Search Documents

Why Innovate in Mining? ?Obvious, right? ?Increase productivity and profitability ?Improve safety and ergonomics ?Improve our environmental record and eliminate liabilities ?Implement process control methodology ?Introduce information systems technology to gain control ?Low hanging fruit ?Reference ?Heather Ednie, Innovation CIM Magazine Feb. 2006 ?Peck & Skinner, Getting better bang for your buck with technology

May 1, 2006

By S. Kelebek, C. Gibson, M. Aghamirian

"Global niobium production is currently dominated by three operating mines, Araxá and Catalão in Brazil, and Niobec in Canada. Although over 90% of the world’s niobium is mined and processed in Brazil, a number of high grade niobium deposits exist worldwide. The advancement of these deposits depends largely on the development of operable beneficiation flowsheets. Pyrochlore, the primary niobium bearing mineral, is typically upgraded by flotation with amine collectors at acidic pH, and often includes a reverse gangue flotation stage prior to pyrochlore flotation. Challenges related to the flotation of niobium ores include complicated flowsheets which require pulp pH adjustment from alkaline to highly acidic conditions, difficulty recovering fine grained pyrochlore, producing concentrates that meet specifications, and minimizing the losses to reverse pre-flotation gangue concentrates, slimes, and tailings. The specific flotation challenges associated with different niobium ores are discussed. In some cases, the use of alternate flotation reagents and flowsheets are required to achieve reasonable gangue rejection and maximize recovery, particularly of very fine pyrochlore grains.INTRODUCTIONNiobium is a transition metal primarily found in the oxide minerals pyrochlore (Ca,Na)2Nb2O6(OH,F) and columbite (Fe,Mn)Nb2O6. After physical upgrading, pyrochlore is converted into a ferroniobium product which is largely used in the production of high strength low-alloy steel. Today’s niobium market is dominated by the Companhia Brasileira de Metalurgia e Mineração, whose Araxá operation produces over 80% of the world’s niobium. There are two smaller operations, Niobec in Canada, and Catalão in Brazil, which account for the remaining production (U.S. Geological Survey, 2013).A number of niobium deposits exist globally, their advancement dependent on the development of operable beneficiation flowsheets. Pyrochlore, the predominant niobium bearing mineral, is commonly upgraded by flotation with cationic amine collectors in acidic pulp conditions. However, many niobium ores do not respond to this typical flowsheet because they are either highly refractory or niobium deports to other minerals such as columbite, ilmenite and rutile, which are not as responsive to this reagent scheme (Bulatovic, 2010). Other reagents, such as alkyl hydroxamic acid, have been studied extensively and while promising, are not without their own inherent issues including lack of selectivity over iron oxide minerals, and high addition rates (Ni & Liu, 2012; Gorlovskii, Eropkiny, Koval, Strelstin, Khobotova, & Shtchukina, 1968; Gorlovskii, Khobatova, & Shtchukina, 1966).It is the aim of this report to highlight the challenges associated with the physical upgrading of niobium minerals through examination of the flotation behavior of two different ore systems. In order to overcome these challenges it is important to thoroughly understand the limitations of typical flowsheets/reagent schemes currently employed in operation."

