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The philosophy of computer control of grinding and flotation at ZC/NBHC is presented. The performance and reliability of the in- stalled systems are discussed.

Jan 1, 1978

By Charles H. Wells

This paper describes a commercial installation of a sophisticated instrumentation and control system designed to maximize the performance of heavy medium cyclones. Samples of plant feed and its products were collected and analyzed for ash content so that measures of efficiency could be determined for plant operation under (1) manual control and (2) automatic (computer) control. The heavy medium cyclone control strategy and its digital computer implementation are discussed in detail. The sample results are analyzed and the economic benefits of automatic control are discussed. Results from the initial data sets quantify the economic benefits of automatic closed-loop control; viz, increased recovery and reduced clean coal variability have been clearly demonstrated.

Jan 1, 1981

By Elber L, Whiten WJ, Cunningham KD, King GL, Bailey CW, Clay PA

The Savage River Mines concentrator treats magnetite ore at about 300 tonne/h, and produces feed for a pelletising plant. The plant incorporates two parallel grinding lines, each consisting of an autogenous mill, in closed circuit with a screen, a rougher mag- netic separator, a ball mill in closed circuit with parallel cyclones, and a finisher magnetic separator. Significant fluctuations in ore grade and grindability make it difficult to maintain pro- duct size in the narrow range desired, and to achieve maximum possible throughput at the same time, using the present largely manual control system. The present paper describes the develop- ment of a control system based on a mini- computer. It has been possible to implement a scheme of on-line estimation of product size which is sufficiently accurate for use in an automatic control system. The size estimation is essentially derived in terms of plant variables which control the ball mill cyclone cut size. Three control functions have so far been implemented and tested. These are control of the feed rate to the autogenous mill, control of water addition to the autogenous mill, and control of the ball mill sump level.

Jan 1, 1978

By D. F. Cooper, J. G. Paterson, K. H. Pang

"Effective control of metallurgy by manual adjustment of cell levels is common flotation practice. With an on-stream XRF analyzer interfaced to a process control computer it is possible to program the computer to carry out this function automatically. This paper describes the development and implementation of closed loop control of the concentrate and tailing grades at the Clarabelle Mill of the International Nickel Company of Canada, Limited, The XRF analyzer was used as the sensor, cell level as the control and the computer as the controller.IntroductionThe International Nickel Company of Canada, Limited recently brought on-stream Clarabelle Mill having a rated capacity of 35,000 tons per day. The plant was required to increase milling capacity in the Sudbury area by 9,000 tons per day and to improve milling efficiencies by replacing the obsolete crushing and grinding equipment at the Copper Cliff Mill. This represents the fourth mill built since 1959 and incorporates the latest thinking in a continuing evolution of instrumentation and control concepts. Table 1 illustrates control progress at Inco since 1959.In 1967 Frood-Stobie Mill came on-stream incorporating a central control room, an on-stream analyzer, a data gathering computer, and a significant change in instrumentation from direct-contacted pneumatic to miniature electronic. The computer successfully controls the analyzer but has very limited process control capability. Based on this experience a process control computer system was installed at Clarabelle Mill with the objective of carrying out extensive supervisory control and a limited amount of direct digital control."

Jan 1, 1973

By Raivo Maripuu

The Boliden Group encompasses Sweden's foremost operations related to the mining and production of copper, lead, zinc, precious metals and metallic by- products. It is also the dominant swedish producer of sulphur-based heavy inorganic chemical products and fertilizers and has an international trading organization covering, in adition to the group's basic products, industrial minerals and oil. Boliden's activities in- clude the marketing of proven Boliden technique and know-how. Boliden Metall - the mining and metallurgical company within the Boliden Group - produces about 13 million mtpy of ores at mines in northern and central Sweden. Boliden has, over the years, become a specialist in processing poly- metallic sulphide ores and its eight concentrators presently serve 15 mines. Boliden has a long history of close cooperation with Swedish and foreign manufacturers in developing new products and processes.

