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By L. Jurca, C. Gligor

After 1990, a great process of re-organisation and economic reform has occurred in the Romanian mining sector and especially in the pitcoal mining in the Jiu Valley. This process has included both legislation and the main aspects for getting an economic efficiency in the environment issues and for dealing the problems with social impact. Accordingly, starting with the year 1993 a new mining method has been introduced to turn efficient the pitcoal mining, and we speak about mining with caved in bed. This method has two variants: - with transverse strips and caved in bed; - with long face and caved in bed. Each of the above-mentioned variants has in turn several subdivisions, depending on how the longwall is prepared and on other characteristics. By using this method, the output has increased compared to other mining methods. The main safety aspects concerning caved in mining refer to: - great emissions of methane; - technical aspects (a mining method system, supports, discharging process); - pressure driving (analysed for the case of mining with long face, with transverse strips as well for the case of transverse strips when mining a subsequent sublevel).

Jan 1, 2003

By A. M. Hefny, F. P. Siew, P. G. Ranjith

Fracture initiation and propagation, being one of the most intensive subjects in rock mechanics; contribute significantly to the deformation of jointed rock masses. An experimental study on fractured granitic rock was carried out to determine the peak strength of specimen under triaxial loading conditions. The commonly observed failure mode for rock specimens in this study was found to be the shearing of the plane of weakness. The minimum peak strength of fractured rock is observed when the joint orientation is approximately 70° to the horizontal axis. Based on experimental test data, an empirical expression was developed to accommodate the effect of joint orientation and joint trace length in estimating the peak strength of fractured rocks. The predicted values of peak strength using the proposed equation well agree with the experimental results carried out on singly fractured specimens under triaxial loading conditions. The threshold stress values of crack initiation and propagation depend on joint geometrical parameters, their degree of interconnectivity, as well as surrounding stresses on the fracture plane.

Jan 1, 2003

By F. M. C. C. Vieira

Four mining alternatives for exploiting an ultra-deep orebody were assessed through a multidisciplinary evaluation process which involved: the generation of a 3D geological model; the design and scheduling of life-of-mine layouts; the analysis of anticipated ventilation and cooling conditions; the study of rock-related risks of mining in ultra-deep stress environments; the logistic implications of transporting men, rock and materials; and, lastly, the economic implications of each option. Once results from the integrated mine design assessment were available, mine planners were faced with an important problem to solve: how to identify the optimal mine design alternative when numerous assessment measures and multiple decision criteria needed to be considered simultaneously? To address this ‘multiple-attribute decision problem’ and arrive at the ‘optimal layout for ultra-depth’, a generic decision methodology that uses principles of ‘utility’ was applied. The methodology assumes that ‘single-value risk estimators’ do not account for the inherent variability of real conditions. Therefore, risk estimators were represented by statistical distributions of their incremental changes, where applicable. The stochastic variables, once defined, are used as inputs in the ‘utility’-based layout decision scheme. This ‘utility’-based decision methodology offers a framework for mine design decisions to be made objectively, when complex trade-offs between multiple risk domains need to be considered simultaneously. Upon applying it, one of the layouts emerged as the preferred alternative. Keywords: Utility; mine design; multiple-attribute decision; layout selection

Jan 1, 2003

By W. Biermann

All industrial processes are economically driven, resulting in the ever increasing need for process optimization in order to stay competitive and profitable. Numerous models has been published depicting the optimization of the raw material usage in an arc furnace, as well as the thermal and electrical efficiency; however, to obtain a holistic view of the cost-effectiveness of the process one needs to expand the model to include the cost of all the operational variables. This project therefore aimed to not only include the raw material feeds and power consumption as input variables, but also the labour, maintenance, and environmental costs to generate an all-inclusive financial balance. In the end, the model was able to mathematically optimize the ferrochrome (FeCr) production process through evaluating the effect of a specified combination of input parameters. It could therefore be used as a tool to aid in managerial decision-making; to appraise and correspondingly adjust certain operational variables in order to achieve a maximum return on investment. This paper fully describes the reasoning behind the choice of the essential model components, the assumptions made during the models development, the calculation approach, as well as the advantages, limitations, possible applications, and areas for expansion of the final model. Through running simulations with plant data, it was found that the accuracy of final model remained fairly constant when applied to stable furnace conditions, but was met with a number of limitations when applied to more complex situations. These limitations could, however, be overcome through further development and expansion of the existing model to include a larger number of process variables.

