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By C. Anderson, K. Nikkhah

This paper outlines the role of simulation software in design and operation of a typical metallurgical plant with mineral processing and hydrometallurgical units, to produce concentrate and pure metal. It addresses the role of simulation and mass balance software in the conceptual, feasibility and detailed design stages. It discusses the use of JKSimMet for sizing of mineral processing units, and METSIM and IDEAS for development of energy and mass balances. In detailed design of a plant, the complex interaction and variation in performance of various units makes it difficult to predict overall system performance and availability. Simulation is used to: assess operating strategies that affect surge capacities at various stages compare different ore types and mining strategies that affect concentrate product quality. optimize transportation logistics for raw materials, concentrate and metal products

Jan 1, 2001

By Lynn B. Hales, Randy A. Ynchausti

There is a large economic driving force associated with improving metallurgical performance in mineral processing plants using process control. Because of this and other benefits, control systems of the future will develop towards more sophisticated user friendly computer based systems that use powerful software analysis and control techniques. Auto-tuning, adaptive control and process models will gain expanded use because of their transparent availability to the system designer. Control of individual unit operations will be optimized and coordinated through expert systems that monitor economic conditions and management directives and direct operations accordingly. Plant areas, considered cost centers for years, will be integrated into plant-wide control systems for economic control and optimization. New control hardware, process sensors, control strategies and software development tools will be presented, as well as an overview of the economics driving the continued development of advanced process control systems.

Jan 1, 1993

By B. Cristol, G. Benier

Laboratory and pilot tests have shown that the grinding of some aluminas makes two populations appear : agglomerates’ and ultimate crystals’. Classical breakage functions (Size Mass Balance Method) aren't able to describe correctly this kind of grinding. So we have optimized a particular breakage matrix which takes into account the fact that the agglomerates can either be reduced in size or either be blown up to liberate the ultimate crystals. The models which were developed using this breakage matrix are in good agreement with the experimental results of the pilot tests. The industrial breakage functions were estimated from pilot breakage functions, using scale up prediction procedures and plant tests. The agreement between predicted and actual plant performance is excel1ent.A 20 % increase in capacity was predicted to be available by improving the grinding circuit classifier performances.

Jan 1, 1992

By James Warren Andrews

The values of saturated water vapor pressure from steam tables have been found to be inaccurate for mine ventilation usage because the effect of air on the saturated water vapor was disregarded. Presented here are the newest and most accurate currently available tables from the National Bureau of Standards (NBS). Also included are: (1) a formula for correcting the saturated water vapor pressure for temperature and altitude. (2) a formula for computing unsaturated water vapor pressure, and (3) a formula for air density. Because Systeme International (SI) units are used in the formulas, conversions are given from U. S. conventional units to SI units. The intent of this paper is to show by means of six steps the accurate calculation of mine air density for use on modern computers.

Jan 1, 1989

By J. J. Davis, C. A. J. Fletcher, M. Li, T. Jancar

This paper summarises the experimental approach to spiral modelling at the Julius Kruttschnitt Mineral Research Centre, University of Queensland, involving the use of plastic density tracers to determine partitioning performance on three models of coal spiral. This work has led to phenomenological models of the three spiral profiles most widely used in the Australian coal industry. The results from a parallel computational fluid dynamics approach to spiral modelling currently underway at the University of New South Wales are also presented. The computational simulation has been successfully applied to generic spiral geometries and is capable of predicting the fluid phase three dimensional flow fields and corresponding free surface profiles for moderate Reynolds' number and Froude numbers. Simulation predictions are compared with experimental results from a Mineral Deposits LD9 coal spiral.

Jan 1, 1995

By Vas Choudhry, Randhir Sehgal

Conventional clean coal technologies which consist of coarse coal cleaning by gravity methods and treatment of natural fines by flotation can only remove a portion of the pyritic sulfur and ash in the coal. Higher (+90%) pyritic sulfur rejection is attainable when coals are ground to ultrafine sizes to enhance liberation of the mineral matter and then cleaned. However, cleaning of coal at very fine sizes poses a number of unsolved problems, the chief one being the loss of cleaning efficiency. This, of course, means that liberation of pyrites does not always equal its rejection. In addition, the dewatering of fine- cleaned coal, and its handling, transportation, and acceptability to the utility industry a1 so pose considerable technical and economic problems, especially when compared to the FGD alternative. This paper addresses some of the critical issues involved in the cleaning of ultrafine coal s.

