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By Paul Schmidt, John Barber

This paper discusses the determination of cutoff grade (COG), including all revenue and cost factors and how to apply the COG in the world of engineering studies and mine planning for underground mines. It provides the engineer with important considerations and practical methods to establish COG and methods of using the COG in the work of mine planning, including the application of Mineable Stope Optimizer (MSO) software which is available on several 3D mine planning packages.

Feb 1, 2024

By Megan Badonie, Devlon Shaver, Evan J. Owen, Virginia T. McLemore, Jakob Newcomer

Critical minerals are becoming more important in our technological society because they are used in many of our electronic devices, batteries, and magnets. In New Mexico, low to moderate concentrations of critical minerals are found in Late Cretaceous coal and related strata in the San Juan and Raton Basins. These rocks are being characterized as part of the DOE’s CORE-CM (Carbon Ore, REE, and Critical Minerals) program. The New Mexico coal, humate, and clinker deposits are relatively low in REE (<325 ppm TREE), Li (<90 ppm), V (<168 ppm), Co (<51 ppm), Ni (<108 ppm), Zr (<557 ppm), and many other critical minerals compared to normal economic deposits. Some of these rocks are enriched in Al2O3 (<40%) and Sr (<3740 ppm), both critical minerals. Common minerals hosting the critical minerals in these rocks include clay minerals, zircon, and rutile/anatase. As the demand for some of these elements increases because of increased need and short supplies, the dollar value per ton of ore rises, enhancing deposit economics. Ultimately, economic potential will most likely depend upon production of more than one commodity, maybe even from coal, humate, and clinker deposits.

Feb 1, 2024

By Kevin Erwina, Rajiv Chandramohana, Connor Meinkea

This paper explores prevalent operational challenges encountered globally in SAG mills, including suboptimal throughput, liner wear, excessive energy consumption, and SAG mill load stability. The paper delves into the root causes behind these issues, such as ore variability, poor operating strategy, or inadequate process control. Drawing on industry experience and case studies, the paper highlights the significance of addressing these challenges to enhance overall mill performance and efficiency. It underscores the necessity of tailored strategies, encompassing improved monitoring, optimized liner designs, and refined control techniques to mitigate these challenges and promote sustainable SAG mill operation.

Feb 1, 2024

By Robert Bissonette, Samir Sbai

Machine Situational Awareness (MSA) requires the ability to efficiently evaluate the probability of interaction of objects within the environment, without creating false alarms or ignoring materializing hazards. To do this, an MSA system needs to assign context to observed object activity and integrate as much information about object identity, kinematics, behavior, and current state as possible. This paper describes how known object characteristics, attributes, and activities (drilling, dumping, driving, etc.) can refine interaction probabilities and help identify rogue actors that introduce anomalous risks to the health and safety of miners. Path projections need to incorporate velocity and direction as a function of time while accounting for terrain, safety response, environmental factors, current assigned activity, etc. This paper also describes the methodology for properly prioritizing responses to place the highest value on human safety.

Feb 1, 2024

By Andrew McGrath, Geraldine Lyons, Sarah Barcelona

In the dynamic and challenging modern industry landscape, understanding and unleashing the true role and contribution of technical teams is crucial to business success. The cyclical nature of industries has led to shifts in the technical professional’s place within the organization and the technical skills that are desired most. This paper reframes the pivotal role that technical professionals play within complex operating assets to maximize value and realize full potential. This investigation focuses on the Rio Tinto Kennecott Technical group’s cultural journey, which is underpinned by an investment in its people. The conflict between legacy industry beliefs and the necessity for cultural change emerges. This is illustrated by a deep dive into the evolving case study of Kennecott’s Bingham Canyon Open Pit Mine Technical team. Here, a multi-faceted approach to cultural change is helping to unlock the team’s contribution to the life extension of an aging asset. Guided by a vision and strategic roadmap, this approach is part way through a 5-year implementation period and is yielding encouraging business outcomes.

