crack size were determined in an experimental setting. An automated algorithm was used to analyze the data. The results show that it is possible to detect as small as ~1mm cracks.

Aug 1, 2013

By A. E. M. Warner, P. J. Mackey

Copper metal is produced in large or small tonnages in almost all countries of the world—handling raw materials in the form of either as-mined or milled ores, custom concentrates, or other custom materials including scrap and recycled copper. The scale of operations and type of technologies used around the world varies widely. There is a certain concentration of both mining and smelter-refinery production as a total of ten countries produce some 80% of world mined copper, while ten countries—mostly different ones— produce about 80% of smelted and refined copper. As a result, international copper trade is significant. The present paper takes the reader on a virtual tour of the copper plants throughout the world with a focus on smelter facilities. Operations and technology employed at each plant visited are discussed including a brief historical sketch. Future trends identified during the world tour are also discussed. The present authors considered sufficient time was required for a thorough study tour and settled on eighty days—the same as that for the celebrated fictional story of world circumnavigation in the 1870s. INTRODUCTION The celebrated French writer Jules Verne published his book “Around the world in 80 days” in English in1873 and it is the story of Phileas Fogg and his French valet Passepartout circumnavigating the world in 80 days in the fall of 1872 on a £20,000 wager (equivalent to over 2 million pounds today) from the exclusive Reform club in London. This is an interesting period for copper as it started trading on the London metals Exchange in 1876 and the start of global copper production chains started to take off at this time with the rapidly increasing electrification of the world. The production chain includes mining, mineral processing, smelting, refining and fabrication. Since 1880 annual world copper production has increased by over 150 times from 154,000 tonnes in 1880 (nominally considered as smelted copper—essentially the only route at the time to marketable copper) to over 23 million tonnes today (including total refined copper of 19 million tonnes of smelted copper including scrap and 4 million tonnes by solvent extraction-electrowinning), in tandem with increased electricity usage, along with significant transportation usage and for manufactured products (Figure 1).

Jan 1, 2019

By P. van Zyl, M. Lombaard

The 14MW SAG mill at Tarkwa, Ghana, experienced a frozen drop charge incident on 10 February 2010. This caused downtime of 112 hours, a repair cost of $200k and production loss of 162,000 tons, corresponding to a loss of $8.9M. A new locked charge protection system was installed on the two Tarkwa mills on 30 July 2010, mitigating this risk. This system calculates the ore angle in real time while the mill is starting up and trips the mill if the ore angle exceeds a trip angle setting. The calculation of the ore angle is derived from the mill motor rotor currents only - no mechanical transducers are required. The head of Gold Fields West Africa, Peter Turner, says of the new system: "This is excellent work and the type of technology that has had and will continue to have, major opportunity cost impacts on our business."

Jan 1, 2012

"Discrete Fracture Network (DFN) modelling has increasingly being used in many geotechnical and mining engineering problems, the authors believe there is an ever greater demand to provide updated guidelines that address the collection of discontinuity data in the specific context of DFN models. In general terms, the generation of a DFN model requires collecting information on i) fracture orientation, ii) fracture intensity, iii) fracture length and iv) fracture terminations. The International Society of Rock Mechanics (ISRM) suggested methods for the quantitative description of discontinuities in rock masses directly include most of these parameters. However, there are important differences engineers should be aware. To what extent discontinuities can be sampled and which limitations are inherently introduced in the analysis by the sampling methods being adopted represent important aspects that should drive the collection of discontinuity data for DFN analysis; this will require the introduction of a more appropriate set of guidelines bridging the gap between the current, very practical, ISRM methods and the data requirements imposed by the use of new DFN technologies.INTRODUCTIONThe last decade has seen a major increase in use of the Discrete Fracture Network (DFN) approach, both as a stand-alone tool or integrated within more complex geomechanical simulations (Rogers et al., 2014 and Elmo et al., 2014). In particular, the DFN approach offers the opportunity to maximise the use of fracture data collected from mapping of rock exposures and to construct synthetic rock mass (SRM) models. However, the potential of DFN based modelling is limited if there is insufficient care in collecting the necessary structural data at the required engineering scale. DFN models are also subject to the process of data calibration and validation (Hadjigeorgiou, 2012). With DFN modelling becoming an almost integral part of many geotechnical and mining engineering problems, the authors believe there is an ever greater demand to review the process of collecting fracture data in the specific context of DFN modelling.The value of the DFN model depends directly on the quality and quantity of available field data. For example, fracture length (persistence) is an important parameter in DFN modelling; however, this parameter is either seldom available at the pre-feasibility stage due to a lack of exposures (man-made or natural), or engineers have access to limited length data collected along exploratory drifts. Characterisation of rock exposures should also take into account limits of window/scanline mapping techniques with respect to both trace length bias and the effect of cut-off assumptions inherent in the mapping methodology."

Jan 1, 2015

By Evans B. Mayo

ABSTRACT Orange Footwall 'sill' is locally concordant locally discordant, with the structure of its sedimentary walls. The sediments were folded in two directions. Folds, following both these directions, are preserved in the concordant portion of the 'sill'. It seems, therefore, that the porphyry has replaced the sediments, thus preserving within itself their structure. During replacement, the nascent porphyry may have been much weaker than its walls. Accordingly, under directed pressure, the porphyry could have flowed locally, disarranging the replaced structures within it and developing a flow structure discordant with the folds in the sediments. Some such action may account for the discordant parts of the 'sill'. INTRODUCTION The senior author has seen certain granitoid massifs that have an internal structure vastly different from, and discordant with, the structures in their wall rocks. It seems that? such massifs have moved independently of their surroundings. Yet, a structure section elsewhere in the same mountain range may reveal granitic rocks with internal structures that appear to continue the structure of the invaded rocks. In such a case, it is at least thinkable that the granite has replaced the older sediments or volcanic rocks. In February, 1950, the writers mapped, on 15 level of the Nickel Plate mine, near Hedley, B.C., a diorite or gabbro porphyry 'sill' that, in one cross-cut (1503), appeared to be quite concordant with the wall-rock structures, whereas in another cross-cut ( 1500) about 100 feet to the south, the same porphyry was discordant (see Figure 1).

Jan 1, 1951