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The recent trend of installing flotation cells with volumes as large as 200 m3 in concentrators is driven mainly by economic considerations such as lower capital, operating and maintenance costs. Despite the economic advantages, the metallurgical benefits from these large cells have not yet been fully realised by the industry. This is mainly due to the lack of understanding of cell operation, viz cell mixing and hydrodynamics, gas dispersion and froth transportation behaviour in large cells. There is still no rational basis for selecting optimum cell operating conditions and down-the-bank operating profiles. The relationship between cell operating conditions and metallurgy is not well established. This has resulted in poor utilisation of cell capacity in many operations. The present trend of installation of fewer cells in a bank requires each cell to be operated very efficiently. Optimisation of cell operation provides an opportunity for significant metallurgical improvements in a flotation circuit with minimal capital expenditure. Extensive work on optimising of cell performance has been carried out at various Teck Cominco operations in Canada, Peru and USA. Three different levels were involved in this work. The first level was aimed at identification of cell operating conditions for optimum mixing and hydrodynamics, gas dispersion, entrainment and froth flow behaviour in individual cells. The objective of the second level was to identify the optimum bank operating profile for cells down the bank in a circuit. The third level then focused on controlling these cell operating conditions and bank operating profiles for tighter control of concentrate grade and recovery for optimum bank metallurgy. This paper presents some of the major findings at all three levels and demonstrates the importance of each level in optimising the performance of flotation banks installed with large cells.

Jan 1, 2005

By F Mavroudis, M Gaastra

Due to the increasing demand for resources worldwide, efficient utilisation of raw material deposits and recycling technologies become more and more important. Growing industrial nations and increased living standards require a large raw material supply. Hereby responsible handling of existent primary and secondary raw materials is indispensable. By utilising state-of-the-art technologies resources are extracted, recovered and recycled more efficiently which increases sustainability. Hereby sensor technologies combined with intelligent data processing systems in particular provide a considerable research area. Innovative sensor technologies are already implemented during recognition of material-specific characteristics, during elemental recognition as well as during machine control. They are applied to attain increased automation levels of mining machineries, higher recoveries during mining and processing as well as higher recoveries. To be able to face the increased demand for sensor technologies and the integration into raw material industries, an interdisciplinary association of three RWTH Aachen University Institutes has been founded. The association has expertise on increasing productivity and capacity utilisations by automating mining and recovering processes by sensor technologies. Due to the utilisation of sensor systems, materials and structures can now be detected and elementary analysed on a real-time scale. The developed and enhanced techniques are the key for any ambition of autonomous plants and machineries. This paper gives an overview on the regarded sensor technologies for material recognition, machine automation and mineral processing. The authors present concepts based on extensive laboratory and field studies of successful implementation and application the technologies considering special mining conditions. Overall three applications are described to demonstrate the potential of sensor technologies for autonomous and sustainable mining: real-time analysis: recognition of elementary compounds during extraction processes; multi-sensor system EiControlPlus: designed for automation of longwall shearers by complete detection of the machineÆs environment; and sensor-based sorting: applied in recycling and mineralÆs industries.

Sep 26, 2011

By D Monaghan

Pumping water for dewatering and water supply is a major component of electricity consumption at mining operations and hence is a significant contributor of greenhouse gas emissions. Pump systems at a typical mine site can be broadly split between above ground centrifugal pumps (generally used for water transfer) and submersible borehole pumps (generally for dewatering and/or water supply). In contrast to above ground pumps, submersible borehole pumps can be subjected to varying duty points (total pumping head and flow requirements) as a result of changing bore water levels and yields, particularly in mine dewatering bores. Typically, much higher pumping rates are required at the commencement of dewatering to remove groundwater storage and to intercept sufficient groundwater throughflow to achieve target drawdowns. Once target drawdown levels are reached it often only requires much lower pumping rates to maintain target drawdowns. Pumps sized to remove the large initial volumes of stored groundwater often end up too large for the lower flow rate required for æmaintenance pumpingÆ. This often results in pumps operating inefficiently, a problem which can be made worse when pumps are throttled to reduce the pump output to better match the reduced bore yield. Current standard operating practice places little emphasis on the electricity consumed by pumps, with the focus often being on minimising capital expenditure (æIf it ainÆt broke donÆt fix itÆ). Submersible pumps can have extended service lives of ten to 20+ years. However as the capital cost of a pump typically represents only five per cent of the life cycle cost, the vast majority of the life cycle cost is energy usage.Through the implementation of a regular review of the operation of borehole pumps, significant reductions in electricity use and associated greenhouse gas emissions can be achieved without impacting the dewatering schedule. In most cases, the capital cost of replacing pumps is more than offset by savings in operating costs. These potential savings become even more significant when considering proposed future carbon tax levees.This paper presents examples of the opportunities for significant reductions in energy, greenhouse gas emissions and overall costs that can be achieved for a range of dewatering scenarios.

