Search Documents

Newmont?s Twin Creeks Mine, located in northern Nevada, is producing gold ore from surface mining operations. The ore is currently processed at three different on site facilities depending on the ore type and the grade. The processing facilities operate under stringent geochemical blending constraints that must be met from mine ore deliveries and off site sourced ore. To analyze various strategic options, the technical team utilizes the mathematical optimization approach. However, due to the size and the complexity of the operation, there are unique challenges in optimizing life of mine production scheduling. This paper describes those challenges and the methodology developed to take advantage of different scheduling software systems that effectively compensate each other and result in reasonable guidance. The paper also describes how those scheduling results are reflected in detailed mine plan and cost estimate work.

Feb 27, 2013

By H. Do

In flotation, hydrophobic particles are selectively collected by air bubbles, and the bubble-particle aggregates enter the froth phase. However, less hydrophobic particles drop off from the froth phase, while more hydrophobic particles are recovered. Thus, the froth phase provides an important cleaning mechanism. In the present communication, the froth-phase recovery process has been modeled by considering particle retention times and the carrying capacities of bubbles. The model predictions are compared with the experimental data reported by Seaman et al. (2006). The results show that the froth-phase recovery varies with particle size, particle hydrophobicity, and bubble coarsening.

Jan 1, 2008

By A. Davis, C. Webb, J. Sorensen

The abandoned Belle Eldridge Mine near Deadwood, South Dakota, is on land controlled by the U.S. Bureau of Land Management (BLM). The mine produced lead and zinc during the first half of the 1900s. Because of acidic drainage and elevated levels of metals in tailings and waste rock, the site was evaluated in 1998 and 1999. After evaluation, the mine was remediated during 1999-2001 by the BLM. Since remediation, values of pH in water samples have been nearly neutral and specific conductance values have been much lower than before remediation. The Grizzly Gulch forest fire of July, 2002, consumed much of the Belle Eldridge site and resulted in greater than normal erosion and sediment flushing during the months following the wildfire. Had the site not been remediated and the tailings emplaced within a capped repository, generation of acidity and off-site migration of heavy metals within sediments could have been severe at downstream locations.

