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By Ashutosh Kumar Bharati, Rajesh Rai, B. K. Shrivastva, Arunava Ray

Opencast mining method is one of the most productive mining methods available at present, which is generally associated with the removal and handling of a huge amount of overburden material. Hence it imposes a serious challenge of dump slope stability and that too, mainly in the case of internal dumps. The study is primarily focused on the stability of dragline dumps and the subsequent development of a rating system to classify the stability of dragline dump profiles. Initially, numerical simulation is executed through RS2 (Version 9.0) software, which is based on the finite element method. Thereafter, simulation results are used to perform the sensitivity analysis of various geometrical and strength parameters of the dump slope, and the two-factor interaction method is also incorporated into the analysis, this method included the dependency of closest parameters while calculating the sensitivity index, and thereafter, it is converted into the rating of each parameter. The strength parameter like the angle of friction and the geometrical parameter like slope angle of the bench between the coal-rib roof and dragline sitting level are assigned the highest rating value. Based on the overall rating of the dragline dump, the dump slopes are classified into various classes, viz., very safe, safe, vulnerable, unstable, and highly unstable. This classification proved to be handy in the quick estimation of the stability of the dragline dump and also gives an idea of designing optimum and safe dragline dump profiles. The developed classification chart has been validated by the previous research works and has found similar results.

Feb 15, 2021

By Luke Clarkson, David Williams

The intent of this paper is to provide overview context to allow broader understanding of conventional tailings dam failure mechanisms. The research leverages global knowledge, experience, and data collection and interpretation for the safe and controlled management of the geotechnical stability of a tailings storage facility. The motivation for this review is to facilitate transparent access to tailings dam background and understanding. This paper addresses the core understanding of geotechnical failure mechanisms, and how these eventuate to instability and failure of tailings dam structures. This research focuses on foundation failure, internal erosion and piping, overtopping, seepage, seismicity, and slope instability and provides insight into what factors contribute to failure, how failure progresses due to such failure, anticipating and monitoring for the aforementioned failure modes, and designing to mitigate their risk.

Feb 15, 2021

By Sadegh Elyasi

TBMand roadheader are two dominating excavation machines in underground tunnelling projects. The performance of these two tunnelling machines has been reviewed and analysed individually by many researchers from multiple points of view. However, there are almost no studies that have made an extensive comparison between these two machines, mostly from financial points of view. The current study is intended to characterize both financial and technical status of these two mechanical tunnelling machines in one of the biggest coal mines in Iran. The main objective of this study is to define the best method and equipment that meets a predefined economic goal, which is mainly to maximize the net present value. To this end, a technical and financial model based on the geomechanical and financial parameters involved in the project has been prepared and the financial part of the project has been carried out by applying COMFAR III financial analysis software. Subsequently, a sensitivity analysis of the model was conducted in order to evaluate the effect of involved parameters on the project. According to the results, a roadheader has better economic justification than a TBM, while the TBM has a better advance rate than the roadheader.

Feb 12, 2021

By Isabel F. Barton, Matthew J. Gabriel, CARSON ROBERTS, JOHN LYONS-BARAL, LEON DUPLESSIS, Mark D. Barton

Geometallurgical assessment of orebodies in the mining industry typically relies on bench-scale or lab-based characterization techniques. In this study, we investigate drone- and tripod-based field hyperspectral imaging as a potential addition to the geometallurgy toolkit in multiple applications. This pilot study tests hyperspectral imaging for largescale mineral mapping in and around the active Lisbon Valley copper mine, including natural exposures, previously producing U-V mines, highwalls, dumps, and leaching sites. Tests include different (supervised and unsupervised) mineral data classification methods, varying mineral spectral reference libraries, comparison with ground-truth geological and spectroscopic mapping and sampling, and integration with LiDAR data. The results show that hyperspectral scans can produce spatially registered maps of the distribution of different spectrally active mineral types over dumps, highwalls, leach pads, and natural outcrops. Clays, other phyllosilicates, carbonates, and sulfates showed up particularly well. The sensor was also able to distinguish dry from lixiviant-saturated areas and map different clay types on the leach pads, and shows promise for differentiating types and health of vegetation. These results suggest that hyperspectral imaging, if coupled with robust ground-truthing, can be a useful complement to existing geometallurgical techniques in the mining industry, such as geological mapping, blast hole sampling and automated mineralogy identifications, and handheld spectrometry. In particular, hyperspectral imaging has promise for mapping the distribution of acid-consuming minerals; mapping the distribution of swelling, sliming, and heap-blinding clays; and pinpointing problem areas on heap leach pad surfaces.

