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By André Pomerleau, Michel Grégoire, René del Villar

"The operation of industrial flotation columns requires the control of at least two variables, the interface position and the bias rate, by manipulation of some appropriate operating variables. Problems arise due to the reliability of existing methods of measuring the bias (i.e bias = tailings water - feed water), a situation which has often forced the industry to disregard this control loop. Moreover, when using such a measuring approach, the identification of the process dynamics is impossible. A second problem arises from the possible interaction between both control loops that might call for the use of a more complex multivariable control strategy.Recent work done at Lava1 University has demonstrated the feasibility of an independent sensor for bias, which models the relation between the conductivity profile across the interface and the bias value using a neural network algorithm. A 250 cm height, 5.25 cm diameter Plexiglas laboratory column was equipped with a series of conductivity electrodes in its uppermost part (across the interface) to measure both interface position and bias rate. Using such equipment, the flotation column dynamics were identified. The results thus obtained permitted the design and implementation of a distributed PI control strategy, where bias was associated to wash water rate and froth depth to tails rate. Both PI controllers were tuned using a frequency-response tuning method. Results of both identification and process control are presented and discussed.INTRODUCTIONFlotation columns are used for the separation of valuable minerals from a carrier gangue. Typically, this device is a tall (9 to 14 m height) cylinder (1 to 3 m in diameter) although other cross sectional shapes are also used. Finely ground ore is fed as a pulp at about 2 m from the top of the column, and pressurized air is introduced through a sparger at the bottom. If the pulp has been properly conditioned with adequate chemical reagents (collectors and modifiers), the valuable mineral particles falling by gravity will attach themselves to the rising air bubbles, and the air-particle aggregates will rise to the top of the column where they overflow as a stream called the concentrate. The gangue particles,, that do not attach to the air bubbles, fall down the column being withdrawn at its bottom in a stream called the tails.A particular characteristic of flotation columns is the addition of a fine spray of water at the top. As the water flows down through the froth zone, it washes out the entrained gangue particles from the mineralized bubbles, thus improving the quality of the concentrate recovered at the top. As a result of its cleaning action, this water stream is called the wash water and the upper zone, the cleaning zone. In order to ensure a downward flow of wash water, a proper water balance must be kept in the froth zone, otherwise the water added at the top might shortcircuit to the concentrate without performing any cleaning action. This net downward flow of water inside the froth zone is called the bias and represents an important operating variable of a flotation column."

Jan 1, 1999

By N Ganjian, A Delavar, F Rashidi Nejad

Iran is one of the most seismically active countries in the world, being crossed by several major fault lines that cover at least 90 per cent of the country. As a result, earthquakes in Iran occur often and are destructive. So, it is important to consider the seismic stability and reliability of all structures including tailings dams.In this study, the tailings dam stability of the Sangan Iron Ore Mine in Khorasan Razavi, Iran is considered for the case study. The tailings storage facilities of the mine have three cells with the capacity of 45 million cubic metres. The first cell, which has three stages of dam raising, has been recently brought into operation. This cell has a downstream-raised retaining embankment. As the risk of seismicity in this area is high, seismic response of this dam was evaluated by numerical methods. To do this, appropriate models were developed for materials used in foundation and body of the embankment. Then for seismic stability analysis, Tabas (Iran – 1978) and Chi-Chi (Taiwan – 1999) earthquake acceleration simulations were applied.The results of this study indicated that the upstream portion of Stage 3 of the dam and dam crest did not experience significant horizontal displacements during earthquake period, but the downstream portion of Stage 3 of the dam showed a maximum horizontal displacement of 60 cm at the third stage of dam raising. This is three times more than what was estimated by the designer. Also, the maximum vertical displacement resulting from simulation of the Tabas earthquake was 35 cm. The results of dam response to Tabas and Chi-Chi earthquakes indicate that displacement, shear stress and pore pressure by the Tabas earthquake were higher than the case of Chi-Chi earthquake. The higher energy of Tabas earthquake and the higher frequency near to the natural frequency of Tabas earthquake could be the reasons of this difference. The results of this case study confirm that if the studied tailings dam impacted by an earthquake of a similar magnitude to Tabas, the dam will be seismically stable and the developed strains will not be significant.CITATION:Delavar, A, Rashidi Nejad, F and Ganjian, N, 2015. Seismic stability analysis of Sangan Iron Mine Project tailings dam, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 173–182 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By Paul H. Atkinson