Feb 1, 2024

By William H. Langer

I spent 41 years as a geologist with the US Geological Survey (USGS) conducting geologic studies and preparing peer reviewed maps and reports describing the results of those studies. Since retiring from the USGS in 2011, I have been a consultant specializing in aggregates and other industrial minerals. Consequently, I have had the opportunity and pleasure to apply the information contained in those kinds of geologic maps and reports to real-life situations. About half of my consulting is performing due diligence for mineral resource evaluations of one type or another where resource information has been provided by the property owner. Many of those jobs necessitate that I conduct desktop studies followed by field work. I then use my information to review and comment on the written reports of others; reports variably referred to as geologic reports, resource studies, reserve analyses, and so forth. While there are many well written reports addressing geologic resource issues, I was surprised to see that there are also a significant number of so-called geologic reports that only pay cursory attention to geology. Unfortunately, that lack of rigorous geologic investigation commonly leads to erroneous conclusions. This paper addresses three such reports covering concrete sand, metallurgical gravel, and proppants (frac sand). Although all three examples are located in the Gulf Coastal Plain Province, I do not reveal the exact location of any of the properties for purposes of confidentiality. Furthermore, I have generalized the site descriptions and illustrations. However, all the descriptions faithfully define the geologic situation.

Feb 1, 2024

By Brendan Howard

Rio Tinto has a large globally distributed technical workforce and needs to ensure these employees have the requisite skills to not only manage technical risk and enable safe efficient production, but also ensure they are keeping pace with a fast-changing technological landscape. Traditional approaches to learning struggle for scale and an inability to respond to the extreme diversity of capability development needs. In response, Rio Tinto has successfully introduced innovative approaches to learning and employee engagement via leveraging the power of globally distributed networks for peer-to-peer knowledge transfer and providing mechanisms to recognise, reward and retain the individual technical contributors.

Feb 1, 2024

By Jenna Wundrack, Evan Thibaud

The advanced cryogenic treatment is a post-manufacturing metallurgical process that involves subjecting off-theshelf materials to extremely low temperatures, significantly improving wear resistance and reliability. These case studies explore whether the claims of Enrich Bits & Tools benefit metals and their specific in-field application to drill bits in the blasting industry. This paper reviews the application of the treatment to button drill bits for enhanced wear resistance in two operations. The first is a civil construction project with highly abrasive rock. To confirm the remarkable benefits of the treatment, a second case study was performed. This case study utilized measure-while-drilling technology in consistent rock characteristics to reduce variables in the field study.

Feb 1, 2024

By Ron Derrick

SX operators have conducted extensive shut-downs and repairs over the years to mitigate solution leaks from failed stainless steel false floors and walls in rectangular mixersettler mix boxes. Hydrodynamic modeling using first principles and constitutive equations of fluid mechanics can inform an efficient structural redesign sufficient to eliminate the plate failures. Updated mix boxes have been performing without failure for over a decade. Given the extensive construction of the original Holmes and Narver mixer-settler design throughout the world that includes stainless steel lined rectangular primary and auxiliary mix boxes, SX operators may benefit from the approach, eliminating costly shutdowns, leaks to containment, and hazardous repairs.

Feb 1, 2024

By R. E. McIvor, Brian Cornish, J. A. Finch, Yue Tan, Claude Gagnon

Fred C. Bond is recognized throughout the mineral processing world as the father of comminution equipment applied science and engineering. The Bond Work Index became a universal standard, and is the most widely used measurement tool for comminution energy consumption. This biography is the story of his lifetime of study, work experiences, experimentation, analyses and findings. His numerous published writings are reviewed. His legacy is one of comminution process engineering that will be used in perpetuity.

