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By L Mottola

Three decades ago mining companies, principally in North America, aided by machine and explosive manufacturers, started significant attempts to develop and implement automated mining systems, mainly underground. These tended to be motivated by decreasing cost, increasing productivity, reducing labour requirements, and improving safety. These are important business drivers, however, little attention was given to the underlying goal of mining automation, namely to bring upstream processes in control and reducing variation, as seen in downstream mineral processing plants.This paper first reviews the nature of Lean Thinking and its application in the context of the growing commitments by industry to develop future automated mine production systems. The paper then makes reference to prior and current experiences in open pit blasthole drill and shovel performance monitoring, to demonstrate the principle that machine performance data offers as a means, not only to characterise the dynamic geological and working environment, but also to provide a foundation for automation. In this case, drill and shovel monitoring was originally motivated as a means to optimise blast fragmentation through more effective drill and blast designs that are based on an accurate determination of the bench geological and geotechnical characteristics, hence managing variation in the drilling and blasting process. This paper considers how automating and integrating such components of the mine production system would bring processes into a controlled state, creating value at the face, within a framework of Lean mining.

Nov 22, 2011

By Han Jie

The results of full scale plate load tests on stone columns on soft clay in coastal areas are presented in this paper. Four load tests were made, two of which were performed on the ground treated with stone columns, one on an isolated stone column and the last one on the untreated ground. For a given stress range, the settlement of the rigid plate, the stress concentration factor, and the excess pore water pressure were measured. It is found that the distribution of vertical stress beneath the rigid plate supported by the composite ground of stone columns is very different in shape from the one by the untreated ground, that the stress concentration factor has a relation with the stress level and time, that the stone columns increase the bearing capacity up to by 2 times, and that the ground stabilized by stone columns is of great advantage to keep the foundation stable.

Jan 1, 1991

By Art Cooper

Granulation systems are customarily viewed as problem areas in metallurgical operations. The inherent risk of explosion when combining a high temperature melt with water creates a safety hazard. Separation of the granulated material from the quenching medium generally involves equipment that can have significant maintenance and operating costs. Granulation systems' reliability and availability can negatively affect the plant production. Against this background, granulation systems have been treated by design firms and producers as an add-on and a necessary evil. The technology is becoming better understood and solutions to common problems are being found. This paper will discuss typical problems in common systems, and some of the improvements that have been made, with particular reference to non-ferrous applications.

Jan 1, 2006

By B. Caro Vargas

The Toulon South Tunnel in France is the second part of a project started 20 years ago. After the problems and delays suffered during the construction of the North Tunnel, due to a complex geologic context of highly fractured and soft rocks under a highly urbanized environment, a very dense automatic monitoring system was implemented to control the settlements of surface (more than 1000 points), the structures adjacent to the tunnel alignment and the underground galleries being constructed. The latest automatic instrumentation systems were installed, using for example AMTS capabilities in terms of ?automatic prismless settlement monitoring?. All the data (geotechnical, structural and geological) was gathered in a global automatic data acquisition system and continuously available on a web based interface. Three different threshold levels (notification, anomaly, alert) were set up, each one with a differential and an absolute value for settlements. Depending on the actual geological site conditions and the actual monitored settlements, different supporting systems and excavation techniques were used. Furthermore, the monitoring data was also used to predict and anticipate the future settlement, by comparing it continuously with the theoretical Peck settlement curves. This method allowed a better risk management by limiting the settlement on existing structures and helped to secure the Works progress schedule, for a project that lasts from July 2007 to March 2011. The implementation of this observational method application is presented in this paper.

Jan 1, 2012

This Bureau of Mines publication presents an overview of mine electrical power systems research currently being conducted by the Bureau. The papers, given at a Technology Transfer Seminar, emphasize the increasing importance of research related to the safety considerations of underground coal mine electrical systems. Selected topics are included that summarize results of research in the areas of electrical shock prevention, explosion-proof enclosures and load centers, discriminating circuit breakers, and trailing cables. Other topics discussed at the seminar are published as separate sections of the Bureau of Mines Hand- book "Application Notes--Mine Electrical Power Systems."