Jan 1, 2012

By F. A. Camisani-Calzolari

The latter half of the 20th century has seen the proliferation of a series of codes to address commodity needs which were brought about by rapidly advancing technologies and the globalization of markets and consumerism. This paper addresses the specific needs and the origin of this surge and presents these codes in the context they were developed. It also compares the main codes or groups of codes and elaborates upon their strengths and weaknesses. Three main categories of codes are identified, namely: codes for reporting to international agencies, codes addressing government needs and, finally, codes for the investors and the stock market. Codes governed by international agencies usually relate to strategic commodities which have highly specialized fields of usage like nuclear power generation where international cooperation is eventually the only viable approach for both the development of technologies and their applications. Codes for reporting to governments address the necessity of each state to exploit their mineral potential profitably and to secure the preservation of wealth for future generations. Reporting to investors is experiencing a considerable popularity as of late because of globalization in mining and the growing need for outside financing of mining projects, whose capital requirements are getting out of reach for the average mid-cap mining company. All these codes have advantages and shortcomings dictated by the specific circumstances under which they were developed, therefore necessitating the definition and implementation of some kind of international standard whereby investments and the spread of information across political boundaries would be facilitated. Though none of these codes might ever become international in the true sense of the word because of significantly different legislations at national level, a step that would greatly contribute to the cross-border disclosure of information would be the reciprocal recognition of competent persons by the major mining countries, including China and Russia. It is also becoming essential that financial institutions and investors be properly advised on mining projects by reporting reserves and resources in a transparent and responsible way with the relevant public disclosures being compiled by professionals who take full responsibility for their submissions. Keywords: reporting codes, mineral resources, mineral reserves, competent person, UN Framework Classification, IAEA classification, JORC Code, SAMREC Code and CRIRSCO.

Jan 1, 2003

By J. -P. Gisiger

On the basis of laboratory test results a comparison of various parameters (unconfined compressive strength, CERCHAR and LCPC abrasivity indexes, mineralogy) is presented and discussed in order to outline certain correlations between them. Samples cover a wide range of lithological types coming from various sites of tunnels. A partir de résultats d’essais de laboratoire, une comparaison de divers paramètres (résistance à la compression simple, indices d’abrasivité CERCHAR et LCPC, minéralogie) est présentée et discutée dans le but d’en tirer certaines corrélations. Les échantillons couvrent un large éventail de types lithologiques provenant de plusieurs sites de tunnels. Basierend auf Laborversuchen, werden verschiedene Gesteinseigenschaften (Druckfestigkeit, CERCHAR und LCPC Abrasionsindexe) präsentiert und Korrelationen aufgezeigt. Die untersuchten Proben verschiedenster Lithologien stammen aus mehreren Tunnelprojekten.

Jan 1, 2003

By A. Sariisik

This study analyses the results of a pilot trial of a newly developed armed-chained stone-cutting machine. The machine was developed in Turkey and trialed at the Kaklik/Kocaba travertine quarries in the Denizli District. An armed-chained cutting machine is an alternative to the diamond wire cutting method more frequently used in the production of natural stone quarry blocks, and increases production efficiency and quality. Since there is no need to collapse the blocks using the armed-chained cutting production process, there is no risk of the block developing cracks. This results in a considerable increase in the efficiency of natural stone block production. The armed-chained cutting machine is easier both to assemble and run when compared to other block cutting methods. This process resulted in the production of a larger number of blocks at a lower cost within the same time frame, particularly in travertine quarries and in all other natural stone quarries. The block efficiency in travertine quarries was calculated as 65?80%using the armed-chained cutting machine, compared with 7?14% using the normal diamond wire cutting method.