Jan 1, 2007

By Joël P. T. Kapusta

Back in 1995, Air Liquide and Union Minière presented a joint paper at the Copper 95 – Cobre 95 Conference in Santiago, Chile, describing the first full scale plant trials of shrouded sonic injection in a Hoboken converter at the Hoboken smelter in Belgium. Almost a quarter of a century later, the technology known as ALSI, or Air Liquide Shrouded Injection, has been tested or commercially implemented in several copper and nickel smelters. Despite these successes, the copper industry did not adopt it widely in the same manner the steel industry adopted the Savard-Lee tuyere in the 1970s and beyond, not even in the way the lead industry adopted it with the Queneau-Schuhmann-Lurgi, or QSL, process. The development and implementation of bottom-blowing smelting and converting technologies in China in the last ten years, however, changed the industry’s perception that high- and ultra-high oxygen injection in copper smelting and converting was indeed possible under specific process conditions. In this paper, I retrace the key learnings of my journey with sonic injection over the twenty five years from my humble beginnings in my early years with Air Liquide, through plant trials and technology implementation in the late 1990s and into the first decade of the new millennium, and ultimately, to the most conclusive proof that the sonic injection design methodology I established is valid, and the calculation tools I developed are accurate. I conclude by sharing my thoughts about whether the deployment of the Savard and Lee legacy within the nonferrous industry was just a pipe dream or whether it will become a reality. INTRODUCTION In the context of lower quality ores and changing economic markets, copper smelters need to continuously innovate and improve to remain competitive and respect their corporate social responsibility engagements. One avenue towards this business, social, and environmental goal is to increase process intensity while lowering fossil fuel consumption to lower greenhouse gas emissions and reducing process off-gas volumes to better capture As and SO2–laden emissions. I believe high oxygen sonic injection for submerged tuyere copper bath smelting and converting is one technology that can help smelters achieve that goal of higher business, social, and environmental performance. Twenty five years ago, when I discovered that the Savard-Lee tuyere had revolutionized the steel industry (Savard & Lee, 1966; Knuppel, Brotzmann, Fassbieder, Savard, & Lee, 1972), I had a dream — or was it a vision? — that within the first decade of the new millennium, modern copper smelters operating submerged tuyere bath smelting and converting vessels will have implemented high oxygen sonic injection and will be reaping the financial and environmental benefits that the steel industry enjoyed in the 1970s. As we approach the end of the second decade of the new millennium, I have to admit that my dream has been all but shattered as the majority of copper bath smelting and converting vessels today continue to operate under bubbling regime conditions. This mode of operation is archaic, still requires tuyere punching and blows at inherently low enrichment levels, particularly in converting, producing large volumes of process off-gases. Under such operating conditions, regulations and emission quotas for As, SO2, and particulate matter oblige smelters to use not just primary or secondary hoods, but sometimes even tertiary hoods. I vividly recall being told, fifteen or twenty years ago when visiting smelters to promote the application of the Savard-Lee tuyere in nonferrous processes, that implementing sonic injection was not economically viable due to the high cost of compressing air and oxygen. Some of the smelters I visited back then have since mandated their engineering partners to design and build secondary or even tertiary hoods. I cannot fathom how secondary and particularly tertiary hoods, with all of their auxiliary equipment and added ducting, could be more economically viable than purchasing and installing a few compressors, expanding the pipeline network for compressed air and oxygen, and installing a new control valve train to feed sonic tuyeres. Besides, adding hoods does not address the problem of As and SO2-laden fugitive emissions at its source but merely provides a costly mitigation for it by capturing larger volumes of process off-gases rather than reducing these large volumes in the first place. Moreover, hooding does not reduce energy consumption nor does it increase process intensity, two aspects that I believe are critical for smelters to remain competitive and sustainable in a deeply changing market environment.

Jan 1, 2019

By H. P. Willard, R. W. Gates

Basic Inc., has been mining magnesite and brucite for 27 years at Gabbs, Nev. This is a medium sized open-pit mine. The magnesite deposits are in north-western Nye County about 30 miles east of Luning, Nev., on the west slope of the Paradise Range, at an elevation between 5000 and 6000 ft. The magnesite and associated brucite is used to make magnesia refractories employed principally in the steel industry and magnesium oxide for various chemical uses.

Jan 10, 1963

Like it or not, CPD is upon us. As from 1 January 2006, all registered engineering professionals, i.e. professional engineers, professional engineering technologists, professional certificated engineers and professional engineering technicians, were required to undertake CPD in order to keep their professional registration current. The rules regarding CPD have been gazetted under Government Gazette No. 28328, Board Notice 131 on 23 December 2005, and they also appear on the ECSA website?www.ecsa.co.za. For the convenience of our members they are reproduced in full in this issue of the SAIMM Journal.