Jan 1, 1982

By R Yang, M Lownds

This paper reports studies showing the effects of delay scatter on the peak particle velocity (PPV) of blast vibration using a multiple seed wave (MSW) vibration model developed in recent years. The case studies also show the advantage of accurate delay timing on frequency control of blast vibration. The site parameters used in one of the studies are from a case in which the MSW model has been tested and confirmed to yield accurate predictions. This study uses an open pit blast design and a tunnel design in which blast vibrations using electronic detonators are compared with those from pyrotechnic detonators. Mean peak particle velocity (PPV) and the 97.5% upper bound PPV are compared. It is found that both these values increase significantly with the increase of the coefficient of variation of the site parameter. Using an open pit blast design, the modeling shows that electronic initiation shifts vibration energy to the expected frequency for a selected point of interest. However, for the same design of nominal initiation timing pyrotechnic detonators fail to shift vibration to the expected frequency due to its large scatter of timing.

Jan 1, 2011

By D G. Randall, R Jivanji, J Nathoo, T Reddy

Paradoxically, the increased emphasis on water treatment in mining has generated a new problem û hypersaline brines. Currently brines are either disposed of into ash systems, lined evaporation ponds or hazardous waste sites. Evaporative crystallisation (EC) is an alternative, but the energy requirements can be prohibitive and the salt product is still a waste that must be disposed of. Eutectic freeze crystallisation (EFC) is an alternative technology that is capable of separating aqueous solutions into pure water (as ice) and pure, solidified solutes. It is highly energy efficient and does not depend on the introduction of any solvents. In addition, the simultaneous production of pure ice and potentially saleable pure salt(s) is a major advantage. Although EFC has been shown to be effective in separating a single salt and water, it is still in the early stages of being applied to the multi-component hypersaline brines that are typical of reverse osmosis retentates generated by mining and extractive metallurgy.This paper presents an EFC brine treatment protocol developed by the Crystallisation and Precipitation Unit at the University of Cape Town. The protocol incorporates brine analysis, thermodynamic modelling to establish which salts will freeze out and at which temperatures, followed by experimental studies to determine the kinetic parameters, such as nucleation temperatures, salt yields and crystal purity.Case studies showing the application of EFC for the purification of typical brines containing high levels of sodium, chlorine, sulfate and ammonia (Brine 1) and a mixture of sodium and magnesium sulfate (Brine 2) are covered. Modelling tools were applied to describe the phase behaviour of the multi-component saline systems under different process conditions. Experimental validation was carried out using synthetic brines of different (and increasingly complex) compositions. The results showed that EFC could be used to selectively recover the sodium as a sodium sulfate salt from both different brines. The simulation tools were useful in the analysis and understanding of the process.A preliminary economic analysis showed that the operating costs for EC were approximately nine times those for EFC, but the capital costs were much less- equipment for EC cost about half that of EFC. However, it is important to note that the capital cost calculations for EC are based on a technology that is already well established and with only relatively marginal future equipment cost savings expected. In contrast, EFC is a new technology, with significant future technology improvements expected.

Jan 1, 2009

By P. Forbes

Mining and metallurgical processing companies that have adopted the principles of good environmental management often find it difficult to carry out an environmental assessment that yields meaningful opportunities for improved performance. This topic was investigated by means of a case study of a South African Base Metal Refinery (BMR) producing primarily nickel. A process-based Life Cycle Assessment (LCA) was carried out on the refining process, with the environmental impacts related to the production of reagents and utilities forming part of the assessment. The lifecycle inventory (LCI) was based on plant operating data spanning 31 months of production, from which a baseline environmental profile could be generated and interpreted to indicate the main sources of potential environmental impacts. Consequently, opportunities for improved environmental performance could be identified from the LCA model, which expressly related potential environ-mental liability to specific sub-processes in the assessed industrial operation. The on-site steam plant was found to be the primary source of potential environmental impacts in most of the impact categories considered. In closing, the paper discusses some of the limitations encountered in use of the LCA method. Keywords: life cycle assessment; LCA; life cycle inventory; LCI; base metal refinery; improved environmental performance; environ-mental management systems; nickel refining.

