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By V. O. Tenorio, P. P. V. Coronado

"INTRODUCTION Productivity in Open Pit mines depend on the observation and adjustment of critical phases of operation. As one of the most expensive activities in Open Pit production, optimization of the load-haul-dump cycle becomes a critical aspect to address. Using simulation techniques and an ad-hoc methodology for analyzing the Key Performance Indicators (KPIs) involved in the production cycle, it is possible compare actual performance and ideal operating conditions and develop an alert system when operating conditions are sub-par with the expected production standards. STUDY OBJECTIVES The purpose of this work is to implement a methodology for optimizing the haulage cycle by identifying and adjusting the factors that affect the cycle time performance. The methodology includes the implementation of an alert system emitting warning messages when one or several trucks are idle or the time of completing production tasks is falling outside a predefined value. This alert is compared with pre-defined Key Performance Indicators (KPIs) and determine corrective actions: • Demonstrate the benefits of time analysis and how this affects the productivity results in the mining process; • Demonstrate the utility of KPIs in the extraction of ore and waste, and how they help to identify equipment performance; • Develop software interfaces to visualize the Alert System in order to increase awareness in the operations supervisor; and • Make recommendations for future applications that can help improve the productive process of an Open Pit mine. PROBLEM STATEMENT Transporting material in Open Pit mines may require the utilization of high capacity equipment, which also represents an elevated cost per hour. A supervisory system that controls the adequate distribution of trucks and shovels by providing the operational status of each unit shall contribute to increase productivity and subsequently reducing operational costs. Nevertheless, there is an issue with certain dead times such as queue trucks for loading, trucks waiting to be loaded, and other delays. This creates inefficiencies in fuel consumption and energy utilization. For the identification of delays, a context-based system could be required in order to help optimizing the haulage cycle time by controlling delays in loading, haulage, and dumping. After applying this methodology, efforts were focused in correcting out-of-standard performance values."

Jan 1, 2016

By A. B. Cecala

The US Bureau of Mines performed a study to determine optimal locations for longwall face methane monitoring equipment. Longwall face ignitions continue to be a concern to the US coal mining industry. Gains in ignition control technology have been somewhat negated by advances in longwall productivity. More reliable, heavy duty longwall face systems generate higher production rates and increase methane liberation rates. These rates will likely continue to rise as further coal production increases occur. Efforts will continue in the areas of methane drainage, methane containment and methane dilution. In addition, more effective face methane monitoring is needed. As technology continues toward automated longwall panels, the importance of monitoring for methane at the shearer becomes even more significant. Since the primary face ignition source is the shearer mining machine, the Bureau ran tests to determine the best location to take methane readings on the shearer. This information, in conjunction with data obtained from field studies, provides a knowledge base for selecting optimum face methane monitoring locations.

Jan 1, 1995

By D. M. Conner

An innovative patented process has been developed to convert high volume wastes--fly ash from coal-fired power plants, municipal solid waste (MSW) ash from incineration, solids from waste water treatment and paper mill sludge into a high value and environmentally benign product in the form of a lightweight aggregate. Lightweight Aggregate is widely used in the building construction industry in the United States, Europe and some Asian countries. This paper will present the development of the process, the process itself and details on the first commercial scale plant. The commercial plant is owned and operated by Wisconsin Electric Power (WEPCO).

Jan 1, 1997

By E. Topuz, M. J. McPherson, J. Banik

This paper summarizes the analyses of ventilation layouts for mines that experience both spontaneous combustion. The major focus is placed on the longwall coal mine layouts used in several countries. Each of the different layouts is modeled in the form of a ventilation network. The gob of a longwall panel is the most critical location for the occurrence of spontaneous combustion. Airflow leakage paths inside the gob are simulated by using a simplified grid-like network. Computer simulations with this model indicates that the W-system of ventilation is most effective in minimizing air leakage into the gob. Homer, the U-system of ventilation, with pressure balancing behind the face support line, is also found promising for longwall panels. The magnitude of air leakage into the gob is observed to change with the advance or retreat of bee, thus requiring appropriate balancing of pressure to maintain the leakage at a minimum.

Jan 1, 1995

By Robert Cooke

This paper shows how technology developed to analyse stabilised slurries can be applied to paste flows. The rheological characterisation of paste mixtures using the generalised yield pseudoplastic rheological model is described. It is noted that the slump test does not provide a complete rheological characterisation of a paste. Methods for calculating pipeline pressure gradients for laminar and turbulent flow are presented. The minimum pressure gradient is an important consideration to ensure that solids do not settle on the pipe invert. Important points to be considered for a pipe loop test programme are noted. The usefulness of the pseudo shear diagram for scaling pipe loop test measurements is demonstrated. Issues to be considered for the design of paste reticulation systems are discussed.

