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By William Gleason

The numbers tell the story of this one. More than 50,000 people and 1,890 exhibitors took over the Las Vegas Convention Center Sept. 24-26 for the largest mining trade show in the world ? MINExpo. Inside the convention center, some of the largest machines used in mining were on display. Caterpillar, Liebherr, Komatsu and Hitachi displayed ultraclass offroad mining trucks and shovels. Atlas Copco and Schramm were among companies that rolled in mining drills and Bridgestone, Goodyear and Michelin were among the companies showing off the massive tires used by the trucks. Throughout the three halls and an outdoor display area, just about every kind of product, gadget or service used in the mining industry could be found on display somewhere.

Jan 1, 2012

By U. Richter

Conveyors are a highly effective means of transporting material over long distances. Recently there has been a trend toward long conveyor systems with high capacity single flights. These conveyor systems are an efficient alternative to costly truck fleets. Also with deeper mines, the use of diesel driven trucks becomes more difficult. Another trend is in underground mining, where conveyors are an efficient alternative to drift hoists or dedicated rail systems.

Jan 1, 2012

By Craig Faulkner

Discharge cones for large Semi Autogenous Grinding (SAG) and Autogenous Grinding (AG) mills are subjected to high wear as significant volumes of ground ore and slurry exit the mill. With the larger diameter mills of 32ft to 40ft in size becoming the norm, very high, concentrated wear is highlighting the limitations of conventional discharge cones and frequent changes are subsequently required. This paper outlines the advances made in the design of the Bullnose discharge cone. Superior wear materials to increase wear life over conventional rubber or chrome-moly steel discharge cones and the introduction of key design features to reduce reline times and improve fit and safety during installation, offer significant opportunities for the mill operator. Collated from multiple case studies, the wear data and reline history from 2004 to present clearly illustrate the way in which superior component longevity has reduced the frequency of relines over the life of the product to increase mill availability and effectively increase the tonnes milled in a period.

Jan 1, 2012

By J. M. Benson

Metal powder compaction offers unique advantages in the manufacture of net-shape components using techniques such as laser sintering, conventional press and sintering, metal injection moulding, direct rolling, direct forging, and hot isostatic pressing. If the output from the primary metal production process is in powder form, then considerable cost and energy savings can be realized by direct conversion to semi-finished or final shapes. This possibility exists for titanium and possibly also for Ta, Zr, Hf, and Nb metals. However, these attractive benefits are associated with some significant risks. The high surface-to-volume ratio of powder particles coupled with the reactive nature of these metals means that special care must be taken when handling them. Powder explosions are unfortunately still a regular occurrence internationally and these often result in serious injury and loss of life. Even seemingly 'safe' compounds such as sugar, flour, and grain can be extremely hazardous when handled or milled and dust clouds are produced. In addition, exposure to airborne particles can have adverse effects on the human body, especially when particles are inhaled on a regular basis. Furthermore, the medical consequences of these are not fully understood, especially in the case of nanoparticles. The impact is often not observed immediately and debilitating illnesses may emerge only years or decades later. As far as is known, there are no South African guidelines for handling of metal powders. This paper attempts to provide an awareness of the risks associated with metal powders (including those produced indirectly by other metalworking/finishing operations) as well as some guidelines for their safe handling, based on international best practices.

Jan 1, 2012

The Santa Rita mine is located in north eastern part of Bahia in Brazil and is owned and operated by Mirabela Mineração do Brasil Ltda. Typical SABC circuit was designed as the preferred option for the 4.0 mtpa (500tph) to produce a P80 of 125um for flotation. Although the SAG was originally designed to operate with conventional radial pulp lifters, later it was fitted with Outotec?s Turbo Pulp Lifters ? TPL (Latchireddi, 2005). The milling circuit commenced commissioning on the 24th of October 2009 and the milling circuit achieved the nameplate capacity within days. with small and relatively simple measures to rectify. Since commissioning, the SAG mill has been working in fully autogenous grinding (FAG) mode with no balls (in contrast to the estimated 10% ball charge) and has been consistently treated up to 650tph. This paper examines the comminution design process, the operating philosophies, start-up experiences, post commissioning optimization and future development works. An evaluation of mill performance relative to the design criteria for the project life to date is also included.

