Search Documents

By M Costa, L Polizzi

Process optimisation and continuous improvement are usually acknowledged when making a process more effective, efficient and transparent. During the last few decades, thousands of companies around the world have used total quality concepts in order to establish a continuous improvement process in their companies. Typically these companies apply some kind of Kaizen-type tools and expect results in the short term; however, the great majority of companies are poorly implementing these continuous improvement programs.Usually the most common reasons for failure of the program are lack of commitment from leaders, lack of discipline and engagement from the team to follow process and lack of clear targets for the program. When the results do not come at the expected timeline, it is common to simply drop the current process and apply a different approach from another company or consulting firm.This paper will explore some successful cases of companies that have invested time and effort to establish a reliable and sustainable process of continuous improvement. The focus will be case studies of mines and smelters around the world that use the plan–do–check–act (PDCA) cycle to increase productivity with the best services and lowest costs. The main tools and processes used by these companies will be discussed, as well as results achieved.CITATION:Costa, M and Polizzi, L, 2014. Introducing and sustaining a continuous improvement program in mines and smelters, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 55–62 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By S F. Rogers, K Doumis, J H. Graaf, B J. Barsanti

Advances in technology now allow geotechnical practitioners to better describe the properties and variability of a rock mass through advances in surface and underground mapping, borehole technology and geophysical imaging. Yet the way in which practitioners use this data is not being realised to its full potential and the quality and quantity of data that is collected is often superior to the conventional design approaches that are typically adopted. A discrete fracture network (DFN) approach provides the ideal basis for using this data to generate geologically-realistic rock mass models based on parameters derived from field data, which more effectively capture the variability and rock mass behaviour. However, until recently, the DFN approach has mainly been applied to cave mining and small-scale models associated with synthetic rock mass modelling or groundwater flow modelling for the nuclear waste and oil and gas industries.Ground support design for blocky rock masses in Australia is often dealt with in a rather traditional manner, adopting either an observational empirical approach through rock mass classification systems or conventional wedge stability analysis techniques. Using these methods requires several generalised assumptions about the rock mass fabric and excavation geometry. As such, the support system is often designed for a worst-case scenario based on a predetermined risk tolerance that the mine is willing to accept and a design block size that is generally determined by the proposed excavation dimension.A study by Doumis (2014) used conventional wedge stability analysis and the probabilistic key block analysis software JBlock (Esterhuizen, 1996) to estimate potential block sizes and support requirements. A DFN approach has also been adopted at Callie underground mine using FracMan™ software (Golder Associates, 2014). The methodology of the DFN wedge analysis will be compared with the key block analysis work undertaken by Doumis.CITATION:Graaf, J H, Barsanti, B J, Doumis, K and Rogers, S F, 2014. Towards the implementation of discrete fracture network modelling as a geotechnical design tool – case study of callie underground mine, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 399–408 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By Tam Tran

Over the last decade, halide (chloride, bromide and iodide) systems have been evaluated as alternative lixiviants for the processing of gold to replace cyanidation which has been widely used in commercial practice. This paper first reviews the development of processes promoted by Kaljas Ltd / Lachlan Resources (Australia) and Great Lakes Corp (USA) using different bromide/bromine systems in the early 1990's. Several research groups subsequently evaluated the use of iodide/iodine and chloride/chlorine for gold extraction, showing similar characteristics of gold/silver dissolution and recovery. A critique is :given on the advantages and the ,shortfalls of halide systems as alternative lixiviants. The stability of gold? halide complexes is discussed, based on practical experience and thermodynamic modelling of their speciation, The iodide system provides the most stable gold / silver complex for easier handling. However, the cost of iodide inhibits its application for are processing. In this critique, emphasis is given on the cheapest system, which involves the use of chloride for leaching (in conjunction with an appropriate oxidant). However the chloride-base leachant has a major drawback which is related to the unstable nature of gold chloride in a reducing environment.

Jan 1, 1998

By Siwiec A

The laboratory investigations which are necessary to evaluate the mineral processing effectiveness usually include density separation of narrow size fraction of the feed and one of the products. In each size - density fractions the content of valuable mineral has to be determined. These data and yield in each size - density fraction can be specified by a matrix of partition coefficients. They are counterparts of recoveries. These coefficients can be compared with the mean recoveries at each density or size fraction or the total recovery, to determine which density - size fractions are processed in the best or worst way. The basic categories are: vector of metal content l _i 1711, 7t2, òòò, ltM I ò vector of particle size distribution x = I d1, d2, ..., dN I ò matrix of partition coefficients P11, P12, Pi N P _ P21, P22, ..., P2 N PM1 PM2..., PMN These three conceptions allow one to determine all the basic metallurgical parameters of a mineral processing unit. Losses of valuable mineral are connected with: ò mineralogical composition of the ore (types of minerals, their properties, dissemination, crystallochemical affinity, type and properties of gangue minerals), ò applied technology and technical equipment (beneficiation as a stochastic process, processing methods, process control, intergrowth liberation, water quality). Examples of application of the analytical method proposed are given for zinc - lead and coal processing plants.