"Sampling in the mineral processing industry has always been a subject which has received considerable discussion. There have been many volumes written on theory, techniques and practical application of sampling. However, until recently, the companies were not completely aware of the potential savings available with properly designed sampling systems both to assist in pieces: control and final product values.Definition In our discussion today, we will define sampling as the operation of removing a part, convenient in quantity for analysis, from a whole, which is of much greater hulk, and removing it in such a way that the proportion and distribution of the quality to be tested, i.e. size of particle, moisture content, specific gravity content, mineral and chemical composition, are the same in both the sample and the whole.Application It has been well established that undetected errors can result in large economic losses, thus most firms depend upon some type of sampling and sample analysis as a control in their continuous processing of materials. Despite the large investment in facilities and personnel the ""analysis"" of a sample can be no more accurate or reliable than the sample on which it is being based. The importance of sampling is recognized by a great many but it is appreciated by only a few, largely because it is sometimes one of the items which is taken for granted."

Jan 1, 1976

By K. Barbetti

"The carbon-in-pulp (CIP) process has been the dominant gold recovery process since the early 1980s. CIP has proven to be very adaptable for a wide range of ores and circuit configurations. The key performance indicator for CIP circuits is the minimisation of soluble gold losses to tailings, however, it is also important to operate the circuit efficiently (maximising gold loadings on carbon and minimising carbon inventory). Over the last 30 years the Curtin Gold Technology Group has studied CIP circuits as part of an on-going collaborative industry funded project (the AMIRA Gold Processing Technology Project). In the early years the project undertook basic research into understanding activated carbon, and its management in the circuit. More recently the development of process models and instrumentation has provided additional tools to assist operators. The results show that while most CIP circuits operate well, there are still significant opportunities for further cost savings, or additional revenue. This paper reviews the observations arising from this work, including key requirements for good carbon management, the results of benchmarking and industry surveys of carbon circuit over 20 years, the value of process modelling of CIP circuits to establish operating parameters, and the use of automated instrumentation to better optimise carbon control in the circuit.INTRODUCTION The introduction of activated carbon to recover gold from cyanide leach solutions in the last quarter of the 20th century was the most significant development in gold ore processing since the advent of cyanidation seventy years before. Replacing the Merrill–Crowe zinc cementation step with carbon-in-pulp (CIP) or carbon-in-leach (CIL) circuits provided a process that allowed the treatment of lower grade and problematic ores (e.g. high-clay ores), at lower capital and operating costs, and higher metal recoveries. The CIP circuit was first developed in the 1950s at the Carlton Mill, Cripple Creek, Colorado. All the components of the modern CIP process came to fruition at the Homestake Mine in South Dakota in 1973 (Fast, 1988). From the late 1970s onward a variation of CIP, carbon-in-leach (CIL) which combined the leach and adsorption stages, became the preferred circuit design in most parts of the word."