Jan 1, 2012

By Ray Brainard

The Jollyville Transmission Main will be a 10.5-km- (6.5-mile)-long, 213-cm (84-in.) diameter rock tunnel. The tunnel will pass beneath the Balcones Canyonlands Preserve, which was established to protect two endangered bird species, six endangered cave invertebrates and a threatened salamander. To address the sensitive habitat that the transmission main is to pass through, the city of Austin developed an environmental commissioning (EC) process that brought together environmental engineers and scientists, the city?s project management team and the designer team to work collaboratively to meet the city?s goals of producing a cost-effective design while also protecting the environment. This paper describes the environmental commissioning process and the benefits it brought to the project and environment through some unique environmental mitigation measures to protect this sensitive area.

Jan 1, 2012

By C. J. Pretorius

More than 30 percent of the global demand for zircon (ZrSi04) is supplied by South Africa. A significant amount of the zircon is exported, and beneficiated products are then imported for industrial applications locally. Beneficiating the zircon locally could have a positive impact on the local market, since zircon is only one of many such cases. Ammonium acid fluoride serves as an alternative anhydrous fluorinating agent for zircon in the synthesis of several metal fluoridesl.2. It provides an effective dry fluorinating method and is easier to handle than hydrogen fluoride or fluorine gas. Zircon exposed to extreme plasma temperatures dissociates and becomes more reactive. The reaction of the plasma-dissociated zircon (Zr02?SiO2) with the ammonium acid fluoride (NH4F?XHF, where x= 1 to 5) forms two main intermediate compounds (NH4)3ZrFr(s) and (NH4) 2SiF6(s), the latter decomposing to form volatile products at relatively low temperatures, providing easy separation of the silicon and zirconium compounds. The ammonium zirconate compound decomposes to form zirconium tetrafluoride (ZrF4), which can be further manufactured into zirconium metal, to name but one product. Data on the kinetics of the reaction of ammonium acid fluoride with zircon and plasma-dissociated zircon, combined with the thermo-dynamic parameters of the reaction, is essential for the development of an industrial process for the production of a precursor for the manufacturing of zirconium metal, namely anhydrous ZrF4. Both the reaction kinetics and reaction parameters will be included in this study, as well as some proof that the reaction proceeds to ZrF4 on a small batch scale. If the exact reaction parameters can be pinned down, a wide spectrum of anhydrous metal fluorides can be synthesized through this fluorination route.

Jan 1, 2012

A typical sub-level block cave mining extraction method employs an undercut level to establish a cavity in hard rock, and as such requires special support methods and products to be installed during the development phase. The undercut level development in the block cave orebody is then sacrificial, and support elements will eventually report to the crusher and perhaps conveyor belt systems for transportation to surface. The choice of support products installed in the undercut level development should take cognizance of the detrimental effect these could have on the mining system such as cutting of conveyor belts, obstructing crushers, safety aspects, and productivity. This work explores the probability and practicality of making use of new-generation support products to make the operation safer as well as enhance productivity in the development phase and during the undercut operation. This paper will investigate the use of glass reinforced plastic(GRP) rockbolts and GRP mesh instead of conventional steel bolts and mesh along with resin capsule-filled holes with the GRP bolts. Complementing this with thin spray liner (TSL) application as another means of creating a safer operating environment, as well as a productive support medium, will also be addressed. These proposed items are envisaged to reduce production downtime and improve the safety of our people. These items are all easy and light to handle, cuttable and crusher friendly, as they will break up during the crushing process.