Jan 1, 2015

By E. Lehtila, J. J. Talja, R. Jahila

Kopar Oy is acknowledged for engineering and manufacturing of robust systems for bulk material handling, especially at power plants and non-ferrous smelters. We have over thirty years of experience with systems specifically designed for hot and abrasive conditions, aiming at low cost of ownership, low operational expenses and high availability. Although Kopar has numerous applications in mechanical conveying, there is an increasing number of pneumatic conveying applications at copper smelters. They relate to conveying of concentrate, and primary and secondary flue dusts. Challenges of pneumatic conveying for concentrate are mechanical and do relate to broad particle size distribution and high abrasivity of the concentrate and the silica. Therefore, special attention shall be paid to system design and ceramically lined bends in the pipeline. Challenges of pneumatic conveying of primary flue dust relate predominantly to material stickiness and poor flowability which are mainly due to fine particle size and formation of sulphates and furthermore, crystalline water. Additional challenges of secondary dust, the white converter dust, are primarily due to the extremely fine 0.1–1.5 µm particle size and problems which come with this. Effect of material characteristics like size distribution, morphology and chemical composition in pneumatic conveying are discussed in detail. INTRODUCTION Fine materials like concentrate, feed mix, flue dusts (from waste heat boiler and electrostatic precipitator) and secondary dusts need to be conveyed at smelters. Both horizontal and vertical conveying and combination of those are used. For the purpose, both mechanical and pneumatic conveying are applied. Most widely used equipment are drag chain conveyors and various combination of pneumatic systems, e.g. air lift, dense-phase and dilute phase pneumatic conveyors. Kopar has 30 years’ experience with multiple material handling systems. Furthermore, acquired companies like Elmomet Oy and SITE Oy (both currently fully merged and integrated into Kopar Oy) have even longer history, especially in pneumatic conveying. It is commonly known that the finer the dust the more difficult it is to be conveyed pneumatically. Sulfates with crystal water makes it all even more difficult, if not ineligible. Challenges related to pneumatic conveying of various fine materials is discussed in detail in the paper.

Jan 1, 2019

By Jacques J. Eksteen

Metallurgical accounting around toll treatment smelters pose a number of challenges. This paper reviews the requirements for good sampling practice, and how conflicting requirements for good furnace operation and design often makes reliable closure of the metallurgical balance tenuous at best. Typical physical causes of variance and bias will be identified. The propagation of error (in the form of variance) will be discussed for a copper smelter.

Jan 1, 2006

By A. D. S. Gillies

Inertisation is used to enhance the safety of underground mine areas either to avoid the potential for a combustion event or to stabilize a situation after an ignition, fire or heating. The primary objective of a recently completed Australian Coal Association Research Program (ACARP) study was to review coal mine inertisation and in particular to focus on use of the Polish mine fire simulation software Ventgraph to gain better understanding of how various inertisation units interact with the complex ventilation behavior underground during a substantial fire. Critical aspects targeted for examination under the project grant included location of the unit for high priority fire positions, size of borehole or pipe range required, time required for inertisation output to interact with and extinguish a fire, effects of seam gases on fire behavior with inertisation present and main fan management. A major accomplishment of the project has been to take findings from the simulation exercises to develop inertisation related modifications to the Ventgraph fire simulation program in conjunction with the Polish program authors. Selected mines were ?evaluated or audited?as to the ability to deliver inert gases generated from GAG units to high priority underground fire locations .A coding system has been developed and many potential underground mine fire sources cannot be successfully inertized with the GAG docked at the current specified point; this is particularly so for fires in extended areas of workings or in panels. There is a limit to the ability of the GAG jet engine to deliver exhaust down smaller dimension borehole. There is a need to examine the use of the GAG for production or proactive uses in a wider application in Australian mines responding to recovering from mine fires, spontaneous combustion heating?s, elimination of the potential explosibility of newly sealed gobs or inert mines or mine sections on closure. Some of the current uses of low flow inertisation facilities could be more effectively undertaken with the GAG unit.

Jan 1, 2009

By Marco Sonnenschein

As time is costly, engineering companies have developed methods, procedures and mechanical equipment to tunnel faster. But the best excavation method will not be able to cope with the time pressure if there is not a reliable backup system. Therefore, the application of belt conveyors for tunnel boring machine (TBM) drives as well as for drill-and-blast driven tunnels assure a quick and smooth removal of excavated soil in order to enhance the efficiency of the tunneling equipment. During the last 10 years, belt conveyor systems have achieved ?state-of-the-art? levels and have become the first choice for muck removal systems in both TBM and drill-and-blast driven tunnels. Because time has become such a key criterion in tunneling projects, it is essential that all equipment is operated so as to derive optimum efficiency and minimize costs. Efficiency also means to think about new tasks for existing technologies.

Jan 1, 2012

By David P. Reddick

"Suncor Inc. Oilsands Group mining operation in Northern Alberta, Canada, has been blasting to loosen the oilsands to increase production and decrease maintenance of the bucketwheel excavators for over twenty years. In 1991 an area of the mine was encountered which had a working face of 130 feet rather than the usual 20 to 57. In order to maintain production objectives, the planning and blasting departments of the mine took on the task of blasting as much of the working face as possible. McGinnis Rathole Drilling Company provided the drilling for the project and Mining Services International (MSI) delivered the bulk explosives to the boreholes. It is believed the resultingblasts exceeded several known records in production blasting."

