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By A. Oja, M. Lahtinen, P. Salonen, B. Saxen

Most of the secondary and low grade zinc raw materials cannot be treated successfully by either conventional roasting - leaching - electrowinning (RLE) process or even by atmospheric direct leaching process. The problems arising especially from high impurity content of these raw materials can be effectively solved by implementation of the solvent extraction process. The utilization of solvent extraction process has been demonstrated by Outotec with raw materials like Waelz oxide, crude zinc oxide and zinc containing concentrator tailings. Based on batch and continuous test work it has been shown that SHG quality zinc can be produced even from the lowest grade raw materials. Impurity control in the solvent extraction process has been examined. The solvent extraction process is the key feature of the whole zinc plant for such raw materials. However, design of the entire zinc process including neutralization and bleed treatment is important for optimization of investment and operation costs of the plant. Very careful evaluation of the zinc process with modern simulation tools is essential. The optimized Outotec zinc process ensures a sustainable and profitable process containing minimal effluent and requiring little residue treatment.

Jan 1, 2014

By Michel Masse

1. A battery-powered wireless mesh network for dynamic diesel machinery tracking and operating status monitoring. 2. A real-time ventilation model and fan speed optimizer. 3. An OPC server for information interchange. 4. OPC linkage to existing control infrastructure. 5. A Human Machine Interface (HMI) providing data archiving, trending and reporting. 6. Live MS-Excel to interrogate the simulation, controls and optimizer. 7. The battery-powered network mesh also provides SCADA functionality to route optimized setpointsto the fans and automated regulators not linked to PLCs.

Feb 1, 2008

By G. E. Rodger, R. Jugoon

"SUMMARYSamples of Aunor gold precipitates which varied widely in gold content were fluxed to produce a bisilicate slag with various oxidizers and combinations of oxidizers. On the basis of some preliminary tests a flux composition was chosen which appeared to show the most promise.The different components of this flux were then incorporated into a matrix for a 23 factorial design experiment to determine what were the most important variables and what changes should be made to the flux composition to optimize the resultant total bullion fineness.The results of the 23 factorial design experiment showed that the flux composition as calculated was very close to an optimum as only very minor changes were required to give bullion in excess of 995 fine.INTRODUCTIONEarly in 1969 the results from the Aunor Gold Mines refinery showed that wide variations existed both in precipitate grade and in total bullion fineness. An analysis of this data showed that as the precipitate grade increased, the gold bullion fineness also increased (see appendix 1). Therefore, to improve the refinery results test work was initiated to: 1) improve the precipitate grade and 2) to determine, with the help of statistics, a flux composition which would be able to handle wide variations in precipitate grade and give a total bullion fineness in excess of 950 fine."

Jan 1, 1970

By Mario Gerards, Axel Wellendorf, Arulnesan Rajesh

"In times of increasing energy cost and global demand for improved machine technology, the optimization of industrial mineral processes in terms of efficiency and production cost is an important factor when choosing industrial equipment suppliers. Of course this applies for screening machines, feeders and distributers as well!Besides of the ability of a screening machine for being adjustable to changing requirements during the production process itself, it becomes more and more important to choose the correct screening machine type, peripheral equipment for arising screening tasks and to optimize the overall design of the screening machine starting at a very early stage.The different types of screening machines bring many advantages and disadvantages with them. The selection of the correct type of screening machine can improve the flow rate, energy, efficiency, yield, quality, output, availability and decrease the maintenance costs and structural steel work.The machine optimization has to be a consecutive process in which at any time results of simulation and “real-life measurement” are compared and the findings are implemented in machine development and design. As an example, it is possible to reduce machine weight and reinforce the steel structure of a screening machine at the same time, which enables the manufacturer to use smaller drives for the screen.This paper will present the methods ANSYS and 3D Solid Works used at RHEWUM GmbH for this way of optimizing machine design and construction and examples for results gained from this continuous improvement process."