Jan 1, 1989

By Thomas A. Colbert

Permanent reclamation of tailing and acid forming mine wastes in the western United States has been largely a losing proposition. There have been few if any successes without actual burial of wastes with soil, overburden, waste rock or other material more amenable to reclamation. Rather than major breakthroughs, development of new techniques has been slow and steady. Revegetation of acid forming wastes with little or no soil cover is now probably feasible. Three key elements include the use of adapted plant species which are now becoming commercially available, lime and selective bactericide for controlling acid, and organic amendments such as manure or sewage sludge. Benefits of this type of reclamation often include reduced mobility of toxic metals and improvements in water quality. With a stringent regulatory regime for mine wastes impending under Strawman II, the importance of good, economical reclamation techniques will become critical to successful and profitable western mining operations.

Jan 1, 1991

By David J. Hammel

This chapter will summarize some of the important applications in the geotechnical (pit slope, spoil pile and tailings stability, and hydrology), the environmental (including reclamation), and equipment selection and analysis areas. Virtually all aspects discussed are applicable both for planning of new mines and for evaluating existing operations. Probably the most influential item which has affected the areas discussed in this chapter and possibly most areas discussed in this book is and will continue to be, in the next decade, the myriad federal and state environmental, safety, and reclamation regulations affecting new mine development and continued operation of existing properties. Computer applications have been and will continue to be instrumental in assisting in planning to meet the challenges of the requirements dictated by these regulations.

Jan 1, 1979

By Raivo Maripuu

The Boliden Group encompasses Sweden's foremost operations related to the mining and production of copper, lead, zinc, precious metals and metallic by- products. It is also the dominant swedish producer of sulphur-based heavy inorganic chemical products and fertilizers and has an international trading organization covering, in adition to the group's basic products, industrial minerals and oil. Boliden's activities in- clude the marketing of proven Boliden technique and know-how. Boliden Metall - the mining and metallurgical company within the Boliden Group - produces about 13 million mtpy of ores at mines in northern and central Sweden. Boliden has, over the years, become a specialist in processing poly- metallic sulphide ores and its eight concentrators presently serve 15 mines. Boliden has a long history of close cooperation with Swedish and foreign manufacturers in developing new products and processes.

Jan 1, 1979

By Robert A. Jankowski, George E. Niewiadomski

INTRODUCTION The utilization of longwall mining technology in the United States has steadily increased since the first longwall plow system was installed in 1952. At the errs of FY 1992, some 76 coal mines were employing longwall mining systems for coal extraction, and approximately 78 shearer and 3 plow faces are operating nationwide at any given time. Although the number of operating longwalls has remained relatively constant over the last five years, longwall production levels have increased significantly during this period. During the same timeframe, the number of continuous miner sections has decreased by 13 pct., from approximately 1438 in FY 1988 to less than 1250 in FY 1992. According to Mine Safety and Health Administration (MSHA) data, the average production of longwall sections increased from approximately 2400 tons per shift (tps) in FY 1988 to more than 3100 tps FY 1992. In fact, the average production has more than tripled since 1978, when it was only 850 tps. Approximately 25 pct. of operating longwalls are capable of producing in excess of 4000 tps. Longwall production currently accounts for nearly 36 percent of U.S. underground coal production, compared to 4 pct. in 1978. These improvements are attributed to improved longwall equipment and increased availability, larger longwall panels and automation. While longwalls are highly productive and offer other advantages, operations employing this method of mining continue to experience dust compliance problems more frequently than other mining system. Although dust levels have remained relatively unchanged over the past five years, averaging 1.6 mg/m3 and 1.9 mg/m3 based on results of operator and inspector sampling, respectively, during FY 1992, approximately 25 pct. of the operating longwalls were in noncompliance during any given bimonthly sampling cycle. Although modest gains in longwall dust control technology have been made, these have been overshadowed by significant increases in production rates. As more coal is mined, more dust is generated (Figure 1). Therefore, the increase in longwall productivity has meant that far more dust is being produced which must be controlled. [ ] In view of the current compliance record, any efforts to further increase longwall output, as has been forecasted, must be accompanied by: (1) the reduction of dust levels at existing operations through the proper installation and maintenance of suitable engineering dust controls; and (2) the advancement of dust control technology for today's and future longwalls that will enable all face personnel o work in an environment that is free of excessive levels of respirable coal mine dust. MSHA'S RESPIRABLE DUST CONTROL PROGRAM Since 1972, federal regulations have required each coal mine operator to continuously maintain the average concentration of respirable dust in the mine atmosphere during each shift in the active workings at or below 2.0 mg/m3 through the application of environmental dust control methods. The regulations provide for further reduction in the dust standard whenever the