Jan 1, 2017

By Alexey P. Tatarinov

Under modern economic conditions in Russia, gold heap leaching is the most effective way of investing into gold-mining industry. Gold is recoverable from small-size deposits, low-grade ores from oxidation zone, cut-off grades, and overburden rocks using heap leaching. This technology is cost-effective and allows a saleable metal to be obtained within the first year of operation. The investments for heap leaching are lower than those of for a traditional plant technology. Production cost per one gram of Au is 5-7 times lower than that of during a plant flow sheet. A seasonal development of mines can be possible. With reference to this, heap leaching resembles the technology of placer deposits development. One of the major advantages of heap leaching is the form of the product. Gold can be obtained as dissolved in a clarified PLS, which allows the further quick treatment. The amenability of ores to heap leaching depends on their mineralogical composition. Oxidized porous ores with a good access of a lixiviant to valuable particles can be treated without pre-crushing. Clayish minerals are often found in oxidized ores with free gold. In order to build ground for heap, several major methods combined with various pad materials are used. These methods have been used at many plants and are reliable. The development of heap leaching technology for gold ores for the deposits from Yakutia, Zabaikalsky region, Primorye region, Uzbekistan, Tadjikistan, and Kazakhstan began in the 70s. However, it has been commercially used only since 1990. The first heap leach plants were built and commissioned in the USSR in 1991 at Vassilkovsloye deposit (Kazakhstan) and at Maiskoye deposit in Russia in 1994. Pilot plant testing was conducted in 1996 using ores from Kuranakh ore field, deposits Phiskulturnaya-Kholodnaya and Lopukhovskoye from the Aldan region. After the first successful commissioning of heap leaching plant in Russia, this technology has been commercially applied for deposits. Every year 1-2 heap-leaching plants were commissioned. More than 30 heap-leaching plants have been commissioned both in Russia and in the former Soviet Union using technologies developed by IRGIREDMET. Keywords: cyanide leaching, heap leaching, ore, percolation, solutions, lime technology

Sep 1, 2012

By F. N. F. le Roux

This paper describes the method used for excavating the upper 33m of emergency access shaft E2 for the underground single track tunnel running between Park and Rosebank station of the Gautrain Rapid Rail System. The soil was decomposed shale and diabase from the Witwatersrand Supergroup. The location was in the car park of The Wilds (a public park) in Johannesburg. The method proved very simple and required less complex plant and equipment than normal when excavating the shallow soil sections in shafts. It involves driving steel sheets ahead of the shaft sump into the soils and then excavating inside the ?tub? created by the sheets whilst supporting the sheets above with regularly spaced circular Steel Rings. It is the intent of this paper to discuss the method and design approach to the method. This will be done at the hand of experiences at E2 shaft..

Jan 1, 2009

By A. W. Fahrenwald

"The rate of progress in the last three years in the development of differential flotation has been rapid beyond the realization of most people. Differential flotation is no longer a ""delicate"" and unreliable process, but is now in wide use. Its ""safety"" is due to the wide use of chemicals which either depress or enhance floatability by definite modification of surfaces.The extent of the development and reliability of differential flotation methods any be emphasized by pointing out that there are now several customall-flotation"" plants in this country treating complex lead-zinc-iron ores from widely separated mines. While these ores differ in chemical composition and apparently in physical nature, the various ores treated in such a plant are passed through the same crushing and grinding equipment and through the same flotation machines and flow sheet with only slight changes, if any, in quantity and kind of chemicals and oils added.Some of the development in differential flotation is due to intelligent research on the part of well-trained chemists and metallurgists; much of It must be attributed to empirical testing.Much of the success in differential flotation is due to more care being given to constant conditions with regard to such factors as (1) fineness of grinding, (2) density of pulp entering flotation machines, (3) quantity and constancy of oils and chemicals added to the pulp, and (4) place of addition of reagents, and time of ""conditioning"" treatment of pulp with reagents."

Aug 1, 1925

By R. V. Lundquist

This report describes results of tests on the desilication of solutions resulting from the leaching of lime-soda sinters. Desilication was accomplished by heating the solutions in an autoclave. A liquor relatively free of silica was obtained after 30 minutes of heating at 200 p.s.i.g. in the presence of lime. The addition of lime improved desilication, but the rate and efficiency of desilication was effected by the quality of lime used. The optimum quantity of lime for effective desilication was about 6 grams per liter. A lesser quantity gave poorer desilication, and a greater quantity increased the alumina loss without improving desilication. The alumina loss was approximately proportional to the lime added. A complex structure, called artificial noselite in this report, was the only silica bearing compound detected in the desilication precipitate. Other compounds present were Ca(OH)2 (calcium hydroxide), CaCO3 (calcium carbonate), and Ca [A1(OH)6]2 (hydrated tricalcium aluminate). Sodium carbonate in the leach liquor retarded the formation of the calcium aluminate; hence it decreased the alumina lost to the precipitate. The extraction of alumina from aluminum silicate materials by the limestone soda-sinter process has been investigated by the Bureau of Mines for many years. The process consists of the following major operations: Blending the aluminum silicate with limestone and soda ash in such proportions that dicalcium silicate and sodium aluminate are formed on sintering; leaching the sinter in a carbonated caustic solution to extract the soluble alumina; purifying the leach liquor by the precipitation of soluble silica (this precipitate is designated desilication precipitate in this paper); precipitating alumina trihydrate from the purified liquors by carbonating with carbon dioxide gas; and calcining the trihydrate to alumina. Commercial grades of