Jan 1, 2016

By James Anstey

BHP Billiton?s Cannington facility is a mining and minerals processing plant near Mt. Isa in Central Queensland, Australia, producing silver, lead and zinc. Mine ore is processed in a concentrator, which consists of grinding, flotation, thickening and filtration. Grinding is carried out in a fully autogenous (AG) mill. The mill operates in closed circuit with a pebble crusher. Throughput is approximately 380 tph. Cyclone overflow from the grinding circuit is fed into a flotation circuit for the recovery of lead, zinc and silver. Two concentrates are produced (lead and zinc), which are then thickened and filtered. The filtered concentrate is transported by road to a rail receiving station. From here the concentrate is railed to port in Townsville for shipment to the smelter. Matrikon and Engineers at BHP Billiton?s Cannington Mine have used ProcessACT to develop a flexible, nonlinear dynamic simulator for the grinding circuit to further enhance process understanding, as well to investigate various optimization strategies. An online charge volume estimator was also developed for the AG mill to aid in the understanding of overload conditions, which for the previous two months had been the primary contributor to downtime. The models were developed using a combination of first-principles modeling along with input-output dynamic responses. Examples of models used include: Morrell ?C? model for power and charge shoulder/toe angle prediction; Whiten?s mixing model for breakage and hold-up; Nageswararao cyclone model for predicting cut size; slurry recovery and water recovery. The composite model simulates system dynamics starting from the stockpile reclaim system and finishing at the feed for the flotation process. The objective was to provide a tool that assisted Cannington in understanding their Grinding Circuit and allowed them to develop and evaluate circuit optimization strategies. BHP Billiton Cannington Mine is now considering development of a Grinding Circuit Optimizer utilizing the models developed for the simulator.

Apr 1, 2005

By M. L. Smith

"In the Phosporia formation of SE Idaho, ore quality varies by depth, seam and distance along strike; phosphorus recovery is sensitive to these variations. Plant ore feed can be blended over time to minimize this fluctuation by using a combination of mine production and inventory stockpile scheduling. Mixed-integer and goal programming has been used to optimize short-term mine production, but the seasonal nature of mine haulage requires the use of stockpiles both at the mill and the mine. The contents of the stockpiles can also be optimized as part of the production scheduling problem, but introducing inventory control introduces a nonlinear term into the formulation. A solution using a piecewise linear formulation is modelled and solved using AMPL/Cplex, and solution strategies are discussed for similar large-scale problems. IntroductionIdaho’s minable deposits of phosphate rock are found in the Meade Peak member of the Phosphoria Formation; two separate zones of this formation are mined with a combined thickness of 30 ft to 60 ft. A generalized stratigraphic section of the Phosphoria section is shown in Figure 1, illustrating the degree of complexity encountered when scheduling mine production. Alteration of the formation results in higher grade ore zones near the surface and variable in P2O5 levels between seams and along strike. This variability is seen as well in other quality characteristics critical to the production of acid and elemental phosphorus. Further, plant recovery and nodule quality are sensitive to variations in ore feed; variability in SiO2, carbonates, moisture, organics (carbon), P2O5 and other constituents of the ore can strongly affect plant recovery. Because ore quality characteristics can vary as a function of the alteration zone (or seam) being mined as well as the depth and distance along the strike of the formation, scheduling of mine production can have a highly significant effect on recovery in the plant. As illustrated in Figure 1, there are nine seams containing 20% to 35% P2O5. Phosphoric acid and elemental phosphorus production requires an ore content of 30% and 25% P2O5, respectively. Variability between numerous beds that are mined and quality variation within a seam due to alteration greatly complicates production scheduling with the result that erratic mill feed characteristics greatly decrease recovery."

Jan 1, 1999

Microseismic (MS) methods offer one of the few ways to monitor a 3D volume of rock and essentially see into the rockmass and the regions of real time rock fracture. This is a critical component when considering workplace safety as well as the economic viability of a mining operation. New Gold Inc. New Afton Mine, an intermediate copper-gold mining company located 350km northeast of Vancouver in the south-central interior of British Columbia, Canada, has recently installed a MS system to help understand the block caving process in space and time. For a block cave mining operation is it important to utilize the MS events to map out the seismogenic zone related to the regions of stress concentration and fracturing mechanisms which lead to caving. The geological setting within the local array is complex, consisting of several distinct lithologies with unique material properties that each affect the microseismic signal differently. The block cave consists of a muck filled void, also affecting the seismic waveform path. This paper compares the use of a single velocity model to a variable velocity model which accounts for the differing lithologies and cave. The variable velocity method determined 3D raypaths for all source to receiver possibilities through five irregular shaped geological domains and the estimated cave. For calibration blast data, the variable velocity model is found to successfully decrease the error for event location from an average of 38m to 20m (47% improvement), and its importance to location accuracy is expected to increase as the cave develops in size.

