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By Thomas M. Barczak

The initial Support Technology Optimization Program (STOP),Version 1.0, was released at the 19th Ground Control Conference. This original program has since been updated to Version 2.3 which was released in May, 2001. This paper describes the additional features of Version 2.3, focusing primarily on the following three aspects: (1) including uncontrolled convergence into the design requirements for standing roof supports, (2) the addition of design procedures for cable bolts as an alternative secondary roof support, and (3) the addition of new standing roof support technologies. Another new feature which should facilitate the development of design criteria for standing roof support is the capability to define ground reaction curves through convergence measurements alone without having to make support loading measurements. There are several other new features provided in Version 2.3 which are only briefly addressed in the paper. These include: (1) additional graphics capabilities to facilitate rapid assessment of support comparisons, (2)an East-West designation for support selection to more accurately provide cost and support availability data, (3) additional safety measures including a safety factor to identify support design near the peak support capacity, checks to see if the support dimensions comply with aspect ratio requirements, and a measure of roof coverage for the design layout of the support system. These new features of STOP provide more capabilities to design and analyze secondary roof support systems for conditions which could not be fully analyzed in the original version of the program.

By S. C. Langvik

The presentation named 'Dewatering of fines by Rotary Vacuum Disc Filters' has an opening why the filtration process is important to the Iron Ore Industry. It goes on to describe the various types of dewatering machines which have been used in this industry in the last 30-40 years, and where the vacuum disc filters now dominates. It presents also the most important design changes which have been made during this period to enhance performance. Further are discussed the principles of filtration and the factors and parameters which influence performance and operating costs. As a closing is presented today's ideas and thoughts about what can be foreseen of design modifications and improvements in disc filter design in the coming ten years.

Jan 1, 2001

The optimisation of a mining operation requires precise ore grade control, metallurgical accounting, and laboratory sampling protocols, which are implemented by using accurate and flawless sampling systems. Good sampling practices, and sampling technologies in these fields have been historically poor and too many existing sampling systems available on the market are flawed in many ways. This is mainly the result of a poor understanding of the Sampling Theory, and the natural result of international standards on sampling that fail to present the Sampling Theory in a logical way, that still promote non-probabilistic sampling, and that fail to address the important details that make a correct sampling system. Many standards barely mention the Sampling Theory in appendices when it should be clearly the main body of a reliable standard on sampling. As a result, many standards show only little expertise in the Sampling Theory. Conventional statistics should only be a scientific tool for the Sampling Theory to reach its height, which has always been well understood by its creators. Conventional statistics can indeed be addressed in appendices of standards in sampling, but not the other way around. Until the Sampling Theory is recognised as the main body of a standard on sampling, incorrect sampling technologies will plague the market, and make it impossible for mining operations to optimise their mining and metallurgical processes. This paper makes a short list of correct new sampling technologies that have been created with respect to the principles taught in the Sampling Theory. Also, suggestions are presented to create better international standards on sampling, which would provide a stronger incentive for manufacturers to build correct sampling systems, and for engineering firms to install only sampling systems that respect the rules of sampling correctness listed in the Sampling Theory.

Jan 1, 2004

By N. V. . Panishev

The Bakal (South Ural, Russia) deposit of iron ore bearing iron carbonate (siderite) with the capacity of more than 1 billion tones belongs to the MMK. This ore cannot be fully processed via blast furnace technology because of high content of MgO. According to the investigations carried out in the USA and Japan in 1999-2004 the ITmk3 (Ironmaking Technology mark three) RHF technology is a breakthrough in Ironmaking. Four iron ore types (hematite, magnetite, high and low Al2O3/SiO2) were tested. Reduction, melting and slag removal can be achieved in just 10 min. The main objective of the investigation is to establish optimum operation conditions for the production of iron nuggets from iron carbonate bearing ore via the ITmk3 by means of the lab scale testing. Samples of iron ore and carbon reductant were chemically and physically analyzed. Green pellets were processed via a lab tube furnace to simulate RHF conditions. The nuggets and slag were chemically analyzed. This preliminary test work provides valuable information which may be used for large-scale testing in a commercially sized RHF.