Jan 1, 1962

By Manish Uttarwar, Rajendra Yerpude

India is the third largest producer of coal and the fourth largest in terms of coal reserves in the world. However, new research quite ironically projects that despite the continuing growth in domestic coal production, the country’s exploding economic growth will position it to be the biggest coal importer by 2020. India’s inability to meet the domestic coal demand is mainly attributed to low rate of production, increasing stripping ratio, non use of appropriate technology etc. of coal mining operations here. Presently Indian surface mines which have to shoulder the onerous responsibility of augmenting the coal extraction rate at an even brisker pace are mulling bigger, better and more efficient operations ensuring commensurate rise in stripping work as well. This mammoth task can be accomplished only by deploying smart technologies. In this perspective, cast blasting of overburden emerges on the horizon as a promising alternative for enhancement of the production and productivity of Indian open-pit coal mines.

Jan 1, 2009

By BHAMIDIPATI S. SASTRY, SRIVATSAN J. SRIDHARAN

Pressure losses in mine ventilation systems are estimated using friction factors and shock loss factors. The efficient planning and designing ofmine ventilation systems depend on the accuracy of the friction factors as well as the shock loss factors that are taken into consideration. While there is a much more acceptable knowledge of what constitutes friction loss in mine roadways, the shock loss factors are in general readily not available for all possible contexts of flow separation phenomena in mines. One such special case of shock loss in mines is the train of mine cars in the airway. Mine cars are widely used for the transportation of material, and the information on shock loss factor for mine cars is limited. This paper examines the pressure loss occurring due to a train of mine cars in an airway using scale model studies and numerical investigations. Computational fluid dynamic (CFD) studies are conducted using four different turbulence models. The performance of different turbulence models is analyzed by comparing it with the experimental results. The study suggests that the boundary layer resolution method is significant in the simulation of shock loss. From the study, it is found that the shock loss factors from presently available model overestimate the pressure loss by 7 to 15 times. A better prediction model for the shock loss factor of a train of mine cars in the airway is proposed using the experimental results.

Jul 24, 2020

By D. Shink

A small scale continuous flotation cell was designed and constructed at Noranda Technology Centre to develop a mobile testing flotation circuit located next to the production circuit. This mobile small scale flotation pilot plant can easily and economically be set up at any circuit in a mill and used to evaluate and predict plant performance against a given flotation condition. The main feature of the cell, beside the provisions of automatic pulp level and feed rate control, is to provide a reduced surface to volume ratio approaching to that of an industrial machine. This paper describes the basic design and the results of various testwork carried out to date including aeration, conditioning, reagents, recirculation, flotation gas, etc. are presented in comparison with the plant production results.