Jan 1, 2010

By J. Cygankiewicz

Efficient prevention of mine fires is impossible without predicting the self heating processes in the given geological and mining conditions. The respective forecasting method is presented in this paper based on the following assumptions: - factor deciding on fire hazard in the underground workings is the process of heating of coal from the primary rock temperature to the critical temperature when the heating rate growth rapidly - another important factor is the fire incubation time defined as time needed to achieve the critical temperature. This time is determined by balance of heat and mass in the heated coal - contact of crushed coal with oxygen in air cause some exothermic processes as : physical and chemical sorption of oxygen , oxidation reaction and evaporation of humidity Heated coal transfers its thermal energy to the environment by conductivity to the rocks and by convection to the flowing gases. The heating is possible if thermal energy generated from coal is greater then the share transferred to the environment. The paper presents the laboratory method of measurement of heat generation in adiabatic conditions. Also the mathematical model with examples of computation enabling to forecast the self heating process of crushed coal is presented.

Jan 1, 2003

By K D. Wilkes

The WEMCO Heavy Media Drum Separator was first introduced by WEMCO in California in the 1940`s, initially from their base in San Francisco and later when the company moved to Sacramento. The WEMCO Company became a part of EIMCO Process Equipment in 1985, and in 2002 EIMCO became a part of the GL&V Group when Dorr-Oliver EIMCO was created. Throughout this period of time the WEMCO Drum has been installed on a variety of different applications and is now operating at the heart of many of the world?s largest Minerals and Coal Processing Plants, as well as being used by many smaller producers and metal re-cycling operations. This paper looks at the practical aspects of using WEMCO Drums in a representative range of processing applications.

Jan 1, 2006

By M. A. Jensen, J. J. Bettencourt

SYNOPSIS An analysis was made of records of accidents involving Bantu mineworkers and which resulted in either minor injuries or hospitalizations to determine patterns in underground accidents from which to formulate priorities in accident prevention in gold mines. The results showed that: (i) specific labour categories, such as inexperienced men, are exposed to certain types of hazards the extent of which warrant the separate design of safety programmes to meet their specific needs; (ii) the systematic study of minor accidents provides a dependable source of. information of which safety departments could make greater use in their efforts to control and prevent mining accidents.

By Peter Townsend, Sergei Diachenko, Allan Moss

The Palabora Mining Company has successfully extended the life of its operation by developing a 30,000tpd block cave underground mine below the now closed open pit. The process of transitioning from surface to underground mining has been technically, operationally and managerially challenging. This has been due to a number of factors; in particular, the development of a block cave in a very competent rock mass. The competence of the rock mass is clearly demonstrated in the open pit that preceded the block cave, one of the steepest deep open pit excavations in the world. With cave breakthrough, however, the pit was ?instantaneously? deepened by 400m causing a major failure of the northwest wall involving close to 100Mt of waste material.

Jan 1, 2006

By K. M. Li, Y. D. Zhang

The selection of stripping dragline is a complicated problem. Several factors, such as the deposit buried conditions, the demand of mine production rate, cast blasting result, the mining/stripping operation method and parameters, etc. may comprehensively influence the optimal selection of technical specifications of the dragline. Under these circumstances, the basic thinking and procedures for dragline selection are put forward as follows. •Step 1—Initially estimate the dragline annual stripping rate and stripping bench height according to the annual coal production rate and advancing speed of mining front. Then the feasible alternatives of dragline sizes can be calculated and selected from the existing dragline series. •Step 2—A computer simulation model is developed to simulate the dragline stripping operation, to obtain a series of working face parameters, then to select the best dragline alternative. This step can be interactively iterated until the satisfactory results are obtained. •Step 3— Sensitivity analysis can be done with the systems simulation model by changing the stripping bench parameters, e.g. stripping bench height and cut width, etc. to verify and modify the selection results if necessary. The mathematical model for dragline stripping simulation has been set up. The flowchart of the model is shown. A case study for a large surface coal mine with annual production rate of 16 Mt/a is followed. The dragline bucket capacity and operation radius, stripping bench height and cut width as well as other parameters are comprehensively optimized and selected. Keywords: Open cast, dragline, specification, selection, cast blasting

Jan 1, 2003

In today?s high tech world, systems are getting bigger, faster, better. To remain at the leading edge, in any business, depends on accurate but flexible design thereby allowing operational managers to provide alternatives to improve their operations. The ultimate goal is to deliver to plan, with optimum economics. Mining is no different, with falling prices and escalating costs, improved margins become the focal objective. There are many ways to achieve this, ranging from operational efficiency improvements through production scenarios to planning initiatives. Of all, planning usually receives the least attention, yet it is the area of most influence on the NPV of the reserve. With computer technology, numerous concepts and iterations are possible thereby closing the gap between optimal and actual design. This paper discusses the application of the split shell design at the De Beers Venetia open pit in South Africa.