Jan 1, 2009

In process industries, time-dependent random fluctuations of raw material characteristics and mass flow rates in bulk material or pulp flows cannot be always prevented for different reasons, eg because of the geological situation (no uniform formation of the deposit) or/and because of technological reasons (segregation in bunkers or on stockpiles). Since a long time, there has been practical experiences that such fluctuations can have negative consequences, eg: ò fluctuations of the final products characteristics, ò higher expenditure for process control, and ò worsening of technological characteristics (recovery, sharpness of separation etc). In the literature, there can be found a lot of details as to, eg the improvement of the sharpness of separation in a jig in dependence on the raw material blending (Kubitza, 1981; Gathen, 1983) or the decreasing flotation recovery with increasing raw material characteristics fluctuations in iron and potash ore processing plants (Bubnova, 1978). Up to now, however, these consequences of random fluctuations, eg on the separation efficiency were not predictable theoretically. It could be shown by means of the general model for mechanical macroprocesses (Graichen, 1989), that the reduction of input fluctuations passing a blending facility can be calculated in this way. In this example, the steady state of the process is the wanted one, but, in general, the model is able to describe also non-steady states of the process regarded. On the other hand, the general model of mechanical macroprocesses has been used successfully for modelling separation processes, eg cross-flow and air classification (Molerus, 1969; Neesse, 1991; Senden, 1979; Tichonov, 1973). That is why it was tried to model the influence of input fluctuations on the separation efficiency, that means, the impact of non-steady states - as a consequence of random fluctuations - on a separation process. The models discussed in the literature are related nearly exclusive to the steady state of the process. The reasons for that lie in the (relative) simplicity of the models and the fact that the steady state is aimed at by means of blending processes under practical conditions - because of the advantages mentioned above. These models cited have proved to be superior to other models, since the basic general model for mechanical macropocesses makes possible the consideration of turbulence acting in the process unit and influencing the separation process essentially. This is valid also for modelling the turbulent cross flow classification, applied to mechanical classifiers and hydrocyclones, where the correspondence between the separation characteristics (cut size, separation sharpness) calculated and determined experimentally is much better than for other models.

Jan 1, 1993

Until the early 1960s the world aluminium industry was dominated by six principle pro- ducers with integrated activities from bauxite mining to aluminium production. The growth in consumption of aluminium since that time and the emergence of additional producers has broadened the market for bauxite. In addition the increase in the optimum size of alumina refin- eries has influenced competing metal producers to unite in large joint ventures to minimize alumina costs. From these bases the paper examines present and likely future markets for Australian bauxite; differing marketing phil- osophies for serving those markets; factors influencing successful marketing; and the sources and relative strength of competition which Australia faces.

Jan 1, 1974

The reasons for using SFRS, including the way a SFRS performs in comparison to plain shotcrete as a support element in mining tunnels, are discussed. The mechanisms by which steel fibres reinforce shotcrete and the need for specifying performance criteria are highlighted. A description of current testing procedures, including an overview of æquantitativeÆ design recommendations provided from various international authorities, is provided. A summary of international recommendations on suitable æqualitativeÆ performance classifications is also reviewed, including a critique of their suitability. Finally recommendations on the practical considerations necessary to ensure good quality, in-place SFRS, are made, including a calculation method for determining minimum steel fibre dosages.

Jan 1, 1999

By Wadsley MW

This paper gives an overall view of the CSIRO-SGTE computer system for thermodynamic calculations. The basis of the system is the coupling of a large self-consistent numeric data bank of thermodynamic information to a modular set of application programs. These seven programs cover management of data files, calculation of thermodynamic properties for species and reactions, plotting of predomin- ance area diagrams, equilibrium and enthalpy balances for complex processes, analysis of thermodynamic efficiency and the estimation of unknown properties. The data bank contains a wide coverage of species and data types so that the system may be applied to many areas of chemistry and metallurgy.