Aug 1, 2013

By Gurupraveen Ramanathan

Shallow-dipping orebodies (45°–60° dip) present significant challenges for underground longhole stoping, particularly due to limited gravity flow, drill misalignment near the footwall, increased potential for dilution from hanging wall overbreak, and deviation from drill string sagging at shallow angles. These geometrical and operational constraints often lead to unblasted ore wedges and excessive overbreak when standard practices are applied. This study develops a structured, data-driven framework to optimize longhole stoping in such conditions by integrating five key focus areas: (1) mining method selection, (2) stope and drift design, (3) drill and blast optimization, (4) equipment selection, and (5) performance evaluation. The suitability of longitudinal longhole stoping was validated for narrow vein geometries using orebody analytics and prior case studies. Geometric modeling was employed to determine optimal stope height (15–20 m) and stope width (1.5–2.5 m), with drift widths adjusted based on orebody dip to maintain drill access and minimize unbroken ore. Drill and blast design emphasized sequential blasting over multi-ring methods to improve void control, reduce wall damage, and enhance fragmentation. Specific burden and spacing guidelines (e.g., 1.8–2.3 m burden; 2.5–3.0 m spacing) were applied based on stope width and dip angle, and patterns were selected based on geometry—dice-5 for narrow stopes, and 3-hole rows for wider stopes. Drill rigs—including top hammer and ITH models from Sandvik, Epiroc, Boart Longyear and CMAC-Thyssen—were evaluated for compatibility with drift dimensions and alignment accuracy. Equipment was matched based on dip, drift width, and the ability to access the footwall at shallow angles. Sensitivity analysis quantified how changes in geometry, drilling accuracy, and blast design affect ore recovery, dilution, and operating cash flow. Results show that tailored drift and stope geometries, combined with proper blasting and rig selection, can boost ore recovery to over 95% and reduce dilution to below 5% in optimal conditions. This methodology offers a practical and economically optimized solution for shallow-dip mining scenarios.

May 4, 2025

By K. Meyer

"The largest cost centres of the David Bell Mine concentrator are grinding, leaching and effluent treatment. Optimizing results during the 6th year of operation are listed below: o SAG mill slurry density control and operating strategies improved liner life and media consumption by 10 and 25%, respectively.o Poly-met liners clad the SAG mill except for the feed end. Lower noise levels and reduced mill downtime have resulted in an improved and more efficient workplace (time required for liner changes is 2 to 3%).o A comparative grinding media study using seven different marked media at the same time showed media wear rates range 120 to 198 mg/kWh and ball mill charge replacement frequencies of 8.3 to 13.1 per year, and that a meaningful wear test must include all media to be tested at the same time in the same mill. High quality carbon steel cylinders had the best economics.o Pre-aeration, using pure gaseous oxygen is accomplished in pipe reactors. Small bubble generators provide oxygen in the first three leach tanks. 1500 to 3000 kg of oxygen is consumed per day. Leach kinetics have improved and trends indicate increases in gold recovery of three to seven ounces per day at reduced costs. Effects of reduced cyanidation of accessory metals on the effluent treatment plant will be discussed in a separate paper."

Jan 1, 1991

By Jean-François Lapointe

Many advances have been made concerning the automation of heavy equipment teleoperators such as those found in mining. Complete automation, however, is not achieved yet and the operation of these vehicles still relies on the presence of a human operator. Fortunately, a lot of research has been done in order to improve the performance of these human-machine systems. This paper presents the characteristics of different control modes and input devices used for the control interface of those telemanipulators. We describe the benefits and drawbacks of each particular control interface on the overall system performance, based on a review of research in the field. We conclude with some recommendations and a discussion of future research needs, given the new potential advances offered by virtual environment technology and embedded computing.