Jan 1, 2010

By L. Su, S. Liu, K. Jiang, K. Xie

The reduction of iron dissolution and acid consumption is fairly important in the extraction of Ni and Co from laterite ores from both economic and efficiency perspectives. BGRIMM conducted detailed research to investigate the behavior of iron in a nickel laterite leaching process. The mineralogy of Ni and Co was studied. In limonite ore about 76% of nickel is present in goethite while in saprolite ore 79% of nickel is associated with magnesium and silicon minerals. Test work revealed that limonite can be decomposed completely with enough acid concentration during atmospheric leaching. More than 98% of Ni and Co were leached into solution while 85% of the iron was also dissolved with 130-140 g/L iron in solution. Iron precipitates as hematite in the temperature range 250-270?C without neutralization reagents. That’s why limonite is treated by high pressure acid leaching (HPAL) technology to achieve nickel extraction and iron precipitation in the same autoclave. BGRIMM’s test results indicated that the remaining acid in atmospheric leaching solution and acid released by iron precipitation at a lower temperature was enough to leach saprolite efficiently. The so-called inverse leaching technology leaches limonite at atmospheric condition and the leaching slurry combined with saprolite is pumped into an autoclave to leach saprolite at 150-170?C. In the autoclave iron precipitates as hematite without acid consumption. Total nickel and cobalt extractions in the test program were more than 90% with iron content in solution below 8 g/L. In this inverse process iron dissolves in the atmospheric leaching stage and precipitates as hematite in the low temperature leaching stage. Compared with HPAL the leaching temperature is reduced to 150-170 ºC from 250-270 ºC. Compared to atmospheric tank leaching acid consumption is reduced from 850-950 kg/t ore (atmospheric) to 550-650 kg/t ore (inverse).

Jan 1, 2016

By R. Abela

Heavy mineral sands are usually beneficiated in a spiral concentrator circuit prior to separation of heavy minerals into streams of zircon, rutile and ilmenite. The performance of the spiral concentrators is heavily affected by the presence of slimes in the rougher feed. The paper quantifies the effect of slimes content and discusses the beneficial effect of spiral feed de-sliming. The net effect of inefficient slimes removal can cause significant recovery losses of the heavy minerals present in the feed.

Jan 1, 2003

By Robert E. Barieau

In the design of plants to separate helium from natural gas , it is necessary to estimate the enthalpies of the various streams at various positions in the process . This Bureau of Mines report surveys the various methods that have been used to determine enthalpies and gives information on the organizations with such capabilities . The minimum information required for developing an enthalpy diagram is presented , and the relative merits of the various methods are discussed . It is concluded that methods that require no mass flow rate or energy measurements are to be preferred .

Jan 1, 1965

By I Clark, S C. Dominy

Bulk sampling programs are typically applied in coarse gold mineralised systems to verify resource/reserve grades. In recent years, there have been controversies surrounding some results of underground bulk sampling exercises compared to the predictions using diamond drill data. Just how realistic is it to predict 100 t lots from drilling that was designed to model blocks of several thousand tonnes? This study looks at the variation of relatively small units within larger planned mining units and compares some of the geostatistical techniques which purport to provide tools for such studies. Relative difficulty of application, computer timings and summaries of results will be used to illustrate the likely variation in bulk sampling units as opposed to mining units and large-scale planning units. A case study based on publicly available data from a gold project in North America is presented. A simplistic and unconditional geostatistical simulation model demonstrated that up to 50 per cent of a relatively high-grade mining block could show as uneconomic low-grade subblocks. A subsequent study will consider a similar demonstration using uniform conditioning. Erroneous impressions of early sampling results can lead to unsupported prejudgements of the final results. Bulk sampling programs require detailed planning based on ore characteristics, where protocols must fit the mineralisation type. Any program requires definition of aims and data quality objectives across grade, geological, geotechnical and geometallurgical parameters.CITATION:Clark, I and Dominy, S C, 2017. Underground bulk sampling, uniform conditioning and conditional simulation – unrealistic expectations?, in Proceedings Eighth World Conference on Sampling and Blending , pp 3–20 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2017