Jan 1, 1984

There are many different challenges when sampling mineral commodities. Sampling is part of many decision-making processes, from control of the number of drops of a reagent to all aspects involved in determining how much to pay for a mineral consignment. However, if all decisions must be supported by correct assumptions, or at least agreed terms, how can this be guaranteed? The main approach is to emphasise the importance of continuous surveying of sampling practices. If they are based on non-recommended protocols, this raises concerns. In addition, safety failures and lack of appropriate behaviour from the technical perspective can lead to disasters, both from the human and business perspectives. Impacts on safety and health are clearly unacceptable. It should be noted that imperfect safety and health practices in sampling operations have a strange correlation with incorrect sampling techniques. The commercial interface can also be affected. Companies have studied extensively the various aspects of measuring quality parameters for mineral commodities to understand the risks for investors and owners, and they take decisions that fundamentally respect the interests of parties in contracts and not result in losses. Every result should be obtained in defensible ways, and neither losses nor profits taken in indefensible ways. Most of such situations are related to bias; a significant systematic difference between a measured value and a reference value for a contractual quality parameter. Bias is always undesirable, because it always implies an incorrect advantage for one party and without doubt an undesired disadvantage for the other party. These situations are solved financially through a third-party arbitrator becoming involved in delicate situations, such as a commercial claim, but the outcome is always tangibly or intangibly bad for one of the parties. Another possibility is a permanent or temporary loss of precision. Poor precision, due its nature, generates reasonably balanced losses and profits, but it may hide out-of-control situations, generate instability and induce financial losses due to actions taken towards clearing commercial disputes involving interlaboratory programs, sample exchanges and duplicated sampling and sample preparation procedures, in the end wasting time and resources and creating a permanent source of commercial tension. While bias situations demand immediate adjustments for correctness, poor precision has to be understood as something that cannot be just calibrated out and is a situation that demands investment of time and effort. Precision optimisation has to take into account best practice for obtaining the required precision as well as cost/benefit analysis studies. Purchasers, engineers, salesmen and all personnel need to recognise that sampling is a major area to understand when taking decisions. The aim is to spread concepts that can really help, such as simple in-house actions to improve productivity and completion of surveys on commercial sampling operations, in order to ensure correct results are obtained and assertively take corrective actions, thereby establishing a healthy relationship with investors, suppliers and purchasers and in the process optimising the business.

Jan 1, 2008

The mining industry has a well deserved reputation earned over the years for innovation, engineering, management and the quick application to mining of emerging technology. The cumulative result is the economic exploitation of lower grade resources. The developments during the last decade have done nothing to tarnish the reputation. There are many that come easily to mind: the use of contractors for both surface and underground operations, a trend toward mine management contracts, the increasing recognition of the economic potential of ground support, and the development of physical measures to achieve it, - sophisticated measures to analyse blasting , and thus improve fragmentation, - instrumentation to assist geotechnical appraisal, - the development and application of the powerful and flexible, excavator, - the evolution of measures to improve grade control, - massive improvements in equipment productivity and reliability built largely around the application of hydraulics, - the development of powerful computer packages for orebody modelling, mine design and extraction, - simple "dense" fill systems, - maintenance management techniques including the greater use of off-site maintenance of exchange components, - the utilisation of communication systems for data transfer.

Jan 1, 1989

By C Gormley, G Lane, J Kwak, A Hopkins

Complex processing plants present a myriad of safety issues to the design engineer. The extent to which the design engineer manages to lay the foundations for a safe plant ultimately sets the stage for life long safety performance. Industry traditionally measures engineering safety performance by indicators such as Lost Time Injuries, Restricted Work Case Injuries, Overall Incident Frequency Rates, etc. While these measures are useful indicators of performance for the construction, commissioning and operations phase of a project, they do not necessarily drive the most appropriate behaviours for Safe Plant Design. Achieving an inherently safe design requires a diligent focus on low frequency, high consequence events. First and foremost the engineering team needs to have a design culture and methodology which leads to a plant which is as close as possible to being inherently safe. Such a culture might come from an organisation that has æmindfulnessÆ about safety, and which is nurturing a culture where warning signs are recognised and addressed. This paper explores the development of mindfulness and warning signs in design.

