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By Peter Amelunxen, Kain Nugent, Brandon Akerstrom, Willem Duyvesteyn, Todd Harvey

In 2024, Capstone Copper Corp commissioned a new sulfide flotation plant at Mantoverde in the Atacama region of Chile to process copper ore at a design rate of 32,000tpd. The pyrite associated with the copper ore body contains cobalt in solid solution, with Co replacing Fe in the pyrite matrix. As per the existing sulfide flotation flowsheet most of the pyrite is depressed and sent to tailings via the cleaner scavenger tail stream. A new project considers the recovery of the pyrite from the cleaner-scavenger tails via froth flotation to produce a cobaltiferous pyrite concentrate, which is then leached via the existing dynamic copper leach pad to oxidize the pyrite and dissolve the cobalt. The cobalt is recovered from the solution by treating a bleed stream of copper SX raffinate through a continuous, counter-current ion exchange (CCIX) facility. This approach to by-production of cobalt confers numerous benefits, including reduced costs compared with alternative cobalt recovery processes, reduced acid consumption in the heap leach, increased copper production, and reduced acid mine drainage potential due to the removal of pyrite from the mill tailings.

Feb 1, 2025

By Roberto Fustos, Gonzalo Nelis, Víctor Sanhueza, René Gómez

Hang-ups are a challenging operational problem in block caving mines. They interrupt ore flow and imply hang-up removal activities, which take time, increase operational costs, and involve safety risks for workers. In block caving, the number of hangup events of mechanical arches that appear in the drawbell could be decreased if the drawbell geometry is adequately designed based on the expected rock fragmentation. Here, we compile and analyze hang-ups reported in several block caving mines to evaluate the impact of drawbell geometry, rock size, and vertical load on hang-up frequency at the mine scale. Results show that the ratios between drawbell length and d80 (dL/d80), between drawbell width and d80 (dW/d80), between drawbell volume and rock volume (VDB/VP), and vertical stress are critical parameters that define hang-up frequency. These findings confirm previous experimental studies, where a decrease in hang-up events is associated with an increase in these ratios. Additionally, these outcomes are used in a support vector machine algorithm to define categories of hang-up frequency. The results of this classification algorithm are presented in diagrams, which can be used to estimate the hang-up frequency in block caving projects.

Oct 15, 2022

By Rambabu Pothina, MELO EDUARDO PIMENTA DE, Rajive Ganguli

 The mining industry is home to a mass of sensor-generated data that are critical to real-time and long-term optimization. This heavy reliance on sensor data has resulted in an undesirable development. The industry is reluctant to verify the accuracy of sensors as it would mean shutting down important processes. Sensors are typically calibrated once a year, if at all. Errors in sensors go undetected until the next calibration or until errors are so gross as to be obvious

By D. Shink

A small scale continuous flotation cell was designed and constructed at Noranda Technology Centre to develop a mobile testing flotation circuit located next to the production circuit. This mobile small scale flotation pilot plant can easily and economically be set up at any circuit in a mill and used to evaluate and predict plant performance against a given flotation condition. The main feature of the cell, beside the provisions of automatic pulp level and feed rate control, is to provide a reduced surface to volume ratio approaching to that of an industrial machine. This paper describes the basic design and the results of various testwork carried out to date including aeration, conditioning, reagents, recirculation, flotation gas, etc. are presented in comparison with the plant production results.

Jan 1, 1992

By H. K. Lin

Elemental sulfur is founded to be the predominant sulfur-containing species in a leaching residue resulting from ferric chloride leaching, under given conditions, of a chalcopyrite concentrate. The mineralogical study of the leaching residue which consists of 52% elemental sulfur reveals that the sulfur formed at the end of leaching process is in the form of discrete crystal rather than coating film. Flotation has been applied to recover the sulfur successfully using xanthate as a collector. Dispersants arc needed to prevent the mechanical entrapment of silicate and quartz by sulfur. Very high recovery of sulfur with satisfactory grades can be achieved with a relatively simple notation scheme.