Jan 1, 1992

The prime objective of geometallurgy is to improve the profitability of mines through the use of spatial models of rock properties that have a significant impact on value. Although a key property is the grade of the component of interest, because it directly influences the revenue from saleable material, increasingly attention is being focused on other attributes. These 'non-grade' variables may have a less direct, but equally profound impact on value, either by reducing potential revenue (eg lowering recovery, deleterious elements, etc) or increasing mining or treatment costs (eg comminution, grindability, throughput, reagent use, etc). Collectively, these variables have been described as 'geometallurgical'. There are three main areas of activity required to realise the value of geometallurgy: 1. acquisition of appropriate data through sampling and measurement, 2. building spatial models of geometallurgical variables, and 3. using these models to optimise value. Each of these is built on the foundation of the preceding step. In building reliable spatial models, it is critical that the amount of error introduced to data by the sampling and measurement processes is understood and quantified, in order that the inherent variability of the component of interest can also be properly understood. Management of the quality of grade variables is now applied (with different levels of diligence and success) across nearly all sectors of the mining industry, not least because of the necessity to adhere to Codes of practice (eg JORC, 2004). The necessity for quality management and at least the broad framework of what to do in practice is reasonably understood by many relevant professionals. There are also a number of tools, including software products, statistical analyses and presentation formats, available for those managing grade data. It is also abundantly clear, that in many cases people have little understanding of why they are doing particular quality control activities, or how to sensibly interpret the results. The same is not true for many geometallurgical variables. In almost all instances the authors have seen, the magnitude of sampling and analytical/measurement error variance embedded in geometallurgical test data is untested and unknown. This is partly because until relatively recently, metallurgical data has mainly been collected for the purpose of process and mill design, with few, expensive tests carried out on 'average' samples of the orebody. Increasingly however, there is a move towards collection of much larger data sets from spatially distributed sampling, and thus a growing necessity to understand the errors inherent in both sampling and analysis of these types of variables, and how to manage them. In order to understand how the quality management practices applied to grade variables can be extended to geometallurgical variables, it is essential to understand the theoretical foundation that supports these practices. This requires an analysis of the concepts that underpin the 'principles of additivity' (Matheron, 1963), the 'theory of sampling' (Gy, 1982, Pitard, 1993), and 'statistical process control' (Shewhart, 1930). Relevant concepts are then integrated to form a foundation to develop methods to improve the quality management of geometallurgical variables. Application of this framework will significantly increase the integrity of geometallurgical data, the reliability of geometallurgical models and ultimately the value derived from implementing geometallurgy. This is an ABSTRACT ONLY no paper was prepared for this presentation.

Mar 1, 2010

By Luiz Felipe Mendonça de Amorim, Adimir Fernando Rezende, Gustavo Sampaio Lopes, Claudio Cesar Gajardo Arraño, Eltton de Sousa Veras, Manuel Villalobos Calderon

Many technical challenges were encountered while conducting near-field construction blasting between the critical intersection of Interstate 10 and multiple active railroad tracks in El Paso, Texas, for the Loop 375 Border West Expressway Project. Blasting was utilized for the removal of an andesite bedrock ridge in preparation for the construction of a new elevated super structure to be suspended over the existing railroad tracks. There was concern that the excessive vibrations and/or permanent rock deformation produced from the blasting within near proximity (20 feet, or 6.09 meters) of the railroad tracks would induce excessive stress and foul the tracks by shifting the alignment. This could result in a major loss of scheduling control between the two major railroad companies that operate in this area. There was also concern that the blasting may cause rock fragments to land on and interfere with critical interstate transportation. Blasts

Jan 1, 2019

By A. P. Schissler

Mining has several characteristics, uncommon in other business sectors, which pose additional challenges to the implementation or design of IT and management systems that use the information. Understanding these characteristics would improve the chances of successfully importing new information technology and management techniques to mineral producers. The most important characteristics that should be understood are workplace issues, the industry’s dual nature of being a continuous construction project using cyclical factory processes, labour challenges, workplace culture, information availability, integrative data elements, and the current technical education of mining engineers. These characteristics were taken into account in two applications of information technology and systems design at operating companies. The research and consulting projects focused on the development of an IT-enabled performance management system at several underground metal mines in Canada and an integrated data warehouse for surface mines spread throughout the United States and Latin America.