Jan 1, 2004

I wish that in addition to being a Pro- fessional Engineer I was also a communications expert. My principal task this morning, and yours after this meeting, is to convince a wide variety of individuals that steel industry slags are a high quality material that can be used for many purposes; and that their use can significantly alleviate some of the problems facing engineers, public officials, and the general public in our countries. By actual in- place performance over a long period of time steel industry blast furnace slags have proven that they are as good as the best natural aggregates, and better than some, for any type of construction or purpose for which natural aggregates are used. Steel furnace slags have many unique favorable characteristics and prop- erties when compared to other types of aggre- gate even though they cannot be used for all types of construction. We have the facts, all we have to do is present them to the right people in the proper manner.

Jan 1, 1979

By Williams DJ, Battino S

The rapid crushing technique for the measurement of gas content of coal consists of accelerating the rate of gas desorption from coal by crushing. This technique allows the determination of gas content in the space of hours rather than days or weeks as required for the traditional slow desorption technique. The crushing technique is used particularly when gas content determinations are urgently required for mine safety purposes. The method is now routinely used in underground coal mines of NSW and to a lesser extent in QLD. Despite the rapidity and efficiency of this method, concerns have been raised upon the reliability of the method to deliver accurate results. Experience in Australia has shown that there is in fact some discrepancy in results between gas laboratories using the rapid crush technique. The development of rapid crushing techniques for seam gas content measurements in Australia and the main causes of variability in the gas content test results were investigated. The gas laboratories participating in the gas content testing were CSIRO Division of Coal and Energy, BHP Technical Services and GeoGas Pty. Ltd.

Jan 1, 1998

By Liu Z. C

Evans' theory for chisel shaped picks is well known in the field of rock cutting technology. It has been widely accepted as a good mathematical description of how coal and other rocks break under the action of a simple wedge or chisel. Subsequently, Evans proposed a corresponding theory for pointed shaped picks. Theory along with experimental evidence from the laboratory has consistently shown that chisel picks are more efficient than pointed picks. However despite such evidence, pointed picks continue to be the preferred shape in most practical cutting applications. Evans' theory for pointed picks was developed in an attempt to shed light on this apparent incongruity. The theory although predicting forces of the right order was found to be deficient in several respects. This paper examines Evans' theory for pointed picks and proposes changes to it, which brings the theory much more into line with measured data. The issue of the relative efficiencies of chisel and pointed shaped picks is also examined on a theoretical basis and the apparent incongruity is Resolved.

Jan 1, 1995

By Little T. N, Bettess D

For many mining operations the challenge of equalling World Best Practices has become the key motivator for increasing mine productivities and for lowering total costs. In most instances this will only be achieved if mines optimise their total system rather than minimising specific costs within unit operations. In the past, drilling and blasting have been viewed as a cost to be minimised rather than operations which should have their impacts fully leveraged. Once a hardrock orebody is defined the activity which has the most substantial impact in determining the efficiency of a mining operation is the blasting. The output from a blast affects every downstream operation; only by understanding the extent and interactions can the mine be optimised. Substantial improvements to hardrock mining, quarrying and excavation operations are achievable. Instead of seeking the regular one to three per cent improvements based on reduction of consumables, mine operators would be well advised to go for much bigger targets of ten to 30 per cent by fully leveraging the drill and blast operations.

Jan 1, 1995

By S A. Ravishankar

An overview of flotation reagents used in sulfide and non-sulfide separations, from an industrial perspective, is given in this presentation to highlight the current applications knowledge. The historical and theoretical aspects, which are well documented in numerous books and reviews, will only be highlighted, when necessary, to support the theme of this paper, viz critical analysis of reagent research, design, selection and optimisation with an emphasis on relevance to plant needs and practice. The three types of flotation reagents; viz collectors, frothers and modifiers, used currently in the industry are briefly reviewed; pitfalls and gaps, arising from somewhat arbitrary and reductionistic practice in reagent applications, are identified; and the impact of environmental regulations on current and future reagent development is discussed. The importance of frothers and modifiers, which have received less overall attention than collectors, is highlighted. The need for a rational, holistic (or ætotal systemÆ, ætop-downÆ) approach for reagent design, selection and optimisation is discussed with a view to provide remedies for pitfalls and a platform for filling gaps in reagent chemistry and applications, and to develop reagent technology that can deliver robust solutions to plant needs. Flotation Matrix 100TM, a comprehensive package designed at Cytec to incorporate all the elements of the holistic approach û viz definition of mineralogy and plant needs, rule-based expert system rational reagent selection, and laboratory and plant best practices û will also be described.No paper available for this abstract