Jan 1, 2006

By M. Olalde, I. Watson

"The consequences of ineffective mine closure in South Africa are evident from the number of abandoned mines and operations on extended care-and-maintenance, the on-selling of mines to less well-resourced companies to close, and increasing illegal mining activities. However, the data to substantiate these observations and provide insight into the underlying issues has not been available. Through the Promotion of Access to Information Act, a list of mine closure certificates applied for between 2011 and 2016 and a list of certificates granted over the same period for all nine regions of South Africa was obtained. From the analysis of this data, we show that the mine closure system as implemented in South Africa is largely ineffective. Although closure certificates are being granted, these are for prospecting sites and small-scale mines, which have a relatively small environmental impact. No large mines of any environmental significance were relinquished over the period under review, with very few applying for closure certificates. Furthermore, the issuing of closure certificates varies significantly between regional offices, with the success rate for applications being generally low and issuing of certificates taking an extended period. IntroductionThere are a number of concerns with the mine closure process as practiced in South Africa, and these have largely been laid at the door of government. Alberts et al. (2017) stress that the legislation generally conforms to international best practice. However, the system is ‘complex and unwieldy’, involving various pieces of legislation and different government departments with overlapping requirements and different interpretations of the law. A further area of concern is the capacity and competence of government to implement legislation. The ‘shortage of relevant mine closure skills and knowledge within the regulator’ was identified by van Druten and Bekker (2017) as a key contributor to unsuccessful closure. Lack of capacity and resources within the regulator has also been highlighted by Botham, Kelso, and Annegarn (2011) and Milaras, McKay, and Ahmed (2014). A recent study of the mineral application process by Corruption Watch (2017) indicates that positions in the regulator have been frozen for many years, leading to a shortage of staff, and that unqualified individuals have been appointed. There is also the perceived reluctance of government to grant closure in order to limit transfer of the liability to the state and delay the inevitable job losses."

Jul 1, 2019

By R. Codell, D. L. Hughson

While benchmarking the integrated finite-volume code MULTIFLO against the analytical solution of Philip et al. (1989) for cylindrical underground openings, we found numerical simulation of dripping threshold flux consistently higher than the analytical solution for both rectangular and unstructured grids. The magnitude of error is proportional to the alpha parameter characterizing capillarity. This may bias estimates of repository performance towards non-conservatism.

Jan 1, 2000

By R. Thornton

Montana Tech is located in the historic mining town of Butte, MT and is adjacent to the Orphan Boy mine. This abandoned underground mine will be the heat source for a down-hole heat exchanger (DHE)/heat pump system. The mine was abandoned in the 1950?s and has since filled with water to within approximately 30 m of the surface. The shaft is composed of a 245 m vertical shaft connected with horizontal crosscut drifts at 60 m and 150 m below the water level that connect to a large stope with approximately 1250 million liters of water at a consistent 75-78°F temperature. The intent is to build this heating system to augment or fully heat a newly built 2,000 m2 building on the Montana Tech campus. As designed the system uses ?off-the-shelf? parts making the basic configuration straightforward with the exception of the DHE?s which need to be placed into the vertical shaft. Because there is little or no examples of placing the heat exchangers in a vertical shaft, the primary focus of this work was to model the heat exchanger placement and configuration in the vertical shaft such that thermal currents develop between the stope and vertical shaft in, via the horizontal crosscut drifts, in order to move the water and thereby provide the required energy. This study includes the modeling of water flow, temperature profiles, and the heat contribution from the surrounding rock walls.

Feb 27, 2013

By M. Kanefsky

Two channel polarity coincidence and polarity difference statistics are analyzed. The signal, common to both channels, consists of sinusoidal bursts where the exact frequency of the signal is nearly known, but other parameters such as amplitude, phase, and pulse starting time are unknown. The noise inputs are dependent, narrow band, Markov processes. It is shown that the performance depends not only on the signal uncertainties, but on the precise shape of the cross-correlation functions between the noise in-puts. By using two polairty difference statistics in addition to the polarity coincidence statistic, it is shown that the decrease in performance, as well as the cost of hard limiting due to correlated inputs, can be made small.