May 1, 2001

By Sanjeeva Latchireddi, Travis Orser

"Today’s high capacity semiautogenous grinding (SAG) mills expend vast amounts of energy and in doing so consume tons of shell liners and steel balls, while processing ore. The energy efficiency of these high throughput grinding mills can be attributed to the field of breakage and slurry discharge system. The charge motion and breakage of particles inside the mill depends on the shell lifters design, while the discharge of ground particles is controlled by the grate and pulp lifters. The limitations imposed by poor grate and pulp lifter design become increasingly apparent with increasing size of ag/sag mills and their operation in closed circuit. The design of these mill components has been largely based on trial and error and hence varies considerably between manufacturers. This paper discusses the use of two state of the art design tools - Millsoft™ and FlowMod™. Millsoft™ is an effective tool to design the shell lifters and optimize charge motion, whereas FlowMod™ simulates the slurry discharge system to design grate and pulp lifters. The application of these simulators will be discussed using case studies of full scale mills.INTRODUCTIONMany large mining operations around the world have one or more semi-autogenous (SAG) mills doing bulk of the work in their size reduction operation. The SAG mill is usually followed by a ball mill to finish the size reduction prior to the concentration step. In the past when primary, secondary and tertiary crushers fed material directly to large ball mills, the energy efficiency of the concentrator was determined for the most part by the ball mill operation, whereas now the energy efficiency of a plant often rests largely on the SAG mill operation. As a result mines have shifted their emphasis in optimization from ball mills to SAG mill"

Jan 1, 2005

By Kevan Ford, Getulio Junior, Rob Henderson, Wayne Philips, Chris Martin, Rob Thorpe

"Plant 2 at the Kinross Paracatu gold operation in Minas Gerais State, Brazil, was commissioned in late 2008. Designed to be the largest tonnage, lowest grade gold milling operation in the world, Plant 2’s throughput has steadily increased towards its design capacity of 5087 tons per hour.The plant employs a gold-specific flotation scheme to recover the majority of gold, which is present as discrete free gold particles. Additional gold is recovered by jigs in the grinding circuit, and the jig concentrates are reground, upgraded and subjected to intensive cyanide leaching. The flotation cleaner concentrate is reground and leached using a conventional CIL circuit.One year after start-up, with the plant stabilizing operationally, plant circuit surveys were completed by a joint team from Kinross Paracatu and Blue Coast Metallurgy Ltd. The surveys audited the flotation and concentrate treatment circuits to investigate the metallurgical performance.This paper describes the Plant 2 operation and how the surveys were designed and executed. Some of the quality control systems that were employed to provide meaningful data from such a low grade gold ore are described and findings and actions taken to improve metallurgy as a consequence of the surveys are discussed.INTRODUCTIONThe Paracatu mine is located two kilometres north of the city of Paracatu, in the north western portion of the state of Minas Gerais, Brazil, 230 km southeast of the national capital Brasília (shown in Figure 1). The present day Paracatu mining operation, fully owned by Kinross Gold, through its Brazilian subsidiary Rio Paracatu Mineração (RPM) is designed to be the largest tonnage, lowest grade free milling gold operation in the world.The deposit currently hosts some 1.2 billion tonnes of ore at a grade of ~0.41 g/t gold, hence contains a total gold reserve of over 20 million ounces. At a designed plant throughput rate of 61 Mt/year the mine life goes beyond 2030."

Jan 1, 2011

By R. D. Hossack

"The selection of a site for plant facilities is a function of several factors and has as its objective the maximization of profits, given fixed markets and sources of raw material locations. In practice there are several sites, any one of which or a combination of two or more would be suitable to meet the basic requirements of source of supply of raw material and labour and still fulfill market demands. The model used to select the optimum profit combination utilizes both computer programs and traditional financial analysis techniques. Of the three computer programs used in the mode), one is a linear program and another is a transportation simulator. Basic cost and price data are required. In examining costs, three levels are used: (a) distribution costs of raw material to the plant and finished goods to the market; (b) direct production costs at the plant, such as labour and locally supplied material; and (c) capital and overhead costs at the plant, such as construction costs, taxes, insurance, and federal and provincial cost allowances. The direct costs generally depend on the scale of operations, so that a large plant in one location may have a lower unit cost than two smaller plants. This, of course, must be balanced against distribution costs. In examining profit, it is necessary to think in terms of the price and volume of sales at each of the market locations. Given basic data and relationships, the model can be used to optimally locate production facilities or, alter-natively, optimally structure a transportation network given existing locations of plants and markets. It is dynamic to the extent that it can react to changes in volume, price and cost to optimally locate an additional plant, the expansion of existing plants, the shutting down or cutting back of plants, or the restructuring of distribution networks."

