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By J. Leinart

As is readily apparent, the reliability of the early-stage costs estimated for any mining project are critical to the viability of that project. An estimate too high might leave a potentially profitable deposit undeveloped or worse yet, available to a competitor. One too low might waste investment dollars in a project not yet economically ripe. There are two aspects critical to any estimate: 1. The cost data used to represent the values of the wages, salaries, supplies, and equipment. 2. The design used to determine the engineering parameters upon which the above estimated values are based. Given that all of the information contained in Mining Cost Service is provided by suppliers, equipment manufacturers and mine operators, one wonders why there is any question as to the reliability of cost estimates developed using this information. Given that it is all actual (as opposed to statistically derived) data, where do the problems with estimate reliability lie and what is the impact of the data on that reliability? The following presents a series of analyses designed to assess the reliability of the cost estimating process. Both the actual cost data and the engineering parameters upon which they are based are examined in an attempt to quantify and understand the importance of each. While several sources of cost information are available (Means, Richardson, Primedia?s Equipment Watch, and individual suppliers and manufacturers), the following rely solely on data contained in InfoMine USA, Inc?s, Mining Cost Service and in its Sherpa Mine Cost Estimating Software.

Feb 27, 2013

By J. Torma-Krajewski, M. Lehman

In 2005, NIOSH and Badger Mining Corporation entered a partnership to implement ergonomic interventions, including a systematic process, to address exposures to risk factors that may result in musculoskeletal disorders or other types of injuries/illnesses. As a result of this partnership, an ergonomics process was integrated with the existing safety and health program to promote an on-going application of ergonomic principles, and over 40 task-specific interventions were implemented during the first year of the process. This paper presents details of the process integration, and several examples of task-specific interventions that reduced exposures to risk factors.

Jan 1, 2007

By William G. Schultz

Sylvite of Canada, a wholly owned subsidiary of Hudson Bay Mining and Smelting Co., operates an 8000 TPD potash mine and refinery located nine miles North East of Rocanville, Saskatchewan. Prior to Hudson Bay's entry in 1968 into potash mining and refining, it was one of the more traditional and conservative Canadian Mining Companies whose principal business had been for many years a successful copper-zinc mining and smelting operation located at Flin Flon, Manitoba. The potash reserves being mined by Sylvite were acquired through the acquisition of Francana Oil and Gas. This acquisition was at the time when several major potash mines were being developed or had recently been brought into production in the Province. These mines are owned by either very substantial Canadian Mining Companies or Multi-National Mining Companies with considerable potash mining experience. At that time, it became very apparent because of the new mines coming into production, potash mining and refining would quickly become a very competitive industry. Because of long term considerations, Hudson Bay decided to proceed with the development of its potash reserves, recognizing the Mine and Refinery would have to be the most advanced available in order to successfully operate. This report deals with the mining operation at Sylvite and the degree of success Sylvite has achieved.

Jan 1, 1972

By L. E. Eary

Many of the major international gold mining companies provide data on rates of greenhouse gas (GHG) emissions as part of their environmental reporting commitments. These data are evaluated by an index defined as the annual GHG emission rate in metric tons, divided by the annual amount of gold produced in grams, and referred to as GHGgold. This paper examines ranges of GHGgold values for a cross section of gold mines as a function of mining method (openpit, underground and combined operation) and ore-processing method (mill, heap leach and combined methods) for reported ranges of operational data, including annual total tons mined, ore processed and gold grade. The evaluation shows that ranges and distributions of rates of GHG emission are approximately similar across different mining methods and ore-processing methods. The data presented in this paper provide the context needed to make comparisons of GHG emissions reported in companies’ annual reports to the ranges reported for the overall gold mining industry.