Jan 1, 2001

By W. Jacobi, F. Steinhausler, A. C. James

INTRODUCTION In 1979 the Committee on Radiological Protection and Public Health of the Nuclear Energy Agency (OECD) defined a programme of work needed to improve radon dosimetry and monitoring. A Group of Experts in this field was established by the NEA and at the first meeting of the Group the authors were designated an initial task with the following terms of reference:- To review dosimetry of radon, thoron and their daughters, and in particular:- - to examine analytical models for the assessment of dose to individuals who are exposed to aerosol mixtures of these nuclides; - to examine the state of knowledge of the characteristics of aerosol mixtures of these nuclides and other factors that influence the dose to the lung, and identify those parameters which should be measured for dosimetric purposes in radiological surveillance programmes; - to identify areas where further study or research are needed. In this presentation we attempt to examine, with these objectives, the relationship between exposure to radon and thoron daughter aerosols expressed in terms of the working level month l (WLM), or its SI equivalent, and dose accumulated by sensitive tissues of the lower respiratory tract. Over the past two decades many attempts have been made to calculate the lung dose equivalent to l WLM exposure in mine atmospheres, usually in terms of the maximum dose to basal cells in a small part of the bronchial tree. The calculations have employed variously detailed models of airway anatomy, aerosol deposition, ciliary clearance and dosimetry of tissue at the bronchial surface, and are well reviewed elsewhere (Walsh, 1970; UNSCEAR, 1977; Jacobi, 1977; Fry, 1977). They agree in the conclusion that basal cells in segmental bronchi (between about the third and fifth bronchial generations) receive the highest dose, although estimates of this dose differ by more than an order of magnitude, ranging from about 0.2 to 12 rads per WLM (2 mGy to 120 mGy). The most critical parameters of these models are the assumed depths of basal cells below the bronchial surface and the fraction of the WL carried by free ions. When more realistic values of these parameters are substituted (Jacobi, 1977), the dispersion in calculated maximum doses to basal cells is reduced to give a much smaller range from about 0.3 to 1 rad/WLM (3 to 10 mGy/WLM). The parameters and methods employed in these various models, however, remain too diverse to infer the sensitivity of the dose conversion to practical variations in aerosol characteristics and the additional factors determining lung deposition and clearance. We have therefore taken the approach of developing newer models (Jacobi and Eisfeld, 1980; James et al, 1980) that can encompass the range of available experimental data on the physical and biological behaviour of radon and thoron daughters and also accommodate the different interpretations that can be put upon them. We have paid particular attention to the averaging of dose over tissues of equal sensitivity in the lung

Jan 1, 1981

By V. Karra, G. Beerkircher

Application of the innovative WaterFlush® crushing technology to the processing of gold, copper, and iron ores is presented for retrofit circuits and productivity gain in each case is stated. New operations containing WaterFlush are described in brief.

Jan 1, 1995

By Joshua Farmer, Mike Gianforte, Tao Jiang, William Gettings

The Two Rivers Water Reclamation Authority (TRWRA) in Monmouth County, New Jersey, is replacing its aging Pleasure Bay Interceptor (PBI) with a new 54-in interceptor in a 3,250-foot long 8 to 10-foot diameter tunnel and a new 50-mgd main pump station (MPS). A comprehensive phased geotechnical investigation was performed, including SPTs, CPTs and geophysics. A channel filled with soft marine sediments was identified. The tunnel is set in stiff to hard marine soil to enable using a less expensive open-face TBM. The thickness of tunnel cover under the channel is optimized through numerical analyses to avoid a deeper pump station yet maintaining tunnel stability with controlling seepage.

Jun 13, 2021

By Robert J. Collins

Computer-aided design drafting systems have been employed in plant design for nearly ten years. Current and future systems will include computer-aided engineering as well. This paper will explore the history and development of such systems including computer and workstation hardware, graphics software, and plant design applications software. The paper will also address future systems and will present both the system vendor and the mine mill designer's view. Specific examples of particularly successful applications will be included.

Jan 1, 1985

By W. J. Mahoney

A good quality assurance program at a coal mine or power plant is accurate, timely, and consistent. The quality analysis is accurate due to a complete sampling of the coal stream loaded into the unit train. The sample analysis is accurate because standardized testing procedures are applied. Once the analysis is completed, the results must be communicated to the electric utility in a timely manner. The electric utility needs the results to better manage the coal inventory at the power plants. A quality assurance program can also help the mine deliver a consistent product to the electric utility's power plants. The importance of the three major tenants for a good quality assurance program: accuracy, timeliness and consistency, are based on major changes that are taking place in the electric utility industry.