Jan 1, 2000

By A. Ansari

Standard depressants used in the selective separation of copper and molybdenum sulfides by flotation pose environmental and health hazards. In this investigation, the floatability of chalcopyrite and molybdenite in the presence of six well-characterized lignosulfonates was studied through Hallimond tube flotation and adsorption tests. The results define the physicochemical conditions (lignosulfonate type and dosage, pH, presence of ions) for possible selective separation of molybdenite from chalcopyrite. Dissolved polyvalent cations, especially calcium, appear to serve as "activators" for lignosulfonate adsorption on both minerals. From this point of view, the use of lime as a pH modifier is not always appropriate for optimum selectivity since high dosages of lime to produce high pH tend to indiscriminately depress both sulfides.

Jan 1, 2006

By S. P. Mishra, G. R. Chaudhury

The adsorption of Cu2+ ions by Penicillium sp. displayed a dual rate, with an initial faster phase followed by a slower one. The adsorption rate increased with increasing pH due to chemical and biochemical reactions. The Cu-loading capacity of the biomass increased at higher initial Cu2+ concentrations. Above 40 degrees C the adsorption rate decreased which may be due to partial hydrolysis of biopolymers which are essential constituents of the cell wall. Adsorption kinetics followed the Freundlich isotherm and the equilibrium concentration that was calculated on the basis of the isotherm matched the observed value well. A series of theoretical adsorption curves were produced using mathematical correlations between the mass transfer coefficient, the Cu2+ ion concentration at equilibrium and at time t. The correlation between the theoretical and observed adsorption rates for different experimental conditions was good. It was concluded that the results from the study were best explained using a mass-transfer adsorption model

Aug 1, 1995

By L. F. Albert

The paper describes solutions given to foundation problems during the reconstruction of a power plant set on fire, located adjacent to several still Working Units. After a detailed site and laboratory investigation, it was decided that it could be possible to include within the new foundations the preexisting cast in situ driven piles with enlarged base 50 cm in diameter and let them work with new 41 cm driven, cast in situ piles without enlarged base. Demolition of existing caps was carried out with expansive mortar in order to avoid any possible damage to piles, whose actual conditions were checked by several load tests. New piles were designed to support service load by shaft resistance, in order to limit total and differential settlement. When piles had to be driven adjacent to nearby structures, measurements of peak soil particles velocity were carried out while driving piles at decreasing distance from critical locations. By preboring most of the upper clay layer it was possible to reduce within safe limits for structures the induced vibrations.

Jan 1, 1989

By Eiji Kojima

In this research, dynamic and static load tests were performed on permanent foundation piles which had a pile length of 30 m, 800 mm in outer diameter and 15 mm in wall thickness. In this site the dynamic horizontal load test on a smaller test pile, 12 m in length, 500 mm in outer diameter and 12 mm in wall thickness, was also carried out. The static horizontal load versus horizontal displacement derived from the dynamic load test conformed well to that measured in the conventional static horizontal load test of the pile with 800 mm diameter. Then an attempt was made to predict the horizontal load displacement of the pile with 800 mm diameter based on the results of the dynamic horizontal load test of the pile with smaller diameter of 500 mm.

Jan 1, 2006

By Jim Sadowski, Steve Stewart, Bob McMurdy, Martin Nevens

"Mohawk Garnet has been operating a small pilot plant near Sudbury, Ontario for several years attempting to produce commercially viable garnet. The challenges of operating a pilot scale mining, processing, and product handling operation as a full time plant have led Mohawk Garnet to seek a better way. In co-operation with Mohawk Garnet, Outotec (USA) Inc. has taken on the technical and design challenges of increasing garnet product from twenty tonnes per day to two hundred tonnes per day.Outotec performed a comprehensive test and flowsheet development program applying Outotec’s density separators, spirals, flotation, and other technologies to design a successful process for the separation and recovery of the valuable garnet for Mohawk.This paper explores the test program, the process flowsheet development work, plant design and preliminary engineering of a new garnet processing. The various technical challenges, process technologies involved, and design concepts will be discussed.INTRODUCTIONMohawk garnet has been operating a small-scale garnet mine and process plant in Wahnapitae, Ontario near Sudbury.The current operation was intended to be a pilot plant and so only produces 20-25 tonnes of garnet concentrate per day. The garnet is bagged and sold for use as abrasive. The process is inefficient with low yields, poor material handling and very high cost per tonne. Mohawk garnet approached Outotec to help them improve their garnet process and transform themselves into a larger scale and more efficient operation."