Jan 1, 1993

By Thamiris Auxiliadora Gonçalves Martins, Isabela Falconi Brandolis Alves, Viviane Tavares de Moraes

Reverse flotation process is a method used for remove impurities from the most abundant iron ore; the itabirite. In this process, amines surfactant are used which may prevent the reuse of water in processes. The Fenton oxidative processes and the synthesis of nanoparticles are highlighted in catalysts application and in organic substances degradation. This study performed the synthesis of copper nanoparticles (CuNPs) to employ them as catalysts of the modified Fenton reaction to degrade an amine surfactant used in reverse flotation and compared with the classic Fenton (Fe2+) reaction. CuNPs were synthesized by chemical reduction, pH 11 with copper sulfate and ascorbic acid. They were characterized by UV-Vis, DRX and DLS and Zeta potential. The nanoparticles had diameters of 125.00 to 17.22nm and stability during 50 days. The tests were prepared with 180mg/L of amine and 1890mg/L of H2O2 in 150 minutes. The degradation was assessed by UV-Vis and FT IR. The results showed that CuNPs degraded 84% of the surfactant while Fe2+ reached 89%. In this way, both processes can be used for surfactant degradation, although the CuNPs method is easier to operate at neutral pH.

Oct 3, 2019

By Hongling Wang, DI WU, Shuai Li, Hui Shu

Isothermal reduction experiments on carbon-bearing pellets of copper slag were investigated by the thermogravimetric method with biomass carbon as a reducing agent. The results indicated that the reduction process of copper slag‑biomass composite pellets was dominated by gas phase diffusion, and the apparent activation energy was 88.44 kJ/mol. In the temperature range from 1000 to 1200 °C, the metallization rate of pellets increased with increasing temperature, and the maximum metallization rate was 78.4%. The optimal reduction temperature of CSBCP (copper slag-biomass composite pellets) was 1200 °C.

Nov 23, 2022

By John P. Gooch

The solubility of 1,1,2,2-tetrabromoethane (TBE) in water was determined from 1.0° to 97.0° C. The solubility (S) of TBE in grams of solute per 100 grams water was correlated with [S = 1,920.55 [exp (40292L7 11, T2 10 T 737.577 + 9.923962 ] where T is in degrees Kelvin. A thermodynamic analysis conducted on a system consisting of a TBE phase and a water phase in equilibrium with a vapor phase led to the calculation of the activity coefficient, vapor-liquid equilibrium distribution coefficient, relative volatility, and heat of mixing for saturated solutions of TBE in water. Data required for these calculations were the solubility of TBE in water and the vapor pressures of TBE and water as a function of temperature.

Jan 1, 1972

By Vladimiros G. Papangelakis

During the past five years, chemical modelling work at the University of Toronto has elucidated the role of soluble magnesium on the autoclave acidity and has demonstrated why feeds rich in magnesium, and other divalent metals, require more than the stoichiometric requirements in acid to produce a leaching performance comparable to that of low magnesium feeds. This understanding has allowed the calculation of acid additions to the pressure acid leach (PAL) on a less empirical basis. Optimizing acid additions to the PAL confers savings in neutralization costs, ensures high productivity and minimises corrosion problems. Hence, our picture of the solution chemistry inside the autoclave during the PAL process has been substantially improved and is reviewed here. Experimental techniques based on solubility and direct acidity measurements that support the theoretical predictions are presented. Concepts of chemical modelling of electrolyte systems at high temperature and software issues are also discussed. Finally, a better understanding of the solution chemistry at temperature has led to better kinetics models because all metal dissolution and precipitation reactions are acid driven and controlled. . Therefore, reactor modelling efforts by our group are also presented and a reactor model with very good performance, as compared to pilot-plant data, is also made here. Finally, in spite of the above success in PAL solution chemistry and reactor modelling, significant challenges lie ahead in theoretical data gaps and instrumentation; these are also discussed in this paper. Keywords: Laterites, process modelling, pressure acid leach, solution chemistry, chemical modelling, reactor simulation