Feb 1, 2024

By Justine Ealy, Daniel Yang, Christina Foster

Maintaining stable high walls can be a challenging task. Complex geological and structural features, alteration zones, rock mass properties, and hydrogeological conditions must be well understood to design a safe mining environment. Economic considerations must also be taken into account as the mine operator must provide ore deliveries and protect reserves. However, even when good engineering practices are followed, and proper blasting and mining techniques are implemented, slope movements may still occur. When these slope instabilities are minor, the mine is often able to continue operations with minimal impacts on safety or production. When these occurrences are excessive and coupled with high rates of movement, a robust monitoring system is crucial to continuing mining activities while protecting personnel. This paper summarizes the approach an open pit mine in Nevada took as excessive and rapid high-wall movement was experienced in an integral area. Creative mining approaches, combined with slope monitoring radar technology, were utilized to maintain safe and successful mining activities despite active movement that exceeded an average velocity of 30 inches per day.

Feb 1, 2024

By Jonathan K. Hrica, CASSANDRA L. HOEBBEL, Jennica L. Bellanca

Accidents involving powered haulage and mobile equipment such as haul trucks often account for the greatest number of fatalities in the mining industry each year. Despite previous analyses that have identified root causes and other contributing factors, there is still a need to better understand the events leading up to these types of accidents, what lessons may be learned, and what strategies can be employed to prevent fatal accidents from occurring. This study examines Naturalistic Decision Making (NDM) using the critical decision method (CDM). The CDM is a retrospective interview approach used to explore timelimited, high-stakes, decision-making. In this study the CDM is used to obtain more information about what happens prior to, during, and after a potentially fatal situation such as a near-miss event, loss of control, or minor accident involving equipment damage. Researchers captured firsthand accounts from 21 haul truck operators involved in near-miss events from mine sites of various sizes and commodities throughout the United States. These accounts provide rich and detailed narratives from the perspective of haul truck operators themselves and reveal insights into what decisions haul truck operators make, what sensory cues they perceive, and what strategies they employ during challenging and non-routine situations. Decision-related themes that emerged from the data are presented and discussed. These results, along with potential solutions offered by study participants, can help to inform future research, raise awareness about hidden hazards, and build more creative interventions and realistic training scenarios for use by the industry to address haul truck safety issues.

Feb 1, 2024

By Milan Yekich, Emanuele Cauda, Justin Patts, Cody Wolfe

A worker’s personal exposure to respirable dust in occupational environments has traditionally been monitored using established methodologies which entail the collection of an 8-hour representative sample that is sent away for laboratory analysis. While these methods are very accurate, they only provide information on the average exposure during a specific time period, generally a worker’s shift. The availability of relatively inexpensive aerosol sensors can allow researchers and practitioners to generate real-time data with unprecedented spatial and temporal granularity. Low-cost dust monitors (LCDM) were developed and marketed for air pollution monitoring and are mostly being used to help communities understand their local and even hyper-local air quality. Most of these integrated sensing packages cost less than $300 per unit, in contrast to wearable or area dust monitors specifically built for mining applications which have been around for decades but still average around $5,000 each. At the National Institute for Occupational Safety and Health (NIOSH), we are leveraging the power of high-volume data collection from networks of LCDM to establish baseline respirable hazard levels and to monitor for changes on a seasonal basis as well as following any application of control technologies. We have seen the effective use and advantages of monitoring live data before, during, and after events like shift changes, operational changes, ventilation upgrades, adverse weather events, and machine maintenance. However, many factors have prevented a systematic adoption of LCDMs for exposure monitoring: concern for their analytical performance, the complexity of use, and lack of understanding of their value are some factors. This contribution outlines a one-year case study at a mine in Wisconsin USA, covering the installation, maintenance, data visualizations, and collaboration between NIOSH researchers and the industrial hygiene professionals at the mine.

Feb 1, 2024

By L. Alagha, L. A. Sanchez-Calderon

The existing methods for recycling lithium-ion batteries present initial hurdles related to the safe handling and preparation of the batteries to avert potential explosions. Submerging batteries in sodium chloride (NaCl) solution has become an acceptable industrial practice. However, the use of NaCl to discharge lithium-ion batteries rusts the batteries’ cases and releases metals which impacts the downstream processes that involve selective recovery of Li. This study aimed to determine the optimal concentrations and pH range of NaCl for the discharge of lithium-ion batteries for the purpose of minimizing the leach of Al, Co, Cu, Fe, Li, and Ni.