Feb 10, 2021

By E. Petrakis, K. Komnitsas

The main objective of batch grinding modeling is the estimation of the product particle size distribution over time or specific energy input to the mill. So far, the developed analytical methods require often complicated calculations which are timeconsuming. Thus, more simple approaches that allow the reliable prediction of the complete product size distribution need to be developed. In the present paper, an approach, based on the population balance model (PBM), that reliably predicts the product size distribution is proposed. In order to enable this, the simplified form of the fundamental batch grinding equation was transformed into the well-known Rosin–Rammler (R-R) distribution, thus allowing the determination of the breakage rate for each grinding period. A time-dependent breakage rate framework was developed where the traditional linear theory of the PBM is considered a partial case. This approach allows the deviations from the linear theory to be categorized and the degree of the acceleration-deceleration of the breakage rate to be predicted. Modeling results were validated by laboratory grinding studies using two homogeneous materials, quartz and marble, and one heterogeneous, a limonitic laterite. The experimental data revealed that grinding exhibits non-first-order behavior and the degree of deviation from the linear theory depends on the tested material. The reliability of the proposed model was validated with the use of the distribution modulus n, the a value of the breakage rate parameter, and the optimum n values that minimize the sum of the differences between the experimental and estimated particle size distributions.

Feb 8, 2021

By Jafar Safarian, Leiv Kolbeinsen, Stian Seim, Hossein Salehi

The present work aims to investigate the link between the oxidation and reduction of a weathered ilmenite concentrate in terms of phase transitions, microstructural changes, and element distribution. An ilmenite concentrate sample was pelletized and fired at 1000 °C in air, and as a result, the pellets were oxidized. The oxidized pellets were reduced by hydrogen gas at 1000 °C, which yielded almost complete metallization of the iron content of the pellets. The ore and the pellets were characterized in each step by XRD and SEM techniques, and distribution of elements and phases were investigated. Ilmenite, pseudorutile, and rutile were the main phases detected in the ilmenite concentrate sample, and depending on the weathering degree of the particles, different fractions of the phases were identified in their microstructure. It was found that irregular rutile grains dispersed in a pseudobrookite matrix is the morphology of the oxidized ilmenite phase. However, increasing microcracks and porosities were the only microstructural changes in the pseudorutile phase after oxidation in air. Studying the specific types of the ore particles and their oxidized and reduced forms indicated that the phase distribution in the ilmenite ore particles dictates the phase distribution in the oxidized and reduced ones. Results show that the morphology of the reduced particles includes a titanium (III) oxide matrix in which reduced iron globules are dispersed.

Feb 8, 2021

By Patrick Scott, Germán Schmeda, Morgan Mullins, Liam Knudsen, Bradley S. Van Gosen, Carma A. San Juan, Nicholas A. Karl, Jeffrey L. Mauk, Clayton Forbush

The objective of the US Geological Survey’s mineral deposit database project (USMIN) is to develop a comprehensive twentyfirst century geospatial database that is the authoritative source of the most important mines, mineral deposits, and mineral districts of the US. Since May 2017, the project has focused on critical minerals. Data for critical minerals that are produced as products are relatively robust, whereas data for critical minerals that may be recovered as byproducts are commonly of much poorer quality. Similarly, more is known about critical minerals that occur in conventional deposits than where those critical minerals occur in unconventional deposits. For example, rare earth elements occur principally in deposits hosted by alkaline igneous rocks, but there is potential for their production from phosphate rock mining, which is less documented. Lithium (Li) has been recovered from pegmatites and brines, but other Li-bearing deposit types have been delineated that may go into production. Cobalt may be produced as a byproduct or coproduct from a wide range ofmineral deposit types, whereas rheniumis a byproduct of copper ore. Significant opportunities for research exist that could help identify new sources of critical minerals, and may also help increase production and recovery from existing sources.