Jan 1, 2004

By L. Yuan, J. H. Rowland

"In 1995 and 2003, the U.S. Mine Safety and Health Administration (MSHA) conducted surveys to determine the number of atmospheric monitoring systems (AMS) that were being used in underground coal mines in the United States. The survey reports gave data for the different AMS manufacturers, the different types of equipment monitored, and the different types of gas sensors and their locations. Since the last survey in 2003, MSHA has changed the regulation requirements for early fire detection along belt haulage entries. As of Dec. 31, 2009, point-type heat sensors are prohibited for use for an early fire detection system. Instead, carbon monoxide (CO) sensors are now required. This report presents results from a new survey and examines how the regulation changes have had an impact on the use of CO sensors in underground coal mines in the United States. The locations and parameters monitored by AMS and CO systems are also discussed.IntroductionThe last survey conducted by the U.S. Mine Safety and Health Administration (MSHA) on atmospheric monitoring systems used in underground coal mines in the United States was in 2003 (Francart, 2005). A total of 146 active mines were surveyed. The survey report states that since 1995 there had been a steady increase in the use of atmospheric monitoring systems in underground coal mines as the technology of carbon monoxide (CO) sensors was improved by manufacturers. Atmospheric monitoring systems had become more reliable, and some CO sensors could be purchased with the capability to discriminate between the CO produced by a fire versus CO produced by diesel equipment. This increase in reliability had reduced the number of false alarms and the response time. The faster response time to a developing fire allowed miners to take the necessary action to put out the fire or exit the mine.At the time of the last MSHA survey, some mines still used point-type heat sensors to detect the presence of a fire on conveyor belts. This detection method works by measuring the temperature of the air around the sensor. As a fire starts to develop, smoke and hot gases are produced from the combustion process, and the air is heated up. Once the air and gases reach a designated temperature detected by the point-type heat sensor, a fire alarm signal is generated. Studies have shown that the response times for detecting the presence of a fire using CO sensors are much shorter than when using point-type heat sensors (Conti and Litton, 1995)."

Jan 2, 2018

By J. P. Matoney

In recent years, the diminishing supply of natural gas has led energy suppliers and consumers to consider making synthetic natural gas from coal. A number of processes have been devised to produce gas from coal; many of these have been operated at the pilot stage and some have been operated commercially. Each process has specific coal feed stock requirements with respect to size consist and moisture content. The purpose of this presentation is to compare the estimated costs for coal handling, live storage, size reduction and drying facilities that would be required for delivery of coal feedstock to different gasification processes.

Jan 1, 1977

By Taylor GP

Mt Kasi in Fiji is a high sulphidation style of gold deposit exposed at a high crustal level. Individual alteration centres are localised at the intersection of cross structures within a through-going structural corridor, the Mt Kasi Fault System. A two stage alteration/ mineralisation model suggests that much of the high sulphidation alteration is derived from the initial rapidly moving gas-rich portion of the hydrothermal fluid. The gradual cooling and neut-ralisation of hot acid fluids by mixing with oxygenated ground waters forms the characteristic zoned alteration assem-blages which grade from cores of residual silica through silica-alunite to peripheral clays. The liquid-dominated phase of the hydrothermal fluid brecciates the competent, altered rocks and deposits sulphide mineralise-ation within the breccia matrix. High gold grades occur in the matrix-rich breccias and decline from the hydro-thermal fluid upflow to outflow zones.CSAMT (controlled-source audio magneto-tellurics) geophysics has been used to define the geometry of the alteration centres while strike slip movement on the major structures accounts for the dilational structural environment in which the ore hosting breccias form.

Jan 1, 1994

By Xianjun Lu

This paper presents gold occurrence investigations on the altered rock gold deposit from Jiaodong area of China, and comparisons of gold occurrence in the ore samples from different mining levels. According to the results, the chemical and mineral compositions of raw materials from different mining levels are quite similar. However, the relative content and grain size of gold minerals are quite different between the two mining levels of -130m~-340m and -550m~-650m. In the ore of upper mining levels of -130m~-340m, electrum is the dominant gold mineral and accounts for about 80% of the total gold minerals, while native gold is minor and accounts for about 20%. As for the ore of deep mining levels of -550m~-650m, the major gold mineral shifts to native gold which accounts for 67%, while the ratio of electrum drops to about 33%. Coarser gold grain size was observed in the upper mining level ore with a mean size of 33.05µm while the gold grain size was much finer in the ore of deep mining levels with a mean size of 22.85µm. Furthermore, the gold mineral associations also show different patterns between the upper mining level samples and the deep mining level samples. Of the three observed gold association types such as inclusion gold, fissure gold and interparticle gold, more inclusion gold was found in the ore of deep mining levels. The inclusion gold accounts for 62% in the ore of deep mining levels, while that in the ore of upper mining levels accounts for about 56%. Further study revealed that the dominant gold associated minerals are pyrite and sulphides and only a small amount of gold is associated with quartz and silicates. It was shown that the altered rock gold ore from Jiaodong area can be regarded as a free milling gold ore, but the processing parameters should be optimized for the ores in different mining levels according to the different gold occurrence. In addition, it was predicted that enhanced gold liberation is necessary for the ore in deep mining levels.