Jan 1, 1994

By P. E. Snoek, R. L. Gandhi, C. S. Miller

Slurry operations are an integral part of mineral processing. There is therefore reason to consider using slurry pipelines for long distance mineral transportation. This paper reviews the current state-of-the art of such systems and, in particular, the design factors which must be addressed. It also discusses the selection of major components such as pipe, pumps, valves and storage facilities. Finally, the major steps required to determine the economic feasibility of a slurry system are listed and the major advantages and disadvantages of slurry pipelines compared with other forms of land transport are summarized. SLURRY PIPELINES: GENERAL OVERVIEW Minerals Transported Long distance slurry pipelines have been successfully used for transporting coal, iron concentrate, copper concentrate, limestone and phosphate. Additionally, several tailings disposal pipelines of considerable size and length have been built, but these generally are not categorized as long distance commercial mineral transportation systems. Table 1 lists selected examples of commercial slurry pipelines.

Jan 1, 1986

By T. J. Dudek

To be competitive in automotive applications, polymer composites must be processable by high production rate processes like injection molding (IM), reaction injection molding (RIM), structural rim (SRIM) and compression molding. With current fiber reinforced composite materials, performance properties are sometimes compromised to make them compatible with these processes. This is done by decreasing the amount and length of the reinforcing fiber and the viscosity and molecular weight of the polymer matrix. Sheet molding composite (SMC) and thermoplastic polymer blends are examples of polymer composites which are cost effective in many applications and meet the high speed processing requirements for automotive parts.

Jan 1, 1993

By Antoon W. van der Vooren, Colin R. Phillips

A comparison of analytical models used to describe deposition in the first generation of lung bifurcations is presented. In order to allow testing of the mathematical models, experimental data were obtained from radon daughter deposition in simplified lung bifurcations. The experimental data for particles deposited by diffusional mechanisms is best described by the assumption of a thin concentration boundary layer at the entrance of a right circular tube. Other more complex models do not accurately describe the deposition of submicron particles. The angle of bifurcation was found to have a minor effect on deposition.

Jan 1, 1981

By Alexander B. Ikonnikov

All known bauxite deposits in China occur in its eastern half, and almost all of them are found in the Carboniferous and the Permian. They are of platform origin, but contain diaspore as the major ore mineral. There is only one known deposit composed of gibbsite. The most valuable deposits are sedimentary ones formed in local depressions on the edges of platforms during marine transgressions. They lie on Upper Cambrian or Middle Ordovician limestone that was weathered for a long period of geological time. Generally, Chinese bauxites are low in iron, and have a rather low alumina/silica ratio.

Jan 1, 1984

By J. Abbott

This paper gives a brief description of the Compania Ninera del Pacifico (CNP) a subsidiary of the Campania Acero del Pacifico (CAP), its participation in the Chilean Iron Ore mining and the gradual development of its activities. mainly in this paper, it is explained the CNP experience in the production of 34 million tons of self-fluxing pellets for Blast Furnace in a period of ten years in its Huasco Pellets Plant.

Jan 1, 1989

By R. A. Jankowski

Laboratory tests were conducted to evaluate the silica collection efficiency of flooded-bed scrubbers using six different filter panel designs at two operating velocities. Test results indicated that reductions in filter density negatively impacted respirable dust collection. Silica collection efficiency for the least-dense filter was as much as 33 % lower than the collection efficiency of the most-dense filter. At the low operating velocity, the least-dense filter allowed more than 40% of the respirable silica dust in the scrubber intake air to pass through the unit and back into the mine environment. Operation of the scrubber at the higher test air velocity increased silica collection efficiency regardless of the filter panel tested The density of the filter panels also impacted the quantity of air moved through the scrubber, with higher-density filters reducing scrubber airflow. For each filter, the relationship between dust-collection efficiency and air-moving capacity must be considered to determine the overall effectiveness for each mine application.

Jan 1, 2000

By G. Q. Huang, Q. X. Yun, Z. Y. Gui

This paper provides a new approach to deal with control of ore-rock excavation by means of the optimal control theory-an important branch in cybernetics. In the optimal control theory, the elementary functions are state-transition function and objective function. According to the characteristics of mining planning and production, a set of formulation are established to cope with ore- rock excavation. The formulations include basic formula, anti-disturbance formula as well as other special formula. The new approach has been successfully used in several mines of China.