Jan 1, 1991

By O. Babak, O. Leuangthong, M. A. Cuba

Integration of data from multiple sources and/or multiple scales is a common, yet challenging aspect of geostatistical resource modeling. Common approaches to data integration are based on a cokriging framework that assumes a consistency of scale in the information that leads to a requirement to composite the data prior to model construction. It is well known that the geostatistical model parameters are scale dependent. In particular, the volume variance of integrating these various scales has a direct impact on the semivariogram that should be used in model construction and/or the assessment of volume-variance relations as it affects resource estimation. This paper reviews and compares two different approaches for semivariogram upscaling. The first approach is the scaling laws. It is an empirically derived approach, involving several simplifying assumptions, one of which is a strict assumption of invariance of the semivariogram shape. The second approach is a theoretically derived direct upscaling of the semivariogram. This approach has been around for a number of years, but is seldom implemented due to software limitations. In this paper, we present a numerical integration approach to facilitate direct semivariogram upscaling. The advantage of direct upscaling over the scaling laws approach is shown by considering a synthetic example and a case study. Further, in the case of multiple codependent random variables, the extension of the direct semivariogram upscaling to the cross semivariograms is derived and an upscaled consistent linear model of coregionalization is presented.

Jan 1, 2013

By J. L. Ellenberger, G. S. Esterhuizen, T. Miller, M. M. Murphy

A limestone mine in Ohio has had roof instability problems that have led to massive roof falls extending to the surface. This paper describes a collaborative study of these events undertaken by the National Institute for Occupational Safety and Health and the mine owners. The study focuses on the roles that weak, moisture-sensitive floor and weak bands in pillars play in a general instability that led to roof falls at this mine. The NIOSH Stone Mine Pillar Design software (S-Pillar) does not include analysis for weak floor or weak bands and recommends that when such issues arise they should be investigated further using a more advanced analysis. It is important to recognize that without the impact of the floor or weak bands, the calculated inherent stability factor for these pillars is within the recommended design range. Therefore, to further investigate the observed instability occurring on a large scale at the Ohio mine, FLAC3D numerical models were employed to help determine the failure mechanism. Roof-to-floor convergence monitors were also installed in the areas predicted to have further instability. This case study will provide important information to limestone mine operators regarding the impact of weak floor causing the potential for roof collapse, pillar failure, and subsequent subsidence of the ground surface. This recent case demonstrates that weak floor can be a significant factor in pillar stability and should be assessed during the design stage of the mine.

Jan 1, 2015

By H. W. Judges

A 16.5-kt/day underground molybdenum mine is being developed at Questa in Northern New Mexico by Molycorp, Inc., a wholly-owned subsidiary of Union Oil Company of California. Construction of the underground mine began in 1979, and first production is scheduled for early 1983. A gravity block caving method has been selected for mining the ore. Access to the mine will be through a service shaft, development shaft, and a conveyor decline. The shafts are being sunk under contract and the conveyor decline is being driven by Molycorp. The driving of the decline began in February, 1979 with a 10-man mining class. By the first of May, enough men had been trained to begin a continuous operation and by March 1, 1980 the face had reached the 1500 m mark. The heading is being driven with trackless rubber-tired equipment using a three-boom drill jumbo, 2.7 m3 LHD units and 7.3 m3 trucks. Ground support has been by rock bolts and wire mesh, followed by Fibercrete. A 16.5-kt/d underground molybdenum mine is being developed at Questa in northern New Mexico by Molycorp, Inc., a wholly-owned subsidiary of Union Oil Company of California. The new $200-million underground project will revitalize mining and milling activity at Questa, where small scale underground mining first began in 1920. Large scale open-pit mining was initiated in 1965 but now, because of the high stripping ratio, surface mining is being phased out. Construction of the underground mine began in 1979, and first production is scheduled for early 1983. The company expects full capacity - 9 Gg of molybdenum per year - to be reached in 1984.

Jan 1, 1980

By Gunjan R. Bhattarai, Kumar Bhattarai

Recently, there has been an enormous increase of interest in artificial intelligence (AI), machine learning (ML), and their applications by researchers, government agencies, and the underground construction industry. Ultimately, these tools have the potential to automate the design and construction processes and boost productivity, safety, quality, and operational stability. This paper presents ongoing research and applications of artificial neural networks (ANNs), robotics, and 3D technologies in ground characterization, tunnel ground support prediction, risk projection and reduction, and productivity enhancement in TBM operations. The paper further investigates potential uses of AI, robotics, and 3D technologies in the underground construction industry

Dec 1, 2022

By Manoj Kumar, Anil Kumar Singh, Prabal Patra, Ashish Agrawal, Souvik Ghosh, Subhashis Kundu, Kamma Ramakrishna Rao, Manish Kumar Gupta, Anindya Sarkar