Jan 1, 2006

By John D. Janak

Thank you for inviting me to come here and be your keynote speaker. Texas also thanks you for being included as part of the Rocky Mountain Coal Mining Institute. We'll kind of think of Texas as Baja Rocky Mountains. I've always wondered why coal miners were the only people to go to the mountains in the summer time-and now I know why. The program committee should be given a big hand for selecting this RESORT. And the golf course is stimulating to say the least. This is a very beautiful location. I was asked to talk about CHALLENGES, OPPORTUNITIES and INNOVATIONS as they affect the coal industry. I am going to do that from a Texas perspective. But first, since Texas is the newest state to belong to the Institute, I would like to give you a little background on how our coal industry got started and where we are at today. The vast majority of our coal is called lignite-it has a little lower heating value than most other coals and ranks somewhere between buffalo chips and sub- bituminous. Lignite is found In three geological formations running Northeast to Southwest through South and East Texas. In-place reserves lying within 200 ft. of the surface total 14 billion tons. This slide shows the lignite formations with cur- rent mine operations colored in RED. Mines that are planned to be built in the next 10 years are shown in BLUE. Lignite was used mostly by settlers in Texas during the 1800s. It was used as a fuel to fire locomotives during the Civil War. Between 1900-1930, about 100 mines, mostly underground, were operating in Texas producing lignite for home heating and as a boiler fuel. Here are some slides showing underground access, [lie tipple used to process the lignite, and the underground workings. This is the "BIG LUMP COAL COMPANY" as shown here. The typical underground mine was 100-150 ft. deep and each miner produced 7-10 tons per day-all by hand. In 1926, the Texas Power & Light Company built the Trinidad Power Plant and began using lignite as a boiler fuel. The lignite was mined by the McAlester Fuel Company at the nearby Malakoff Mine. Here are some slides showing a stripping shovel at Malakoff uncovering lignite. The lignite was loaded into railcars in the pit for transport to the power plant. This is a picture of the Trinidad Plant which had two 20 MW units and one 32 MW unit. At the time, Trinidad was the largest power plant in the United States using lignite exclusively as a fuel. Trinidad operated until 1942 when it was converted to natural gas that was sold to the plant for 3 ½ ¢ per MMBT'U. The mine closed after having produced 7 million tons. Lignite was mostly forgotten about until 1953 when Alcoa started an aluminum smelter. Our Company formed a subsidiary called Industrial Generating Company to operate the power plant that furnished electricity to the smelter. We also operated the nearby Sandow Mine that supplied lignite as a fuel to the power plant

Jan 1, 1989

By R. L. Grayson

Conventional mine safety wisdom states that "the most efficient mines are also the safest." Since the 1980s, small mines (and contractors) have been targeted as the most dangerous ones because of their fatality records. Statistical testing of 1993 West Virginia safety and production data indicated that the most efficient WV mines were not the safest ones, considering correlations between the severity measure and tons per employee-hour, except for very small mines. This paper will present the results of an extended analysis of WV mine safety using 1993 and 1996 data, concluding with the method used to suggest current priorities for focusing interventions.

Jan 1, 1998

By J. Jeffrey Wagner, Michael J. Bailey, Peter M. Douglass

The Chambers Creek Interceptor Sewer Tunnel project consisted of 2-1/2 miles (4 kilometres) of nominal 9-foot (2.7-metre) O.D. tunnel driven through predominantly glacially overridden soils. Mole-Collucio Construction Company initially elected to drive the entire tunnel with a Lovat TBM. However, this machine could not control the fast raveling ground conditions which developed when the TBM encountered sands overlying very dense, hard glacial till or boulders. As a result, a shield and digger machine was brought in for a 1700-foot (518-metre) long segment. Pumped wells spaced roughly 50 to 125 feet (15 to 38 metres) apart were utilized to dewater about two-thirds of the alignment during construction. Initial support consisted of steel ribs and wood lagging, with a final lining comprised of pre-cast concrete pipe segments grouted in place.