By Thomas J. Albin

U.S. Bureau of Mines research has found that maintenance of surface mining equipment is involved in slightly more than one-third (34.1 pct) of all surface mining accidents. Two groups of machines, haulage trucks and power shovels, accounted for over one-half of all surface mining mobile equipment maintenance accidents in 1978-84. Maintenance work-time histories for these machines were compared with accident records to identify the most hazardous-to-maintain systems within the machines. Recommendations to reduce the accident risk associated with maintenance of these hazardous systems are presented.

Jan 1, 1990

By Wallace W. Key

This report concerns types, quantities, specifications, and uses of non-metallic minerals as a basis for improving their supply, conservation, and utilization. Supply-demand details concerning mineral fillers, roofing granules, and roofing rock used in asphalt are incorporated in this report, along with highlights on production and sales of roofing, floor tile, and other related asphalt products of California. Comparable data for the United States are included. Although large quantities of commercially prepared mineral fillers are used in asphalt for paving and related applications in other States, addition of commercial fillers for these uses rarely is required in California because of the natural fines available. On the other hand, California manufacturers of asphalt products other than paving utilize about 300,000 tons of asbestos, diatomite, limestone, mica, soapstone, slate, and other nonmetallic minerals as filler, mainly for roofing and flooring. Also, about 500,000 tons of roofing granules is produced in California, most of which goes into roofing manufacture in California. In addition, a significantly large and growing tonnage of relatively coarse mineral aggregates are used on low-angle, built-up, asphalt roofs to produce an attractive surface and offer protection against the elements. Nearly all minerals used in asphalt products manufactured in California come from local sources, except asbestos and mica--and there are indications that local deposits of these commodities could be utilized in some use categories.

Jan 1, 1966

By Mark S. Sanders

Six underground coal mine shuttle cars (three high seam and three low seam) were used to assess visibility using the concept of visual attention locations (VALs) and an improved human eye reference measurement instrument (HERMI Mark II). Each machine was assessed in the inby and outby direction of travel with no canopy and with the canopy in its highest, and lowest position. In addition, the illumination level at each VAL was determined. Results showed that the most important variable determining visibility was operator eye position. When this variable is controlled, the addition of a canopy has no effect on visibility. Further, with eye position controlled, there is no difference in visibility between high and low seam machines. The visibility and illumination assessments found blind spots in the operator's field of view located on the opposite side of the car from the operator and ahead of the machine. Suggestions for reducing the blind spots were made. The report also included a procedure manual for using HERMI and the system of VALs to assess visibility from underground shuttle cars, continuous miners, and scoops.

Jan 1, 1983

By M. W. Grabinsky, M. S. Diederichs, E. Hoek

Provided that they are used correctly, numerical models can be of considerable assistance to mining engineers in designing underground excavations. Guidance is given to the engineer or geologist who is not a specialist in numerical analysis but who is interested in using numerical modelling tools or in employing someone to analyse the stresses, displacements and failure in the rock surrounding underground excavations. A description of the theoretical background to a number of these numerical models and discussion of the advantages and disadvantages of each are followed by guidelines on the selection of appropriate models for each stage in the development of a mine, from exploration to the completion of mining