Jan 1, 1992

IN accordance with a programme arranged by a committee of the Institute, consisting of Mr. William P. Shinn, of St. Louis, chairman, and Mr. Joseph D. Weeks, of Pittsburgh, secretary, the member's of the Institute, with their ladies and invited guests, assembled in Chicago on Sunday morning, August 22d. A special train, provided by the Chicago and Northwestern Railway,. left Chicago on Monday morning at 7.50 o'clock, and conveyed the party to Marquette, arriving at 9 o'clock P.M. Here the steamer Northern Queen, which had been chartered by the committee for the accommodation of the Institute, was in waiting, and the members and ladies at once took up their quarters on the boat. EXCURSIONS IN THE MARQUETTE IRON REGION. Local Committee. EXECUTIVE. -J. C. Morse, chairman; C. Y. Osburn, secretary ; D. F. Wadsworth, treasurer; C. H. Hall, H. Merry. RECEPTION.-S. P. Ely, J. P. Pendill, E. Breitung, W. F. Swift, A. P. Swineford, J. C. Fowle, C. G. Griffey. TRANSPORTATION.-Samuel Schoch, D. Morgan, D. H.. Merritt, J. Pickands. FINANCE.-Peter White, A. W. Maitland, W D. Rees, E. R. Hall. EXCURSIONS.-W. E. Dickinson, H. A. Burt, A.. Kidder, C. E. Wright. REFRESHMENTS.-J. Q. Adams, H. H. Stafford, Joseph Kirkpatrick, D. H. Bacon. On Tuesday the iron mines in the vicinity of Negaunee and Ishpeming were visited, transportation being provided by special trains on the Marquette, Houghton and Ontonagon Railroad. In the morning the McComber, South Jackson, and Jackson mines were inspected, and in the afternoon the Cleveland, New York, Lake Superior, and Barnum mines. Dinner was provided at Negaunee, and gracefully served by, the ladies of the town. In the evening the first session of the Institute was held in the saloon of the steamer. The President, William P. Shinn, of St. Louis, congratulated the Institute on the happy consummation of the wishes of its members to have a meeting on Lake Superior. After tedious and baffling negotiations arrangements had been com-

Jan 1, 1881

By R. van Heerden, T. R. Stacey

In the challenging environments of deep-level, narrow tabular orebody gold mines in South Africa, rock mass classification offers a potential method for predicting hazardous areas and optimising rock support systems. This study evaluates the applicability of various rock mass classification systems, with a focus on the Modified or Mining Rock Mass Rating system tailored for high-stress, deep-level mining conditions. Extensive data collection was conducted at Kusasalethu Mine, involving underground mapping and analysis of the 2020/2021 fall of ground database. The Mining Rock Mass Rating system was adapted to the unique geological and operational conditions, providing a simplified, user-friendly approach for rock engineering and geology personnel. Results indicate that this adapted Mining Rock Mass Rating system effectively quantifies rock mass conditions and influences proactive mining adjustments. The study’s findings highlight the system's capability to enhance understanding of rock mass behaviour and substantially mitigate the occurrence of rockfalls and ground collapses. Further application and refinement of the system are recommended to continuously improve mining safety and efficiency.

Oct 24, 2025

By W. W. Agey

Past investigations on waterborne impurities in the flotation process have been concerned primarily with the treatment of specific ores with particular local waters. Although some anions and cations present in water are known to react with flotation reagents, a definitive study has not been made on the effect of such common ions upon the flotation process. This report describes the fundamental research undertaken to define and measure the adverse and/or beneficial effects of different concentrations and combinations of several common anions and cations when oleic acid is used to froth-float limestone from a pulp of quartz and limestone. Research on the effect of waterborne impurities upon the flotation process was composed of two equally important phases. The first phase comprised development of a procedure for floating limestone from quartz that would give the same results in test after test. Some difficulty was encountered, but once such a procedure was developed, the second phase, comprising study and measurement of the effect of various ions c on to natural water upon the flotation of limestone, was quickly completed.

Jan 1, 1963

By Garry Biles

The Eskay Creek Mine is a high-grade gold and silver underground mine in northwestern British Columbia. The mine started operations in late1994. For the first three years, ore was crushed to -50 mm(-2 in.), blended to satisfy smelter terms and shipped to smelters in Japan and Canada. Preliminary evaluations indicated that a complex metallurgical facility, requiring a large capital investment, would be required to recover the precious and other economic metals. So markets for raw ore were identified and underground mining and ore transportation operations began at a production rate of 300 t/d (330stpd).

Jan 1, 2000

By Frank G. Breyer

THE .following developments in the zinc field during 1935 are listed in the order of their importance. Each will he amplified in later paragraphs. In the field o f Metallic Zinc: (1) Construction of further continuous vertical retort smelting capacity in the United States and Germany. (2) Expansion of fractional distillation capacity in the United States. (3) Great expansion in the zinc-base die-casting industry in the United States and abroad. (4) Wide acceptance of heavy galvanizing by the steel industry. (5) Construction of the first commercial wire electroplating plant for putting on heavy coats of pure zinc. (6) Firm establishment and appreciable expansion of the practice of using zinc dust as a reducing agent in the organic chemical industry.