Jan 1, 1970

By Ali Hashemi, Anna P. Perry

The PQ Deeps (PQD) is a production zone located at Newmont’s Musselwhite Mine in northern Ontario. Development started for the PQD in late 2017, and the first stopes were mined starting in early 2021. Unlike most historic longitudinal stoping of narrower orebodies at Musselwhite, the PQD is a wider orebody following the plunge of a fold hinge and is extracted primarily by transverse stoping. Some geotechnical challenges were experienced during early stoping efforts, necessitating design changes throughout late 2021 and early 2022 to optimize the stope design. This work describes the mining methods and design changes to transverse PQD stoping based on geotechnical lessons learned during early stoping efforts.

Jan 1, 2023

By Shahé Shnorhokian

Numerical modeling is increasingly being used as a tool to examine complex geomechanical issues related to rockmass behaviour and stability of underground openings. The in-situ stress regime and the evolution of mining-induced stresses during the life of an operation, taking into account the planned stope sequence, are topics that can only be handled through the use of a realistic and calibrated numerical model. This paper presents a case study of a deep underground Canadian mine in northern Ontario. A FLAC3D model was constructed and calibrated based on in-situ stress measurements. In the first stage, the evolution of stress regime was studied and compared with the occurrence of rockburst events during a period of three years. The locations of clusters were examined and compared to the mining sequence during that period. In the second stage, stresses within a diminishing ore pillar were examined based on the planned stope sequence and compared to levels deemed acceptable to the mine. Based on the results, an alternative sequence was arrived at to reduce stress accumulation in the pillar, or induce it to occur at a further distance from a brittle dyke in the vicinity of the orebody.

Aug 1, 2013

By M. Tiedtke, T. Crary, P. MacPhail, M. Ounpuu

"The SGS carbon-in-pulp (CIP) / carbon-in-leach (CIL) model was used to evaluate and optimize the carbon circuit at Alamos Gold’s Young-Davidson Mine. Plants samples (pulp and carbon) were tested in a series of small scale batch experiments to determine rates of gold leaching and adsorption on carbon from a combined flotation concentrate/tailing product. The testwork data, along with existing plant data were then used to model the performance of the existing CIL plant and optimize the circuit to improve performance and overall recovery. The primary purpose of the modelling exercise was to determine the most cost effective way to lower solution losses at the plant. The modelling was also used to learn how the various parameters in the CIL circuit affect solution losses and the gold inventory tied up on the carbon. This resulted in recommendations for minor changes in the CIL flowsheet, which were successfully implemented in the plant. The approach, results and plant changes are presented.INTRODUCTION This paper presents the details from testwork conducted on samples from Alamos Gold’s Young- Davidson gold mine which is located near the town of Matachewan, approximately 60 km west of Kirkland Lake in Northern Ontario, within the southwestern part of the Abitibi Greenstone Belt. The objective of the test program (completed by SGS Canada in 2013) was to investigate and model the combined flotation concentrate / tailing carbon-in-leach (CIL) circuit and suggest ways to improve gold recovery. The metallurgical test program included mineralogy, rheology, and carbon modelling testwork. Plant information was provided during the test program and used in the optimization process. Upon completion of the testwork, plant changes were recommended and implemented at site (October 2014). Plant results from 2014 to 2017 confirmed the modelling results."

Jan 1, 2018

By T. J. Bruce, G. E. Agar, R. Stratton-Crawley

"A technique by which the design of a flotation circuit may be optimized is described and examples of the application of this methodology are given.Three interrelated criteria are defined and the application of these criteria to the selection of the optimum residence time for each stage of a flotation circuit is demonstrated. The criteria are:(1) Add no material to the concentrate that is lower in grade than the feed to that separation stage.(2) Maximize the difference in recovery between the desired mineral and the gangue.(3) Maximize the separation efficiency.Three independent systems were examined experimentally and it was shown that application of any of the criteria yielded similar results.It was demonstrated how the application of rate measurements (Criterion #2) could lead to the selection of a set of optimized times for several stages in a flotation circuit and that these could in turn be used to simulate the results of a locked cycle test. The predictions were checked against the experimental results from a locked cycle test and there was substantial agreement between the predicted and observed results."