Jan 1, 2009

By Dennis Ofiara, Michael Lewis

An experimental 1.75 meter Shaft Boring Machine was designed and manufactured by The Robbins Company. The drill was used by contractor Drillcon Raise AB to drill test shafts at an SKB underground test facility. SKB is the Swedish authority responsible for safe management of nuclear waste materials. This “SBM1.8” Shaft Boring Machine was used to drill shallow test shafts ingranitic rock at SKB’s Aspo underground laboratory. The drill used a unique vacuum mucking system. The bored shafts were held to very strict tolerances for bore diameter, straightness, and verticality. This drill was launched and operated from a mobile launcher. Headroom and working space were limited. The SBM1.8 drill produced acceptable test holes. SKB will carry out several studies to determine the suitability of this geology, and of this technique, for safe nuclear disposal. In addition to future use at SKB, many applications are foreseen, particularly in the civil construction industry.

Jan 1, 2005

The title of “the world’s biggest volume-produced hydraulic breaker,” that was held for more than a decade by the Atlas HB 7,000, changed hands with the launch of Atlas Copco’s HB 10,000 at bauma 2007. A service weight of 10 t (11 st) and up to 50 percent higher productivity represent major steps toward a new market segment: the use of hydraulic breakers as cost-efficient production machines for primary breaking and as a true alternative to drilling and blasting. The HB 10,000 has all the technical features developed by Atlas Copco for its hydraulic breakers and includes: StartSelect — the breaker’s start-up and shut-down behavior can be adapted to the conditions. AutoControl that ensures an optimized balance of impact energy and impact frequency to maximize percussive performance. Auto-Control also reduces blank firing force and controls energy recovery. PowerAdapt — if oil pressure is too high, the breaker shuts down automatically. This prevents downtime and is particularly useful when breakers are used on different carriers. DustProtector II — a combination of multiple strippers prevents abrasive rock dust and foreign bodies from penetrating the lower breaker section. Conti- Lube II — the automatic lubrication unit guarantees optimal lubrication of the breaker at all times.

Jan 1, 2007

By Atta Ur Rehman, Kwame Awuah-Offei

"Information diffusion potential of a social media user affects how quickly information about a mineral project can diffuse through that user. If management can use social media and network analysis in community engagement programs to understand how fast and how far information will diffuse to communities and followers of particular social media users, it can selectively focus on the most influential users. This article proposes a method to examine the information diffusion potential of social media accounts. The work uses Gephi, an open source software, to extract and analyze data from different Twitter handles to predict their information diffusion potential. The work uses case studies of real Twitter users (e.g. mining news organizations and bloggers) associated with mining to illustrate the approach. The case study results show that there are significant disparities in information diffusion potential that will demand selective attention. This research will help mines develop effective social media engagement strategies.The mineral industry provides raw material for industrial activity to support society (Martens and Rattmann, 2001). Mines have changed from conventional mining practices to sustainable ones because of the negative impacts of mining in the past and increased public awareness (Wang et al., 2016). The concept of sustainable mining is getting mature, as stakeholders (e.g., governments, investors and host communities) are getting more involved in mining projects (World Economic Forum, 2014). The failure of mining companies to address the demands of these stakeholders might result in the failure to acquire a social license to operate (SLO) (Thomson and Boutilier, 2011). The SLO, if granted, is mutually beneficial to all stakeholders. Mines prefer being granted SLO and keeping it to avoid any kind of social unrest due to their operation (Prno, 2013; Moffat and Zhang, 2014). Mining communities can grant different levels of SLO ranging from withholding SLO to psychologically identifying with the project (Joyce and Thomson, 2000; Thomson and Boutilier, 2011).Most of the previous work to understand community perceptions and SLO in mining is generally qualitative (ICMM, 2012a; Thomson and Boutilier, 2011; Prno, 2013; Moffat and Zhang, 2014; IFC, 2014). In particular, there is limited work on how community perceptions change over time due to information diffusion (Boateng and Awuah-Offei, 2017). However, SLO changes with respect to time (Yates and Horvath, 2013), which can result in risks that are not easy to predict. Mine managers and engineers have a desire to understand these changes so as to mitigate these risks (Que and Awuah-Offei, 2014; Que et al., 2015)."