Jan 1, 1985

By Tomio Tsuchiya

A construction method of bored steel H piles enclosed in soil-cement columns was developed by modifying steel H piles from the driven pile method and soil-cement walls from the earth retaining wall method, the latter of which produces cut-off walls and reduces noise and vibration during construction. In this method, as shown in Figure 1, rich mix cement paste is injected into the bottom of a borehole which is pre-excavated by a casing auger, then a steel H beam is inserted before it hardens. Since the high vertical resistance of piles created with this method has already been confirmed by loading tests, we have been investigating the applicability of this method for piles used to temporarily support building loads for top-down construction on raft foundations until the raft foundation is completed. However, in the loading tests, the bearing capacity at the lower end of the pile was measured by loading from ground surface on test piles which had friction cut to eliminate the shaft friction resistance. In other words, the loading tests neglected the effect of overburden pressure of soil above the lower end of the pile. To investigate the effect of the overburden pressure on the bearing capacity at the lower end of the pile, loading tests were carried out on a bored steel H pile of lm diameter (test pile) bored in a compacted sandy soil layer with N-value of 100 to 250 at each stage of a three-step excavation. The results show no significant change in the bearing capacity at the lower end of the pile when the depth ratio of the pile is in the range of 5.7 to 22.7.

Jan 1, 1996

By Chester M. F. Peters

INTRODUCTION There has been considerable discussion in recent years of the strained relations between owners, engineers and contractors caused by the rapid increase in costly litigation in underground excavation due to construction claims. These time consuming claims are not to the best interests of the industry. It has been a conclusion of some of the concerned parties that there could be a substantial reduction in these claims if a mutual respect for each other's roles could be maintained along with a practical contractual arrangement for sharing the risks of the unforeseen costs inherent in the business. This paper will touch on the overall problem of these relationships, but confine the major discussion to the role of geology in claims and, in particular, changed conditions claims, since they form the base for the bulk of those involving geology. Geologists can make a major contribution to the reduction of these claims if their particular abilities are recognized and used properly. CLAIMS AND GEOLOGICAL RISKS The tunnel contractor is strictly bound by the contract he signs, and the risks he assumes thereby must be priced. The most important variable factor on which he must base his price is the geologic data provided and his interpretation of it. If this data does not give a clear picture of the conditions, making it impossible to price

Jan 1, 1974

The scheme of rehabilitation of surface plant commenced in 1936, included the provision of improved and more hygienic changing and bathing facilities for the employees.At that time the Thompson's Shaft section of the British Mine was being prepared for a resumption of operations, and it was decided to repair and re-equip the existing building. Thus any new scheme adopted could be given a thorough trial, and the proved arrangement used as a basis for the contemplated new main changehouse on the North Section.Investigations were carried out to determine the most suitable arrangement for the Thompson's Shaft changehouse, to provide for a total of 120 men, with particular regard to the internal fittings and fixtures. Also, as the mining conditions were such that a large proportion of clothes worn underground by miners, etc., were wet by the end of the shift, the problem of drying these clothes in the availaole time from a man coming off shift to his commencing again some sixteen hours later was one of the most important to be dealt with.The changehouses in use on the North mine section of the lease were provided with racks around the walls for the men to hang their street clothes on, and a section was partitioned off to house the mine clothes and their drying facilities. The actual drying was carried out by means of hanging the wet clothes over racks between which ran pipe coils heated by means of hot water circulated from the hot water boiler supplying the showers.This method had proved to be far from satisfactory for several reasons, the main objections being:-