Jan 1, 2012

By Michael Karmis, Syed Muhammad Tariq, Zeshan Hyder

Secondary or boulders blasting is a regular feature of quarrying operations in Pakistan, especially in cement and stone crushing industries. The main reason for secondary blasting is the production of a large number of boulders during the production blast. These boulders are larger than the feed hopper of crushers and require further breaking. The complex geometry of boulders, relative lack of restraining burdens, and the availability of number of free faces make this kind of blasting more hazardous than production blasting. Secondary blasts have generally unpredictable results and may cause flyrock, airblast, and over-crushing of rock material. Thus, it is essential to have an appropriate amount of explosive charge/powder factor, and for it to be properly distributed in the blast hole. The greater the amount of explosive over the required amount, the more violent is the blast, which will result in more flyrock, airblast, and excessive crushing of boulders.

Jan 1, 2012

By G. J. Joy

Although rates of pneumoconiosis in coal miners have declined substantially in the United States since the passage of the Federal Coal Mine Health and Safety Act of 1969, new cases continue to occur, including cases of rapidly progressive disease. In contrast, Australia's underground coal mining industry has reported few new cases of pneumoconiosis for more than 20 years. Mortality from coal workers' pneumoconiosis in official health statistics and the prevalence of pneumoconiosis among miners screened in X-ray surveillance programs are also lower in Australia. The U.S. National Institute for Occupational Safety and Health (NIOSH) was requested by both industry and labor stakeholders to examine this issue, with the ultimate aim of reducing the rate of pneumoconiosis among U.S. coal miners. A number of factors, including coal dust exposure, silica exposure and coal rank were examined as potential contributors to the above noted differences. Comparison of coal rank data from each country did not illuminate the issue. Air sample data from the coal mining industries in both countries show that coal dust levels in Australian mines are somewhat higher than those reported in similar U.S. mines; however, quartz exposure for Australian miners is lower than for many U.S. miners. If quartz is contributing to the greater number of cases of pneumoconiosis in the United States, more effective dust control measures, as well as an independent exposure standard for respirable quartz in coal mining, should be implemented to reduce this potentially disabling condition.

Jan 1, 2012

By John Ellenberger

The nature of a stone deposit is rarely defined through exploration and engineering design, but more through the actual experience encountered as the mine develops; hence, issues with ground control are often at the forefront for a new mine. Ground control problems account for over 15 percent of lost-time injuries in underground stone mines. The objective of this work is to present actions taken during early development of a stone mine to mitigate the obvious effects of high horizontal stress on ground control. The mine was developed from a box cut with relatively little cover, and high horizontal stresses were not anticipated. Early recognition of possible high horizontal stress resulted in mapping of the mine using the NIOSH-developed Roof Fall Risk Index (RFRI) to provide a baseline to objectively analyze roof conditions. A program of borescoping the mine roof provided valuable roof beam thickness data and found that the roof beam was of minimal thickness, approximately 10 percent of drift width. As the mine developed, it became apparent that ground control problems related to high horizontal stress existed. A concentrated effort was made to improve ground conditions by implemeting a number of mitigation techniques. Actions taken by the mine included systematic roof support, reorientation of mining direction, a lower roof horizon, reduced span widths and reduced mining height in crosscuts to prevent running falls. These strategies resulted in signifcantly improved ground stability.

Jan 1, 2012

The propensity of coal spontaneous combustion can be evaluated using various laboratory testing methods such as R70 adiabatic tests, thermal gravimetric analyzer (TGA) and critical self-heating temperature (CSHT) methods. Each of the methods has its unique characteristics and index for classifying the propensity of self-ignition of coals. Accountable relationships among the propensity indices of different methods should be established. Using the newly established R and TGA testing setups in our ventilation laboratory, samples from US coal mines have been collected and tested. 70 The TGA is a relatively new quantitative method. A test can be conducted in a relatively short time. The temperature and weight of the sample can be measured with high precision and then used to determine the activation energy of the coal which is a good indicator for potential of self-heating. Under a specific experimental design, the TGA technique could perform the proximate analysis for determining coal quality parameters (e.g., moisture, volatile matter, fixed carbon and ash content). These parameters can be used in an empirical equation for assessing the potential of coal self-ignition. The trend of activation energies determined using TGA techniques and adiabatic tests are reasonably consistent with each other. As a case study, a comparative analysis of these two methods for determining activation energy was made on coal samples collected from Indiana. The kinetics of the spontaneous combustion mechanism has been explained. If the functional groups of a coal are easier to be activated with a small amount of activation energy at a relatively low temperature, the coal will has a higher potential of self-heating. With the kinetic and coal quality parameters determined by the TGA setup, it has been found that the coal with low potential of self-ignition has low self-heating rate, high activation energy and high minimum self-heating temperature.