Sep 1, 2012

By G Britton, P Moynagh

As more than a few mines gradually sink under the weight of emails, whiteboards, notice boards and ever more complex spreadsheets, the holy grail of effective short-term interval planning and control in underground mines is as far away as ever. Despite the mining industry investing ever greater amounts in planning and Enterprise Resource Planning systems, short-term plans become ever more complex and rigid. What the industry desperately needs are not more ‘disembodied voices down the speaking tubes’, but flexible and effective planning systems that encourage people to make reasonable commitments to each other so that everyone can work as a coordinated team to complete the work required each shift.One solution to the challenge has emerged. This paper describes the ‘Fewzion’ shift planning and short interval control system which has been developed at Anglo American’s Moranbah North and Glencore’s Oaky Creek coalmines in Central Queensland. Fewzion has drawn on management theory embodied in Management Operating Systems, Lean and Theory of Constraints approaches to continuous improvement to play a key role in both mines achieving record breaking tonnages.In addition to explaining the Fewzion approach, a case study is presented describing how Anglo American’s Moranbah North improved production by 39 per cent in 2014/2015 and won ‘Coalmine of the Year’ two out of the last four years and how Glencore’s Oaky Creek sustainably improved monthly development meters by 34 per cent within two months of implementing Fewzion.CITATION:Moynagh, P and Britton, G, 2017. How a frontline planning and commitment system improves trust, commitment and results in operations, in Proceedings 13th AusIMM Underground Operators’ Conference 2017, pp 235–240 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 16, 2017

By R. L. Stanton

"The present contribution examines, in some detail, what appear to be the three outstanding features of the field occurrence of the conformable ""pyritic"" deposits. These are their association with fragmental volcanic rocks (and derivatives), their occurrence in sediments of near-shore formation, and their highly variable structural associations.In a recent paper it has been suggested that two such ""pyritic"" de-posits in New Brunswick may have originated as marine concentrations of volcanic base metal and sulphur compounds, and that many of their present features are the result of diagenesis, folding, and regional metamorphism. This is now put for-ward as a general explanation for the particular class of deposit considered.Such deposits should, on this hypo-thesis, be regarded quite simply as an integral part of the particular geological environment in which they occur -as a normal, though minor, sedimentarry type developed, char-acteristically, in near-shore and shelf facies of intravolcanic units formed along the margins of eugeosynclines. They should not be considered -as, for example, is required by the re-placement theory -as later features simply superimposed on a geological situation to which they are genetically unrelated. Where they are associated with folds and other structures, this may be attributed, from one in-stance to another, to mechanical migration during folding, weaknesses induced by pre-existing sulphides, and, occasionally, to fortuitousness.In the light of this postulated origin, it is suggested that the first stages in regional prospecting for deposits of this particular class should be broadly palaeogeographical. Later phases of the search should then be directed to the delineation of sedimentary facies and, finally, to the investigation of geological structure."

Jan 1, 1960

By Jorge Ivan Sabogal Paz

Con este trabajo se desarrolló un sistema para eliminación de un olor no característico en CO2 captado como subproducto industrial de un proceso de producción de alcohol por fermentación de jugos de caña de azúcar. Al incrementarse la producción, este CO2 comenzó a presentar un olor Dulce que afectaba la calidad insabora por lo cual en este trabajo se reporta el diseño y análisis de un sistema de eliminación de este olor no característico basado en sistemas de lavado. optimizado por sistemas de control automático. En los resultados se reporta el efecto en la disminución de los olores no característicos de distintos sistemas con respecto a su eficacia técnica e impacto.