Jan 1, 2005

By Hawes GW

Until 1980 copper, lead and zinc sulphide slurries have been success- fully dewatered for rail and sea transport for many years at the Rose- bery site of North Broken Hill Holdings Ltd. utilizing conventional vacuum disc filtration systems. An upgrading and mill expansion program completed in 1981, which also permitted the introduction of ore streams changes, had resulted in difficulties dewatering copper and lead sulphide slurries to comply with transportable moisture limits. Following an extensive investigation which included both laboratory and pilot plant testing a program was commenced to replace the 2 vacuum disc filtration systems with 2 pressure filtration systems for use on copper and lead slurry dewatering and also to retain other existing vacuum disc filters as standby. An analysis of mill operations performance resulted in slurry storage tanks with a capacity equivalent to 20 hours of normal production being incorporated into the project. The pressure filters are mounted above the concentrate stock- piles. A sealed sloping floor incorporating launders is used to prevent any accidental contamination of the concentrate from pipe leakages, spillage, or from water hoses used for clean up purposes around the area. The project was completed in 1985 and operating performance has been better than that predicted from testwork. Equipment availability at 95076 together with the slurry storage capacity provided results in minimal requirement for the standby vacuum filtration system. Some typical operating results are given.

Jan 1, 1988

This paper comprises a discussion of standards for comparing conditions in mines, of methods for measuring the flow of air, of a comparison of fan performances, and the application of these matters to mines in Western Australia.UNDERGROUND CONDITIONSIn approaching the question of mine ventilation one naturally searches for some standard by which to measure the conditions in a mine.There are several clauses in the Mines Regulation Act defining the conditions which are permitted. The quantity of CO2 is limited to 0·25 by volume, but the estimation of CO2 involves a chemical determination and is not suited for general use in a mine.The maximum temperature is fixed at 87 0 F. (dry bulb), and at 80° (wet bulb). The reading of temperature is easily done in the working places, and this is a very valuable and practical test of the conditions in a mine.The wet bulb temperature is probably the most important factor in determining working conditions. It is obvious that human life cannot be sustained for any appreciable period if the wet bulb temperature is above blood heat (about 97°F.). In places where the wet bulb temperature is 90°F. there is danger of heat stroke.In places where the air in a mine is still, the wet bulb temperature rises to a value close to the rock temperature.Adequate ventilation cools the workings by transference of heat from the rock to the air stream, and the temperature...

Jan 1, 1939

Mining Automation By Professor Hugh Durrant-Whyte, Australian Centre for Field Robotics and Centre for Mining Technology and Equipment, Department of Mechanical and Mechatronic Engineering, The University of Sydney Professor Hugh Durrant-Whyte summarised why the mining industry needs to automate and reviewed the current automation technology - its risks, costs and benefits. Why automate? The drivers for automation include: safety, productivity, quality control and reduced manning, equipment utilisation, maintenance, and organisation and planning. Durrant-Whyte recommended starting out with a picture of a fully automated mine and working backwards through a systematic analysis of benefit and risk. This also involves looking at the impact of the total automation on current mine design, and identifying the key technologies.

Jan 1, 1997

By Price B. D, Staunton W. P

The Mineral Science Laboratory of the Government Chemical Laboratories has recently investigated various procedures for the analysis of the platinum group metals (PGMs). This investigation covered a number of methods for the extraction and preconcentration'of the PGMs from a wide range of geological materials. The nickel sulphide extraction technique proved to be overall the most applicable procedure. Flame atomic absorption spectroscopy (FAAS), electrothermal atomisation atomic absorption spectroscopy (ETA-AAS), inductively coupled plasma atomic emission spectroscopy (ICP-AES) and inductively coupled plasma mass spectrometry (ICP-MS) were examined for their suitability in analysing platinum group metals in solution. ETA-AAS and ICP-MS proved to be the instruments of choice due to their low detection limits.

Jan 1, 1987

Hindustan Zinc Limited has successfully installed an In-Stream Analysis and Process Control System in the flotation section of the Balaria Lead-Zinc concentrator at Zawar Mines. The system comprises In-Stream Analysis to continuously monitor lead and zinc levels in feed, concentrates and tailings streams, field instrumentation for reagent distribution and flotation cell level control linked to a central Distributed Control System for supervisory control functions. An intensive training scheme was conducted by the system supplier for concentrator metallurgical and instrumentation engineers. Since commissioning of the system in April 1989, Hindustan Zinc has enjoyed the benefits of improved lead, zinc and silver recoveries, improved concentrate grade control and reduced reagent costs.

Jan 1, 1991