Jan 1, 1979

By E. M. Sacris

The semi-autogenous grinding mill is the bottleneck whenever treating hard and finely fragmented ore at Benguet Corporation's Kaline Concentrator. Low milling rates result from very high and fluctuating mill power draw. Attempts to use a mill horsepower control loop to regulate feed rate were unsuccessful because of operational upsets caused by fluctuations in feed rate on downstream operations. The objective of the computer control was to maximize tonnage throughput by stabilizing the power draw at a high but safe level without upsetting subsequent operations. The semi-autogenous mill is operated in closed circuit with a stationary screen. Instrumentation consists of a feed weightometer, a power transmitter to measure mill load, a headwater flowmeter and an ultrasonic level sensor to measure the mill discharge sump level. A 64 k-byte FOX-3 Foxboro computer processes field data from various sensors and manipulates the input control variables. These variables are the fresh feed rate and the headwater flowrate. Feed rate is controlled through a supervisor-type computer program aimed at maximizing and stabilizing power draw. The control scheme was according to how the operators responded during an operator-directed automatic control mode. Mill dilution is similarly controlled. Results achieved reflect a 3% increase in tonnage milled because of the reduction in control variability that ensued.

Jan 1, 1987

By Peter Ralph

All copper ore haulage at Isamine was transferred to the new 19 level haulage network by mid 1975. Previous experience together with design studies had indicated that a three train operation would be required to haul the scheduled ore production. The ore train with a gross weight of 600 tonne is made up of 15 bottom dumping trucks hauled by twin electric locomotives (Figure 1). Present train speeds reach 40 km/hr and, in the future, this speed could be increased to 55 km/hr. The planned operation on the restricted track network and the relatively high train speed meant that the train driver operated block light system would be inadequate on the grounds of haulage safety and meeting production targets. Some form of Centralised Train Control (CTC) system emerged as a necessity, and as an initial step, tenders were called for a relay control type CTC system. The high cost of these systems and the anticipated high maintenance costs and inflexibility of the offered systems led to the rejection of the tenders. It was decided to develop a CTC system locally and to use a digital computer to perform the basic track [ ] equipment interlocking tasks and monitor haulage operation.

Jan 1, 1979

By R. J. McLeod

"CONTROL STRATEGYThe Lake Dufault Division of Falconbridge Copper Limited has been concentrating a complex copper zinc ore since late 1964. An ARL X-ray on stream analyzer was installed in 1966 for process control. A Digital Equip-ment Corporation PDP8 was added in 1968 for more complete control. To improve the system the computer was exchanged for a Moded PDP-81 in 1971.The new computer is time sharing with 8K core memory and 32K disc storage. A new interface was installed to accommodate 14 X-ray streams and additional analog signals for process control. The system gave us additional capacity and flexibility to make changes in operating programs and control strategy while on line. As the computer is used for process control a modified focal language was chosen as the operating language for ease of operation. This language is more suitable for process control than for statistical work.The main components of the control system are(a) Computer(b) Interface(c) Production Control X-ray Quantometer(d) Teletype terminals(e)Reagent feeders(f) Sample SystemThe operation of the system consists in the computer selecting the various streams to be analyzed by a PCXQ Quantometer. When the flowing sample is presented to the X-ray the intensities of the various elements are read by the computer from analog to digital converter, the assays are then computed. From the tonnage and assays the computer is programmed to determine the amount of reagent added to various parts of the circuit. The computer drives the feeders via the interface for the required amount of reagent. After following a certain sequence the computer prints out the performance and control data on an ASR35 Teletype. The data is printed out approximately every seven minutes. Any des¬ired changes in the program or strategy can be made during operation via an ASR33 Teletype connected to the computer."

Jan 1, 1973

By Stephen R. Holsinger

During 1972, Asarco's Silver Bell Unit embarked upon a project to test a digital computer-controlled grinding circuit against the performance of its other five grinding lines. The planning, implementation, and subsequent outcome of that project has been previously reported in a paper by Pitts 1, et al. This paper will describe the solutions to major problems incurred during the implementation of this control strategy on the remaining five primary grinding lines. Changes made in operating philosophy and methods during the expansion will also be discussed.

Jan 12, 1978

By Stephen R. Holsinger

During the year of 1972 ASARCO's Silver Bell embarked upon a project that would test a modified grinding circuit using direct digital compute against the performance of its other five grinding lines, implementation and subsequent outcome of that project has been previously reported in a paper by Pitts, et al. The main purpose of the present paper will be to describe major problems incurred during the implementation of this control strategy on the remaining five primary grinding lines and their solutions. Also included will be a discussion of changes made in operating philosophy and methods used since that report was written. Description The Silver Bell concentrator is a 10,436 tonne/day copper sulfide plant supplied by ore from two separate open pits approximately 4 km. apart. As well as receiving ore from these two main pits, ore is received from several exten¬sions of both pits. The ore bodies are variable in rock type and the extensions have increased this variability. Grinding is carried out by six primary, single-stage, 3.20M x 3.66M Allis Chalmers grate discharge ball mills in closed circuit with four Krebs D20B cyclones (Fig. 1). Each of these grinding circuits is controlled by four independent but interactive control elements. These control elements are the fresh ore feed, the water added to the feed end of the mill, the water added to the ball mill discharge sump, and the cyclone feed pump speed. At the present time, instrumentation for measuring primary process variables consists of Merrick weightometers for fresh ore feed, orifice plates coupled with differential pressure transmitters (dp's) for incoming water measurements, back-pressure diaphragm coupled with a dp for estimating ball mill discharge sump level, a magnetic flowmeter for determining cyclone feed velocity and a nuclear density gauge for measuring cyclone feed density. All measuring instruments develop electrical signals that are measured as 2-10 V DC "inputs o the computer interface.