Jan 4, 2018

By Edward Holloway

The basis for the selection of the ultimate pit for an open-pit mining operation is generally opaque. Some form of value-based analysis will generally guide the final decision; however, the value will often gradually plateau while the ultimate pit size continues to increase. There is no established framework to guide specialists in the selection of the ultimate pit, with such decisions regularly made on a somewhat arbitrary basis. The key component that is missing from the analyses typically used to select the size of the ultimate pit is risk. Once risk is quantified within the analysis framework, the decision-mak-ing range is significantly reduced and the process for select-ing the ultimate pit becomes more consistent, replicable and defensible. The technique outlined in this paper provides an approach to including risk in the process used to select the ultimate pit.

Jun 1, 2024

By R. W. Carn, D. Vincent

Environmental Considerations With significant increases in bulk coal movements through terminals, operators are under constant social and political pressure to reduce or remove environmental pollution problems incidental to their operations. To meet these requirements, both equipment manufacturers and terminal designers are endeavoring to design equipment and systems with stringent environmental controls. The most challenging environmental problems facing coal terminal designers and developers are terminal siting restrictions, dust control, and noise abatement. Terminal Siting Finding a suitable site can be a difficult problem because of public concern over coal dust or the impact of a terminal on the surrounding community or natural habitat of the area. Often the only suitable flat land available for terminal development is on a tidal estuary or salt water marsh with great environmental value. In many cases a period of four to six years of full environmental and social assessment has been needed. A recent example of such difficulties is the expansion at Roberts Bank, British Columbia, where environmental impact assessment studies and their public review took almost six years from initial expansion applications until the time of approval. Dust Control Modern coal terminal dust control techniques usually consist of water sprays at strategic locations to suppress dust. The application points include rail car or barge dumper, main conveyor transfers, perimeter sprays around stockpiles, stacker/reclaimer, ship-loader transfers, and loading spout. The water sprays may include a chemical wetting agent or surfactant to reduce the water requirement and increase effectiveness. Recently there have been advances with development of effective micro foam agglomerating agents. In these systems, a micro foam with very small bubble sizes is sprayed into the coal stream. The foam fills the interstices between coal particles and wets the coal fines. These systems have proven to be very effective and usually one application before stockpiling and one upon reclaiming will markedly reduce the coal dusting. Stockpile perimeter sprays can be operated either manually or at the sophisticated terminal, actuated by a computerized control system that senses key environmental conditions such as humidity, precipitation, and wind velocity. Most modern terminals collect the drainage from the stockpile area, remove the solids in settling basins, then recirculate the water to reduce water requirements and effluents from the site. Dusting of long-term storage stockpiles can be reduced by spraying the piles with chemical resin or latex binding compounds to seal the surface. These compounds also can minimize erosion of the pile by rainfall. Dust collection with air evacuation systems and cyclone or wet scrubbers can be used at key areas such as rail car dumpers, main conveyor transfers, and ship-loader spouts. The trend in dust control is away from dust collection since most dust collectors are high maintenance items requiring good operator supervision and servicing. Coal handling conveyors are usually open and uncovered. However, in areas requiring special attention they may be covered or even completely enclosed. Dust generation from terminal roads is often a significant amount of the total dust emitted from a terminal. To reduce this dusting, roadways where traffic is heavy can be paved or sprayed by water trucks. Speed limits can be enforced and use of tracked mobile equipment for stockpile handling rather than rubber-tired loaders is encouraged by authorities. Noise Abatement Terminals located close to residential areas are often faced with noise control problems. Noise can be one of the most difficult environmental problems to solve. Usually, use of electrically-powered equipment is encouraged to reduce noise levels. Rail car dumper houses can be totally enclosed to reduce both dust and noise emissions. Diesel locomotives can be fitted with special muffling devices. Green belts of trees surrounding a terminal or the ap-