The slag measurement systems in the cast house are very important. In the conventional method, the slag is granulated in a slag granulation system, and the slag flow rate is measured by the associated belt scale. However, in places where a slag granulation system is not available, the alternate approach is to deduce a theoretical calculation and develop the measurement because the commissioning of such slag granulation requires huge capital and has inherent geographical limitation. However, the theoretical approach suffers from several drifts and is far from the reality. In the present paper, we have innovatively engineered a sensor by designing the stellite-coated thermocouple that can measure the temperature of the slurry and placed it in such a way that the abrasive slag granules do not obstruct it, but we could measure the temperature of hot water, and further based on the thermodynamic approach, the slag flow rate is determined that can be compared with the theoretical approach. This approach of slag rate measurement is cost-effective and long-lasting.

Oct 2, 2023

By Raja V. Ramani

Worldwide, promulgation and enforcement of health and safety laws and regulations have been the primary means of ensuring minimum and uniform standards of health and safety in the mining industry. In U.S. coal mines, a new era was ushered-in in 1969 for the control of health hazards from respirable coal mine dust. Since then significant progress has been made on all aspects of the respirable dust problem-its definition, monitoring, reduction, and control. In the intervening years, our ability to monitor, analyze, and characterize the mine atmospheric environment and the health of miners has increased many fold. Also, advancements in production technology have far outdistanced enhancements in environmental control technology. Therefore, questions are continuing to be raised on the adequacy of the characterization and control measures with regard to both the airborne respirable dust in mines and the health effects of respirable dust. Late in 1995, the Secretary of Labor appointed an Advisory Committee on the Elimination of Pneumoconiosis Amona Coal " Mine Workers (Dust Advisory Committee) to review the progress towards elimination of coal worker's pneumoconiosis (CWP) and silicosis, and in the program to control respirable coal mine dust in underground and surface mines, and make recommendations including improved standards and other appropriate measures for the control of exposure to airborne coal mine dust. The Committee's report was released in October, 1996. In this paper, a summary of the recommendations of the Committee is presented. A brief discussion of the background, and the issues and findings leading to the recommendations is also presented. The Committee concluded that the progress made towards making mines safer from the health hazards of respirable coal mine dust is substantial but that it is not sufficient to achieve the intent of the 1969 Coal Act. The Committee's recommendations encompass a wide range of issues addressing permissible exposure limits (PELS), sampling, dust control plans, hazard and medical surveillances, role of miners, training, and research and development.

Jan 1, 1997

By Yong Pan, Srivatsan Jayaraman Sridharan, Purushotham Tukkaraja

Block cave mining method poses unique ventilation challenges compared to other underground metal mining methods. This research study focuses on assessing the airflow behavior in regulated airflow distribution systems by developing a 1:100 scaled block cave experimental model and a numerical model. This study also investigated gas flow behavior under various airflow conditions. Based on our findings, we observed that reduction in particle size and porosity of caved materials, decrease in cave footprint, and closure of undercut drifts would increase cave airflow resistance. The increased airflow is found beneficial for gas dilution regardless of its source locations, while the regulated airflow distribution system might deteriorate gas dilution situation when the source is located in the extraction drifts.

May 12, 2022

By Inoka E. Perera, Robert Hildebrandt, Gerrit V. R. Goodman, Krzysztof Cybulski, Zdzisław Dyduch, Michael J. Sapko, Marcia L. Harris

To prevent coal dust explosion propagations, rock dust needs to be lifted and suspended in the air with the coal dust during an explosion. The addition of anti-caking agents prevents caking of rock dust in the presence of water. Mining and rock dusting processes can frequently create alternating layers of rock dust and float coal dust on mine surfaces. For this test series, a thin layer of coal dust was distributed on top of a layer of either treated or non-treated rock dust in the Experimental Mine Barbara, Poland. The experimental results compare the effectiveness of treated and non-treated rock dusts to attenuate a propagating coal dust explosion initiated with either strong or weak methane explosions. Experimental results indicate that the treated rock dust performs better than non-treated rock dust in arresting a propagating explosion, especially in the presence of moisture.