Aug 17, 2017

By Ana Maria Pérez Ceballos

Os aços inoxidáveis duplex e superduplex são caracterizados por uma estrutura bifásica contendo ilhas de austenita precipitadas numa matriz de ferrita. Estes aços possuem boas propriedades mecânicas e boa resistência à corrosão. No entanto, estes aços podem apresentar fragilização por hidrogênio. No desenvolvimento deste trabalho se estudou a difusão e fragilização por hidrogênio de um aço inoxidável superduplex SAF 2507 nos estados como recebido e tratado térmicamente. Para avaliar a influência da microestrutura sobre a difusão do hidrogênio foram realizados ensaios de permeação electroquímica de hidrogênio. Observou-se que o coeficiente de difusão aparente aumenta em função da temperatura de recozimento. A influência de hidrogênio na resistência à fratura do material recozido a 1300°C foi estudada a partir de ensaios de tenacidade à fratura (CTOD). Determinou-se que a resistência à fratura do material diminui consideravelmente quando o mesmo é submetido a uma carga de hidrogênio. A presença de hidrogênio também modificou o mecanismo de fratura do material, observou-se uma fratura completamente dúctil no material que foi testado em ausência de hidrogênio e uma fratura frágil, caracterizada por clivagem, foi observada no material hidrogenado. Determinou-se que a fase austenítica pode ser fragilizada sob certas condições de carga de hidrogênio.

Aug 17, 2017

By AIME AIME

HE State of Utah has an area of 84,990 sq. mi., and like other inland states in the West its population, although steadily increasing, is relatively small. The fact that it is a state possessing vast mineral resources is attested by a careful study of statistics which have been compiled by Federal and State investigators. Some idea of the extent of these resources and the degree of development of a particular state or region may be gained by such a study, but in the case of Utah statistics and other available information fail to portray completely the true extent and value of its existing metallic and non-metallic resources. The State is probably more widely known for its production of metallic ores which has placed it in an eminent position among the metal mining states of the Nation.

Jan 1, 1925

By M. Orchin

THIS PAPER is concerned with two aspects of the behavior of coal: (1) Dispersion by solvents atmospheric pressure and high temperature and (2) the destruction and regeneration of the coking properties of coal. Several pure polycyclic compounds and a coal-tar fraction were found to extract 95 percent of the organic material of a bituminous coal. About 20 percent of the extract was soluble in benzene, and this fraction contained the ?coking principle? of the coal. From an extensive chemical spectroscopic, and x-ray study of the benzene-soluble material, some conclusions could be drawn concerning the composition and structure of this fraction of coal. A possible commercial application of the extraction technique is in the preparation of low-ash carbonaceous material for the manufacture of electrode carbon.

Jan 1, 1951

By Franco Gandin

With increasing demands for highly performing and at the same time efficient and running-costs saving vacuum-degassing equipment, dry mechanical pumps have been confirmed a proper choice to completely fulfill the expectations of steel-making companies worldwide. Regarding the production of both special carbon steel and stainless steel grades, the usage of mentioned pumps allowed reaching simultaneous remarkable results from different viewpoints in various Danieli worldwide installations (treating up to 200 t of liquid steel). As a matter of fact, in front of the replacement of a widely spread and renowned technology such as steamejector pumps with the recently developed technology embodied by the dry mechanical pumps, well-established metallurgical performances in terms of carbonhydrogen- nitrogen-sulphur removal have been repeatedly attained while meeting at the same time the client’s expectations concerning, for example, running-costs and push-button availability. Additionally, thanks to the very flexible, modular, redundant and maintenance-friendly equipment design, random problems occurring to the singular mechanical pumps can be easily solved without affecting the VD-VOD plant availability and metallurgical performance. With a particular regard to the VOD process, a very short overall process-time has been repeatedly performed (averagely less than 58min under-vacuum time at ChMP1) while guaranteeing the expected required quality of the final refined stainless steel. Moreover, in several VOD installations (ranging from 6 t up to 110 t of liquid steel) an efficient automatic process control such as dynamic pressure-regulation during oxygen-blowing has been attained thanks to the controllable variable-speed drives with which each mechanical pump is provided.

Aug 17, 2017

By M. Mokgohloa, T. R. Stacey

Boring of tunnels and shafts in hard rock under high stress conditions is becoming more common as mines and tunnels are developed at greater depths. Under the high stress conditions, fracturing of the often-brittle rock occurs in the walls, backs, and ahead of advancing faces of excavations. Fracturing can have a significant impact on boring activities: sidewall spalling, which affects machine gripper capacity, and fractures can also develop in the rock ahead of the face, leading to blocky rock conditions, which may have a significant effect on machine excavation. Fracturing may develop dynamically, leading to rock bursts manifesting in the form of strain bursts, which can be hazardous and destructive. In brittle rock, fracturing is commonly extensional in nature. The focus of this paper is on fracturing in the face of the excavation. Examples of such fracturing behaviour are described briefly in the paper. Numerical analyses were carried out to predict the initiation of extension fractures and their orientations ahead of excavation surfaces, and the resulting formation of rock slabs/plates, and the stability of these plates. The results should be beneficial for the evaluation of the conditions prior to, and during boring operations.

Nov 27, 2024