Jan 1, 1993

By Steven J. Schatzel

A study was made of frictional ignitions in the underground coal mining industry from 1980 to 1992. The population of frictional ignitions was correlated to a variety of potential contributing factors including the mined coalbed, geographic location, mine production, methane gas emissions, and the type of mining equipment in use. The number of frictional ignitions reported in 1991 and 1992 surpassed the annual totals in all previous years included in the study. Most frictional ignitions occur during cutting operations at a coal face by a continuous miner. The average coal production of mines experiencing frictional ignitions is greater than the average of all underground coal mines throughout the survey period. Methane drainage may have produced a drop in the ratio of gas emissions to coal production (E/P) in mines experiencing frictional ignitions.

Jan 1, 1995

Acid mine drainage is still a common problem in the northern Appalachian high sulfur coal region despite mining and reclamation practices applied to control it. Mining companies must treat water with alkali to raise pH and precipitate metals in order to discharge the water into receiving streams. Common chemicals used to treat drainage are limestone, hydrated lime, soda ash briquettes, caustic soda, and ammonia. Each chemical has advantages or disadvantages under specific conditions. A simple spreadsheet program was developed to evaluate costs of treating acid mine drainage across several specified water quality parameters and time horizons. Caustic soda and soda ash were shown to be cost effective for treating low flows and low acidity over short time periods. However, as quantity of water increased, quality decreased, and time horizon increased, the ammonia and hydrated lime systems were found to be much cheaper than caustic soda.

Jan 1, 1991

By E. D. Dainty, B. E. Enga, D. L. McKinnon

Following considerable laboratory studies concerning particulate control systems for underground use, a program was commenced to develop practical real life implementation systems. This program covers the implementation in seven mines of particulate filter systems to 10 engine models from three engine manufacturers in 12 different vehicle types, a total of 24 vehicles. As the program ran, one mine had to drop out and a mutually agreed upon system could not be arrived at for another. Hence, the program included five Canadian mining companies. Several of the vehicles trialed at Brunswick Mining were trialed by Brunswick themselves. Nonetheless, the data is presented. This paper covers the work performed from the beginning to the end of the demonstration program. Data collected to properly select and design filter systems along with technical conclusions of the demonstration are presented. Also presented are the results of a survey that highlights the participating mines' acceptance of the technology.

Jan 1, 1991

By Phil D. Newman, Robert J. Pine, Kevin Ross

The Stratoni Operations in northeastern Greece rely on a selective backfill method to exploit high-grade lead-zinc deposits. Underhand cut and fill often results in spans approaching 6-9 m (depending on the mining method employed) and a competent backfill is required to avoid dilution problems. Cement consumption represents a significant mining cost and through improving the control of the backfill batch preparation, the cement content could be greatly reduced without jeopardizing the grade control. A new distribution system was installed and a QAIQC system designed in cooperation with the operators to allow a wide range of backfill recipes, providing cost savings to the mine. A review of possible failure modes and the consequent strength required for the chosen mining method was also completed and indicated potentially significant cement content reductions. The calculations are supported by 12 years of experience at the mines which provides a valuable insight into the applicability of the approach developed.

Jan 1, 2001

By M. Leroux, S. R. Rao, J. Kim, V. Gervais, J. A. Finch, G. Labonté, N. Macminn, M. Ounpuu

Collectorless flotation of sulphide minerals from Lyon Lake ore (Mattabi Mines Ltd.) has been studied both in the laboratory and plant. Among the four major minerals chalcopyrite showed the greatest response to collectorless flotation, followed by galena. Flotation of sphalerite and pyrite was minimal. Collectorless flotation was influenced by pulp potential and pH. Experiments using different gas compositions showed collectorless flotation was promoted when the pulp potentials were greater than about 0 mV (SCE). The study of the effect of depressants showed that SO2 at pH < 8.0 depresses both galena and chalcopyrite but at pH 9.5 flotation of chalcopyrite recovers. Use of NaCN preferentially depressed chalcopyrite compared to galena. Preliminary results from plant tests at Mattabi Mines Ltd. confirm that collectorless flotation occurs and that it is preferential for chalcopyrite and to a lesser extent galena. Practical implications of collectorless flotation in plant practice are discussed. A critical factor will be silver recovery.