Jan 7, 1983

By D. M. Ziebarth

"During the mid to late 1960s, the underground potash industry in Saskatchewan was born. For the next four decades the industry operated at a steady pace, supporting a large part of the world demand, until 2008 when the potash market heightened. Operators were motivated to capitalize on this increased demand, new mines were proposed while existing mines were planning upgrades. Potash Corp. of Saskatchewan (PCS) was one of the major producers planning upgrades to its production facilities quickly, including modifying the existing headframe and shaft at the PCS Cory Site to accommodate a new 1.5-kt/h (1,650-stph) hoisting plant. Upon completion of the project, the innovative operations group continuously reviewed methods to increase production and reduce operating costs, allowing PCS to continue being competitive on the world market.BackgroundPotash production is a major Saskatchewan industry and has played a significant role in the economy for more than 40 years. Production commenced in 1962 when water problems were overcome at the International Minerals and Chemical (IMC) Mine near Esterhazy, Saskatchewan. A surge of development by other companies resulted in 12 companies opening 10 mines by 1970. In 1975, Potash Corp. of Saskatchewan was created by the government of Saskatchewan, and shortly thereafter purchased several mines in Saskatchewan, including the Cory Mine, near Saskatoon.Cory has been in operation since 1968 and is located 12 km (7.5 miles) west of Saskatoon in central Saskatchewan. The mine is located in the center of the world’s largest potash deposit, 1,000 m (3,300 ft) below surface.PCS has embarked on sizable capital expansions of more than CDN$7 billion.The $1.6-billion Cory expansion was expected to raise operational capability of the site to 2.7 Mt/a (3 million stpy), an increase of 1.9 Mt/a (2.1 million stpy). To achieve 2.7 Mt/a (3 million stpy) of finished product and considering the 22.6 percent average production recovery (Potash Corp, 2013), 12 Mt/a (13.2 million stpy) of ore must be hoisted to the surface for processing. To deliver this rate required upgrading of the hoisting plant to 1.5 kt/h (1,650 stph). To accomplish this ambitious challenge, creative thinking, careful planning and a cohesive team was needed to work together to ensure the schedule, budget and most importantly that the work was completed safely (Potash Corp., 2013)."

Apr 1, 2017

By N. T. Lowe

The National Institute for Occupational Safety and Health (NIOSH), Spokane Research Laboratory (SRL), investigated a means to evaluate the potential impact of surface conditions above underground mines on emergency response activities. Recent events have highlighted the need to conduct critical emergency operations on the surface above underground work areas. Accessibility and usability of the surface, such as the ability to drill holes or deploy seismic monitoring or through the earth communications systems, are an important consideration for emergency response planning. This paper identifies critical surface conditions such as: surface waters, valley fill, highways, railroads and significant structures that must be considered in emergency response planning and in the conduct of emergency operations as they relate specifically to the seismic detection of trapped underground miners. Results of case studies indicate a need to consider the impact surface conditions may have on emergency response capabilities.

Jan 1, 2009

By Allan E. Koski

Ceveland-Cliffs uses a specialized software package in mine planning at the Empire Mine, an iron ore mine it manages on Michigan’s Marquette Iron Range. The application puts together years of mining experience that began in the early 1960s on the eastern end of the Marquette Range. The Empire Mine is in its 38th year of production. It uses the software to model a complex and highly variable low-grade magnetite ore body, capturing the economics of mining and processing to the final product. With special attention given to geostatistical methods, the software is used for all geologic modeling, ore reserve estimation, ore control, pit design and short- and long-range planning.