Jan 1, 2001

"In mechanized mining, poor equipment efficiency (availability, utilization, productivity, and quality) can endanger the success of the operation. This case study will show how an initiative to improve equipment performance developed into a comprehensive turnaround plan for the mine that placed it in the forefront of performance achievement.As part of a company-wide review process, poor overall equipment effectiveness (OEE) was identified as a major reason for the mine not achieving its targets. A project to improve the OEE identified eight improvement areas (elements) that contributed significantly to the poor performances. Measurement metrics were determined for these elements, followed by determination of baseline and target (improved) key performance indicators (KPIs). Cost savings associated with the improved efficiencies were calculated and tracked throughout the project. The mine team determined the specific actions required to achieve the target KPI in each element. These were individually developed and managed like mini-projectswith allocated responsibilities for delivery. The paper will indicate how this OEE improvement initiative triggered an improvement in almost all sections of the mine. Soon after launch, the initiative gathered momentum as the KPIs starting to improve. A visible tracking system exists at the mine and each employee can see the improvements and feel the success. The original eight elements were extended by five more, and the mini-projects grew as participants saw the success of the initiative.This paper concludes that through management and worker involvement, visible measurement and controls, and carefully chosen improvement elements, the mine was turned around. It is now achieving and exceeding its targets, and employee relations and motivation as well as safety have improved considerably. All of these achievements are reflected in the bottom line."

Jan 1, 2016

By A. Patri, D. S. Nimaje

Wireless sensor networks and wireless communication systems have become indispensable in underground mines. Wireless sensor networks are being used for better real-time data acquisition from ground monitoring devices, gas sensors, and mining equipment, whereas wireless communication systems are needed for locating and communicating with workers. Conventional methods like wireline communication have proved to be ineffective in the event of mine hazards such as roof falls, fires etc. Before implementation of any wireless system, the variable path loss indices for different workplaces should be determined. This helps in better signal reception and sensor node localization, and also improves the method by which miners carrying the wireless devices are tracked. This paper proposes a novel method for determining the parameters of a suitable radio propagation model, which is illustrated with the results of a practical experiment carried out in an underground coal mine in southern India. The path loss indices, along with other essential parameters for accurate localization, have been determined using the XBee modules and ZigBee protocol at 2.4 GHz frequency.

Jan 1, 2015

By P. W. Lotz

Traditionally, bottle roll tests have been used to optimize the extraction process for best gold extraction and recovery. Such tests typically involve exposing the ore to defined reagent concentrations (lime, cyanide and sufficient oxygen) and balance the gold input with recoveries and losses. With mounting pressures to accommodate sustainability issues during development work, it became apparent that much more information would be required on the interactions and kinetic behaviour of solid and solution species during the entire leach process. This information is vital to enable proactive management of critical issues such as cyanide, arsenic, water and tailings management. Inadequate management of these aspects has led to temporary closures and, in cases of non-compliance, to the dynamically changing regulations. MINTEK?s advanced leach facility (ALF) is being developed with the aim of bridging the knowledge gap between the gold leach process and the predictable environmental impacts upon discharge. The facility aims to monitor all parameters of relevance such as pH, Eh, dissolved oxygen, metals, cyanide species, and viscosity during the entire process to enable more informed decisions on practical interventions. The presented set of data reflects first experiences gained from processing a refractory gold ore concentrate. Attempts at optimizing the process were limited due to the developmental nature of the work. Data relating to leaches with differing preoxidation conditions and cyanide staging is presented.