Jan 1, 1977

By Stephen R. Holsinger

During 1972, Asarco's Silver Bell Unit embarked upon a project to test a digital computer-controlled grinding circuit against the performance of its other five grinding lines. The planning, implementation, and subsequent outcome of that project has been previously reported in a paper by Pittsl, et al. This paper will describe the solutions to major problems incurred during the implementation of this control strategy on the remaining five primary grinding lines. Changes made in operating philosophy and methods during the expansion will also be discussed.

Jan 1, 1979

By Murakami T, Tamiya M, Mizokawa T, Matsumoto T

In the expansion program of the iron ore pelletizing plant at Kakogawa Works of Kobe Steel Ltd., an automatic computer control of products fineness on grinding department is practised. The main problem of the process control of a grinding system is scattering of measured fineness values of products. The scattering comes from the inherent nature of grinding systems, sampled powders and measuring systems. A method is developed to presume the exact status of the plant from scattering products (fineness values and to achieve a stable con trollability of the plant by utilizing the computer. An on-line fineness analyzer, an automatic sampling device and vari-speed air separators are also developed to compose the automatic grinding plant. This report introduces the fundamental epts and results of the automatic fineness rol system of the grinding plant.

Jan 1, 1977

By Thorvald Wetlesen

Computer controlled drilling is now proven technology. It was first introduced by the development of the Furuholmen system for a prototype three boom tunneling jumbo in Norway in 1978. Now, 13 rigs with this concept are in operation in Europe, 3. in mining in England and. 10 in tunneling elsewhere in Europe. The system is also adapted to roadheader guidance. Practical experience has shown that the computer control system makes it possible to drive tunnels with a more accurate contour thus reducing the total amount of rock excavated, and where a full concrete lining is required a reduction in concrete volume is achieved. The total tunneling economy is improved. In the future we expect to see a wider range of instrumentation on jumbos, from the simple direction instruments to computer guidance systems for monitoring only, as well as fully automatic drilling to a programmed drilling pattern. More compact and reliable electronics will be available. Systems with low power consumption will fit easily into flameproof applications. Cabling complexity will be reduced by connection of sensors to serial signal lines.

Jan 1, 1989

By S. Gallagher, C. A. Hamrick, A. G. Mayton, R Sonier, R. L. Unger

Introduction Industrial safety professionals recognize that adequate illumination is essential to a safe and productive work environment. The need for effective, lighting in underground coal mines is even greater.1 Designing appropriate lighting systems for these mines is no easy [ ] task because of the unique environment and work procedures encountered in underground coal-mining operations. Miners must depend totally on artificial lighting systems to see. Moreover, the working face is a low-reflectivity and low-contrast environment and is continually advancing or retreating.2 Laboratory mock-ups have been a major part of the process lighting equipment manufacturers must under- go to design an underground machine-mounted lighting system. The mock-ups often have taken considerable time. Furthermore, modifications to a lighting system (using different luminaires with an existing configuration or changing a luminaire's location, orientation, etc.) could require more time with additional mock-ups and laboratory measurements. Understanding the need to improve this situation, the US Bureau of Mines has developed an alternate method for facilitating lighting system mock-ups. A PC-Program (CAP),* with the latest software technology enables users to design, alter, and evaluate under- ground machine-mounted illumination systems. Lux levels and distance are measured as the luminaire is moved incrementally through angular traverses about horizontal and vertical axes. The measurements and angles subsequently are entered into the model. From this input data, three-dimensional isolux or isofootcandle profiles are constructed for luminaires that can be placed at various locations and orientations on a mining machine. As an example, Figure 1 shows a computer display of 21.5 Ix or 2.00 fc profiles for luminaires mounted on a simulated mine-shuttle car. Using this information, the model allows the user to determine the lux level at different locations in space about the shuttle car. How the model calculates illumination During initial development of the CAP model, the isolux profile of the luminaire was determined using the inverse square law (ISL) .3 The method of gathering data comprised recording a single measurement of distance at 21.5 ± 1.21x (2.00 ±11 fc) for angular traverses following 0.09 rad (5 degree) increments. This data was then used to find the illumination in space for any other distance at a given azimuth and elevation using the ISL. Limitations, however, exist with this method.4 The main one is that the ISL assumes a luminaire is a single point source of light, so long as the distance is greater than five times the 1al;gest dimension of the luminous area of the luminaire.5 Also, by using a single measurement to calculate the illumination for a given luminaire in the CAP model a large error could result from an inaccurate measurement.