Feb 8, 2021

By Morgan M. Sears, Gamal Rashed, Michael M. Murphy, Brent Slaker

In this study, a parametric study was conducted using FLAC3D numerical models to examine the impact of oblique loading, generated from seam dip, on the strength and the failure propagation pattern of a stone pillar using two simplified geometry types. In type 1, the sidewalls of the pillars were assumed to be perpendicular to the roof and the floor, while in type 2, the sidewalls of pillars were assumed to be vertical. The complex pillar geometry in dipping mines was frequently modeled using these two geometries. To capture a complete picture of the effect of seam dip on pillar stability, the modeled width-to-height (W/H) ratio of the pillars, in situ stress field, and pillars roof/floor interfaces were systematically varied to account for the potential distribution of values for these parameters across the underground stone mines in USA. Results from the numerical modeling indicate that dipping pillars have reduced strength compared with horizontal pillars. Also, an asymmetric failure propagation pattern could be obtained depending on an interaction between the W/H ratio, seam dip, in situ stresses, and pillar geometry.

Feb 5, 2021

By Muhammet Mustafa Kahraman

Despite technological advancements and organizational adjustments, lost time accidents are major issues in occupational safety. However, there is very limited work that focuses on variables influencing days lost as a result of occupational accidents. In this study, decision tree and artificial neural network methods were used as machine learning techniques to investigate the impact of factors on accident lost day duration. Degree of injury, worker age, and worker activity were found to be the top three variables impacting loss of time from work. It was also identified that the mining method, location, and nature of injury had a moderate influence on duration lost due to occupational accidents. However, worker experience and ore type did not have any significant impact on the duration, which is an unexpected result. These results confirmed that some accident factors that might have a large influence on the number of mine accidents can be less critical when it comes to accident lost day duration.

Feb 3, 2021

By J. Miller, B. Slaker, M. M. Sears, G. Rashed

Ground falls represent a significant hazard at underground mines in the stone, sand, and gravel (SSG) sector in the USA. Researchers from the National Institute for Occupational Safety and Health (NIOSH) are currently conducting detailed investigations into the complex loading conditions at underground stone mines operating in challenging conditions. This paper presents the application of numerical modeling to analyze pillar and roof stability at a dipping underground limestone mine. A validated numerical model was used to explore the potential behavior of the pillars and roof as loading conditions change. The validated model was used to compare changes in mining sequence, overburden depth, and the in situ stress field. This will allow mine operators and engineers to have a better idea of the conditions that could be encountered as mining progresses. Results from the numerical modeling indicate that roof displacement more than doubles as the vertical stress increases from 10 MPa (1450 psi) to 19 MPa (2750 psi) when the maximum and minimum horizontal stresses were 41 MPa (5950 psi) and 22 MPa (3190 psi), respectively. Consequently, as the pillar load increases, the safety factor of the pillars is projected to decrease by about 25%. The impact of the practical application of numerical models can result in a reduction of ground-fall accidents and injuries as well as generally safer working conditions.

Feb 2, 2021

By J. Zhang, A. J. S. Spearing, L. Ma

Ore deposits are becoming more complex to mine as a result of the exhaustion of surface and other easily mined deposits. There is also increasing socio-political pressure to design more environmentally sound, sustainable, and safe mining practices. Wang and Ma designed a mining method for coal, similar to a modified drift and fill using a continuous miner to take sequential cuts (rooms) that are subsequently backfilled. The authors have modified the concept to make it more autonomous, safer, and less costly using highwall coal mining techniques, modified and adapted for underground applications. The method is more flexible than longwall mining and the percentage extraction would seem to be in the same range. In addition because of the backfilling, surface subsidence would not be a major issue and could be more effectively managed.

Feb 2, 2021

By J. S. Contreras, E. Córdova, I. Gottreux, A. Anani, A. Ferrada

Cave mining is an underground mass mining technique. The largest projects, which are known as ‘super caves’, produce hundreds of thousands of tons of ore per day, which involves large footprints with considerable column height, and have a life of mine of over 20-40 years. These operations are typically located deep, under high stresses and in competent rock masses, making initiation and propagation of the caving process harder to manage. These challenges must be confronted by optimizing the fragmentation of the orebody to achieve smaller size blocks that will result in consistent caving and improved flow of the ore from the drawpoints. To achieve better performance from the drawpoints, preconditioning is applied to fragment and damage the material required to cave. We present a proposed design for preconditioning in underground mines, considering the challenges that these large-scale mines are already facing, based on a comprehensive analysis of current design parameters, case studies, and sensitivity analyses using numerical models.