Jan 1, 1996

By D. Nilsson, B. Aaro

To find out if there are any potential savings in "in-the-wall haulage for open pits," the Swedish companies ASEA and Kiruna-Truck in 1984 gave us financial support to study this solution in more detail. In the study, the use of in-the-wall haulage was studied for three hypothetical open pits with different sizes and shapes. Annual ore production rates also varied. A part of this thorough study was published by the Swedish Mining Research Foundation (see Report F 8444, "The Use of Electric Trucks and In-the-Wall Haulage in Open-Pit Mining," in Swedish with an English Summary). Although in-the-wall haulage is of interest in some open pits, the local terrain is important for profitability. The authors do not think in-the-wall haulage is of any major interest for the mining industry. The following is a summary of some of the author's findings. To place the haul road in the wall is not of interest in open pits with declining metal contents in the bedrock. In such mines, the volumes from the haul roads will not yield revenues. The cost per m3 for an underground haul road is much higher than for a haul road in the pit. This means that it is only of interest to place the haul road in the wall when mining gets deeper than about 50 m (165 ft). In-the-wall haul roads will reduce flexibility in the pit, and it will make necessary the use of smaller equipment with lower productivity and higher costs per ton. As Hustrulid, et al. show (Table 4), excavation savings of material hauled are very low, $0.10 to $0.25/t (0.09 to 0.27 per st). The extra operating cost, due to lower productive equipment, will normally be much higher and thus destroy the whole idea with in-the-wall haulage. If electric trucks are profitable for in-the-wall haulage, it is normally also profitable to use electric trolley assist for trucks on the haul road in the pit. But the profitability of using electric power is different in different countries, and depends on the relation between the cost for electric power and diesel fuel. In the US, diesel fuel is inexpensive compared with electricity, but in a country like Sweden, diesel fuel is much more expensive. In most open pits, the trucks have to move a considerable distange from the loader until they reach a final haul road in the wall. A trolley line along such temporary haul roads will be exposed to flyrock. It is normally less expensive to perform rock support from the open pit than from underground ramps in the wall. In Fig. 8, Hustrulid et al. gives the impression that the underground haul roads will be very close to each other. This is seldom the case. Figure 1 shows a haul road in the wall. The haul road passes through each cross-section only once. Arranging a reliable dewatering and rock support system from only one underground ramp is probably impossible. Many more drifts are therefore necessary. In our report, we also studied what would happen if the final pit slope is increased by 5°, using underground drifts in the wall. Our conclusion was that, the extra cost for drifts, rock support, pumps, etc. destroys the whole idea, and that it was better to accept a higher stripping ratio with the haul road in the pit and to use conventional low-cost open pit equipment. Finally, we think it is would be difficult to try to reduce the safety factor when determining the slope angle by moving the haul road in the wall. Minimizing the risk for pit wall collapse is also important with in-the-wall haulage, primarily because men and equipment will be working in the pit, but also to guarantee many accesses between the pit and the haul road in the wall.

Jan 1, 1990

By R. A. Burns

The production of kaolin and calcium carbonate in North America exceeds 13 million tons sold into higher value market segments. With a few exceptions, the markets supplied exhibit mature growth rates. In some market sectors, technology changes have and continue to occur shifting pigment-type consumption and growth. New sources of supply will impact current businesses. New product and process developments for kaolin and calcium carbonates are continuing. Each of these issues is examined in developing a view of the future for kaolin and calcium carbonate in North America.

Jan 1, 1997

By Balesh W. Konda, Andrew B. Cecala

Face ignitions occurring during longwall mining are increasing each year and are expected to continue to increase as deeper and gassier seams are mined. Effective methane monitoring strategies are needed to supplement techniques developed either to control the ignition sources or to dilute the gas to an acceptable concentration. Present monitoring strategies do not always detect dangerous concentrations as rapidly as they should. In a number of instances, dangerous concentrations have been observed at the shearer, but are diluted to acceptable levels when measured at the tailgate monitoring location. To effectively monitor and control methane concentrations, methane liberation and emission patterns must be identified. This need has led to a joint research effort between the Canada Centre for Mineral and Energy Technology and the United States Bureau of Mines. By combining the knowledge and experience of both organizations, the methane hazard facing underground longwall operations can be addressed more effectively. A comprehensive plan was developed to monitor methane levels throughout the panel and for an entire longwall mining cycle. In June-July 1986, a case study was performed at the Cape Breton Development Corporation's Lingan colliery in Sydney, Nova Scotia. This initial study was performed on two advancing longwall panels. Methane concentrations and flow patterns from this study are described in this report. A similar study is planned on a retreating longwall panel.

Jan 1, 1987