Jan 1, 1981

By P. J. Petit

Changing mining conditions, legislative issues, rising costs, and the constrained supply of skills and electricity in South Africa, have been some of the criteria forcing mine operators and engineers to review the traditional use of compressed air to power underground hand-held drilling operations in narrow-stope, hard-rock mines. In answering the question, 'What is the best way to power this mine?', they have resorted to trade-off studies with results of limited usefulness, because they are site-specific, and use only a few comparative parameters, based on a small data set. This paper aims to provide definitive, objective, and quantitative decision-making approaches to evaluating alternative energy-delivery systems for stoping in narrow-reef hard rock mines, based on primary and relevant criteria. These include quantifiable criteria such as capital expenditure, operating costs, resulting financial returns, energy and water usage, production performance, life-of-mine, etc. Other important criteria with qualitative aspects are integrated. These are safety, health, and environmental concerns, legislative requirements, business risk, technology change, etc. The paper begins with a review of decision-making processes available, and proposes the use of the analytical hierarchy process (AHP) method as a multiple-criteria decision-making tool and the decision tree based on milestone-driven uncertainties, to validate the selection of the energy delivery system. The results of a multiple-criteria questionnaire completed by a variety of industry experts and professionals, such as production and operation managers, consultants, suppliers, and techno-financial analysts, are discussed. The evaluation indicates the potential for hydropower to be the best solution for narrow-reef hard rock mines, based on current information, mine design layout and production.

Jan 1, 2013

By Secis R

Northparkes Mines is located 27 km northwest of Parkes in central west New South Wales. The E26 deposit is the largest of all defined to-date in the area, containing over 50 per cent of Northparkes' resources and reserves. The combination of orebody geometry and geotechnical characteristics provide ideal conditions for the block cave method of mining of the first lift of the E26 deposit. Although this method of underground mining has been used for decades in other countries, E26 is the first example of its use in Australia. Copper-gold mineralisation at Northparkes is related to quartz monzonite porphyries that have intruded coeval Ordovician volcanics. Sulphide mineralisation (dominantly bornite and chalcopyrite) occurs principally within quartz veins associated with the porphyry intrusions. Veining and mineralisation occurs within both the porphyries and volcanics. To optimise the recovery of a resource within a block cave mine, a good understanding of the rock mass and ore flow characteristics is essential. These have a significant effect on the fragmentation size and range and on parameters such as the drawzone spacing, height of interaction zone and dilution entry. As ore within a cave column moves and mixes when material is extracted from below and beside it, the total reserve extracted is unique for a particular draw strategy/production history. Until recently, reserve estimates and production schedules were based on the application of a uniform dilution factor to the tabulated resource. However, given the complicated flow and mixing within the cave column, such a simplistic approach can produce erroneous results. Northparkes Mines purchased and sponsored the upgrading of a commercially available software package specifically developed for modelling removal of resource blocks under caving conditions. This Gemcom software package, PC-BC, has been used for mine planning, reserve reporting and production scheduling. Blocks within it resource block model are converted into a mineable reserve taking into account mixing and dilution during depletion of drawcolumns (by horizontal and vertical redistribution of insitu tonnage and metal). As PC-BC gives individual drawpoint reserves, it can be used during the planning stage to determine whether or not a drawpoint is economic. For E26 Lift I an optimal layout containing 130 drawpoints has been developed based on a nominal 14 m x 14 m drawpoint spacing and a 0.8 per cent equivalent copper (eCu) cut-off grade. Annual production schedules for the depletion of material above this layout are based on: I higher tonnage removal from higher grade drawpoints in the early years of production; and 2 drawpoint production rates proportional to the total tonnage of orr remaining in the drawcolumn up to the optimal height of draw tier subsequent years. The reserve is tabulated from the combined annual production schedules over the life of the lift. The pre-mining reserve for Lift I of E26 is 26.6 Mt at 1.43 per cent copper and 0.39 g/t gold, of which approximately 23.4 Mt will be extracted under caving conditions. By scaling down the annual production schedule, weekly drawpoint tonnage calls can be given for short-tern production scheduling.

Jan 1, 1997

A wide range of materials are used in hydraulic backfilling operations and the pipeline flow behaviour of these mixtures varies considerably. It is shown that despite the large differences in constituent materials and flow behaviour, a common approach can be applied to analysing the flow of all hydraulic backfills. This is extended to include a rational design approach for backfill distribution systems. The use and limitations of pipe loop tests as a design aid is discussed. Backfill quality control is identified as a key area where improvement needs to be made to enhance the reliability of backfill system operation.