Jan 1, 1980

By Pierre Gy

"Abstract - This paper deals with industrial complexes such as: (1) a mine producing metal-bearing ore and a furnace(s)/converter(s) where the ore is melted into metal, either directly, or after a mineralurgical concentration; and (2) quarries producing the raw materials required for the manufacturing of cement and the kilns to which they are fed.Each mine or quarry operation results from the exploitation of a mineral deposit. This deposit is never homogeneous. The raw materials which are extracted from the mine/quarry can never be safely fed to a "process" such as a cement kiln or a metal smelter, because the devices involved lack the flexibility required to absorb a very inhomogeneous feed. Furnaces and kilns are known to be very sensitive, sometimes dangerously so, with regard to deviations from a certain ideal feed composition.The purpose of this paper is to present the conditions required to optimize the operation of such a complex, so as to maximize the production, the quality of the product, as well as the profit generated. Two key operations are involved: sampling (to know accurately the materials being dealt with) and bed-blending (to achieve the desired degree of homogeneity). The theories of sampling and bedblending have been developed by the author and presented in various books (Gy, 1992, 1998)."

Jan 1, 1998

By G. Beckstead, L. F. Sawatsky, R. Nutbrown, D. Long, G. Gould

"This paper presents a case study for optimizing water management at Gregg River Coal Mine located near Hinton, Alberta. The optimization study was derived based on a review and assessment of existing management practices and plans for future operation and final reclamation. A proactive water management strategy was developed to assist mine staff in adopting a rational, environmentally sound, and economical approach to water management. A plan was developed to provide for safe operation, self-sustaining operation, low maintenance, minimum negative environmental impacts, and anticipation of future needs for existing and future operations. A plan for final reclamation drainage was developed including establishment of effective, sustainable, and maintenance-free water management systems. The study demonstrated the importance and benefits of a proactive approach for integrated mine water management. This approach is recommended for other similar mine operations because it will improve environmental compliance and reduce costs of water management. IntroductionGregg River Resources Ltd. (GRRL) operates an open pit coal mine on the eastern slopes of the Rocky Mountains, located about 45 km south of Hinton, Alberta. GRRL opened the mine in 1982 and expects to continue operations after Year 2000. GRRL has progressively reclaimed the disturbed area and expects to complete mine-land reclamation shortly after mining in the area is complete. The existing disturbed area and reclaimed area covers approximately 9.5 km2 and will expand to about 10.5 km2 upon mine closure.Like other coal mines in the mountainous areas of Alberta and British Columbia, the GRRL coal mine is subject to highly variable temperatures and moisture conditions. Average monthly precipitation varies from a low of 12.6 mm in January to a high of 113.0 mm in August, based on the precipitation record at the mine site since 1982. Despite the relatively high rainfall during the spring and summer months, excess water problems during rainfall events are quickly replaced by water deficit conditions during periodic droughts. Surface runoff varies from near zero in the winter to a mean annual monthly maximum of 78 mm during the month of June. The mean annual surface water yield is 345 mm."

Jan 1, 1997

By Helmut Lerchs

An open-pit mining operation can be viewed as a process by which the open surface of a mine is continuously deformed. The planning of a mining program involves the design of the final shape of this open surface. The approach developed in this paper is based on the following assumptions: 1. the type of material its mine value and its extraction cost is given for each point; 2. restrictions on the geometry of the pit are specified (surface boundaries and maximum allowable wall slopes); 3. The objective is to maximize total profit-total mine value of material extracted minus total extraction cost. Two numeric methods are proposed: A simple dynamic programming algorithm for the two-dimensional pit (or a single vertical section of a mine), and. a more elaborate graph algorithm for the general three-dimensional pit. ASURFACE mining program is a complex operation that may extend over many years, and Involve huge capital expenditures and risk. Before undertaking such an operation, it must be known what ore there is to be mined

Jan 1, 1965