Jan 20, 2020

By Luzheng Chen

The study aimed to evaluate the separation performance of a full-scale continuous centrifugal concentrator in the reconcentration of fine hematite from high-gradient magnetic separation (HGMS) concentrate in a tailings recovery plant, and to investigate the usefulness of the technology in industrial applications. The effect of changing the operating variables on concentrate grade and recovery was studied. The results indicate that among the variables considered in the study (water spray pressure, centrifugal acceleration, feed volume flow rate, feed percent solids and the reciprocation and spacing of water sprays), the change in centrifugal acceleration affects the recovery the most and continuous concentration can be achieved only when the water spray has a sufficient pressure. In addition, the reciprocation and spacing of the water sprays have a significant influence on the concentrate grade. Although performance of the full-scale concentrator is slightly inferior to pilot-scale trials, due to limitations in the scale-up design and the fluctuations of feed material characteristics, this concentrator provides a potential way to achieve continuous concentration and obtain a high-grade concentrate from tailings.

Jan 1, 2010

By B. T. Lusk, Q. Q. Huang, R. Q. Honaker, K. A. Perry

Rock dust is applied in underground coal mines to prevent the propagation of coal dust explosions. It is applied either dry or wet. Both methods have advantages and disadvantages, but the formation of caked rock dust particles is cited as a significant concern for wet applications. We conducted a study to evaluate the effect of modifying the rock dust particle surfaces to repel water and each other by the addition of oleic acid and sodium oleate. At a sodium oleate dosage of 1 kg/t, a contact angle of 112o was measured, indicating strong surface hydrophobicity and thus the ability to repel water. Fourier transform infrared spectroscopy (FTIR) studies indicated a chemisorption mechanism, which is necessary for long-term stability of the surface modification. The dispersibility of the modified rock dust samples was elevated by the application of both oleic acid and sodium oleate, thereby indicating a significant reduction or elimination of the detrimental effect of caking. Tests in an explosion chamber showed an 82.8 percent reduction in the dust explosion potential relative to untreated rock test applied by the wet technique.

Jan 1, 2015

By Rui Xiang Yang, Cong Li, Jia Zeng, Rong Liang Zhang, Wei Zhang, Chao Fan Tang

This research took the roasted products obtained by leaching copper (Cu) refining slag using waste acids and roasting leaching residues with calcium oxide (CaO) as raw materials and used oxidative leaching to extract Cu from roasted products using waste acids. Influences of the leaching temperature, liquid–solid ratio, and sulfuric acid ( H2SO4) concentration in waste acids on the leaching rate of Cu in the oxidative leaching process of roasted products using waste acids were investigated. The unreacted-core shrinking model of heterogeneous reactions was adopted to reveal the leaching kinetics of Cu in the oxidative leaching process of roasted products using waste acids. Results show that the leaching rate of Cu reaches 91.68% when the leaching temperature, liquid–solid ratio, H2SO4 concentration in waste acids, and injected airflow are 80 ℃, 8:1, 1.5 mol/L, and 200 mL/min, respectively. If the leaching temperature is below 80 ℃, the leaching process of Cu is controlled by the solid-film diffusion, and the apparent activation energy Ea is 11.0835 kJ/mol; at a leaching temperature above 80 ℃, the leaching process of Cu is governed by the interfacial chemical reaction, with an apparent activation energy Ea of 42.3183 kJ/mol. The liquid–solid ratio can positively influence the reaction rate constant. The apparent order of the leaching reaction of Cu is 0.632.

Jan 11, 2023

By Jamal Rostami, Mark Board, Clayr Alexander, Muthu Vinayak Thyagarajan

In the past several decades, many major equipment manufacturers have ventured into developing new technology for underground hard rock excavation. This includes variety of configurations for full and partial face mobile excavation units. Mining industry prefers machines that can excavate noncircular, flat invert profiles and be able to make tight turns in hard rock. The need to use disc cutters for cutting hard rock has impeded the development of such machines due to the need for gripper system or large mass of a machine to support the force requirements of the disc cutters. Most of the prior attempts have been partially successful and the operations have faced some practical limits and challenges. Among the units that have been successfully used, one can name mobile miner, which was used for rock excavation in some projects. A redesigned mobile miner, called the “Remote Vein Miner,” or RVM, has been developed by Epiroc for underground hard rock mining in Hecla’s Lucky Friday Mine. This equipment potentially opens numerous opportunities for innovation in civil tunneling projects, where the operational flexibility and accessibility of a TBM’s limited tunnel path, design of the profile, and cost are limiting factors. This paper explores the application of the RVM in tunneling projects, its advantages and possible areas of innovation in tunnel planning and design.