Feb 2, 2021

By S. Schutte, J. Pelders

Worker participation in equipment development can result in improved user acceptance and product quality. This paper focuses on worker engagement in equipment development processes in the South African minerals sector. Qualitative data was gathered during interviews with original equipment manufacturers (OEMs) and industry experts. A lack of inclusion in equipment design from workers from all organizational levels in mines was reported. Meanwhile, the historical context and workplace culture of the mining industry (including leadership, trust, training, performance, and remuneration factors) were evident barriers to the implementation of new technology. Worker engagement processes should include securing management commitment, creating multidisciplinary teams, effective facilitation, shared understanding of needs, training and development, and iterative design. Human-centred design approaches and independent platforms for engagement on equipment design requirements are recommended.

Feb 2, 2021

By A. M. Garbers-Craig, T. Coetsee, T. M. Nemavhola

Accretions often form in furnaces when slag and charge materials attach to the refractory wall and build up over time. Accretion formation is usually unwanted because it reduces the working volume of the reactor and hinders material flow through the reactor. However, in some instances a thin, stable accretion layer may be desirable to protect the underlying refractory material. In order to prevent and/or manage accretion formation, it is important to understand the underlying principles of this phenomenon in the particular reactor. Excessive accretion formation hampered production at the Exxaro FerroAlloys ferrosilicon melting and atomization plant. This plant uses induction furnaces in which a 15% silicon-iron alloy is produced by batch smelting a mixture of ferrosilicon of 75%Si grade and low-carbon steel. The molten ferrosilicon alloy is then gas-atomized to a powdered product for use as a dense medium in mineral processing plants. The objective of this study was to investigate the effect of different impurity levels in the ferrosilicon feed material on the extent of accretion formation as well as the effect on the accretion properties, which influence the ease of accretion removal upon furnace shut-down. Refractory and accretion samples were collected after a furnace shut-down and characterized using X-ray diffraction and scanning electron microscopy–energy dispersive spectroscopy. It was concluded that the trace elements in the FeSi-75 feed material (Al, Ca, Mn) were mostly responsible for accretion formation, but that rust on the low-carbon steel and oxidation of the steel contributed to accretion attachment to the lining. The total contaminant content, calcium to aluminium ratio in the FeSi-75 feed material, and thereby the liquid to solids ratio in the accretion at temperature determine the strength of attachment as well as growth of the accretion.

Feb 2, 2021

By L. Scott, M. A. Goncalves

Effective communication is a sought-after non-technical skill in the health, safety, and environmental (HSE) function and is fundamental in achieving an organization’s safety objectives. While different channels are used to communicate HSE matters, many organizations employ posters, videos, and/ or signs containing images to convey information. Communication through signage and graphical hazard symbols has been regulated in standards, but vast sections of HSE communication are bespoke communications and exist outside the sphere of standards. Effective HSE communication through images requires an understanding of the organizational culture in which the images will be used, as well as an understanding of the semiotics of the images themselves. Creative interpretation within HSE communication can create situations where the message that was received is not the message that was intended, leading to confusion and misinterpretation. This paper is aimed at elucidating the semiotics of South African HSE visual content. It was found that the indexical mode of images was most preferred in visual communication, and text-only designs the least preferred. Senders and receivers of messages differ in their opinions on the complexity of HSE communication.

Feb 2, 2021

By Margreth Tadie, Chalwe Chibwe

Physicochemical properties of copper electrolytes are a strong fundamental consideration in electrodeposition processes during electro-purification and recovery of copper. Their influence extends to mass transfer as well as energy consumption during the electrodeposition process. In this study, the influence of electrolyte composition on electrolyte physicochemical properties was investigated to review the existing literature data. This review of data is considered necessary as more and more electrowinning models are being developed for process prediction and optimisation and a need of such data is required for accurate prediction of physicochemical properties. The major components of importance to the formation of smooth high-quality and high-purity copper cathodes at optimum current efficiency are considered the species in solution. These include Cu ions, Fe ions (major impurity), H2SO4, and a smoothing agent additive. A 5-factor, 2- and 3-level experimental design was employed to determine the effect of copper (35 and 45 g/l), sulphuric acid (160 and 180 g/l), iron (1, 3, and 6 g/l), polyacrylamide additive (2, 5, and 10 mg/ l), and temperature (45 and 55 °C) on electrolyte density, conductivity, and the diffusion coefficient in synthetic copper electrowinning electrolytes. The major species in a copper electrowinning electrolyte are found to be the most relevant for prediction of physicochemical properties. These results indicate that relatively simple empirical models are sufficient for modelling of the electrolyte domain in electrowinning, without the need for the generation of vast amounts of complex experimental data.