Jan 1, 2000

By Eduardo Pimenta de Melo, Rambabu Pothina, Rajive Ganguli

Sensors are everywhere in the mining industry, with sensor information being used to monitor and operate processes. Therefore, when sensor information is wrong, economic losses can occur. Unfortunately, sensor errors are usually not detected till they become large. This is problematic as most calibrate their sensors no more than once a year (Beamex, n.d.). Using principles of data mining, where all relevant information is tapped to glean hidden information, Pothina [8] designed an algorithm to detect errors in temperature sensors in gold stripping circuit in Pogo mine, Alaska. This paper continued his work by analyzing the behavior of the algorithm on baseline data and testing the algorithm in new data and under more rigorous conditions. It also made a change to the algorithm. The modified algorithm performed very well in the new data. It also worked well under the new error conditions. Three types of errors were seeded, a fixed additive error (+ 2%), a fixed subtractive error (− 2%), and a noisy, normally distributed error, with a mean value of + 2%. Artificially seeded errors were detected within about 20 gold stripping cycles. Inherent bias in operation impacted algorithm performance by increasing the number of cycles needed to detect errors. This paper reinforced Pothina’s [8] conclusion that when data mining approach is used, sensor errors can be detected even when they are pretty low. Significant economic losses can thus be minimized.

By Bruce Watzman

"Few issues are more important to the National Mining Association (NMA), the U.S. mining industry and NMA’s MINExpo International 2016 exhibitors than safety.Global mining safety and health is a journey necessitating continuous improvement, collaboration and innovation on the part of both mining operators and their suppliers.MINExpo 2016, which takes place Sept. 26- 28, 2016, in Las Vegas, provides attendees with the opportunity to view technologies to help refine management of mining safety and health, utilizing NMA’s CORESafety system. CORESafety ‘One of the best’Launched by NMA in 2011 and moving forward ever since, CORESafety is driving continuous improvement in safety and health performance among participating industry companies by shifting from a command-andcontrol regulatory approach to a risk-based systems approach built on the Plan-Do-Check-Act model (Fig. 1).Considered an exemplary safety and health management system, NMA’s CORESafety system helps mining operators change their approach to safety and health management by enhancing the safety and health culture throughout their organizations. Although it is challenging to consistently and completely control all the factors and variables occurring in daily mining operations, experience has shown that applying systematic controls to as many variables as possible is the most successful approach for improvement in mining safety and health.When embarking upon the development of the CORESafety framework, NMA’s leadership set an ambitious goal to eliminate fatalities and reduce the injury rate 50 percent in five years, or the “0-50-5” goal. While the goal has not been met yet, the steady progress has been extraordinary with fatalities among participating companies dropping 45 percent during the period 2011-2015 (Fig. 2). Data also demonstrate that, as participating companies increase their level of implementation, total injury rates have also declined (Fig. 3).In a September 2015 interview with NMA, Penn State University mining engineering Professor Jeffrey Kohler praised CORESafety as “an inspired and timely program that brings together key elements to achieve safety and health goals.”"

Sep 1, 2016

By J. W. Davis

In the last few years major industrial companies have begun to realize the importance of Reliability as an enterprise strategy that, properly implemented, will improve financial performance. Typical results of an effective Enterprise Reliability Strategy include a 20% -50% reduction in maintenance cost accompanied by a 5% - 10%increase in real production capacity, with no capital investment in production equipment. One factor fueling the race to acquire and implement enterprise reliability is the pressure for companies to be increasingly cost-effective and competitive in global markets. In a recent study, Asset Productivity: The Next Wave, the Boston Consulting Group (BCG)stated that, “In order to compete for funds, companies must offer investor returns that are competitive with other opportunities. Alternative investments such as dot-com and others with non-traditional business models have raised the bar.” (APDF version of the study can be downloaded at www.bcg.com). BCG views asset productivity as the most powerful mechanism for increasing shareholder return. The author believes that the most effective way to increase Fixed Asset Productivity is to maximize asset utilization by increasing the Reliability of the Assets and the associated processes. Developing and implementing an ERS requires significant effort and knowledge. Most companies have difficulty finding a sufficient supply of these valuable commodities to implement an ERS Program internally. Many companies also struggle with figuring out how to get started and what direction to proceed.