Jan 1, 1936

By Angel Rafael Arce Chilque

O presente trabalho trata do estudo micrográfico e mecânico de junta soldada a multipassesde tubo de aço API 5L X70, pelo processo manual com eletrodorevestido (SMAW) para os passes de raiz, enchimento e acabamento na posição vertical 3G. Em acordo com API 1104, o consumível escolhido foi eletrodo revestido básico E 9018 – M, a fim de atender a parâmetros de soldabilidade e permitir a comparação dos resultados com trabalhos anteriores. Foram realizados ensaios macrográficos e micrográficos qualitativos da junta soldada e do metal de base, bem como a medição da microdureza Vickers (HV) ao longo da junta e medição do tamanho de grão da região de superaquecimento. Ensaios mecânicos de dobramento, tração e impacto também foram realizados. Os resultados dos ensaios Charpy foram correlacionados com a estrutura metalúrgica, tamanho de grão e microconstituintes presentes na junta soldada.

Aug 16, 2017

By Adam Powell, Matthew Earlam

INFINIUM, Inc. is scaling up a new molten salt electrolysis process for producing rare earth metals. Instead of conventional carbon anodes, this process uses Pure Oxygen Anodes™ which employ a stabilized zirconia solid electrolyte between the molten salt and anode. This eliminates two problems with today's rare earth metal production technology. First, it eliminates carbon anodes and contamination of the product by carbon and its impurities, enabling 10-100 times larger batch size than current practice, and lower labor costs. Second, it eliminates emissions of perfluorocarbons (PFC) such as CF4 and C2F6, which are very problematic greenhouse gases with 6000+ times the global warming potential of CO2. The zirconia also enables a sealed vessel with no LiF emissions, creates a reducing environment enabling use of low-cost welded steel vessels, and either produces a high-purity oxygen by-product or can use natural gas to reduce the necessary electrical energy with no HF production. This paper will describe the technology and its current status for rare earth metal production.

Jan 1, 2014

By J Cronin, R Burgess-Limerick, T Horberry, L Steiner

"Automation offers the mining industry great potential for improvements in productivity and safety. However, the experience of introducing automation in other industries has been that the full potential of new technology is not always realised. Designers are surprised, for example, to find that automation does not eliminate human errors. Unwanted and unexpected consequences also arise if the introduction of automation fails to consider how people will adapt to the new technology. A focus on the technical aspects of automation is necessary but not sufficient for success. The potential for improvements in productivity and safety promised by automation will only be achieved if the joint cognitive system that emerges from the combination of humans and automation is designed to perform the functions required for system success. This case study describes the human factors issues associated with the introduction of automation generally, and describes a case study of the successful implementation of loader automation at Northparkes mine.Information obtained through a site visit and interviews with operators, safety staff and the project manager revealed the following strategies for successful design and implementation of the automation system: involve the people who will be impacted encourage constant communication between operators and designers provide operators with essential information avoid providing non-essential information provide the operators with flexibility empower operators to take action take advantage of the new possibilities automation provides.CITATION:Burgess-Limerick, R, Horberry, T, Steiner, L and Cronin, J, 2017. Mining automation human-systems integration – CMOC-Northparkes case study, in Proceedings 13th AusIMM Underground Operators’ Conference 2017, pp 93–98 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 16, 2017

By M. R. Geer

This report presents the results of washability examinations of seven coals from the principal coal-producing fields of Montana. A complete performance test of the Baum-type jig operated at one of the mines is included, as are the results of cleaning tests made on two of the coals in a dense-medium pilot plant. The coals examined from the Red Lodge, Bull Mountain, and Forsyth fields are comparatively easy to clean. Ash contents of 5 to 10 percent can be obtained at yields of washed coal ranging from 90 to 95 percent. The coal from the Great Falls field, however, could not be cleaned readily to less than 14 percent ash, and the rejection of impurity would amount to over 25 percent. The two coals treated in the dense-medium pilot plant were characterized by sharp separation of impurity, high recovery efficiency, and satisfactory reduction in ash content.

Jan 1, 1955