Jun 13, 2021

By C. D. Iles

The philosophy used in designing and writing Duval's Sierrita mine design programs is discussed. The Sierrita Incremental Design system (SID) is reviewed with emphasis on Pushback Extraction Design (PED). FED is a method by which predesigned pushbacks are sequenced into an optimized period-by-period design that can be directly utilized in daily operations as well as intermediate and long range planning. The advantage of SID is that it provides a practical, mineable open pit design. PED is not a theoretical design system; it is in operational use.

Jan 1, 1981

By Barrie A. Wigmore

There are two aspects of financing western coal development -- whether there is going to be enough money to finance the prospective large development of the industry, and the specific techniques of raising money for that development. To take the first question of whether there is going to be enough money around to finance your industry, I think it is quite clear that the restrictions on the development of western coal are going to be non- financial. Environmental impact problems are creating the greatest delay in coal mine development, at the moment; but getting enough personnel, mining equipment, railroad equipment, and failure of the Department of Interior to act on leasing federal coal lands all appear likely to create significant bottle- necks in the development of western coal -- larger bottlenecks than financing. Financing appears straightforward for the industry. There are many projections of the financing required to meet Project Independence goals. The National Academy of Engineers estimated that development of 500 million tons per annum of western coal would be necessary by 1985 to meet the Project Independence goals which might require $20 billion of capital spending. It is generally agreed that 500 million tons a year is not a realistic possibility. Carl Bagge?s estimate of production of 250 million tons a year by 1983 appears a more reasonable projection. Development

Jan 1, 1976

By Feng Junfa, Du Feng, Li Huamin, Syd S. Peng

"The Ordos coal field is located in the northern midwestern part of China (Fig. 1). Since the mid- 1980s, it has been developed into one of the major coal fields in the world, producing approximately 833 Mt (918 million st) of raw coal in 2013. There were once more than 400 coal mines operating in the region. However, due to the combination of market conditions and implementation of government consolidation policies, the number of coal mines operating in recent years has been reduced considerably, with increasing output.The surface of the Ordos coal field is covered with loess and alluvium layers of varying thicknesses. In many areas, their combined thickness may amount to as much as 100 m (328 ft) underlain by thin bedrock. Many loess and alluvium are aquifers receiving water from rainfalls. There are also gullies of varying depths crossing the coal field. Figure 2 is a typical stratigraphic column highlighting the coal seams and roof and floor rocks of interest.In conjunction with the development of highproductivity coal mines, numerous ground control instrumentation tests have been conducted in the operating longwall panels. Analyses of the results of those tests offer the opportunity to understand the effect of wide-ranging mining and geological factors on the overburden movement. For this reason, trips were made to coal mines of interest to interview mine management and collect their unpublished internal research reports on ground control instrumentation. In addition, literature searches on published thesis/dissertations and papers in the professional journals were performed. Finally, data from a total of 95 fully mechanized longwall panels were collected. The instrumentation involved primarily the monitoring of hydraulic pressures of longwall shields, from which the first roof weighting and first roof caving interval and periodic roof weighting and periodic roof weighting interval were identified and determined. Some panels also included measurements of roofto- floor convergence at the face, roof strata bed separation, longwall face sloughage and the height of caving and fractured zones in the overburden. Those 95 panels were located in 20 coal mines (Fig. 1) congregated along both sides of the Wulunmulun River with the following mining and geological conditions. All together those 20 mines produced more than 224 Mt (246 million st) in 2013, accounting for approximately 27 percent of the total coal production in the Ordos coal field:1. Period of mining: 1991-2013.2. Mining methods: All panels employed the one slice, full-seam natural-caving longwall mining method like those practiced in the United States. All panels were developed with a twoentry system with a single-row of chain pillars measuring 20- x 20-m (65.6- x 98.4-ft) wide.3. Coal seams (Fig. 3): Coal in Ordos coal field is high-quality steam coal, that is very low in sulfur, potassium and ash, but high in Btu. Data were collected in panels mined in a total of 10 seams with 82 panels in four seams and the remaining 13 panels in six seams. The first six seams (1-2, 2-2, 3-1, 3-2, 4-2, 5-2) were mined by the Shenhua Coal Group (the world’s largest coal company) and the #4-2, 5-2, 6R, 62, and 62R seams were mined by both the Shenhua and Yitai Coal groups. In each coal group, the sequence of mining was in descending order. For example, in Shenhua Group, the top seam 1-2 was mined first, followed by the 2-2, 3-1, 3-2, and 4-2 seam in that descending order. In Fig. 3, the top-down sequence of coal seams is listed from left to right in each coal mine group. All seams were near horizontal with dip angles less than 3°."

Jan 1, 2014