Jan 1, 1991

By H. K. Lin

Deepwater discharges of sulfide flotation tailings have been practiced for several decades. Oxygen penetration and organic matter content in such environments are the two major factors that determine their reduction-oxidation condition and hence the rate of sulfide mineral dissolution under such discharge environments. In this study, the effects of solution redox potential and pH on the dissolution of some heavy metals from sulfide flotation tailings were examined. Zn, Pb and Cu concentrations in solution were all higher at a higher redox potential and lower pH. Dissolved Zn concentrations reached 100 ppm even at a low redox potential of 105 mV and near neutral pH after 33 days. Pb concentrations were below 2 ppm at 105 mV and near neutral pH after 165 days. At 105 mV, the Cu concentrations were below 0.2 ppm at near neutral pH after 165 days. At pH 2.3, the Fe concentrations were higher at 420 mV than at 105 mV. But at pH 6.8, the Fe concentrations were lower at 420 mV than at 105 mV, due to the oxidation of Fe2+ to Fe3+ and the subsequent precipitation of ferric hydroxide. Arsenic concentrations in solution were all less than 0.002 ppm. For Zn, Cu and Fe, no significant differences were observed between the tests in solutions prepared using seawater and those using distilled water. However, Pb concentrations reached higher levels in solutions prepared using seawater.

Jan 1, 2009

By Brian P. Stapleton, Bill M. Stewart, Joel R. Warneke, Curtis C. Clark

Of the 28 accident/injury classifications listed by the Mine Safety and Health Administration, handling materials is second only to roof falls in terms of generating the highest number of reportable accidents in active underground coal mines. Two materials-handling activities that cause numerous injuries each year are the categories of “handling supplies or material, load and unload” and “moving power cables.” Mechanization and mine worker activity training are two methods that can aid in preventing these injuries. This paper describes three mechanical methods—the mobile manipulator, the in-mine hoist, and a cable-handling system—being developed and tested at the Spokane Research Laboratory of the National Institute for Occupational Safety and Health. Two of the devices are specifically designed for loading, unloading, and moving supplies and materials, and the third device is for handling trailing cables in the confined spaces of coal mines. Also described are safety solutions developed for underground coal mines geared to showing miners safe and unsafe ways of performing various materials-handling tasks.

By André Oliveira

The present paper describes state-of-the-art Pulverized Coal Injection technology with focus to Dynamic Distribution guaranteeing highest accuracy on equal distribution and being thus one of the key factors enabling constantly highest injection rates. As an alternative to the construction of a new plant, existing plants may be modernized and upgraded to latest technology. Two recent examples are presented. As a conclusion, two case studies of return on investment are showing that the PCI technology, both for new facilities as well as for upgrades, is very profitable and mandatory for high blast furnace operation effectiveness.

Aug 17, 2017

By Tom Short

"Construction blasting covers a very extensive variety of explosive applications. I will discussseveral of these with you and then show slides from my collection, starting in 1956, which will betterillustrate the types of blasting under discussion."

Jan 1, 1991

By David Rahal, Des Erasmus, Ken Major

"Over the past twenty years there has been an increased emphasis on fine grinding in the minerals industry. This spurred the development of a range of new fine grinding equipment in the 1990s. At that time, the Knelson-Deswik mill was developed in South Africa for the pigments industry.Knelson Milling Solutions currently offers a wide range of laboratory, pilot and production scale mills. These mills bridge the gap between traditional low speed vertical mills and the high speed horizontal mills (tip speed < 3 and > 15 m/s respectively). They are designed to run at tip speeds between 10 and 12 m/s and are capable of operating with very dense grinding media. The result is a power intensity that is higher than the low speed mills and overlaps that of the high speed mills. This allows the mill to be customized for a wide range of grinding applications.A case study at Aquarius Platinum’s Kroondal Mine shows that the Knelson-Deswik technology can produce a consistent product size despite feed variations. It also shows that the throughput was proportional to the slurry density at Kroondal. The case study identified increasing the slurry density as a process change that can increase throughput and reduce the specific energy consumption.INTRODUCTIONThe increasing complexity and finer grain sizes of modern ore bodies have increased the importance of effective mineral liberation in obtaining acceptable grades and recoveries (Jankovic, Valery and La Rosa, 2003; Lichter and Davey, 2006; Napier-Munn, Morell, Morrison and Kojovic, 1996). This trend has increased the significance of fine grinding technology because the input energy increases exponentially as the required product size decreases from 100 to 10 microns (Gao and Weller, 1993a).The US Department of Energy recently provided the context for the potential energy savings in the US Mining Industry (BCS, 2007). They reported that grinding consumes approximately 494 TBtu/year. This was over double the consumption of the second highest equipment category, diesel materials handling systems (211 TBtu/yr). The proportion of grinding energy allocated to fine grinding can only be expected to increase as finer ore deposits are mined. It is therefore critical that fine grinding efficiency continue to improve through the selection of appropriate equipment and the development of best practices for existing applications."