Jan 1, 2009

By A. F. S. Schoukens

The Mintek Thermal Magnesium Process (MTMP) was successfully demonstrated in November 2004. The pilot plant was operated continuously for 8 days, during which about 30 tons of magnesium producing recipe was smelted in a DC (direct-current) arc furnace at a feed rate of 525 kg/h. The furnace was operated at power levels of 700 to 850 kW, resulting in slag tapping temperatures of 1600 to 1700°C. Magnesium extraction averaged 77 per cent and was as high as 85 per cent during good extraction periods. The furnace generated 70 to 85 kg/h magnesium vapour that was delivered to the condenser where the temperature was controlled at 680 to 720°C. The novel condenser captured the magnesium in a liquid state, which was tapped periodically as required. In total, 15 magnesium-tapping operations were carried out, proving that online magnesium tapping can be consistently performed without any major difficulty. About 3500 kg of crude magnesium was produced with a quality that was similar to, if not better than, that of the Magnetherm?s crude metal. The condensation efficiency averaged 85 per cent, and peaked at 87 per cent, which exceeded the target of 80 per cent set for the pilot scale. A brief magnesium market study was also carried out. Magnesium demand is expected to keep on growing by 6 to 8 percent over the next 10 years and could reach 2 million tons by the year 2020. The growth will be mainly in the die-casting sector for light-weight automotive applications. China is likely to remain the dominant supplier of primary magnesium but competitively priced non-Chinese magnesium producers will be needed to sustain the anticipated growth of 6 to 8 per cent over the next 10 years. In addition, a prefeasibility study was undertaken for a commercial plant. The study confirmed the relatively low capitalcosts of the MTMP process, as well as the competitiveness of theoperating costs, as compared to the industrial electrolytic process.

Jan 1, 2006

By R. Abela

Heavy mineral sands are usually beneficiated in a spiral concentrator circuit prior to separation of heavy minerals into streams of zircon, rutile and ilmenite. The performance of the spiral concentrators is heavily affected by the presence of slimes in the rougher feed. The paper quantifies the effect of slimes content and discusses the beneficial effect of spiral feed de-sliming. The net effect of inefficient slimes removal can cause significant recovery losses of the heavy minerals present in the feed.

Jan 1, 2003

By T. R. Curr, R. T. Jones

Keywords: Pyrometallurgy, Mintek, DC arc furnace, plasma, smelting, chromite, ilmenite, cobalt, slag, zinc fuming, dust, magnesium, laterite, ferronickel, arc modelling, Pyrosim, thermodynamics The Pyrometallurgy discipline at Mintek was initiated in the early 1970s, to support a growing ferroalloy industry in South Africa. In addition to a range of pyrometallurgical options, Mintek specialises in DC arc furnace technology and has pilot plant facilities up to 5.6 MVA, as well as a strong base in process and arc modelling. Industrial processes have been developed for ferrochromium production, ilmenite smelting, and cobalt recovery from slag. Recent work has been done on such processes as the production of ferronickel from laterite ores, the fuming and condensation of magnesium, and the recovery of platinum group metals from 'difficult' feedstocks.

Jan 1, 2006

By G. R. Lane, A. Vermeulen, S. van de Venter, S. Bhoowanpursadh

Over the past two years Anglo Platinum made use of the specialist skills of Cyest Corporation to develop a Mine Optimization Tool (MOT) to enhance the current suite of in house mine planning tools and processes. The application was built in a multidimensional modelling environment developed by Cyest called CarbonL. This has allowed complex modelling that is transparent to the business users and therefore is not prone to the ?black box? approach that generally exists with these types of complex tools. The purpose of the MOT is to have an integrated software tool that can schedule production activities by half level for a shaft complex, while at the same time integrating the economics concomitant with that schedule. The tool allows the user to configure all activities relevant to the selected mining method, define the mine design parameters and geological parameters, define scheduling rules and then schedule all activities. This allows the user to test various production strategies and schedules very quickly and easily in terms of shaft value, costs and revenue profiles, labour complement and production ramp up so as to determine the option that best fits the overall strategy. This allows assessments of multiple scenarios in a relatively short period of time, after which only the best option is taken forward for graphic design and scheduling. This paper discusses briefly the rationale behind the Mine Optimisation Tool and the underlying workings of the modules that comprise the tool. It also covers the life cycle of this tool from the original prototype through to the final Mine Optimisation Tool software and discusses the positioning of the final tool.

Jan 1, 2007