Jan 1, 2001

By F. Freme

Coal production in the United States in 2007 totaled 1.03 Gt (1,145.6 million st), according to preliminary data from the Energy Information Administration (EIA) (Ta-ble 1). This is a decrease of 1.5 percent, or 15.6 Mt (17.2 million st) from the 2006 record level of 1.05 Gt (1,162.7 million st). Although coal production declined in 2007, U.S. total coal consumption increased for the year. Coal consumption in 2007 in the electric power sector was higher by 1.9 percent, while coking coal consumption decreased by 1.1 percent and the other industrial sector declined by 5 percent. (Note: all percentage change calculations are done at the short-tons level.) U.S. coal exports were significantly higher in 2007, while coal imports remained at about the same level. Total coal stocks increased slightly during the year, as some consumers continued to rebuild their stockpiles that had been seriously depleted in 2005 due to transportation issues. The growth in coal consumption during the year was primarily a result of the weather-related increases in the demand for electricity in 2007. Preliminary data show that total generation in the electric power sector (electric utilities and independent power producers) in the United States grew in 2007. Coal-based generation also increased, resulting in a 17.9-Mt (19.8-million-st) increase in coal consumed in the electric power sector. Coal use in the nonelectricity sector decreased by 3.8 percent to 74.7 Mt (82.4 million st). In the international markets in 2007, U.S. coal exports increased to levels not seen in recent years while coal imports were mostly static. U.S. coal exports totaled 53.7 Mt (59.2 million st), an increase of 8.6 Mt (9.5 million st) above 2006. Coal imports in 2007 ended the year at 32.9 Mt (36.3 million st), 91 kt (100,000 st) higher than in 2006. Coal prices in 2007 were split, with most domestic prices higher for the year while the international prices were overall lower. Although the average delivered price of coal increased for most users in the United States in 2007, the increases were smaller than what had been expe-

Jan 1, 2008

By M. Menéndez

Enhanced gravity separation appears to be one of the most promising methods for processing all types of <200-µm coal feeds and tailings. Systems based on this technology are reviewed, and the results of investigations based on C900 Multi-Gravity Separator tests conducted to assess the treatment of <200-µm, extremely difficult-to-wash coal settling pond tailings are presented. Multi-Gravity Separator processing tests of ultra-fine tailings with a high clay particle size content (22.6% <10 µm and 60.1% <40 µm) and a 69.56% ash content show that this material can be effectively treated after desliming (<10 µm) of clay-size particles to produce a coal with a 20.6% ash at a separator combustible material recovery of 69.3%. Desliming is shown to be critical in reducing coal ash content and combustible material recovery. Similar improvements are anticipated in the recovery and separation pro-cesses for other enhanced gravity separation systems from the desliming of feeds. Although not a conventional form of treating Multi-Gravity Separator data, the existence of well-defined polynomial relationships based on the product of drum shake amplitude and shake frequency relative to product coal recovery, product ash content and yields at varying wash water flows is demonstrated. Low-amplitude and intermediate- to high-frequency bed agitation are shown to produce optimum ash reduction results.

Jan 1, 2007

By Fredrick L. Johnson

Tungsten is the principal mineral commodity in the Laurel-McGee RARE II area; copper and molybdenum would be recovered as by-products with the tungsten. Indicated and inferred tungsten marginal reserves at the Hard Point Mine (fig. l, no. 10) are 16,000 tons (14,000 t) averaging 1.0 percent tungsten trioxide (W03). The mine is outside the RARE II area, but the geologic structure that it is on extends into the area. Indicated subeconomic zinc, silver, copper, and lead resources at the Lucky Strike Prospect (fig. 1, no. 7) are nearly 6,200 tons (5,600 t) averaging 5.45 percent zinc, 0.5 oz silver per ton (19 g/t), 0.40 percent copper, and 0.32 percent lead. Although tungsten has been produced at the Tiptop Mine (fig. 1, no. 12), resources were not calculated because of the spotty nature of the tungsten mineralization. Additional exploration at the Tiptop and Hard Point Mines could reveal significant resources. The potential for tungsten resources at the Payday Prospect, Tungsten Prospect, and Morhardt Mine is also high. The Pine Creek Mine custom mill, located about 35 mi (56 km) southeast, could process tungsten concentrates from the area. Tungsten production has been recorded from three properties, the Hard Point, Morhardt, ant Tiptop Mines. Output was about 405,000 lb (184,000 kg) of W03, nearly all from the Hard Point.