Jan 1, 2010

By C. McAllister, D. Preece, J. Berendzen

The Multiple Blasthole Fragmentation (MBF) model was developed recently and has been reported in previous papers. The MBF model accepts inputs from the blast design, such as: location and orientation of each blast hole, stemming length, blast hole diameter, multiple decking, bench height, initiation sequence, etc. It models the effect on fragmentation of delay timing with its associated scatter for each blast hole. MBF has a statistical modeling capability for geological random variation of the attenuation of particle velocities. Also simulated is wave reinforcement due to the interaction of simultaneously arriving waves or diminishing cooperative contribution from long delay intervals between charges.

Jan 1, 2016

By L. Maday, V. J. Perrone, M. B. Gilbert

INTRODUCTION The Brightwater conveyance system project in King County, Washington consists of constructing about 21 km (13 mile) of effluent and combined influent and effluent tunnels. The influent tunnels will collect sanitary sewerage from the service area and convey it to the new wastewater treatment plant (WTP) site at Route 9 in Woodinville, Snohomish County, Washington. The effluent tunnels will convey treated effluent from the WTP to an outfall at Puget Sound. The tunnels will be constructed primarily under residential areas, busy suburban roads and state highways. This 21 Km (13-mile) soft ground tunneling project faced many design challenges because of the geologic and hydrostatic conditions, long tunnel reaches, and large overburden depths. Boring depths typically varied from 45.7 M (150 ft) to 114 M(375 ft) with a maximum depth of 185.6 M (566 ft) deep. Conventional empirical methods for non-mountain terrain based on a 1:1 ratio of drilled footage per foot of tunnel bore (National Research Council, 1984) for evenly spaced borings provided a good start for the Phase 1 explorations. However a continuation of this approach with closer spacing was deemed inadequate by the geotechnical team for efficiently allocating geotechnical exploration resources for the final design. This paper presents a rational approach that was used to evaluate the value of a particular geotechnical exploration boring, pump test or other in-situ test. The method of analysis, which was initially developed for rock tunnels (Einstein et al., 1978), was modified for the Brightwater project. The method considers the potential construction cost risks resulting from variable geologic conditions, the cost and reliability of the geotechnical exploration and the earned value (cost risk reduction) of performing the geotechnical exploration. PROJECT DESCRIPTION In total the land portion of the conveyance system will include approximately21 Km (13 miles) of tunnels ranging in size from 3.0 to 5.2 M (10 to 17 ft) minimum inside diameter with overburden depths of 30.0 to 168 M (100 to 550 ft) and

Jan 1, 2005

By Yoshinori Iwasaki, Shosei Serata, Yutaka Mochida

A new comprehensive insitu instrumentation technique named this RCC Method has been developed for rapid assessment and improvement of the structural stability of underground openings. When applied to tunnel construction, the degree of present and prospective safety of underground openings can be determined in quantitative terms within 10 to 20 minutes of microcreep observation. When applied to mining, roofs and floors can be stabilized by controlling the stress conditions. This stress control method has eliminated the need for intensive roof bolting and extensive floor renewal in all cases where it was applied. Use of this technique is illustrated by field examples from the Seikan Undersea Tunnel of Japan and deep potash mining in Canada. NEW INSTRUMENTATION TECHNIQUE: THE RCC METHOD Failure problems in underground excavation usually arise in weak non-elastic grounds where conventional rock mechanics theories of elasticity are not only useless but also misleading. Presently, discontinuity planes in the ground are being considered a factor in assessing these failure problems, and while this development is interesting academically, it is not of much use in actual excavation work, where it is nearly impossible to identify and quantize all existing planes of discontinuity. Even if such an extraordinary task could be accomplished at an underground excavation site, effective use of the data would be difficult and impractical for rapid excavation work, with the possible exception of rare cases of ideally elastic ground.