Feb 1, 2024

By H Arvidson, Rondinelli Sousa, Nic Pollock, Cesar Carrasco, Boz Elloy

Global public mineral reporting codes have driven strong governance of public disclosures of minerals information. Recently, we have seen an increase in disclosure of information related to Environmental, Social and Governance (ESG) issues, and governance of ESG information in mining companies has arguably reached a similar level of governance and diligence afforded mineral reporting. We define Resource Governance as the conjunction of environmental, social and minerals governance. A modern systems approach to Resource Governance, which combines mineral and ESG information, would provide not only reporting and governance capability, but also has the potential to sense/respond, predict, and manage ESG risks.

Feb 1, 2024

By NORA Mining Sector Council

The National Occupational Research Agenda (NORA) is a partnership program to stimulate innovative research and workplace interventions. In combination with other initiatives, the products of this program are expected to reduce the occurrence of injuries and illnesses at work. Unveiled in 1996, NORA has become a research framework for the National Institute for Occupational Safety and Health (NIOSH) and the United States. Diverse parties collaborate to identify the most critical issues in workplace safety and health and develop research objectives for addressing those issues. NORA entered its third decade in 2016 with an enhanced structure. The 10 sectors formed for the second decade will continue to prioritize occupational safety and health research by major areas of the U.S. economy. In addition, NORA’s seven cross-sectors will continue to focus on the major health and safety issues affecting the U.S. working population. While NIOSH serves as the steward to move this effort forward, it is truly a national effort. NORA is carried out through councils comprised of members with many diverse interests that are developing and implementing research agendas for the occupational safety and health community over the third decade (2016-2026) of NORA. Councils address objectives through information exchange, partnership building, and enhanced dissemination and implementation of evidenced-based solutions. NORA groups industries into 10 sectors using North American Industry Classification System (NAICS) codes. The Mining Sector encompasses NAICS code grouping 21xxxx where “xxxx” represents the different subcodes of the mining “21” classification. Mining encompasses the extraction of solid mineral and mineral-like substances from their place in the Earth’s crust and supplies them to processing industries that produce economically valuable materials. It does not include oil and gas extraction. The Mine Safety and Health Administration, MSHA separates mining into coal, underground and surface, and metal and nonmetal, underground and surface.

Feb 1, 2024

By D. S. Scovira, T. Gustavsson

Exiting WW2 (mid-1940s), the potential of nitrates (ammonium nitrate, calcium nitrate, sodium nitrate) and hydrogen peroxide for application as a commercial explosives for mining, construction, and other industrial purposes both became known. The technology stream advanced the development and uptake of nitrate based explosives to the point that they are the current global standard for blasting. Today, environmental issues are shaping the strategic agenda across various industries. Most global mineral resource, construction houses, and explosive manufacturers have publicly announced ESG carbon reduction commitments in support of COP26 Net Zero 2050. The mid-2010s saw a renewed interest in hydrogen peroxide explosives to eliminate NOx fume. Carbon reduction initiatives in the early 2020s provided additional impetus to investigate hydrogen peroxide based explosives for industrial use. Hypex Bio has recently pioneered the formulation, manufacture, and end-use delivery of a Hydrogen Peroxide Emulsion (HPE) on an industrial scale. The HPE is composed primarily of hydrogen peroxide (H2O2) plus a lesser amount of fuel and emulsifier phase. The base HPE is produced in a low energy intensity modular plant using industry proven mixing techniques. The base HPE is a white, highly viscous emulsion that is similar in consistency to base nitrate emulsions. To enable end blasting use, a mobile charging unit gases the base HPE to a detonable density. The HPE is compatible with current priming and initiation systems. Hydrogen peroxide explosives offer a significant reduction in total carbon emission as compared to nitrate based explosives. The production of ammonium nitrate (AN) emulsion is energy-intensive and not carbon neutral. Based on the EU Average and for the oxidizer phase only, 1 kg [2.2 lb] of AN emulsion emits 2.3 kg [5.1 lb] of CO2 as compared to the production of hydrogen peroxide emulsion that results in 0.23 kg [0.5 lb] of CO2. This is a difference of 90%. HPE contains no nitrates and does not generate post blast nitrous oxides (NOx). HPE generates no aqueous nitrate or ammonia pollution and is a solution to meeting increasingly regulated mine site water discharge limits. Hypex Bio recently conducted a successful underground HPE evaluation with a major mining company in Sweden. HPE blast designs were the same as those done with nitrate based emulsions. Rock breakage, advance, muck displacement, and excavator performance were equivalent. Ventilation and re-entry times were reduced. The mining company has expressed further interest in assessing HPE and is demonstrating industrial leadership by exploring this transformative explosive technology