Jan 1, 1940

By R. A. Wagstaff

SINCE the time of the early Egyptians, the use of copper has been a boon to the life of most of the civilized world. Its use has been varied; in many connections, the art by which it attained its greatest usefulness has been lost. In this paper an endeavor will be made to take into consideration some of the many changes that have occurred during the last 40 years of copper-smelting operations. During that period the copper blast furnace has been almost forced out of existence by new methods of ore concentration-first, gravity concentration, and then flotation. These new methods of concentration introduced many new factors into the metallurgy of copper. The product was wet, it was fine and it was high grade. To overcome all these factors many changes have been necessary throughout the smelting agenda. New equipment has been necessary for transportation, unloading, sampling, bedding and moisturing in all smelting plants, especially the custom smelter. During the early days of "flotation," little was known about filtering or the use of an alkaline circuit; often the concentrate going to the smelter contained 20 to 25 per cent moisture. It is easy to imagine the difficulty arising with a product of this nature when it had to be shoveled by hand labor. To meet these conditions, mechanical unloading and sampling devices were soon developed. In many instances such good progress was made that actual costs for handling this unfavorable product were lower than those formerly incurred on the old product. Today most sampling of copper ores and concentrates is being done by mechanical sampling, pipe or augur sampling, or shovel sampling. Where concentrates are uniform in metal content, a great many of the plants now use pipe or augur sampling. For spotty ores, the old shovel sample with cone and quartering during the final stages is still in use. Where big tonnages are handled, mechanical sampling of concentrates is being done, with satisfactory results. To curtail slow and tedious cutting and mixing procedure, mechanical mixing boxes, splitters and cutters are used to cut down labor costs. MILLING As crude ores become scarcer, the use of milling operations increases. The few crude ores that are still smelted are used as fluxing types. To use these ores finer grinding has been found advantageous. This has made for better bedding and fluxing conditions, which in turn makes for faster smelting, lower fuel consumption and better metal recovery. The degree of fineness is more or less determined by the nature of the product. Most plants have set a standard of through ¾ -in. mesh screen for roaster- reverberatory smelting and through ¾ in. mesh screen for converter fluxes. For some refractory ores; even finer grinding has been found to be advantageous for good reverberatory smelting.

Jan 1, 1944

By ATF Publications

The following is a summary of the changes that were incorporated into the new Federal Explosives Regulations, 27 CFR Part 55, dated 9/2000. However, in light of the recent events of September 2001, additional changes in the Federal Explosives Laws and Regulations may be forthcoming. The nature and extent of any such potential changes are impossible to gauge at this time. However, this synopsis of the changes contained in the September 2000 Orange Book, ATF P 5400.7 was current at the time of this writing. Any questions regarding this paper should be directed to the Public Safety Branch in ATF Headquarters in Washington, D.C.

Jan 1, 2002

By Treglown N

In any mining operation the curtailment of rising operating costs is of prime concern to management.One area of activity where costs are often disguised is that of longhole secondary breakage.This paper outlines sane operational techniques that have been considered and tested, resulting in improved fragmentation fran longhole stope blasts at New Broken Hill Consolidated Limited mine, Broken Hill, NSW.

Jan 1, 1985

By J. D. Bliss, G. J. Orris, W. O. Menzie

"Analysis of gold placer data from gold placers throughout the world suggests that gold grades and volumes cannot be used to distinguish between most types of gold placers. Only the alluvial plain and fan placers are significantly different among the types of gold placers considered. Gold grades and volumes change when working gold placers go from small-volume methods to large-volume methods. The small-volume methods are either of the surface or subsurface (drift mining) type. The odds that a gold placer will be dominantly worked using small volume methods at the surface are about 5:3. Once small volume mining has occurred, the odds against subsequent large-volume mining are about 4:1. If a placer deposit is suitable for large-volume mining, and the amount of gold produced from small-volume mining was reported, an estimate of the remaining gold (log10kg) can be made using the following equation:The relationship shown by this equation suggests that very large gold placers have over half their total gold content in the rich gravels appropriate for small-volume mining. These relationships in conjunction with other data and computer simulation can be used to estimate placer gold resources for an area targeted for mineral resource assessment. IntroductionGold placers have been an important source of gold throughout man's history and may have been one of the first sources-dating back to around 6000 B.C. (Gregory, 1980). From the primitive basket to the modern floating dredge, a variety of methods have been used to work gold placers. Placers are found in a wide spectrum of geologic and climatic settings. They have been classified by using a mixed set of criteria including age (Recent, Tertiary), climate (desert), fluvial position (modern channel, bench, alluvial fan), environment of deposition (eluvial, alluvial, residual, beach), type of transport (stream, wind, glacier), and whether the placer is buried or at the surface (Boyle, 1979; Wells, 1969). Several mining methods have usually been used to extract gold from anyone placer."

Jan 1, 1987