Jan 1, 1976

By M. W. BERNEWITZ

AUSTRALIANS and New Zealanders, whose countries have respectively yielded gold to the value of £666,000,000 and £96,000,000, are taking full advantage of the current high prices for that metal. There is a marked activity in ordinary prospecting, geophysical exploration, further development of working mines and reopening of old properties, formation of new companies, installation of new equipment and processes, and expansion of operations generally. Australian gold production last year was approximately double the quantity of 1929 and its value three times as great, 1929 being the low of recent years. The 1933 production was about 821,000 oz. From New Zealand, 165,000 oz. was exported last year. Papua and New Guinea contributed slightly over 100,000 oz. What the future price of gold will be nobody knows, but, even if it returns to the former level, Australian producers are almost sure of 110 shillings an ounce until 1940 through the Commonwealth Government's Gold Bounty Act, at present temporarily and necessarily suspended from operation.

Jan 1, 1934

With the change in legislation under the Resource Management Act 1991 (RMA), the responsibility for administering the effects of blasting on the environment, has transferred from an essentially central government system to local bodies. This naturally will allow for a variety of compliance levels and control procedures which will depend on the particular local body and rather ad hoc arrangements. It is anticipated that the existing NZ Standard on blast vibration levels will soon be replaced by the Australian Standard. These changes raise the question as to what should be used as suitable compliance levels to prevent damage to structures. The paper will address the measurement, control levels and the appropriateness of current standards in relation to the overall legal framework of the RMA.

Jan 1, 1996

By Jiann-Yang Hwang

Microwave heating has been proved an effective method to rapidly heat iron oxide. This offers an opportunity to apply microwave heating in the steelmaking process. The reduction reaction of iron oxide is traditionally achieved at high temperature with reducing gases such as H2 and CO generated from various sources, including coke, coal, and natural gas. This study investigates the differences in iron oxide reduction using conventional and microwave heating under H2 and CO atmospheres. A special microwave thermal gravimetric device was designed and built to facilitate the investigation. With this device, iron oxides can be heated by electric resistance heating, microwave heating, or a combination of methods. The incoming CO and/or H2 also can be preheated to simulate a potential utilization of recovered heat. The iron oxide weight and temperature can be monitored during an entire reduction period. A series of reduction experiments have been conducted. The results are presented and discussed.

Jan 1, 2006

By Bill Shand

"Placer Dome - Campbell Mine is a gold mine located at Balmertown in the Red Lake District of North Western Ontario. During the last 50 years, the mine has produced over ten million ounces of gold.A change in ball mill grinding media was made in August 1998 from 1.5” diameter forged balls to 1.5” diameter, 18% chrome balls. This was done to reduce grinding media consumption and to potentially help flotation performance.A marked ball test done in September-October 1999 showed that, of the alloys tested, 18% chrome was the optimum for the ore at Campbell Mine. The test showed that consumption of chrome balls should be 3 times less than forged balls.In December 1999, the ball size was increased from 1.5” to 2” in an effort to reduce the amount of oversize rock discharging from the ball mill. This change in size was successful.Grinding media consumption for the ball mill decreased 73% from 1.20 kg/tonne before the use of chrome balls to 0.327 kg/tonne after the use of chrome balls. This clearly indicates that, for the ore at Campbell Mine, there is significant savings in grinding media by using chrome.Grinding ball costs were reduced by 59% from $O.88/tonne of ore milled to $0.36/tonne of ore milled representing a saving of $298,000 per year. This also clearly indicates that using chrome balls is a benefit at Campbell Mine.Test work to show that chrome grinding media is beneficial to flotation has been inconclusive so far but is still ongoing.No tests have been done to see if there would be a benefit with an even higher chrome percentage in the grinding media. Test work in this area is also planned for the future"

Jan 1, 2001