Jan 1, 2003

By Michael Murphy, Gamal Rashed, Brent Slaker

Many underground stone mines in the United States operate on multiple mining levels. The effects of interburden thickness, pillar offset between mining levels at various depths of cover, and in situ stress conditions are poorly understood. Pillar offset is the degree to which pillars are not columnized or stacked. In this study, calibrated numerical models are used to examine limestone pillar stability in these conditions. Also, the critical interburden thickness required to minimize the interaction between mining levels is explored. The model results show that there is interaction between numerous factors that control the stability of stone pillars in multiple-level conditions. The highest degree of local pillar instability occurs when pillar overlap ranges between 10 and 70 percent. The highest degree of stability occurs when pillars are stacked.

Jan 1, 2023

By VIVEK KASHYAP, PATRICK TAYLOR

Zinc ferrite is the major phase component present in zinc refinery residue (ZRR) and electric arc furnace dust (EAFD). Up to 71 percent zinc ferrite has been reported to be present in ZRR, and in most studies zinc ferrite has been deemed the major phase in EAFD. In 2010, the global annual production of EAFD was 3.7 Mt, with 15.20 kg of EAFD generated per ton of recycled steel [1]. The generations of ZRR and EAFD have been growing over time, requiring a greener approach for the reutilization and extraction of valuable elements. ZRR can be a potential source of zinc, as its zinc content is as high as 30 percent [2,3]. The presence of zinc ferrite makes the extraction of zinc difficult because zinc ferrite is refractory to leaching, and direct leaching is inefficient. The Waelz process is currently employed to extract zinc from EAFD and other metallurgical wastes. The Waelz process operates in the temperature range of 1,100 to 1,500 °C and uses coke as reductant. This study explores a carbon-free and relatively low-temperature process for the selective extraction of zinc from pure zinc ferrite.

By Malcolm D. Flavel

Much has been said and written about the world's, and particularly the united states of America's, energy crisis. The relative changes between cost components of production have altered because the days of cheap energy have now gone. Decisions that made capital investment reduction attractive to treat large tonnage lower grade ore bodies appear to be no longer valid because average energy costs for comminution that were less than 1 cent per kilowatt hour in 1972, are now more than 3 cents and will shortly become 6 cents according to some projections. Increased capital investment to improve processing energy efficiencies are certainly going to be pursued. Energy today is the largest cost component in the average mineral production facility. It takes more than 12000 kilowatt hours to produce one ton of finished steel and more than 60000 kilowatt hours for each ton of copper and aluminum.

Jan 1, 1980

By A. L. Martikainen

In fluctuating airflow, continuous air velocity recording is the most reliable method of air velocity measurement. It allows for fast recognition of changes and the calculation of long-term averages. Also, it enables the mine operator to identify when the airflow has decreased to a point requiring action. Using ultrasonic anemometers provides an accurate option for continuous air velocity monitoring. This paper provides information about the effect of common obstructions in underground mining on air velocity readings. Stationary and moving obstructions are used to represent workers and equipment that would cause discrepancies in measured airflow. Also, it is important to know how large of a sample size is required to ensure reasonable accuracy of results. Statistical analysis is used to evaluate the required sample size. The sampling procedure is further studied by comparing two different sample rates. The results show that obstructions provide noticeable differences in air velocity measurements. Also, movement of obstructions can be recognized from changes in results. Surprisingly small sample sizes provide reliable air velocity information. Standard sample rates are found to be suitable for the underground environment.

Jan 1, 2011

By MEHMET KIZIL, PETER KNIGHTS, ROYAL REA

A 1/20 scale experimental dozer push test rig was designed and constructed to quantify the expected production rates (loose cubic meters per hour) for dozers operating in hard-rock bulk push applications. The particle size distribution of the material employed in the test rig was modeled on a fragmented muckpile representative of that for a typical surface copper/gold mine overburden. Buckingham Pi theory was applied to mathematically develop factors for scaling up dozer productivity parameters, including blade loads and push times. Dozer production rates were investigated for various dozing distances and slope angles. A series of instantaneous productivity curves were produced which are applicable for use in hard-rock dozer push operations. The productivity curves produced demonstrate that dozer productivity declines rapidly over the range of 10 to 40 m.