Feb 1, 2021

By CAIJUN CHEN, MING ZHANG, ZHENWEI WU, FENG ZHOU, BOQUAN LI, XILIANG ZHANG, ZHOU PU

Traveling grate is a widely used process for iron ore pellet production; however, the thermal state of pellets in drying section is still unclear. In this study, the temperature distribution of drying section was investigated using computational fluid dynamics (CFD). Based on the calculated results of airflow velocity, space temperature distribution, and the temperature change of pellets, it concluded that there is a coupling effect in drying section in traveling grate. The gas with higher temperature in DDD transfers heat to UDD through the gap of the insulation board, and the temperature gradient of the pellet bed changed before reaching the insulation board. The characteristics of pellet bed expected to appear in DDD was displayed in UDD in advance. Moreover, a contrast experiment was conducted to verify the model.

Feb 1, 2021

By Fan Yang, Meigui Yi, Lan Xiang, Zhuoying Yang

This paper reported the calculation of the reaction heat in titanium-bearing blast furnace slag (abbreviated as TBFS)-H2SO4 system based on estimation of thermodynamic data of CaTiAl2O6 by mechanical mixture model. The thermodynamic analysis indicated that CaTiAl2O6 was more stable than the corresponding ternary oxides as CaO·TiO2, CaO·Al2O3, and Al2O3·TiO2. TBFS-H2SO4 system was highly exothermic since all of the reactions involved in the system were exothermic. For example, the increase of temperature from 25 to 200°C led to the increase of the release of the reaction heat in TBFS (100.0g)-H2SO4 system from 181.28 to 189.73kJ. Eighty-five to 90%of the reaction heat in TBFS-H2SO4 system was contributed by the reactions among CaTiAl2O6, CaTiO3, CaMgSi2O6, and H2SO4.

Feb 1, 2021

By Cengiz Karagüzel, Ömer Canıeren

The mobility of gold and silver metals from refractory ores is very low due to free metal ions in their bodies that bind the transportable and free metal molecules or they are encapsulated in minerals such as sulfides, arsenosulfides, carbonaceous, and clayey materials which make it difficult to extract them. As known from the literature, the enrichment of oxide refractory gold, silver ores, Ag, and Au-rich flotation concentrated from sulfur refractory ores can be leached in the chloride-hypochlorite solutions. In this work, the leaching approach was studied to extract silver ions from refractory ores in the presence of hypochlorite media under high pressure. The mineralogical and scanning electron microscopy analysis of the sample indicated that the silver was encapsulated in barite and quartz minerals in fine sizes. In order to obtain the optimum leaching conditions for the silver ore, the effects of several parameters, namely, temperature, leaching time, NaCl and NaOCl concentration, solid ratio, and particle size on the leaching recovery were investigated in detail. The leaching experiments showed that the highest silver recovery of 62.35% was obtained under the following conditions: temperature of 150 °C, oxygen pressure of 1800 kPa, leaching time of 2 h, concentrations of 2 mol/dm3 and 0.4 mol/dm3 for NaCl and NaOCl, respectively, the solid ratio of 30%, and particle size (d80) 15 μm. The results obtained from this study indicated that the enrichment of refractory silver ores to extract the silver encapsulated in barite and quartz minerals could be possible in the chlorite-hypochlorite under high pressure, a relatively shorter leaching time compared to conventional cyanide leaching.

Jan 28, 2021

By LUIS ALBERTO TORRES-CRUZ

The assessment of liquefaction vulnerability is crucial to understanding the potential consequences of a tailings dam failure. The “Plewes method” is a relatively well-known and simple screening method to assess liquefaction potential based on results of cone penetration testing (CPT) which may be complemented with laboratory testing. The objective of the current work is to emphasise the screening nature of the method and its uncertainties when applied in tailings deposits. Specifically, the paper highlights the difficulties in assessing the intrinsic uncertainty of the method and the additional uncertainty that results from variations of the slope of the critical state line (λ10) along the depth of the CPT sounding. The results of the method are too uncertain for detailed characterisation of tailings even when a relatively low intrinsic uncertainty is assumed. However, the method characterises weaker soils with lower uncertainty (although still too high for detailed characterisation) than stronger soils. The uncertainty of the method is negatively affected by the relatively low λ10 values that are typical of nonplastic tailings. It is suggested that the results of the method should be presented in scatter plots in which the spread of the data is consistent with the uncertainty of the method.

Jan 28, 2021