Jan 1, 2011

By Serge Rudchenko

A study to determine the potential use of retaining structures in open pit backfilling. Research and review of the open pit mine environment, mine waste disposal, and past and current use of retaining structures. A development of specific structures, the culvert/ tunnel concept, and an anchor block retaining concept. The cost benefit of retaining structures used for in-pit backfilled waste.

Jan 1, 1981

By P. Roy

Smelting or converting of sulphide concentrates and mattes in a batch operation presents a challenge when directing the off- gas to a conventional acid plant. The Hindustan Zinc Ltd. (a division of the Vedanta Group of companies) Chanderia Lead Zinc smelter was presented with such a challenge that was met with the adoption of the Cansolv® SO2 Scrubbing System. The Ausmelt top submerged lance technology used at Hindustan Zinc generates a furnace gas stream that contains between 0.1 vol% and 12 vol% SO2 during the three stages of batch smelting. Cansolv® SO2 Scrubbing Technology captures the SO2 to ensure that treated flue gas exits the facility at a concentration below 100 ppmv SO2 and it releases SO2 in a controlled fashion, to more closely match the needs of the existing acid plant. The application of a regenerable scrubbing system to capture SO2 from a batch-operated furnace and convert it to acid in a conventional acid plant was a first of its kind in the world. This paper provides an update on the design and operation of the Hindustan Zinc SO2 recovery system and suggests two improvements to the basic flow sheet that optimize the cost of SO2 scrubbing further.

Jan 1, 2007

By Rogerio C. Guimarães, Antonio E. C. Peres

The production of phosphate concentrates (phosphate rock) from slimes represents a challenge to the phosphate industry worldwide. In Brazil, this challenge is particularly relevant due to the consistently low P2O5 grades and the igneous origin. The Brazilian phosphate deposits are made up mainly of apatite from alkaline chimneys, representing 80% of the Brazilian reserves; phosphorite deposits contribute 18% and the other sources (guano, phosphorous bauxite, and apatite from veins) reach 2%. The Brazilian industry beneficiates phosphate ores that are mineralogically more complex than those treated elsewhere. The low apatite grade, inherent to the igneous Brazilian ores, added to the mineralogical complexity due to the weathering of the rocks, has represented a permanent challenge to the Brazilian process engineers. The total measured, indicated and inferred reserves reach 3.2 million tonnes of ore with average grade 11% P2O5. The development of local technology for phosphate beneficiation started in the 1960’s. The first industrial experiences of producing phosphate rock from slimes (-44µm or -325#) fraction started at Arafertil, currently Bunge Fertilizantes SA, in Araxá, in the 1980’s. This production corresponds, nowadays, to 35% of the total production of concentrates in the company (830,000t/year) in a circuit consisting of desliming in 40mm microcyclones and concentration in flotation columns, corn starch and fatty acids being utilised as reagents. The performance of slimes flotation and the process control, at Bunge´s concentrator, were improved after the introduction of column flotation technology, in the first half of the nineties. The column flotation technology for slimes recovery was expanded to other Brazilian concentrators still in the nineties: Ultrafértil (Catalão – GO), Bunge (Cajati – SP), Fosfértil (Tapira – MG) and Copebrás (Catalão – GO). At present the Brazilian production of phosphate rock is approximately 4.5Mt/year, with a strong trend for a market increase. Genuinely Brazilian technology is utilised for the processing of slimes, the concentrates representing 11 to 13% of the overall production. The production of apatite concentrates from slimes was relevant to increase phosphate recovery and reduce costs, contributing to the growth of the fertilisers industry.

Jan 1, 2003