Coal strip mine operators in Western Canada often mine steeply-dipping multiple coal seams in mountainous terrain. The ability to fragment the rock waste layers above and below these seams with minimum disruption of the seams in large blasts normally involves decked charges in large rotary boreholes. Mining these seams may take two or more separate blasts to break the waste wedges above and below the coal, but these wedges can be blasted in a single shot for better mining efficiency.

Jan 1, 1985

By T. Gelpe

A digital simulator of classification and grinding circuits is used to evaluate the performances of various flowsheets. For a given flowsheet configuration, unit processes dimensions and operating conditions, the simulator calculates the steady-state values of the process variables. A supervisory algorithm is implemented in the simulator to determine the conditions which meet the required criterion on operation, tonnage and product quality. Calculation illustrations are proposed for the design of wet and dry grinding circuits. The performances of various arrangements of cement clinker and sulphide ore grinding flowsheets are evaluated and discussed.

Jan 1, 1983

By D. Hodouin, T. Gelpe

A digital simulator of classification and grinding circuits is used to evaluate the performance of various flowsheets. For a given flows he et configuration, unit process dimensions, and operating conditions, the simulator calculates the steady-state values of the process variables and determines the conditions that meet the required operation criteria for tonnage and product quality. Calculation examples are proposed for the design of wet and dry grinding circuits. The performance of different configurations of cement clinker and sulfide ore grinding flowsheets is evaluated and discussed.

Jan 1, 1986

By E. M. De Souza, R. Penner

"Water is encountered at the majority of underground mines, both over their lifetime and during each stage of development and production. The dewatering system is one of the most important and costly components of an underground mining operation and it is often not well designed and analyzed. An effective design of a mine dewatering system will greatly reduce its energy cost as well as improve working conditions and reduce production costs. A computer-based system, called Qpump, has been developed to assist the underground operator to effectively design and/or assess over-all and local mine dewatering systems. The design features and principles used in the development of Qpump are introduced and an example which illustrates typical applications is presented.IntroductionTraditionally, dewatering operations have been given lower priority than many other operations in underground mining. Invariably water will be encountered during the sinking of the mine shaft, during development and subsequent production. The dewatering system thus becomes a very important component of an underground mine operation and, in fact, any mine manager will attest to the importance and necessity of an efficient mine dewatering system.The water problem is of varying importance at different mines. There are several factors that contribute to the water encountered. It is a function of the mining method and techniques utilized (backfill system, drilling and raising technology, dust control sprays, shaft water rings, etc.) and of prevailing conditions (ground water, rock structure and permeability). In some cases a mine may be so dry that little pumping is required while in others, the weight of water pumped may exceed by many times that of ore mined.The successful design and application of a mine dewatering system is dependent upon the operating conditions of each specific operation. There are no standard procedures and systems which can be used for all mining situations. However, an effective water system will greatly reduce the energy and production costs of a mine, improve working conditions and eliminate headaches because of flooded working places."

Jan 1, 1993

By C. A. Sobotowski, J. Eagan

Computer programs applicable to coal mining have been available for some time, especially in the academic sector. However, the computer has not routinely been applied to actual mining operations. This paper discusses how a computer system was set up as an important tool in mining design and decision making. The project was completed within the allotted timeframe of two months by taking advantage of existing technology. Key points include the selection of programs to meet the specified needs of the project, conversion of the programs to be compatible with a computer of a different manufacture, simplification of the data entry process, development of procedures for using these programs, and an explanation of how the reports generated from the programs were used for mine planning and decision making.

Jan 1, 1983

By Tad S. Golosinski

The paper presents the computing stream of the mining engineering curriculum at he Western Australian School of Mines (WASM), a branch of Curtin University of Technology. Learning to use computers begins during the first semester of the initial year of studies and culminates in the Mine Design Project done during the last semester of study. It covers all areas of computing which are judged to be of importance to the graduate.

Jan 1, 1996