Jan 1, 1989

By O. Ofor

Finely-ground hematitic ore, too high in silica (quartz) to be commercially viable, was treated by emulsion flotation. A three-component emulsion mixture was used at temperatures ranging from ambient (22° C) to 30° C, 40° C, 49 °C, 59° C and 68° C. The optimal emulsion dosage and composition at ambient temperature were used to determine that dosage for higher-temperature flotation tests. The crushed ore (100%, -8 mesh) was repeatedly washed with tap water, and the filtrate&apos;s ionic content was analyzed. The separation efficiency values (a measure of the selective separation and concentration of hematite from gangue minerals) demonstrated temperature dependence, with marked increases at temperatures above ambient. The optimal separation efficiency occurred within the range from 30° C to 60° C. The improved separation efficiencies at temperatures exceeding ambient are explained by quartz depression. This depression is attributed to: • the precipitation of quartz-activating cations, principally calcium and magnesium, at increasing temperature; and • temperature&apos;s effect on the collector&apos;s solubility and attachment to the aqueous hematite surface.

Jan 1, 1993

By Robert J. Auber, Thomas R. Scotese

The West Leg Interceptor is part of a new sanitary sewer system in the southwest suburbs of Cleveland. The first two construction contracts were excavated in glacial soils varying from hard tills to pressurized silts and flowing sands. These soil and groundwater conditions were locally problematic during shaft and tunnel excavations and final lining construction. A variety of solutions were developed primarily during construction. During the WLI-1R Contract, subgrade pressures, continued ground losses, and displacements necessitated extra eductor wells and modified inverts for stabilization of shafts. At the WLI-2Contract, one shaft excavation in similar ground required only one extra well. In the WLI-1R tunnel, localized inflows of groundwater, silt, and sand through the geotextile fabric were stopped by cement grouting. In one WLI-2 connector tunnel, damage to the TBM flood doors combined with wet, flowing silt and sand led to ground losses, surface settlements, plugging, patching, and chemical grouting. The concrete lining in the main WLI-2 tunnel required remedial work to improve watertightness at joints.

Jan 1, 1999

By Gordon I. McPhail, John D. Nelson

Tailings management represents a major portion of the cost associated with extraction of gold. For each gram of gold extracted, 150 to 200 kg of waste material is produced. Because of environmental concerns and unwillingness of society to accept environmental damage caused by poor waste management practices it has become essential to follow responsible and safe practices in tailings management. This paper presents general aspects of tailings management and discusses different techniques utilized. Characteristics of tailings and the effects that these have on stability and environmental aspects are discussed. The paper also discusses the effect of mine back-filling practices on the surface disposal of the remaining tailings fraction.

Jan 1, 1987

By D. Armour, E. R. Bauer, D. R. Zuchelli, T. M. Durr, E. R. Reeves

A team of noise specialists from the National Institute for Occupational Safety and Health (NIOSH), Mine Safety and Health Administration (MSHA), and Joy Manufacturing attempted to evaluate an engineering noise control on a Joy longwall stageloader. The team developed and executed a test plan to evaluate the noise attenuation of the engineering control in an underground coal-mining environment. An evaluation of the long-term noise effects and durability of the engineering control were also a focus of the research effort. Pre- and postcontrol measurements consisting of a combination of worker dosimetry and task observations, tape recordings, and sound level measurements were used to evaluate the engineering control. A description of the engineering noise control, pre- and post-control sound level measurements, and an evaluation of control success is presented. In the end, no evaluation was possible due to mining practices, miner task variations, and inconclusive data.

Jan 1, 2005

By C. A. Rowland

Comminution efficiency can be expressed in three different ways. Theoretical Efficiency: actual energy consumed, in a comminution machine compared to the theoretical energy required to make the size reduction. Operating Efficiency: compares the operating work index, calculated from production comminution machinery operating data, to the Bond Work Index from bench scale comminution tests or calculated from pilot plant operating data. Economic Efficiency: income compared to planned income. Using the Bond Work Index and operating work index, this paper explains how to determine operating efficiency.

Jan 1, 1998