Jan 1, 1983

By K. Vatterrodt

Thallium is not significantly removed from mining influenced water (MIW) through conventional treatment in hydroxide precipitation plants. We experimentally investigated modifications to hydroxide precipitation schemes to concurrently remove thallium. Our goal was to determine cost effective and efficient hydroxide precipitation process modifications for thallium removal. Strategies for removal targeted multiple mechanisms including sorption, co-precipitation and/or oxidation of monovalent thallium. Modifications were tested in batch and included oxidant evaluation and the role of manganese. Removal of thallium was enhanced by the addition of permanganate as well as oxygen by aeration. In addition, contact with retained solids and the initial manganese concentration played an important role in the extent of thallium removal observed. This paper reports on our findings and discusses the implications in the removal of thallium with minor modifications to the hydroxide precipitation process.

Feb 27, 2013

By R. Hope, C. van Heerden

In any process or organization inefficiencies are costly. In times of abundance this reality often does not receive much attention. During such times the focus is rather on increasing capacity to increase production. However, there is a growing awareness in the world of tougher economic, social as well as environmental conditions, and enterprises find themselves facing greater demands for accountability towards shareholders, the environment and the public, as well as growing competition for market share and limited global resources. This reality is no different in ensuring a sustainable mineral sands operation. In order to achieve this, any operation needs to be stripped of all process as well as operational inefficiencies. In this context it has become essential for any Mineral Separation Plant (MSP) to have the necessary process monitoring and control systems in place to continually monitor and optimize the production of on-spec products and maximize operational efficiency and consistency. The MSP Grade Control Solution developed by Crusader Systems and running on top of the CSense platform contributes towards these goals by improving the consistent production of on-grade product. This allows the process to operate closer to the maximum allowable product grade constraint, which in turn maximizes production.

Jan 1, 2003

By Ian R. Firth

For the majority of open pit precious metal mines in the western United States, grade control practices have evolved as a direct result of the variable geology of the ore body and the lack of a clear visual or geologic distinction between ore and waste material. These practices often include the extensive use of buffer or choke blasting, in an attempt to minimize lateral movement of the muckpile. The Mackay School of Mines is conducting ongoing research, which aims to develop a practical method of measuring the movement of discrete “targets” placed within the body of the blast. The movement experienced by these targets can then be used to interpolate the movement of the blast as a whole. Typically, the boundaries between different material types are known as digging limits or polygons and are marked using colored flagging on the muckpile. If material movement can be measured using targets placed in the blast, these digging limits can be altered to reflect the blast-induced rock movement, reducing dilution and improving value recovery.

Jan 1, 2002

By T. H. Eyde

Estimated natural zeolite production worldwide during 2004 remained at about 3.6 Mt (4 million st), about the same as in 2003. China continues to be the largest producer of natural zeolites followed by Cuba, Germany, Japan and South Korea. This may be changing, however. Since 1988, zeolite production from Australia, Indonesia, Malaysia, New Zealand, Philippines and Thailand has increased rapidly. Most of the production is consumed in aqua culture. Global demand for seafood has exceeded the ability of the oceans to supply it without over fishing. Zeolite minerals remove ammonia compounds from the ponds in which fish and shrimp are grown. It is estimated that, in Thailand and Indonesia more than 55,000 farms produce260 kt (286,500 st) of shrimp. Therefore, as shrimp production increases, so does zeolite consumption.

Jan 1, 2005