Jan 1, 2012

By S. Koski

The Cerro Verde copper-molybdenum porphyry mine, majority owned and operated by Freeport- McMoRan Copper & Gold, is located 30 km southwest of Arequipa Peru. The concentrator, which produces copper and molybdenum concentrates, started operating in late 2006 with a 108,000 tpd design capacity, processing primary sulfide ore (mainly chalcopyrite and molybdenite). Plant capacity was recently increased to 120,000 tpd. The comminution circuit consists of one 60? x 113" primary crusher, four MP-1000 secondary crushers in closed circuit with dry screens, four 2.4m x 1.6m High Pressure Grinding Rolls (HPGRs) in closed circuit with wet screens, and four 7.3m x 11m gearless ball mills in closed circuit with cyclones. The HPGR circuit is fed by the Secondary Crushing circuit product at a T80 of 35 millimeters, and the HPGR circuit product feeds the Ball Mill circuit at a T80 of 3000 microns. This paper describes operating experiences with HPGRs during these first four years highlighting improvements in operating practices and presentation of data regarding operational efficiencies, also discussed are the primary benefits provided by HPGRs such as production of micro fractured particles, reduced ore Bond Work Index, and reduced power consumption. Cerro Verde represents the first installation of HPGRs in both the copper industry and large scale hard rock mining.

Jan 1, 2012

By M. S. P. Rampedi

The paper reports on a vacation work project conducted at Khuseleka No. 1 Shaft, Anglo Platinum, where there was a need to optimize the transport of personnel to level 15 and below. Approximately 900 men per hour need to travel between the shaft and the start of the current chairlift system. Time studies were used as the major indicator of the extent of the current problem, and it is recommended that a new chairlift system be installed to cover the distance from the vertical shaft station at level 15 to the chairlift decline station on level 15. A capital cost of approximately R10 million is necessary to carry out the proposed recommendation. Khuseleka No. 1 Shaft has the capacity to wind 1070 people per hour, and the current labour complement going to the level 15 shaft station stands at 1570 employees; thus at optimum efficiency the proposed chairlift system could transport the entire shift to the start of the current chairlift system in only 1 hour and 45 minutes. Reducing the distance walked at the start of the shift may also have an impact on productivity.

Jan 1, 2012

By W. Burger

Mechanical excavation methods can significantly improve excavation performance and labor safety compared to drill and blast operations. Herrenknecht has developed a mechanized shaft sinking method for soft and medium strength rock. This system combines innovative technologies which allow simultaneous excavation, removal of cut material and the installation of rock support. This Shaft Boring Roadheader ?SBR? is flexible in diameter and can be used in shafts with changing diameters and different shaft support requirements for depth up to 2,000 m. During regular excavation personnel are not required to access or work on the shaft bench. The boom used to cut the shaft profile is based on roadheader technology.

Jan 1, 2012

By M. C. Walton, W. Roelofs

ABSTRACT: In most cases, a refractory repair involves dealing with used refractory linings above shoulder height, defining these as overhead refractories. This paper details a method of personnel protection involving a low-pressure inflatable balloon system, installed to prevent the dislodgement and freefall of in-situ refractories. This system has been successfully applied to numerous types of vessels in the process industries in the last three to four years. This paper, prepared for the CIM Conference of Metallurgists held in Vancouver, British Columbia in October 2010, outlines details of the system and gives examples of successful applications.