Jan 1, 2024

By J. Sanchidrián, A. Fernández, P. Segarra

The combination of chemical analysis techniques as XRF and measurement-while-drilling (MWD) technology in underground mining is a novel approach to gather comprehensive on-line information about physical and mineralogical data. In this work their integration is investigated aiming to delineate the ore/waste boundary. The input data analyzed come from a narrow vein underground mine, where the ore correspond to fluorite, and gathered in two production levels with complex mineralogical characteristics. Two approaches are followed to build a generalizable classification methodology and a site-specific model: a k-means clustering heuristic algorithm to define rock classes based on their physicochemical features, and a machine learning (ML) ensemble model trained with drilling parameters. For an imbalance class problem, a good recognition is obtained for the ore when is related to a high content of silica and for the waste. To predict the ore with low silica content it is necessary to integrate an analysis-while-drilling method to recognize the fluorite content when this mineral is embedded in different rocks. MWD can be employing for the lithologies recognition when representing different structural and mechanical properties between them.

Jan 1, 2024

By M. Araos

Non-ideal explosives can be characterised by different methods like velocity of detonation measurement, double pipe tests, underwater tests, aquarium tests, etc., to name a few. Both aquarium and velocity of detonation tests were selected to characterise a non-ideal explosive that is based on hydrogen peroxide, fuel, and void sensitisation. The detonation process in an aquarium of this sensitised explosive was captured at 80,000 frames per second using a high-speed camera. The explosive product was detonated using 51mm (2inches) diameter acrylic pipe charges. The product was detonated at different densities in an aquarium (cube box containing water). An aquarium provides a homogenous confinement for the detonation of explosives and more importantly, allows observing the shock wave as it changes the refraction index of water. The analysis of the video footage allowed the calculation of the velocity of detonation, pressure, gas rate release, and how the shock wave's shape in water changes with densities. It is suggested that the calculation of the rate of gas release could be related to the bubble data obtained from underwater tests.

Jan 1, 2024

By A. Gontijo, A. Matos, P. Lincoln, L. Fonsecail

This paper investigates how to manage and model the vibrations caused by rock blasting in a Brazilian underground mine. Considering the frequent detonations and the previous lack of effective vibration control, understanding, and reducing the impact of these seismic waves is critical. We emphasize the use of the near field model technique, which considers the varied physical properties of different rocks, optimizes blasting plans, and minimizes damage to the rock mass. We detail a case study that demonstrates a comprehensive approach to vibration control. The discussion includes the creation of a monitoring plan, the methodology used, results and the specific challenges and solutions found during the blasting process. This study provides a practical guide for similar future projects. Finally, we present a predictive model based on the collected data, offering insights into the vibrations caused by blasting. This model helps decision-makers minimize the risk of displacing rock blocks in the blasting area, improving safety and operational efficiency

Jan 1, 2024