Jan 1, 2012

Despite the claims of energy efficiency and the considerable development that has gone into dramatically extending rolls? life and facilitating rolls? change-out, in the six years since the last SAG conference, only a few HPGR operations have entered the realm of mineral processing. Risk barriers to the take-up of new equipment or processes are: a massive increase in materials handling issues as well as in the number of pieces of equipment required, low total circuit potential energy savings, and similar or higher capital costs. An alternative route is to make use of the complementary strengths of the HPGR and SAG in hybrid circuits. Minimising materials handling issues, providing an ideal balanced feed to the AG or SAG mill, and improving controllability through shifting grinding load as the RoM feed changes, are all potential major advantages to this approach. Conceptual circuit layouts, based on real measured ore and equipment data, are presented here to illustrate the potential production upside, the reduction in operating costs and the reduction in the physical and energy footprints.

Jan 1, 2012

As mine haulage vehicles become larger, the danger to a driver during a fire emergency is increased by the greater height of the cab above ground. Also, property damage due to fires on bigger trucks can be substantial. To solve this problem, the Department of Interior's Bureau of Mines, through two research and development contracts with FMC Corporation, San Jose, California, has developed two reasonably priced, reliable automatic fire sensing and suppression prototype systems for large haulage vehicles. At the onset of the large mobile equipment fire protection contract effort, it was learned that fires were frequently experienced in open-pit mine haulage equipment, especially large trucks. As the size of equipment has grown, so has the hazard presented to an operator forced to leave his truck in a hurry when fire breaks out and his normal path to the ground is blocked by flames. His only recourse is to jump from the cab platform to the ground, and the one-story drop of 10 feet or more can severely injure him. It is with these factors in mind that a program was undertaken to provide a fire detection and extinguishing capability tor the large mobile equipment, especially trucks, used in open pit mines.

Jan 1, 2012

By Neil E. Izatt, Ronald L. Bruening, Steven R. Izatt

"IBC has developed environmentally friendly Molecular Recognition Technology (MRT) processes to selectively extract, recover, and purify a wide range of metals from a variety of process streams. The incorporation of MRT into process flow sheets can improve the economics of the processes. MRT separations are effective even at low (mg/L to \i%JV) metal levels. MRT processes are sustainable, being economically viable, energy efficient, and environmentally friendly as well as having a low carbon footprint. Examples of MRT processes will be presented and discussed involving platinum group metals, gold, rhenium, and other metals of interest to the mining community.IntroductionA significant portion of the earth's precious metal resources has been moved during the past century from underground to above ground [1]. This movement has important economic, health, environmental, ecological, and sustainability implications for the earth and its population. There is concern that recycling of certain precious and specialty metals from end-of-life (EOL) electronic wastes (e-wastes), catalyst wastes, mining waste streams, and other waste products such as rechargeable batteries is not adequate to maintain supplies of these metals sufficient for future needs [2-4]. Improved metal recycling rates and more efficient metal recovery from the enumerated wastes would significantly reduce the amount of virgin metals that must be mined to support our lifestyle [5]. More efficient separation procedures in ore processing flow sheets and more effective recovery of metals from low-grade waste streams would reduce metal loss in the mining industry."

Jan 1, 2012

By P. Condori

Palabora Mining Copper (PMC) has two autogenous mills that have been in operation since 1976. The mills were originally designed to treat 30 000 t/d of open cast copper ore in a closed circuit with cyclones. As the ore body went deeper the open cast method of mining was changed to block caving, a consequence of this was the dolerite content (hardest barren material) increased significantly, increasing the production rate of pebbles and thus reducing the milling capacity. In order to cope with the increased ore hardness and to increase mill capacity, a second ball milling stage and pebble crushing were incorporated to the circuit. The above actions created new challenges to the circuit operation and bottlenecks in different areas of the milling circuit. This paper reports the holistic work performed on the Palabora autogenous milling circuit including the implementation of a mill constraint control scheme, the implementation of a pebble removal system from the circuit and a new circuit configuration. The achieved plant stability and increment of ore throughput are also reported in this paper.

Jan 1, 2012